Arcelormittal Nippon Steel India Limited Srt73 Eia1 Tds & All Details

Draft Environmental Impact Assessment & EMP Report
(Oct - 2020 to Dec - 2020)

for
M/s. ArcelorMittal Nippon Steel India Limited
27th KM, Surat-Hazira Road, Hazira-394270

Gujarat, India.
Proposed Modification in Existing Plant by installing Auxiliary Facilities

without increasing Plant Capacity
Project Category: A,
3(a) Metallurgical Industries (Ferrous & Non Ferrous)
Shree Green Consultants

505, SNS Platina, Nr. Reliance Market, Opp. Shrenik Residency, Vesu,
Surat, Gujarat.
Mobile No.: 9712916775

Email: info@shreegreen.com
Website: www.shreegreen.com
June, 2021
SGC/20210702/EIA_04
Executive Summary
for
M/s. ArcelorMittal Nippon Steel India Limited
27th KM, Surat-Hazira Road, Hazira-394270

Gujarat, India.
Proposed Modification in Existing Plant by installing Auxiliary Facilities

without increasing Plant Capacity
Project Category: A,
3(a) Metallurgical Industries (Ferrous & Non Ferrous)
M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-1

Executive Summary
Name of the Project
Modification in existing plant by installing auxiliary facilities without increasing plant capacity by M/s.
ArcelorMittal Nippon Steel India Limited.
Location of the Project

Project site is located in Hazira Notified Industrial Area at Village Hazira, Taluka Choryasi, District Surat,
Gujarat, India. The site is located at around distance of 15 km away from Surat city in East North East
direction. The nearest airport is situated at Surat around 8.0 km in East direction from the project site.
a) Industrial Estate : Hazira Notified Industrial Area

b) Village : Hazira
c) Tehsil/Taluka : Choryasi
d) District : Surat
e) State : Gujarat
f) Co-ordinates (Center) : Lat.: 21° 6'43.72"N, Log.: 72°38'40.29"E
Surrounding Salient Features and Environmental Setting

Sr. No. Nearest Infrastructure Feature Identity Direction from Project Site
1 Nearest Village Hazira adjacent in south direction
2 Nearest City/Town / Nearest Dist Surat 15 km in north-east-east direction
Headquarter
3 Nearest National Highway NH-6 / NH-53 at around 0.1 km
4 Nearest Railway Station Surat Rly Station 20 km in north-east-east direction
5 Nearest Airport Surat Airport 8 km in east direction
6 Nearest River /Water Body Tapi 0.5 km east direction,
Arabian Sea 2.0 km in west direction
7 National Park / Reserve Forest, Reserve Forest 0.6 Km in west direction
Biosphere Reserve Dumas Reserved Forest 5.50 km south-east-east direction
Mangrove Patches Present within 10 km radius
8 Archeological site None None within 10 km radius
9 State boundary None None within 10 km radius
10 Defense installation None None within 10 km radius
11 Seismic Zone Zone-III
Details of earlier ECs

List of EC Year wise
Year of EC
File No. Facility or Plant
Granted
1992 J-11011/4/92-IA-II(I) Hot Briquetted Iron (2 MMTPA), Hot Rolled Coil (2.5 MMTPA)
2005 J-11011/45/2004-IA-II(I) Hot Briquetted Iron (2 MMTPA), Hot Rolled Coil (0.5 MMTPA),
Hot metal (0.735 MMTPA)
2006 11-65/2005-IA-III Extension of Jetty from 456 meter to 734 meter i.e berthing
capacity 1190 meter
2006 J-13011/7/2006-IA.II(T) 525 MW Gas Based CPP
J-11011/74-III/2006-IAII(I) Hot Rolled Coil (1.5 MMTPA), Air Separation Unit (1,405 TPD),
WHRB based CPP 48 MW, Gas Based CPP 525 MW
2008
J-11011/327-I/2006-IA. II(I) Hot Briquetted Iron (1.98 MMTPA)
J-11011/74-II/2006-IA. II(I) Hot Rolled Plates (1.5 MMTPA)
2009 J-13011/90/2006-IA. II(T) WHRB based CPP 25 MW
2010 J-11011/714-A/2008-IAII(I) Pellets Plant (4 MMTPA), HBI/DRI (1.85 MMTPA), COREX
Year of EC
Granted
Plant (1.7 MMTPA), Blast Furnace (2.04 MMTPA), Steel Melting
Shop (5 MMTPA), Lime Plant (0.45 MMTPA), Caster Shop (Slab
Caster 4.9 MMTPA, Billet Caster 2.37 MMTPA), CSP (Rebar 1.6
MMTPA, Wire Road 0.7 MMTPA, HRC 3.5 MMTPA), Air
Separation Unit (5,100 TPD)
J-11011/313/2009-IAII(I) Coke Oven Plant (1.2 MMTPA, Recovery Type)
2013 F. No. 11-1/2011-IA-III 220 KV M/C Transmission Tower Line
2016 J-11011/381/2014-IA II (I) Re configuration of 9.6 million TPA*
*We have not yet achieved 9.6 MTPA (with the proposed modifications, we will be able to achieve 9.6 MTPA by
2025)
Products and Capacities

List of Product
Sr. Name of Facility As per EC dated 9th March Implementation Status as on Dec, 2020
Unit
No. 2016
Existing Proposed Total Status of Existing Units Status of Existing Units
in 2016 in 2020
1. HBI Plant (DRI Mod. MTPA 7.83 -4.0 3.83 Only Mod V & VI are in Mod I to VI 7.83 in
I to VI) operation operation
2. Blast Furnace MTPA 2.04 3 5.04 In operations 2.04 in operations
3. Sinter Plant MTPA 1.48 7 8.48 In operations 1.48 in operations
4. Coke Oven (Recovery Type)
Gross Coke MTPA 1.2 1.35 2.55 Under construction Under construction
Crude Tar (By – TPA 52,200 63,000 1,15,200
Product)
Sulphur (By – TPA 1,700 1,980 3,680
Product)
Crude Benzol (By- TPA 0 18,243 18,243
Product)
Naphthalene TPA 130 0 130
5 Air Separation
Oxygen Gaseous 3,60,544 64,200 4,24,744 In operations 3,60,544 in operations
Oxygen Liquid Nm /hr 2,950
3 500 3,450 2950 in operations
Nitrogen 1,19,944 25,700 1,45,644 1,19,944 in operations
Argon 3,470 1,500 4,970 3,470 in operations
6 Steel Melt Shop- MTPA 4.6 -4.6 0 In operations (partial) 4.6 in operations
1(EAF) (4Nos.)
7 Basic Oxygen MTPA 0 4.6 4.6 Proposed Dropped
Furnace (BoF) (3
Nos.)
8 Steel Melt Shop-2 MTPA 5.0 0 5.0 In operations 5.0 in operations
(4 EAF& 4LF)
9 Corex Plant (2 Nos.) MTPA 1.7 0 1.7 In operations 1.7 in operations
10 Lime Plant MTPA 0.93 0.27 1.2 In operations 0.93 in operations
(Lime / Dolime)
11 CPP MW 31 0 31 In operations (partial) In operations
MW 48 0 48 Not yet established Dropped
MW 525 0 525 Not in operation In operations
12 Plate Mill MTPA 1.5 0 1.5 In operations In operations
13 Pellet Plant MTPA 4.0 0 4.0 Not yet established Dropped

Unit
No. 2016
in 2016 in 2020
14 CSP, Hot Rolling Mill MTPA 3.5 0 3.5 In operations In operations
& Long Product -
HRC
Rebar 1.6 0 1.6 Not yet established Dropped
Wire Rod 0.7 0 0.7
15 Caster Shop
Slab From Slab Caster MTPA 4.9 0 4.9 In operations In operations
Billets From Billet MTPA 2.37 0 2.37 Not yet established Dropped
Caster
16 CRM
Hot Rolled Pickled MTPA 1.5 0.54 2.04 In operations In operations (Consent
Coils/Sheets To Operate received
CR Coils/Sheet 1.3 0.65 1.95 from SPCB)
Galvanized 0.65 0 0.65
Coils/Sheets
Coated Sheets / Coil 0.1 0 0.1
17 Extension of Existing Meters 1190 0 1190 In operations In operations
Jetty
18 Waste Heat Recovery MW 25 20 45 In operations 25 in operations
Based Power Plant
19 Pipe Mill
H Saw Pipes MTPA 0.15 0.15 0.30 In operations In operations
L Saw Pipes MTPA 0.33 0 0.33 (Consent to Operate
received from SPCB)
Coating Plant MTPA 0 0.48 0.48
AM/NS is now envisaging following auxiliary facilities for steel making at Hazira complex with no
increase in the steelmaking capacity
Sr. No. Facility Unit Proposed Capacity

1 Coal briquetting Plant - (1000 TPD) TPD 1000
2 BF – PCI Project- Pulverized coal T/Hr 80
3 Lime Kiln (500 TPD) - Lime and Dolime MT / Month 15000
4 Rotary Kiln (200 TPD) - Calcined Lime MT/Month 6000
5 Blast Furnace Dust Catcher /Dust separation unit-150 TPD TPD 150
6 Acid Regeneration Plant - 100 KL & Pickling Line-3 KL/Day 100
7 BF slag grinding mill (BOO) - 50 TPD TPD 50
8 New Cooling towers for
Mod-1 and 2 M3/HR 3900
9 Slag Conditioning & Metal Recovery plant TPD 7500
10 Thick Plate Normalizing Furnace Tons/year 15000
11 Shot blasting machine Tons/year 300,000
12 VD Cooling Tower m3/hr 3x 500m3/hr,
13 RHD Cooling Tower m3/hr 3x 1065m3/hr,
14 Water Treatment Plant for 500 MW CCPP m3/hr 2 x 500 m3/hr

15 CRM-2
Hot Rolled Pickled Coils/Sheets MTPA 3.2
CR Coils/Sheet 2.2
Galvanized Coils/Sheets 1.0
Annealing coils/Sheets 1.0
16 Ladle furnace - Existing Liquid Steel 4.6 MTPA (Standby LF-5 - -
for Special grades)
17 SMP-1 Fume Extraction System upgradation - -
18 Mod 4 additional VPSA to utilize Corex gas and going forward - -
Coke oven gas
19 Hot metal Pretreatment Station Outside Shop (KR Technology) - -
20 Tank Farm-2 with interconnection between PKL-3 & ARP-2 - -
21 Additional Ladle Furnace (LF7) – Standby for Special grades - -
Project Requirement
Land Requirement
Existing land 770 ha will be utilized for the proposed modification project i.e. no additional land is required
for proposed modification.
Details of Land Breakup

Sr. No. Plant Name Area (In ha)
1 Existing Plant Facilities 351.25
2 Proposed Auxiliaries Plant Facilities 31.37
3 Existing Green Belt Area 170.00
3. Additional Planned Green Belt Area 84.00
4 Admin area 15.00
5 Parking Area 13.00
6 Solid / Hazardous waste storage area 10.00
7 Open Area 25.00
8 Coal Storage area 10.38
9 Raw Material Storage area 11.00
10 Internal Road area 8.00
11 Residential Area 29.00
12 OHC area 4.00
13 Canteen area 8.00
Total 770.00

Major Raw Material Requirement:
Details of major raw material requirement, its source and transportation details is presented in following
table.
List of Raw Materials

Sr. Particulars Name of Raw Raw Material Requirement
No. Material Existing Proposed After Modification
Existing Units
1 HBI Plant (DRI Pellets: 11820 KT 0.0 11820 KT
Mod. I to VI)
2 Blast Furnace Pellets/CLO 2400 KT, 0.0 2400 KT,
Flux 140 KT 140 KT
(Lime, dolime, (Lime, dolime, Quartz),
Coke Quartz), 900 KT
PCI Coal 900 KT, 500 KT
Sinter 500 KT 1480 KT
1480 KT
3 Sinter Plant Internal Fines 185 KT 0.0 185 KT
External fines
as per
requirement
Flux
Coke Breeze 85 KT 85 KT
(Internal return + (Internal return + external)
external)
4 Coke Oven Coking Coal 3.7 MTPA 0.0 3.7 MTPA
(Recovery Type)
5 Air Separation N.A. 0.0 N.A.
6 Steel Melt Shop-1 HBI/DRI 5535 KT 0.0 5535 KT
(EAF) (4Nos.) Internal Scrap 145 KT 145 KT
Lime 271 KT 271 KT
Dolime: 276 KT 276 KT
(Note: Scrap
can be replaced
by HBI/DRI)
7 Steel Melt Shop-2 Hot metal 4073 KT 0.0 4073 KT
(2 Conarc & 3 Twin HBI/DRI 1651 KT 1651 KT
LF) Scrap 29 KT 29 KT
Lime 300 KT 300 KT
Dolime 150 KT 150 KT
(Note: Ideal
mix.,In case of
lower hot metal,
additional HBI,
CDRI required
8 Corex Plant (2 Pellets 3000 KT, 0.0 3000 KT,
Nos.) Flux 550 KT, 550 KT,
Coke: 355 KT, 355 KT,
Coal: 2900 KT 2900 KT
9 Lime Plant 1 (Lime/ Dolime) 828 KT 0.0 828 KT
(Lime/ Dolime)
(Lime/ Dolime)
11 CPP - - -
12 Plate Mill Slabs 1515 KT 0.0 Slabs: 1515 KT
13 CSP, Hot Rolling Slabs 3653KT (HSM) 0.0 3653 KT (HSM)
Mill & Long CSP: 3523 KT 3523 KT
Product -HRC
14 Caster Shop SMP1 Liq Steel 4600 KT 0.0 4600 KT
(CSP Casters INI)
16 CRM-1 HRC 1500 KT 0.0 2000 KT
17 Extension of - - - -
Existing Jetty
18 Waste Heat - - - -
Recovery Based
Power Plant
19 Pipe Mill Plate 330 KT 0.0 330 KT
HRC 300 KT 300 KT
Proposed Auxiliaries Facilities
1 Coal briquetting Coal fines - 300 KTPA 300 KTPA
Plant - (1000 TPD)
2 BF – PCI Project- Coal - 80 TPH 80 TPH
Pulverized coal
3 Lime Kiln (500 - - 345 KTPA 345 KTPA
TPD) - Lime and
Dolime
4 Rotary Kiln (200 - - 138 KTPA 138 KTPA
TPD) - Calcined
Lime
5 Blast Furnace Dust Dust - 540 KTPA 540 KTPA
Catcher /Dust
separation unit-150
TPD
6 Acid Regeneration Spent acid - 5000 liters/hr 5000 liters/hr
Plant - 100 KL &
Pickling Line-3
7 BF slag grinding Blast furnace - 15 KTPA 15 KTPA
mill (BOO) - 50 granulated Slag
TPD
8 New Cooling - - NA NA
towers (Mod 1 to
Mod 6)
9 Slag Conditioning Unprocessed - 4500 TPD 4500 TPD
& Metal Recovery slag
plant
10 Thick Plate - - Plates: 15 Plates: 15 KTPH
Normalizing KTPH
Furnace
11 Shot blasting Hot rolled - 300 KTPH 300 KTPH
machine plates:
12 VD Cooling Tower - - - -
13 RHD Cooling - - - -
Tower
14 Water Treatment - - - -
Plant for 500 MW
CCPP
15 CRM-2 HRC - 2200 KTPH 2200 KTPH
16 Ladle furnace - Ferro Alloy - 4252 TPA 4252 TPA
Existing Liquid (Mn, Ti, Mo, V,
Steel 4.6 MTPA B) –
(Standby LF-5 for Aluminium 3402 TPA 3402 TPA
Special grades)
CPC 850 TPA 850 TPA
17 SMP-1 fume - -
Extraction System
upgradation
18 Mod 4 additional - - - -
VPSA to utilize
Corex gas and
going forward Coke
oven gas
19 Hot metal - - - -
Pretreatment
Station Outside
Shop (KR
Technology)
20 Tank Farm-2 with - - - -
interconnection
between PKL-3 &
ARP-2
21 Additional Ladle Ferro Alloy - 8505 TPA 8505 TPA
Furnace (LF7) – (Mn, Ti, Mo, V,
Standby for Special B) 2551 TPA 2551 TPA
grades Aluminium
CPC 850 TPA 850 TPA
Water Requirement
Existing:
Total raw water consumption in the existing scenario is approximately 145,839.00 m3/day with 1,33,775.00
m3/day used for industrial purposes while 12,064.00 m3/day is used for domestic purposes. This water is
being sourced from the Tapi river.
AMNS has two reservoirs with 360,000.00 m3 and 180,000.00 m3 capacities. For domestic purposes, the
total water requirement is approximately 12064.00 m3/day. Approximately 133,775.00 m3/day of water is
used for the industrial purposes.
Proposed:
Total raw water consumption after proposed modification would be around 1,53,328.00 m3/day (Industrial
purpose 1,41,264.00 m3/day and domestic purpose 12064 m3/day). Water will be sourced from the Tapi
river.
19,793.00 m3/day wastewater will be generated which will be treated thought proposed UF/RO treatment
scheme and follow Zero Liquid Discharge concept. After treatment UF/ RO permeate of approximately
13,968.00 m3/day will be reused as makeup. It is estimated that approximately 5826.00 m3/day of UF/RO
reject water would be generated. RO reject will be disposed to TSDF. There are three STPs dedicated to
treat the domestic effluent generated. Treated water will be used for plantation inside the premises.
Power Requirement
The power requirement after proposed modification is 1163 MW. The power required for existing plant
facility and proposed auxiliary plant facilities is given in table-2.14 and table 2.15 respectively.
Power is being sourced from Captive generation 556 MW (500+31+25), From EPHL 270 MW and
additional (337 MW) will be availed from 400 KV- PSOCL (National Grid).
Fuel Requirement
Coal, Coke & NG will be used as a fuel.
Manpower Requirement
The manpower requirement after proposed modification will be 15270 nos.
Process Description
The integrated steel plant consists of a number of unit processes.

Sr. No. Auxiliary Facility Need for the Auxiliary Facility
1 Coal briquetting Plant Recycling of coal fines, this saves cost and is environment friendly as
transportation of coal fines causes fines spillage and dusty environment
2 BF – PCI Project To achieve an injection rate of 250Kg/THM. An additional Grinding
Mill of 80 TPH capacity is required. With this facility the present
existing Mill, be kept as standby unit and will be operated at the time
of 80TPH Mill maintenances
3 Ladle furnace Installation of Standby ladle furnace to cater need of vacuum degassing
and critical grades.
4 Lime Kiln (500 TPD): For SMP2 operation, there is a shortfall of on an average 331 tons of
lime per day at current production level. This huge quantity will be
difficult to manage from local market. Also handling, storage and
feeding of lime too will be difficult. Hence to meet lime requirement,
Lime Kiln (500 TPD) is required
5 Rotary Kiln (200 TPD) Rotary Kiln converts the undersize chips to Lime unlike Vertical shaft.
By product Limestone chips with by product COREX gas can be
converted into Prime Product Lime which can be used in LF as well
EAF/CONARC
6 Additional Ladle Furnace (LF7) A Ladle Refining Furnace is used to raise the temperature and adjust
the chemical composition of molten metal. Without LRFs, higher tap
temperatures are normally required from steel making furnaces due to
heat losses during refining with conventional ladles.
7 Blast Furnace Dust Catcher /Dust The blast furnace (BF) process is the most important process in
separation unit-150 TPD integrated steel mills for the production of hot metal (pig iron). There
the iron ore is reduced to metallic iron
8 Acid Regeneration Plant - 100 KL Huge savings from reduced hazardous neutralization or difficult
disposal costs, Savings from reduced acid purchases, Profit from Iron
Oxide by-product which is on increasing demand, Waste Rinse water
of Pickling Plant can also be used in Acid Recovery Plant
9 Pickling Line-3 In this process the strip, emerging from entry section enters Pickling
section consisting of three tanks separated by squeeze roll stand. The
Pickling tanks are shallow granite troughs specially designed to
support and guide the strip during all phases of operation. Hot dilute
Hydrochloric Acid (HCl) is circulated in each of the section from
individual recirculation tanks through heat exchangers to make up the
lost heat during the process
10 BF slag grinding mill (BOO) - 50 Granulated blast furnace slag has been used as a raw material for
TPD cement production and as an aggregate and insulating material. and
granulated slag have also been used as sand blasting shot materials
11 New Cooling towers for Mod-1 An HVAC (heating, ventilating, and air conditioning) cooling tower is
and 2 /Mod-3 and 4 / Mod-5 and used to dispose of ("reject") unwanted heat from a chiller. Water-
6 cooled chillers are normally more energy efficient than air-cooled
chillers due to heat rejection to tower water at or near wet-bulb
temperatures
12 Mod 4 additional VPSA to utilize Corex is a smelting reduction process combining a melter gasifier with
Corex gas and going forward a reduction shaft. The process takes lump iron ore or pellets, non-
Coke oven gas coking coal, and oxygen as main inputs. Similar to the blast
furnace process, the reduction gas moves in counter flow to the
descending burden in the reduction shaft
13 Slag Conditioning & Metal Dusts and sludges are collected in the abatement plants, equipped with
Recovery plant filters. the recovery rate of by-products, achieving environmental and
economic benefits, also Another recent important use of BF and steel
slags consists in the high Use of spent refractories for slag conditioning
with the aim to decrease the slag
14 Hot metal Pretreatment Station Pretreatment of hot metal. Pre-treatment of hot metal is the adjustment
Outside Shop (KR Technology) of the composition and temperature of blast furnace produced hot
metal for optimal operation of the oxygen converter process
15 Thick Plate Normalizing Furnace Normalizing is the easiest way to influence the mechanical properties
of carbon steel. For heavy plate normalizing, the process involves
heating to normalizing temperature in a furnace to completely dissolve
the carbon, which is present in the steel in the form of carbides at room

temperature
16 Shot blasting machine Shot blasting is a method used to clean, strengthen (peen) or polish
metal. Shot blasting is used in almost every industry that uses metal,
including aerospace, automotive, construction, foundry, shipbuilding,
rail, and many others
17 VD Cooling Tower The primary task of a cooling tower is to reject heat into the
atmosphere. They represent a relatively inexpensive and dependable
means of removing low-grade heat from cooling water. The make-up
water source is used to replenish water lost to evaporation. Hot water
from heat exchangers is sent to the cooling tower
18 RHD Cooling Tower An HVAC (heating, ventilating, and air conditioning) cooling tower is
used to dispose of ("reject") unwanted heat from a chiller. Water-
cooled chillers are normally more energy efficient than air-cooled
temperatures.
19 Water Treatment Plant for 500 Water treatment is any process that improves the quality of water to
MW CCPP make it appropriate for a specific end-use. The end use may
be drinking, industrial water supply, irrigation, river flow maintenance,
water recreation or many other uses, including being safely returned to
the environment. Water treatment removes contaminants and
undesirable components, or reduces their concentration so that the
water becomes fit for its desired end-use. This treatment is crucial to
human health and allows humans to benefit from both drinking and
irrigation use.
20 SMP-1 Fume Extraction System Capacity enhancement of SMS – FES for improvising the overall
upgradation environmental condition related to Air Pollution This project will
increase the capacity of common Secondary Fume Extraction system
(for EAF1,2 and 3) to achieve cleaner shop condition and also address
the dust escaping from the SMP1 building
21 CRM-2 AM/NS manufacturing facilities at Hazira comprises of iron making,
steel making, and downstream facilities including cold rolling mill,
galvanizing, pre-coated facility, steel processing, an extra wide plate
mill and a pipe mill. In a series of continuous improvement plan and
based on finishing strategy, AM/NS Hazira has planned to upgrade
existing facilities and install new facilities in CRM#2 area in following
three Phases
Phase 1:
➢ Upgradation of existing Continuous Tandem Cold Rolling
Mill (CTCM)
➢ New one (1) number continuous galvanizing line #4 for
(ZnMg) coating (CGL-4)
➢ New one (1) number coil inspection cum repair line #1.
➢ New one (1) numbers coil packaging line #1
➢ Necessary Utility & auxiliary facilities required for the above
mentioned facilities.
Phase 2:
➢ New one (1) number Pickling line coupled with tandem cold
mill (PLTCM)
➢ New one (1) number Acid Regeneration Plant #3 (ARP-3)
➢ New one (1) Effluent Treatment Plant (ETP)
➢ New one (1) number continuous galvanizing line #3 for GA
(CGL-3)
➢ New one (1) number coil packaging line #2.
➢ New roll grinding & roll texturing machines
Phase 3:
➢ New one (1) number continuous pickling line #4 (PKL-4)
➢ New one (1) number continuous annealing line (CAL)
➢ New one (1) number coil inspection cum repair line #3
➢ New one (1) number coil packaging line #3
➢ Necessary Utility & auxiliary facilities required for the above-
mentioned facilities
Project Cost
Total capital cost of the proposed modification project would be approx. Rs. 6413.13 crores. Capital and
recurring cost of the environmental control measures would be 1682.26 and 377.95 crores respectively.
Estimated time of Completion

Estimated time of completion of the project is 34 months.
Site Selected for the project

Our existing project site is located in Hazira, which is inside the notified Hazira industrial area of Gujarat.
Baseline Environment
Primary baseline environmental monitoring studies were conducted during post-monsoon season of Oct
2020 to Dec 2020 in a study area of 10 km radial distance from the project site.
Ambient Air Quality

The baseline levels within the study area with respect to (PM10, PM2.5, SO2, NOX, CO, THC, NMHC (Non-
Methane) and Lead terms of various statistical parameters are presented in tables-3.4. During baseline
monitoring, the values of PM10 varied between 43.12 – 132.52 μg/m3. The values of PM2.5 varied
between 20.21 – 67.90 μg/m3. The value for SO2 was 12.44 – 42.20 μg/m3. The values of NOx varied
between 16.11 – 48.30 μg/m3. The value of CO varied between 0.1 – 1.21 μg/m3, the values of THC varied
between 0.1 – 5.63 ppm and BDL at the Mora, Vanta MRSS building. The values of NMHC varied
between 0.18 – 5.24 ppm and BDL at the MRSS Building, Vanta, Mora. The Lead found only at Hazira
village between 0.1 – 0.5 μg/m3 and at remaining location it found BDL.
Ground Water Quality Monitoring

The pH of ground water showed a variation in the range of 7.08 – 7.61. TDS levels varied in the range of
561-1251 mg/L. Total hardness varied in the range of 450 – 530 mg/L. Alkalinity varied in the range of
390.0 – 450.0 mg/L. The conductivity levels varied in the range of 0.874 – 1.911 mS/cm. Coliform bacteria
were measured as Total Coliform, and E.coli, these bacteria are absent in all samples.
Surface Water Quality Monitoring

The pH of surface water showed a variation in the range of 7.12 – 8.62. TDS levels varied in the range of
were measured as Total Coliform, and E.coli, these bacteria are found below detectable limit in all the
samples.
Background Noise Level

Ambient noise levels monitoring was done at day as well as night time. At Industrial area maximum noise
levels recorded during the day time 65.0 Leq dB(A) and during night time 51.0 Leq dB(A).
Thus, noise levels at all locations were observed to be within the prescribed limits. Noise levels in the study
area are well within the prescribed limits as prescribed by the CPCB. The main sources of noise identified
in the industrial zone are vehicular traffic, industrial and commercial activities.
Soil Quality
Soil is the media for supplying the nutrients for plant growth. Nutrients are available to plants at certain pH
and pH of soils can reflect by addition of pollutants in it either by air, or by water or by solid waste or by all
of these. In order to establish the baseline status of soil characteristics, soil samples were collected at 8
sampling locations. The analysis results show that soil is basic in nature as pH value ranges from 6.8 to 8.56
with Electrical Conductivity of 1.532 to 3.011 mS/cm.
Land Use Pattern
Land use within 10 km radius of the study area has been determined with the help of satellite imagery, and
broadly consists of settlements, Industrial, Tank/River/reservoir, Agriculture, land with scrub, Mud plot,
water logged area, airports, mangroves. Predominant land use is water bodies classified as tank/river, sea
i.e. 55.8 percent.
Socio-Economic Study
Total population of the study area as per year 2011 census was 84075, out of which 54253 were male and
29,822 were female.
Biological Environment
In the project area, the wild animals as well as other fauna are not seen except domestic animals. The study
area doesn’t include any part of National Park or wild life sanctuary.
Anticipated Environmental Impacts & Mitigation Measures

Anticipated adverse environmental impacts due to the proposed modification project during construction
and operation phase, and its mitigation measures are given below:
Air Environment
Construction phase involves site cleaning, excavation, construction, grinding, cutting, erection or
installation of equipment & machinery, transportation and material handling. These activities result in
emission of pollutants like dust, PM10, SO2 and NOx and fumes, into the atmosphere of the surrounding
area.
• Continuous sprinkling of water will be carried out to control dust/fugitive emission.
• Construction activity shall be carried out under a covered shed.
• Construction material will not be stored in open space.
• Regular checking and maintenance of vehicles will be carried out
The impact of such activities would be temporary and restricted to the construction phase only and will be
confined within the project premises.
During operation phase, major air emissions are anticipated as gaseous emissions (PM, SO2 and NOx) from
a single or small group of stacks. Fugitive dust emission will be due to raw materials handling, loading and
unloading of raw materials and finished goods, conveying and feeding point, vehicular movements,
crushing & screening operations etc. The ISCST3 scientific model has been used to predict ground level
concentration due to proposed project and due to cumulative impact, which is as follows.
Sr. Maximum Ground Level Concentration

Parameters
No. Due to Proposed Project Due to Cumulative Impact
1. PM 44.62 µg/m3 at 5.5 km in SSW direction 49.31 µg/m3 at 6.8 km in SSW direction
2. SO2 45.82 µg/m3 at 4.5 km in SSW direction 46.74 µg/m3 at 4.5 km in SSW direction
3. NOx 25.69 µg/m3 at 3.3 km in SSW direction 29.29 µg/m3 at 3.6 km in SSW direction
Mitigation Measures:
• Adequate pollution control equipments like bag filter, ESP scrubber etc. along with online
continuous monitoring system are installed to the existing stack and shall also be provided for the
proposed stacks as per the guideline.
• It shall be ensured that all stacks including proposed stacks shall have adequate stack heights as per
the norms of GPCB/CPCB.
• Periodic stack monitoring and fugitive emission monitoring will be done.
• Periodic checkup of all APC equipment to ensure proper functioning.

Water Environment
river.
19,793.00 m3/day wastewater will be generated, which will be treated through proposed UF/RO treatment
scheme to follow Zero Liquid Discharge concept. After treatment UF/ RO permeate of approximately
reject water would be generated. RO reject will be disposed to TSDF. The proposed water balance diagram
is given in figure 2.7.
Impact of ground water and its mitigation measures

Impact on ground water availability and mitigation measures:
For the proposed modification project entire water will be sourced from surface water source and hence
there will be no impact on ground water due to water consumption requirement. However, rain water
harvesting practice will be followed to improve ground water condition.
Impact on ground water quality and mitigation measures:

During the industrial activities there may be a chance of contamination in ground water by leachate
generation from spillage of hazardous chemicals, storage of raw materials, finish products and solid waste.,
etc. following mitigation measures for avoiding contamination of ground water will be implemented.
- Raw materials, finish products and solid waste will be stored in separate stockyards
- All stockyards will be designed with the impervious flooring.
- Garland drain will be provided to all stockyards area to trap run off material.
- Any spillage of hazardous waste or contamination will be immediately removed.
- Regular ground water monitoring will be carried out.
Noise Environment
The noise generation during the construction phase will be due to movement vehicle, operation of
construction equipment. Noise control measures like mufflers, silencers, use of PPEs like earmuff and
earplugs, regular maintenance of equipment, regular monitoring of noise level will help to reduce the noise
level.
During the plant operation Noice from the rotating equipment, Air blower, Compressor, Diesel generator,
Mechanical operations, Vehicular movements etc. may increase the noise generation pollution during the
plant operation.
- Use of adequate noise control measures such as mufflers, silencers, anti-vibration pad for equipment
with high vibration,
- Use of earmuff and earplugs to the operators, etc. would be provided.
- Housing / casing shall be provided for all noise generating machines.
- Regular maintenance of equipments.
- Limiting activity within day hours
- Regular monitoring of noise level
By these measures, it is anticipated that noise levels in the plant will be maintained below the stipulated
standard prescribed by the pollution control board.
Soil Environment - Solid / Hazardous Waste Management

The main source of impact on land and soil environment will be due to solid waste generated during
construction and operation activities.

During operation phase of the project, there will be generation of solid and as well as hazardous wastes.
Plant wise details of hazardous waste generation and disposal method/Management is given in following
table.
Details of Solid Waste generation and its management

Sr. Quantity (KTPA) after Action plan for Disposal /
Source of waste Solid Waste
No. proposed modification Management
Fines
Modules & Consumed in Sinter Plant
1 Pellet Fines 902
Corex
2 BF BF Return 526 Consumed in Sinter Plant
3 SMP 1 & 2 Chamber Lumps 42 Chamber lump used in sinter plant.
HSM / Plate mill Used in Sinter Plant and in BF plant
4 Mill Scale 150
/ CSP
5 SMP 1 & 2 Scarfing Waste 5 Use in sinter Plant.
6 BF & Corex Coke Fines 68 Used in Sinter plant and SMP1 & SMP 2
Used in CRM ETP/Sinter Plant /micro
7 SMP 1 & 2 Lime Fines 49
palletization
8 SMP 1 & 2 Dolime Fines 35
palletization
Used in BF/Corex/Sinter plant/SMP1&2 as Raw
9 SMP 1 & 2 Limestone Chips 185
Material.
10 SMP 1 & 2 Dolomite Chips 148
Material.
Slag
Granulated Slag
11 Blast Furnace 1280 Being sold to authorized vendor
(IM)
Air Cooled Slag Used for internal roads and approach roads as a
12 Blast Furnace 128
(IM) sub base material
Used for internal roads and approach roads as a
sub base material
Used for internal railway network as ballast
13 SMP I & II Steel Slag 1651 material
Under CSR activities used for making internal
village roads to provide proper approach to
villagers
14 SMP I & II LF Slag 151
sub base material
De Spherization
15 SMP I & II 35 Used in sinter plant
(HMDP) Slag
Dust and Sludge
Used as a raw material in micro palletization plant
16 SMP I and II FES Dust 157
and recycled to sinter plant
17 CRM Iron Oxide 30.8 Consumed in Sinter Plant
Shot blasting Will be sent to TSDF Site.

18 Shots Dust 65 t/p.a.
machine
HBI Sludge Pond Used as a raw material in micro palletization plant
19 Module 1 to 6 258
Fines and recycled to sinter plant
20 Corex 1 & 2 Corex Sludge 117 Used as a raw material in Granules and recycled to
sinter plant
At internal construction sites being used for filling
21 BF BF Sludge 27 holes and voids occurred during excavation
activities
Used in SMP1&2 as a fuel and recycled in sinter
22 BF BF Dust 52
plant as a raw material
23 Module 2 to 5 HBI QT fines 84
It is Being sold to outside agencies
24 Module 1 & 6 DRI Cyclone dust 24
Refractories

25 SMP I & II MgO-C 9
26 SMP I & II Castable 1
27 SMP I & II Magnesite bricks 2
28 SMP I & II Alumina bricks 1 It is Being sold to outside agencies
29 SMP I & II Tundish Grog 17
High Alumina
30 SMP I & II 2
Grog
Coal Fines
31 Corex PCI Coal fines 527 Used in Blast Furnace
Non-PCI Corex
32 Corex 648 It is being sold to outside agencies.
coal fines
Details of Hazardous Waste generation and its management

Sr. Name of Hazardous Existing Proposed Total Quantity Action plan for Disposal /
No. Waste (TPA) (TPA) after proposed Management.
modification
(TPA)
1 Chemical Sludge from 18100 19900 38000 Collection, Storage, Transportation
Waste Water Treatment and disposal at GPCB authorized
(ETP Sludge) TSDF site / Co-processing /
Micropelletization
2 Sludge (Solid Waste) 0 30000 30000 Collection, Storage, Transportation
and Reused internally by the way of
micro pelletization / Co-processing.
3 Used Oil 2775 725 3500 Collection, Storage, Transportation
KL/Year and Disposal by selling to Registered
Vendors.
4 Oily Waste 7 6993 7000 Collection, Storage, Transportation
(Waste oily water + sludge and Disposal by selling to Registered
+ Magnetic sludge + Vendors.
Grinding Sludge + Coolant
Sludge)
5 Discarded Container / 15505 20495 36000 Collection, Storage, Transportation
Barrels / Liners / Paint Nos/Year and Disposal by selling to Authorized
Drums vendor.
6 Discarded Resin 8.3 191.7 200 Collection, Storage, Transportation
and Disposal at GPCB approved
CHWIF.
7 Zinc Dross & Zinc Ash 2340 3660 6000 Selling to registered recycler.
8 Contaminated cotton rags 0 300 300 Collection, Storage, Transportation

(Oily socked cotton waste) and Disposal by selling to Registered
Vendor or disposal at GPCB
approved TSDF site.
9 Paint Dust & Sludge 0 1000 1000 Collection, Storage, Transportation
and Disposal by selling to Registered
approved TSDF site
10 Spent Acid 766500 91250 857750 Acid Recovery in Acid Regeneration
Plant (ARP). Balance Acid disposal
M3/year to authorized recyclers.
11 Tar Sludge 0 600 600 Tar sludge will be mixed with coal
(Coke Oven) blend before feeding it to coke oven

modification
(TPA)
batteries
12 ETP (BOD Plant) Sludge 0 800 800 ETP (BOD Plant) sludge will be
(Coke Oven) mixed with coal blend for charging in
the coke oven batteries.
13 Ceramic based fiber waste 0 1200 1200 Collection, Storage, Transportation
(Glass wool) + Insulation and Disposal at GPCB approved
wool TSDF site
14 Waste photographic film 0 350 Packets (1 350 Packets (1 Collection, Storage, Transportation
disposal packet 100 packet 100 sheet) and disposal by selling to Registered
sheet) Packets Packets /Year Vendor.
/Year
15 Waste photographic 0 5 5 Collection, Storage, Transportation
solution and disposal by selling to Registered
Vendor.
16 Oil Emulsion Waste 0 100 100 Collection, Storage, Transportation
TSDF site
17 Alkali Waste Source 0 10 10 Collection, Storage, Transportation
TSDF site
18 Chromic Sludge 0 8 8 Selling to Authorized Agency
19 Ash 0 5 5 Selling to Authorized Agency /
Recycled through Micropelletization
Ecological Environment
Keeping in view, the importance of biological component of total environment due to the proposed project,
biological characterization of terrestrial and aquatic environments, changes in species diversity of flora and
fauna in terrestrial as well as aquatic systems were studied for impact analysis. The details of flora/fauna
species and the wildlife habitat in the area covering 10 km radius have been collected to determine the
existence of rare and/or endangered species. Few populations of Peacock or Indian peafowl (Pavo cristatus)
were reported from some villages of the study area and conservation plan has been prepared to protect the
same. Moreover, development of greenbelt will help to improve ecological environment of the area and
hence, no major impact on ecological environment will be anticipated.
Socio-Economic
The proposed modification project will generate job opportunities, both direct and indirect due to
development of ancillary industries. During the construction phase, the project will generate substantial
employment and income. Hence, this will improve socioeconomic status of the area but increased in-
migrated population may create impact on culture of the area.
Environmental Monitoring Programme

The environmental monitoring points shall be decided considering the environmental impacts likely to
occur due to the operation of proposed modification project as, the main scope of monitoring program is to
track, timely and regularly, the change in environmental conditions and to take timely action for the
protection of environment. The monitoring points/location and significant parameters analyzed as per
follows.
Sr. Area of Sampling Locations Parameters to be Analyzed Frequency of

No. Monitoring Sampling
1. Meteorology CAAQMS-North Station, Temperature, Wind Speed, Wind Every 15 min. data
Near R&D Building. Direction, RH, Rainfall, recording.
Atmospheric Pressure.
2. Stack Emission All the stacks As per Consent of GPCB Once per month
3. Ambient Air Manual Monitoring. PM10, PM2.5, SO2, NOx, CO, 1,2,3,4 –Twice in a
Quality 1. Briquette House, Ammonia, Ozone, Benzene, Week.
2. SVC – MRSS, Benzo(a)Pyrine, Lead, Nickel, 5,6 – Once in a
3. Near Suprabhat, Arsenic. Month
4. CRM Office,
5. AMNS
Township,
6. Hazira – Village.
CAAQMS PM10, PM2.5, SO2, NOx, CO, Online (Continuous)
1. East Station Ammonia, Ozone, Benzene.
2. West Station
3. South Station
4. North Station
4. Work Zone In the plant facilities PM10, SO2, NOx, Lead, CO Once in a Month
Environment
(Fugitive)
5. Industrial effluent All Effluent generated Flow, pH, Temperature, SS, Oil Once in a Month
plant & Grease, BOD, COD, Iron,
Total Cr., Hexa. Cr., Copper,
Sulphides, Fluoride, Zinc,
Cyanide, Lead, Nickel,
Ammonical Nitrogen, Phenolic
Compounds, Colour, Arsenic,
Sulphate, Chloride, Cyanide,
Bio-Assay Test., Phosphate.
6. Domestic STP Outlet SS, Residual Chlorine, BOD. Once in a Month
Effluent
7. Ground water Outside & inside industry Chemical & Physical test: Odour, Once in a Year
Colour, Taste, pH, Turbidity,
Total Dissolved Solids, Total
Hardness as CaCO3, Alkalinity,
Residual Chlorine, Chloride as
Cl, Heavy Metals & Other
Parameters : Calcium as Ca,
Magnesium as Mg, Oil & Grease
(Mineral Oil), Phenolic
Compound as C6H5OH,
Hexavalent Chromium as Cr+6,
Cadmium as Cd, Copper as Cu,
Zinc as Zn, Iron as Fe, Lead as
Pb, Mercury as Hg, Selenium as
Se, Aluminium as Al, Manganese
as Mn, Arsenic as As, Sulphate
as SO4, Cyanide as CN, Boron as
B, Fluoride as F, Nitrate Nitrogen
as NO3 , Anionic Detergents as
MBAS, Bacteriological :
Coliform, E. Coli.
Copper, Iron, Nickel, Zinc, Once in a 6 Month.
Cadmium, Lead, Chromium,
Manganese, Sodium,
Molybdenum, Selenium, Arsenic,
Mercury, Barium, Aluminium,
Silver, Stannous, Cobalt, Boron.
Soil Analysis Inside Plant-Near R&D pH, Moisture, Particle size, Once in a Year
Building Conductivity, C: N Ratio,
Organic Carbon, N, P, K, Na, Ca,
Mg, CEC, Cl, Fe, Mn, Cu, Zn, B,
Mo.
8. Surface water River near project site pH, Temperature, BOD, do, Once in a month
Ammonia, Nitrites, Nitrates,
Total Nitrogen, Salinity,
Turbidity, Total Suspended
Solids, Potassium, Chlorides,
Calcium, Zinc, Iron, Copper,
Cadmium, Cyanides, Mercury,
Phenolic compounds.
9. Noise Within the plant facilities Noise level Every Month
and outside plant
10. Occupational Pre employment check up Vision, Audiometry, Spirometry, Frequency: Before
Health chest Skiagram, Unrin, RBS, etc. Joining
Monitoring
Periodical check up Vision, Audiometry Spirometry, Frequency: Annually
Urin, RBS, etc.
Post-employment Vision, Audiometry, Spirometry, Periodic medical &
check up chest Skiagram, Unrin, RBS, Etc. Post employment
check-up both are
same.
Additional Studies
Public Hearing
The public hearing will be conducted by Gujarat Pollution Control Board, draft EIA/EMP report
incorporating the compliance of Terms of References issued by Ministry of Environment, Forest and
Climate Change vide letter No. F. No. J11011/44/2004-IA. II(I) dated 8th February, 2021.
Risk Assessment
A detailed risk assessment and consequence analysis has been carried for all the plant operations for the
proposed modification project. A disaster management plan for entire complex is available. The
responsibilities of the officers include identification of the hazardous conditions and unsafe acts of
employees and advice on corrective actions, conduct safety audit, organize training programs and provide
professional expert advice on various issues related to occupational health and safety.
Safety training is being provided by the safety officer with the assistance of experts. In addition to regular
employees, all contractor labors are/will attend safety training.
Occupational Health Monitoring

Potential occupational hazardous work places are being monitored regularly. The health of employees are
being monitored at regular intervals for early detection of any ailment due to exposure to noise, heat,
respirable dust and hazardous chemicals. The audiometry and lung function tests will also be included in
this surveillance program. Company has a detailed occupational health management plan to address the
occupational diseases.
Project Benefits Corporate Social Responsibility (CSR)

The budgetary allocation for the CSR activities is 1600.00 lacs for five years. CSR activities includes
Education, Health & Sanitation, Infrastructure Development, Sustainable Livelihood, Sports and Youth
Development and Environment projects etc. Moreover, this project will add income of the government
through different type of taxes, excise duty etc.
Environmental Management Plan

The Environmental Management department is being done regular monitoring of different monitoring
parameters. Mitigation of environmental impacts has to be implemented according to the suggestions and
will be monitored regularly to prevent any lapse. The company will undertake various training programme
for improving the performance of the working personnel. Special training will be arranged in regular
intervals to combat emergency scenarios that may occur during the plant operation.
Cost of EPCM
Cost for Environment Pollution Control Measures (EPCM) is given in below table:
Sr. No. Particulars Capital Cost in Cr Recurring Cost
1 Capital Cost which is part of new projects 1185.08 355.12
2 Air & Noise Pollution Control 400.00 15.60
3 Water Pollution Control 77.50 5.50
4 Environment Monitoring & Management 12.60 0.67
5 Occupational Health 0.86 0.36
6 Green Belt Development 6.22 0.70
Total 1682.26 377.95
Green Belt Development

Existing greenbelt is developed in the area of 170 ha. And further area of about 84 ha. will be earmarked for
the development of green belt. After establishment, total greenbelt area will be 254 ha. Total 1,83 566 nos.
of trees will be planted at plant boundary, road side, around offices & buildings and in the open land.
Conclusion
The proposed modification plant facilities will have insignificant impact on the local environment.
However, with the implementation of the proposed pollution control and environment management
measures, better impacts anticipated. Further, development of this project will have many beneficial
impacts/effects on various socioeconomic aspect.
Thus, in view of extensive benefits from the project and controllable adverse environmental impacts, the
proposed modification project will be most advantageous to the region and will definitely improve the
regional, state and national economy.

કાર્યકારી સારાાંશ
મેસસસ આસેલરમમત્તલ મિપ્પોિ સ્ટીલ ઇન્ડિયા લલમમટેિ
હજીરા િોટટફાઇિ ઔદ્યોલિક એટરયા, િામ: હજીરા, તાલુકો: ચોયાસસી,

જીલ્લો: સુરત, ગુજરાત

કાર્યકારી સારાાંશ
પ્રોજેક્ટન ાં નામ
મેસસય આસેલરમમત્તલ મનપ્પોન સ્ટીલ ઇન્ડિર્ા લલમમટેિ દ્વારા હાલના પ્લાાંડટની ક્ષમતામાાં વધારો કર્ાય મવના
સહાર્ક સમવધાઓ માટે પ્લાડટન મોિીફિકેશન.
પ્રોજેક્ટન ાં સ્થાન
પ્રોજેક્ટ સાઇટ હજીરા નોફટિાઇિ ઔદ્યોલિક એફરર્ા, િામ: હજીરા, તાલકો: ચોર્ાયસી, જીલ્લો: સરત, ગજરાત,
ભારત ખાતે આવેલ છે . આ સ્થળ સરત શહેરથી પ ૂવય-ઉત્તર-પ ૂવય ફિશામાાં આશરે ૧૫ ફકમી દૂ ર સ્સ્થત છે
નજીકન ાં મવમાનમથક એ પ્રોજેક્ટ સાઇટથી પ ૂવય ફિશામાાં આશરે ૮.૦ ફક.મી. ના અંતરે આવેલ છે .
ક) ઔદ્યોલિક વસાહત : હજીરા નોફટિાઇિ ઔદ્યોલિક એફરર્ા

ખ) િામ : હજીરા
િ) તાલકો: ચોર્ાયસી
ઘ) જીલ્લો: સરત
ચ) રાજ્ર્: ગજરાત
છ) કોિીનેટ્સ .: Latitude ૨૧°૬'૪૩.૭૨ " ઉત્તર, Longitude.: ૭૨ ° ૩૮'૪૦.૨૯" પ ૂવય
આસપાસની મખ્ર્ લાક્ષલિકતાઓ અને પર્ાયવરિીર્ માહીતી

ક્રમાાંક નજીકની માળખાિત સમવધા ઓળખ પ્રોજેક્ટ મવસ્તારથી અંતર
૧ નજીકન િામ હજીરા પ્રોજેક્ટ સાઇટ્થી દ્ક્ક્ષીિ ફિશામાાં
૨ નજીકન શહેર /ટાઉન / નજીકન સરત પ્રોજેક્ટ સાઇટ્થી ઉત્તર-પ ૂવય ફિશામાાં ૧૫ કીમી
જજલ્લા હેડ્કક્વાટર
૩ નજીકનો નેશનલ હાઇવે એનએચ-૬ / પ્રોજેક્ટ સાઇટ્થી ૦.૧ કીમી

એનએચ -૫૩
૪ નજીકન રે લ્વે સ્ટે શન સરત રે લ્વે સ્ટે શન પ્રોજેક્ટ સાઇટ્થી ઉત્તર-પ ૂવય ફિશામાાં ૨૦.૦૦ કીમી
૫ નજીકન મવમાનમથક સરત મવમાનમથક પ્રોજેક્ટ સાઇટ્થી પ ૂવય ફિશામાાં ૮.૦૦ કીમી
૬ નજીકની નિી/ પાનીનો સ્્તોત તાપી/અરબ સાિર પ્રોજેક્ટ સાઇટ્થી તાપી નિી પ ૂવય ફિશામાાં ૦.૫ કીમી
પ્રોજેક્ટ સાઇટ્થી અરબ સાિર પમિમ ફિશામાાં ૨.૦
કીમી
૭ નેશનલ પાકય / રીસવય િોરે સ્ટ, રીસવય િોરે સ્ટ/ પ્રોજેક્ટ સાઇટ્થી પમિમ પ ૂવય ફિશામાાં ૦.૬૦ કીમી
બાર્ોસ્સ્પર્ર રીસવય ડમ્મસ રીસવય પ્રોજેક્ટ સાઇટ્થી િલક્ષિ પ ૂવય ફિશામાાં ૫.૫૦ કીમી
િોરે સ્ટ/ ૧૦.૦૦ કીમીની મિજ્ર્ામા આવેલ છે .
મેંગ્રવ પેચીસ
૮ આકે લોજીકલ સાઇટ નથી ૧૦.૦૦ કીમીની મિજ્ર્ામા આવેલ નથી
૯ રાજ્ર્ની સીમાાંફકતરે ખા નથી ૧૦.૦૦ કીમીની મિજ્ર્ામા આવેલ નથી

10 ફિિેંડસ ઇંસ્ટૉલેશન નથી ૧૦.૦૦ કીમીની મિજ્ર્ામા આવેલ નથી
11 મસસ્મીક ઝોન ઝોન-૩

અિાઉની પર્ાયવરિીર્ માંજરીની મવિતો
Year of EC
Granted
capacity 1190 meter
2008
J-11011/714-A/2008-IAII(I) Pellets Plant (4 MMTPA), HBI/DRI (1.85 MMTPA), COREX
2010 Caster 4.9 MMTPA, Billet Caster 2.37 MMTPA), CSP (Rebar 1.6
2025)
પ્લાડટના નામ અને તેની ક્ષમતા

Unit
No. 2016
in 2016 in 2020
Crude Tar (By – TPA 52,200 63,000 1,15,200
Product)
Sulphur (By – TPA 1,700 1,980 3,680
Product)
Product)
5 Air Separation
Oxygen Liquid Nm3/hr 2,950 500 3,450 2950 in operations
1(EAF) (4Nos.)
Unit
No. 2016
in 2016 in 2020
Furnace (BoF) (3
Nos.)
(4 EAF& 4LF)
(Lime / Dolime)
& Long Product -
HRC
Wire Rod 0.7 0 0.7
15 Caster Shop
Caster
16 CRM
Coils/Sheets
Jetty
Based Power Plant
19 Pipe Mill
received from SPCB)
AM/NS હજીરા એકમમાાં સ્ટીલ મનમાયિની ક્ષમતામાાં કોઇપિ વધારો કર્ાય વિર સ્ટીલ બનાવવા માટેની
નીચેની સહાર્ક સમવધાઓન મનમાયિ કરવામા આવશે.

15 CRM-2
CR Coils/Sheet 2.2
for Special grades)
Coke oven gas
પ્રોજેક્ટની માટેની આવશ્ર્કતાઓ

જમીનની આવશ્ર્કતા
હાલની ૭૭૦ હેક્ટરની જમીન મોિીફિકેસન પ્રોજેક્ટ માટે ઉપર્ોિમાાં લેવામાાં આવશે એટલે કે મોિીફિકેસન
માટે કોઈ વધારાની જમીનની જરૂર નથી.
જમીનના ભાિની મવિતો

4 Admin area 15.00
7 Open Area 25.00
12 OHC area 4.00
Total 770.00
મખ્ર્ કાચા માલની જરૂરીર્ાતો :

મખ્ર્ કાચા માલની આવશ્ર્કતાની મવિતો, તેના સ્રોત અને પફરવહનની મવિતો નીચેના કોષ્ટકમાાં આપેલ છે .
કાચા માલની મવિતો

Existing Units
Mod. I to VI)
Flux 140 KT 140 KT
1480 KT
External fines
as per
requirement
Flux
external)
(Recovery Type)
Lime 271 KT 271 KT
(Note: Scrap
can be replaced
by HBI/DRI)
Lime 300 KT 300 KT
(Note: Ideal
mix.,In case of
lower hot metal,
additional HBI,
CDRI required
Coke: 355 KT, 355 KT,

Coal: 2900 KT 2900 KT
(Lime/ Dolime)
(Lime/ Dolime)
11 CPP - - -
Product -HRC
(CSP Casters INI)
16 CRM-1 HRC 1500 KT 0.0 2000 KT
Existing Jetty
Recovery Based
Power Plant
HRC 300 KT 300 KT
Plant - (1000 TPD)
Pulverized coal
TPD) - Lime and
Dolime
TPD) - Calcined
Lime
Catcher /Dust
separation unit-150
TPD
Plant - 100 KL &
Pickling Line-3
TPD
towers (Mod 1 to
Mod 6)
plant
Normalizing KTPH
Furnace
machine plates:
Tower
Plant for 500 MW
CCPP
Special grades)
CPC 850 TPA 850 TPA
17 SMP-1 fume - -
Extraction System
upgradation
VPSA to utilize
Corex gas and
going forward Coke
oven gas
Pretreatment
Station Outside
Shop (KR
Technology)
interconnection
between PKL-3 &
ARP-2
grades Aluminium
CPC 850 TPA 850 TPA
પાિીની આવશ્ર્કતા
હાલના સમર્માાં વપરાશ :
કલ પાિીનો વપરાશ હાલના સમર્મા આશરે ૧૪૫,૮૩૯.૦૦ મી3/ ફિવસ તેમાથી ૧,૩૩,૭૭૫.૦૦ મી3/ ફિવસ
પાિીનો ઉપર્ોિ ઔદ્યોલિક હેતઓ માટે અને ૧૨,૦૬૪.૦૦ મી3 / ફિવસ પાિીનો ઉપર્ોિ ઘરે લ હેત માટે
થાર્ છે . આ પાિી તાપી નિીમાાંથી મેળવવામાાં આવે છે .
આસેલરમમત્તલ મનપ્પોન સ્ટીલ પાસે પાિીનો સાંગ્રહ કરવા માટે ૩૬૦,૦૦૦.૦૦ મી3 અને ૧૮૦,૦૦૦.૦૦ મી3
ના બે જળાશર્ો છે . ઘરે લ ાં હેત માટે, પાિીની કલ જરૂફરર્ાત આશરે ૧૨૦૬૪.૦૦ મી3 / ફિવસની છે . આશરે
૧૩૩,૭૭૫.૦૦ મી3 / ફિવસ પાિી નો ઉપર્ોિ ઔદ્યોલિક હેતઓ માટે થાર્ છે .
આવનાર સમર્માાં વપરાશ :

પ્લાાંડટમા મોિીફિકેસન કર્ાય પછી કલ પાિીનો વપરાશ આશરે ૧,૫૩,૩૨૮.00 મી3 / ફિવસ (ઔદ્યોલિક હેત
૧૪૧૨૬૪.૦૦ મી3 / ફિવસ અને ઘરે લ ાં હેત ૧૨૦૬૪ મી3 / ફિવસ) રહેશ.ે આ પાિી તાપી નિીમાાંથી મેળવવામાાં
આવશે.

૧૯૭૯૩.૦૦ મી3 / ફિવસ િાંદ પાિી ઉત્પન્ન થશે જેને UF/RO દ્બારા ટ્રીટ કરીને ZLD ર્ોજના અનસરવામાાં
આવશે. આશરે ૧૩૯૬૮.૦૦ મી3 / ફિવસ જેટલ પાિી UF/RO દ્બારા ટ્રીટ થર્ા બાિ િરીથી ઉપર્ોિમાાં લેવામાાં
આવશે. એવો અંિાજ છે કે UF/RO માાંથી આશરે ૫૮૨૬.૦૦ મી3 / ફિવસ જેટલ કડસટ્રેિ પાિી ( Reject
Water) ઉત્પન્ન થશે. આ કડસટ્રેિ પાિી (Reject Water) નો નીકાલ TSDF મા મોકલવામા આવશે.
વીજળીની આવશ્ર્કતા
પ્લાાંડટમા મોિીફિકેસન કર્ાય પછી વીજળીની આવશ્ર્કતા ૧૧૬૩ મેિાવોટ રે હશે. કેન્પ્ટવ જનરે શન માાંથી
૫૫૫૬ મેિાવોટ (૫૦૦ +૩૧ +૨૫ ), EPHL માાંથી ૨૭૦ મેિાવટ અને વધારાની વીજળી (૩૩૭ મેિાવોટ)
૪૦૦ KV-PSOCL (નેશનલ ગ્રીિ) માાંથી લેવામાાં આવશે.
બળતિની આવશ્ર્કતા
કોલસો, કોક અને નેચરલ િેસનો બળતિ તરીકે ઉપર્ોિ કરવામા આવશે.
માિસો ની જરૂરીર્ાત
પ્લાાંડટમા મોિીફિકેસન કર્ાય પછી ૧૫૨૭૦ માિસો ની જરૂફરર્ાત રે હશે.
પ્રફક્રર્ા વિયન
પ્રસ્તામવત પ્લાડટના એકમો અને તેની પ્રફક્રર્ાઓ નીચે િશાયવેલ છે .
EAF/CONARC
temperatures
temperature
temperatures.
irrigation use.

three Phases
Phase 1:
Mill (CTCM)
Phase 2:
mill (PLTCM)
(CGL-3)
Phase 3:
પ્રોજેક્ટનો ખચય
પ્લાાંડટમા મોિીફિકેસન કર્ાય પછી પ્રોજેક્ટનો કલ મ ૂિી ખચય આશરે રૂ. ૬૪૧૩.૧૩ કરોિ હશે. પર્ાયવરિીર્
મનર્ાંિિના પિલાાં માટેનો ખચય અને ફરકફરિંિ ખચય અનક્રમે ૧૬૮૨.૨૬ અને ૩૭૭.૯૫ કરોિ હશે.
પ્રોજેક્ટ પ ૂિય થવા માટેનો અંિાજજત સમર્

પ્રોજેક્ટ પ ૂિય થવા માટેનો અંિાજજત સમર્ ૩૪ મફહના.
પ્રોજેક્ટ માટે પસાંિ કરે લ સાઇટ

હાલની પ્રોજેક્ટ સાઇટ હજીરામા આવેલી છે , જે હજીરા નોટીિાઇિ ઔદ્યોલિક ક્ષેિની અંિર સ્સ્થત છે .
બેઝલાઈન એડવાર્નયમેડટ
પ્રાથમમક બેઝલાઈન એડવાર્રમેડટ મોનીટોરીિનો અભ્ર્ાસ ચોમાસા પછી ઓક્ટોબર ૨૦૨૦ થી ફિસેમ્બર
૨૦૨૦ િરમમર્ાન પ્રોજેક્ટ સાઇટથી ૧૦ ફક.મી. વ્ર્ાસ અંતરના ક્ષેિમાાં કરવામા આવ્ર્ો હતો.
એમ્મ્બર્ડટ એર કવોલલટી
આસપાસ ની હવાના ૮ જગ્ર્ાઓથી નમના લેવામાાં આવેલ હતા અને હવાન ાં પ ૃથક્કરિ PM10, PM2.5, SO2,
NOX, CO, THC, NMHC (Non-Methane) માટે કરવામાાં આવેલ હત ાં. પ્રાથમમક મોનીટફરિંિ િરમ્ર્ાન, PM10
૪૩.૧૨ થી ૧૩૨.૫૨ μg/m3 ની વચ્ચે, PM2.5 ૨૦.૨૧ થી ૬૭.૯૦ μg/m3 ની વચ્ચે, SO2 ૧૨.૪૪ થી ૪૨.૨૦
μg/m3 ની વચ્ચે, NOx ૧૬.૧૧ થી ૪૮.૩૦ μg/m3 ની વચ્ચે, CO ૦.૧ થી ૧.૨૧ μg/m3 ની વચ્ચે, THC ૦.૧

થી ૫.૬૩ ppm ની વચ્ચે મળ્ય. THC મોરા, વડથા અને MRSS બીલ્િીડિ પાસે BDL જોવા મળે લ હત ાં. NMHC
૦.૧૮ થી ૫.૨૪ ppm ની વચ્ચે જોવા મળ્ય અને NMHC મોરા, વડથા, MRSS બીલ્િીડિ પાસે BDL જોવા
મળે લ હત. Lead ની વેલ્ય હજીરામા જોવા મળી હતી. જેની વેલ્ય ૦.૧ થી ૦.૫ μg/m3 ની વચ્ચે છે બાફકની
જગ્ર્ાએ Lead જોવા મળ્ય ન હત.
ભ ૂિભય જળની ગિવતાની મવિત

જિા-જિા િામમાાં અલિ-અલિ આઠ સ્થળે થી ભ ૂિભય જળના નમના લઇ, તેમન ાં પ ૃથકકરિ કરવામાાં આવ્ય ાં
હત ાં. જેમા pH ૭.૦૮ – ૭.૬૧, ટોટલ હાિય નેસ ૪૫૦-૫૩૦ mg/L, આલ્કલીનીટીની ૩૯૦.૦૦- ૪૫૦.૦૦ mg/L,
કડિ -કવીટી ૦.૮૭૪-૧.૯૧૧ μS/cm અને ટી.િી.એસ. ૫૬૧-૧૨૫૧ mg/L છે . ટોટલ કોલીિોમય અને ઇ-કોઇલ
બેક્ટરીર્ા જોવા મળે લ ન હતા.
સપાટીના પાિીના ગિવતાની મવિત

જિા-જિા િામમાાં અલિ-અલિ આઠ સ્થળે થી સપાટીના પાિીના નમના લઇ, તેમન ાં પ ૃથકકરિ કરવામાાં
આવ્ય ાં હત ાં. જેમા pH ૭.૧૨ – ૮.૬૨, ટોટલ હાિય નેસ ૬૦-૧૬૦ mg/L, TDS ૩૯૧-૧૨૧૪ mg/l, આલ્કલીનીટી
૨૮૦.૦૦- ૩૬૦.૦૦ mg/L, કડિ -કવીટી ૦.૬૩૯-૨.૦૦૪ mS/cm અને ટી.િી.એસ. ૩૯૧-૧૨૧૪ mg/L છે .
ટોટલ કોલીિોમય અને ઇ-કોઇલ, બેક્ટરીર્ાના સેમ્પલની વેલ્ય BDL જોવા મળે લ હતી.
બેકગ્રાઉડિમાાં ધ્વમનની માિા

ફિવસ તેમજ રામિના સમર્ે આસપાસના અવાજ સ્તરન ાં મનરીક્ષિ કરવામાાં આવ્ય ાં હત ાં. ફિવસ િરમમર્ાન
૬૫.૦ Leq dB(A) અને રામિ િરમમર્ાન ૫૧.૦ Leq dB(A) જેટલ ઔદ્યોલિક ક્ષેિમાાં મહત્તમ અવાજન ાં સ્તર
નોંધાય ાં હત.
આમ, બધા સ્થળોએ અવાજન ાં સ્તર મર્ાયિામાાં જોવા મળે લ છે . અભ્ર્ાસ ક્ષેિમાાં અવાજન ાં સ્તર CPCB દ્વારા
સ ૂચવવામાાં આવેલી મનર્ત મર્ાયિામાાં છે . ઔદ્યોલિક ક્ષેિમાાં અવાજના મખ્ર્ સ્ત્રોત વાહન વ્ર્વહાર, ઔદ્યોલિક
અને વ્ર્વસામર્ક પ્રવ ૃમત્તઓ છે .
જમીન ની ગિવત્તા
જમીન વનસ્પમતના મવકાસ માટે જરરી પોષક તત્વોની સપ્લાર્ માટેન ાં માધ્ર્મ છે . પોષક તત્વ છોિને ચોક્કસ
pH માિાએ ઉપલબ્ધ થતા હોર્ છે જમીનની pH, હવા, પાિી અથવા નક્કર કચરા દ્વારા પ્રદૂ ષક તત્વો
ઉમેરાવાથી અસર પામતી હોર્ છે . જમીનની લાક્ષલિકતાઓની મ ૂળભ ૂત સ્સ્થમત જોવા માટે, 8 સ્થળોથી
જમીનના નમ ૂના લેવામાાં આવ્ર્ા હતા. જેમા પીએચ ૬.૮ થી ૮.૫૬ સધીની અને ઇલેન્ક્ટ્રકલ વાહકતા ૧.૫૩૨
થી ૩.૦૧૧ mS/cm જોવા મળે લ હતી.
જમીન ઉપર્ોિની પધ્ધમત

અધ્ર્ર્ન ક્ષેિની ૧૦ ફક.મી.ની મિજ્ર્ાની અંિર જમીનનો ઉપર્ોિ ઉપગ્રહની છબીની મિિથી નક્કી કરવામાાં
આવ્ર્ો છે , અને તેમાાં વસાહતો, ઔદ્યોલિક, ટાાંકી / નિી / જળાશર્, કૃમષ, ઝાિીવાળી જમીન, કાિવ પ્લોટ, જળ
પ્રવેશવાળો મવસ્તાર, હવાઇમથકો, મેંગ્રોવ્સનો સમાવેશ થાર્ છે . મખ્ર્ ભ ૂમમ ઉપર્ોિ ટાાંકી / નિી, સમદ્ર એટલે
કે ૫૫.૮ ટકા તરીકે વિીકૃત થર્ેલ જળ સાંસ્થાઓ છે .

સામાજજક-આમથિક અભ્ર્ાસ
વષય ૨૦૧૧ ની વસ્તી િિતરી મજબ અભ્ર્ાસ ક્ષેિની કલ વસ્તી ૮૪૦૭૫ , જેમાાંથી ૫૪૨૫૩ પરષ અને
૨૯,૮૨૨ મફહલાઓ છે .
જૈમવક પર્ાયવરિ
પ્રોજેક્ટ ક્ષેિમાાં, જિલી
ાં પ્રાિીઓ તેમજ સ્થામનક પ્રાિીઓ મસવાર્ અડર્ પ્રાિીસ ૃન્ષ્ટ જોવા મળતા નથી.
અધ્ર્ર્ન ક્ષેિમાાં રાષ્ટ્રીર્ ઉદ્યાન અથવા અભ્ર્ારિાનો કોઈ ભાિનો સમાવેશ થતો નથી.
અપેલક્ષત પર્ાયવરિીર્ અસરો અને ઘટાિવા ના પિલાાં

બાાંધકામ અને કામિીરીના તબક્કા િરમમર્ાન મોિીફિકે સન પ્રોજેક્ટને કારિે અપેલક્ષત પ્રમતકૂળ પર્ાયવરિીર્
અસરો અને તેના મનવારિ પિલાાં નીચે આપેલ છે :
હવા વાતાવરિ
બાાંધકામના તબક્કામાાં સાઇટની સિાઇ, ખોિકામ, ગ્રાઇડિીંિ, કટીંિ, ઉપકરિો અને મશીનરીની સ્થાપના,
પફરવહન અને સામગ્રીન ાં સાંચાલન શામેલ છે . આ પ્રવ ૃમત્તઓથી આજબાજના મવસ્તારના વાતાવરિમાાં ધ ૂળ,
PM10, SO2 અને NOx અને Fumes જેવા પ્રદૂ ષકોન ાં ૂ ઉત્સર્જન થશે.
• ધ ૂળ /fugitive ઉત્સર્જનને મનર્ાંિિમાાં રાખવા માટે પાિીનો સતત છાંટકાવ કરવામાાં આવશે.
• બાાંધકામ પ્રવ ૃમત્ત શેિ ની અંિર કરવામાાં આવશે.
• બાાંધકામની સામગ્રી ખલ્લી જગ્ર્ામાાં સાંગ્રફહત કરવામાાં આવશે નહીં.
• વાહનોની મનર્મમત ચેકીંિ અને જાળવિી કરવામાાં આવશે
આવી પ્રવ ૃમત્તઓની અસર કામચલાઉ રહેશે અને િક્ત બાાંધકામના તબક્કા સધી મર્ાયફિત રહેશે અને તે
પ્રોજેક્ટ પફરસરમાાં સીમમત રહેશે.
કામિીરી િરમમર્ાન, મખ્ર્ હવાના ઉત્સર્જન(PM, SO2 અને NOx) ને સ્ટેક્સના એક અથવા નાના જૂથમાાંથી તરીકે
ધારવામાાં આવે છે . Fugitive emission કાચા માલના સાંચાલન, કાચા માલ અને પ્રોિકટ ની લોફિિંિ અનલોફિિંિ,
કડવીમનિંિ અને િીફિિંિ પોઇડટ, વાહનોની િમતમવમધઓ, ક્રમશિંિ અને ન્સ્ક્રમનિંિ કામિીરી વિેરેને કારિે થશે.
ISCST3 વૈજ્ઞામનક મોિલનો ઉપર્ોિ સ ૂલચત હોવાને કારિે ભ ૂમમ સ્તરની સાાંદ્રતાની આિાહી કરવા માટે કરવામાાં
આવ્ય ાં છે . પ્રોજેક્ટ અને સાંલચત અસરને લીધે, જે નીચે મજબ છે .
મહતમ ભ ૂમમ સ્તરની સાાંદ્રતાની

ક્રમાાંક પેરામીટર
પ્રસ્તામવત એકાંિરે થતી અસર
ઘટાિવા ના પિલાાં
• બેિ ફિલ્ટર, ઇએસપી સ્ક્રબર વિેરે જેવા હવા પ્રદૂ ષિ મનર્ાંિિના સાધનો તેમજ CEMS હાલના સ્ટેક પર
સ્થામપત કરવામાાં આવેલ છે . માિયિમશિકા મજબ પ્રપોસ સ્ટેક્સ માટે પિ હવા પ્રદૂ ષિ મનર્ાંિિના સાધનો
પ્રિાન કરવામાાં આવશે.

• સમનમિત કરવામાાં આવશે કે પ્રપોસ સ્ટેક્સ સફહતના તમામ સ્ટેક્સમાાં CPCB/GPCB ધારાધોરિો અનસાર
પર્ાયપ્ત સ્ટેક હાઇટ રે હશે.
• સમર્સર સ્ટેક મોમનટફરિંિ અને િયજજટીવ ઉત્સર્જન માટે મોનીટરીંિ કરવામાાં આવશે.
• ર્ોગ્ર્ કામિીરીની ખાતરી કરવા માટે તમામ હવા પ્રદૂ ષિ મનર્ાંિિ સાધનોની સમર્ાાંતરે તપાસ કરવામાાં
આવશે.
જળ પર્ાયવરિ
પ્લાાંડટમા મોિીફિકેસન કર્ાય પછી કલ પાિીનો વપરાશ આશરે ૧,૫૩,૩૨૮.00 મી3 / ફિવસ (ઔદ્યોલિક હેત
૧૪૧૨૬૪.૦૦ મી3 / ફિવસ અને ઘરે લ ાં હેત ૧૨૦૬૪ મી3 / ફિવસ) રહેશ.ે આ પાિી તાપી નિીમાાંથી મેળવવામાાં
આવશે.
૧૯૭૯૩.૦૦ મી3 / ફિવસ િાંદ પાિી ઉત્પન્ન થશે જેને UF/RO દ્બારા ટ્રીટ કરીને ZLD ર્ોજના અનસરવામાાં
આવશે. આશરે ૧૩૯૬૮.૦૦ મી3 / ફિવસ જેટલ પાિી UF/RO દ્બારા ટ્રીટ થર્ા બાિ િરીથી ઉપર્ોિમાાં લેવામાાં
આવશે. એવો અંિાજ છે કે UF/RO માાંથી આશરે ૫૮૨૬.૦૦ મી3 / ફિવસ જેટલ કડસટ્રેિ પાિી ( Reject
Water) ઉત્પન્ન થશે. આ કડસટ્રેિ પાિી (Reject Water) નો ઉપર્ોિ coal dust suppression, Lime dust
Suppression, Slag quenching માટે કરવામાાં આવશે.
ભ ૂિભય જળની અસર અને તેના ઘટાિવાનાાં પિલાાં

ભ ૂિભય જળ ઉપલબ્ધતા અને ઘટાિવાનાાં પિલાાં પર અસર:
પ્લાડટન મોિીફિકેસન કર્ાય પછી કલ પાિીનો જથ્થો તાપી નિીમાાંથી લેવામાાં આવશે અને તેથી પાિી
વપરાશની આવશ્ર્કતાને કારિે ભ ૂિભય જળ પર કોઈ અસર થશે નહીં. જો કે, ભ ૂિભય જળની સ્સ્થમતમાાં સધારો
લાવવા માટે વરસાિી જળ સાંચર્ની પ્રથા અનસરવામાાં આવશે.
ભ ૂિભય જળ ગિવત્તા અને ઘટાિવાનાાં પિલાાં પર અસર:

પ્રવ ૃમત્તઓ િરમમર્ાન જોખમી રસાર્િોના સ્સ્પલલજ , કાચા માલનો અને પ્રોડ્કક્ટ નો સાંગ્રહ, ઉત્પાિનો અને
નક્કર કચરો. વિેરેના લીચેટ દ્વારા ભ ૂિભય જળ દૂ મષત થવાની સાંભાવના હોઈ શકે છે , જેના પિલે ભ ૂિભય
જળના દૂ ષિને ટાળવા માટેના પિલાાં લેવામાાં આવશે.
- કાચો માલ, સમાપ્ત ઉત્પાિનો અને નક્કર કચરો અલિ સ્ટોકર્ાિય માાં સાંગ્રફહત કરવામાાં આવશે.
- બધા સ્ટોકર્ાડડ ય સ અવરોધક ફ્લોફરિંિ સાથે બનાવવામાાં આવશે.
- સ્ટોકર્ાિય ના તમામ મવસ્તારને Garland ડ્રેઇન પરી પાિવામાાં આવશે જેથી મટીફરર્લને રોકી શકાશે.
- ઢોળાર્ેલા જોખમી કચરો અથવા દૂ મષત કચરાને તરત જ દૂ ર કરવામાાં આવશે.
- મનર્મમત ભ ૂિભય જળ મોનીટરીિ હાથ ધરવામાાં આવશે.
ધ્વની પર્ાયવરિ
બાાંધકામના તબક્કા િરમમર્ાન અવાજન ાં મનમાયિ વાહનોની અવર- જવર , બાાંધકામ ઉપકરિોના સાંચાલનને
કારિે થશે. મિલસય, સાર્લડસસય, ઇર્રમિ અને ઇર્રપ્લિ જેવા પી.પી.ઇ.નો ઉપર્ોિ, સાધનસામગ્રીની
મનર્મમત જાળવિી, અવાજન ાં સ્તરન ાં મનર્મમત મનરીક્ષિ અવાજન ાં સ્તર ઘટાિવામાાં મિિ કરશે. પ્લાડટ

ઓપરે શન િરમ્ર્ાન, રોટીંિ ઇસ્ક્વપમેડટ, એર બ્લોવર કોમ્પ્રેસર, િીઝલ જનરે ટર, મમકેમનકલ ઓપરે શડસથી
અને વાહનોની અવર- જવર વિેરેથી અવાજ ના પ્રદૂ ષિમાાં વધારો થઈ શકે છે .
ઘટાિવા ના પિલાાં
- ઉચ્ચ કાંપન વાળા ઉપકરિો માટે મિલર, સાર્લડસસય, એડટી-વાઇબ્રેશન પેિ જેવા અવાજ મનર્ાંિિ
કરતા સાધનો નો ઉપર્ોિ કરવામાાં આવશે.
- ઇર્રમિ અને ઇર્રપ્લિ વિેરેનો ઉપર્ોિ કરવામાાં આવશે.
- બધા અવાજ ઉત્પન્ન કરનારા મશીનો માટે હાઉમસિંિ / કેસીંિ પ્રિાન કરવામાાં આવશે.
- સાધનોની મનર્મમત જાળવિી કરવામાાં આવશે.
- ફિવસના કલાકોમાાં પ્રવ ૃમત્તને મર્ાયફિત કરવામાાં આવશે.
- સમર્સર અવાજના સ્તરન મોનીટરીંિ કરવામાાં આવશે.
આ પિલાાં દ્વારા, એવી ધારિા છે કે પ્લાડટમાાં અવાજન ાં સ્તર પ્રદૂ ષિ મનર્ાંિિ બોિય દ્વારા મનધાયફરત મનર્ત
ધોરિની નીચે જાળવવામાાં આવશે.
જમીન ન ાં પર્ાયવરિ - ઘન / જોખમી કચરા ન વ્ર્વસ્થાપન

જમીન ના પર્ાયવરિ પર પ્રભાવ પાિવાનો મખ્ર્ સ્રોત બાાંધકામ ની પ્રવ ૃમત્તઓ અને કામિીરીની પ્રવ ૃમત્તઓ
િરમમર્ાન ઉત્પન્ન થતો નક્કર કચરો રે હશે.
પ્રોજેક્ટના ઓપરે શન તબક્કા િરમ્ર્ાન, ત્ર્ાાં ઘન અને જોખમી કચરો પેિા થશે . જોખમી કચરો ઉત્પન્ન થવાની
મવિતો અને મનકાલ કરવાની પદ્ધમત /મેનેજમેડટની મવિતો અને પ્લાડટની મવિતો નીચે આપેલા કોષ્ટકમાાં
આપવામાાં આવી છે .
ઘન કચરા ન વ્ર્વસ્થાપન
Fines
1 Pellet Fines 902
Corex
4 Mill Scale 150
/ CSP
palletization
palletization
Material.
Material.
Slag
Granulated Slag
(IM)
13 SMP I & II Steel Slag 1651 sub base material
material
villagers
sub base material
De Spherization
(HMDP) Slag
Dust and Sludge

machine
sinter plant
activities
22 BF BF Dust 52
Refractories
High Alumina
30 SMP I & II 2
Grog
Coal Fines
Non-PCI Corex
coal fines
જોખમી કચરા ન વ્ર્વસ્થાપન

modification
(TPA)
Micropelletization
Vendors.

modification
(TPA)
Sludge)
Drums vendor.
CHWIF.

approved TSDF site.
approved TSDF site
batteries
wool TSDF site
/Year
Vendor.
TSDF site
TSDF site

ઇકોલોજીકલ પર્ાયવરિ
પ્રસ્તામવત પ્રોજેક્ટને ધ્ર્ાનમાાં રાખીને, કલ પર્ાયવરિના જૈમવક ઘટકન ાં મહત્વ, સ્થળચર અને જળચર
પર્ાયવરિની જૈમવક લાક્ષલિકતા, વનસ્પમત અને પ્રાિીની જૈવ મવમવધતામાાં િેરિાર વિેરે નો અભ્ર્ાસ
કરવામાાં આવ્ર્ો હતો. વનસ્પમત / પ્રાિીની જાતીની માહીતી મેળવા માટે તેમજ લપ્ત અને ભર્ ના આરે
આવેલી પ્રાિીની જાતીન ાં અભ્ર્ાસ કરવા માટે પ્રોજેક્ટ સાઈટ ના 10 ફક.મી. મિજ્ર્ાના મવસ્તાર માાંથી માહીતી
મેળવામાાં આવી. અભ્ર્ાસ મવસ્તારના કેટલાક િામોમાાંથી મોર ની થોિી વસ્તી નોંધાઈ હતી અને તેને
બચાવવા માટે સાંરક્ષિ ર્ોજના તૈર્ાર કરવામાાં આવી છે . તદપરાાંત, ગ્રીનબેલ્ટનો મવકાસ મવસ્તારના
પર્ાયવરિીર્ વાતાવરિમાાં સધારો કરવામાાં મિિ કરશે અને તેથી, ઇકોલોજીકલ પર્ાયવરિ પર કોઈ માઠી
અસર થશે નહી.
સામાજજક-આમથિક
પ્રોજેક્ટ ના લીધે પ્રત્ર્ક્ષ અને પરોક્ષ બાંને નોકરીની તકો ઉત્પન્ન કરશે. બાાંધકામના તબક્કા િરમમર્ાન, આ
પ્રોજેક્ટ નોંધપાિ રોજિારી અને આવક પેિા કરશે. આથી, આ મવસ્તારની સામાજજક-આમથિક સ્સ્થમતમાાં સધારો
થશે પરાં ત સ્થળાાંતર થર્ેલ વસ્તીમાાં વધારો એ મવસ્તારની સાંસ્કૃમત પર અસર પેિા કરી શકે છે .
એડવાર્રમેડટલ મોનીટરીંિ કાર્યક્રમ

મોિીફિકેશન પ્રોજેક્ટને કારિે થતી પર્ાયવરિીર્ અસરોને ધ્ર્ાનમાાં લઈને પર્ાયવરિીર્ િે ખરે ખ માટે મદ્દાઓ
નક્કી કરવામાાં આવશે, મોનીટરીંિ પ્રોગ્રામનો મખ્ર્ અવકાશ પર્ાયવરિની પફરસ્સ્થમતમાાં પફરવતયનને
સમર્સર અને મનર્મમતપિે પર્ાયવરિની સરક્ષા માટે સમર્સર પિલાાં લેવાનો છે . નીચે મજબના મનરીક્ષિ
સ્થળ અને મહત્વપ ૂિય પફરમાિો મવશ્લેષિ કરે લ છે .

4. CRM Office,
5. AMNS
Township,
2. West Station
3. South Station
4. North Station
Environment
(Fugitive)


Effluent
Colour, Taste, pH, Turbidity, Total
Dissolved Solids, Total Hardness as
CaCO3, Alkalinity, Residual
Chlorine, Chloride as Cl, Heavy
Metals & Other Parameters :
Calcium as Ca, Magnesium as Mg,
Oil & Grease (Mineral Oil), Phenolic
Compound as C6H5OH, Hexavalent
Chromium as Cr+6, Cadmium as Cd,
Copper as Cu, Zinc as Zn, Iron as Fe,
Lead as Pb, Mercury as Hg,
Selenium as Se, Aluminium as Al,
Manganese as Mn, Arsenic as As,
Sulphate as SO4, Cyanide as CN,
Boron as B, Fluoride as F, Nitrate
Nitrogen as NO3 , Anionic
Detergents as MBAS,
Bacteriological : Coliform, E. Coli.

Manganese, Sodium, Molybdenum,
Selenium, Arsenic, Mercury, Barium,
Aluminium, Silver, Stannous, Cobalt,
Boron.
Building Conductivity, C: N Ratio, Organic
Carbon, N, P, K, Na, Ca, Mg, CEC,
Cl, Fe, Mn, Cu, Zn, B, Mo.
Phenolic compounds.

and outside plant
Monitoring
Urin, RBS, etc.
check-up both are
same.

વધારાિા અભ્યાસ
જાહેર સુિાવણી
જાહેર સુિાવણી ગુજરાત પ્રદૂ ષણ મિયંત્રણ બોિસ દ્વારા કરવામાં આવશે, MoEF દ્વારા ૮ િેબ્રઆરી, ૨૦૨૧ ના રોજ
આપેલ TOR નાં (F. No. J11011/44/2004-IA. II(I).) માાં આવેલ શરતોનુ ં પાલિ સમામવષ્ટ EIA/EMP
ટરપોટસ માાં કરે લ છે .
જોખમ મ ૂલ્યાંકિ
પ્રસ્તામવત પ્રોજેક્ટ માટે પ્લાડટિી તમામ કામિીરી માટે મવિતવાર જોખમ આકારણી અિે પટરણામ મવશ્લેષણ
કરવામાં આવ્ુ ં છે . સમગ્ર સંકુલ માટે આપમત્ત વયવસ્થાપિ( Disaster management plan) યોજિા ઉપલબ્ધ છે .
અમધકારીઓિી જવાબદારીઓમાં જોખમી પટરસ્સ્થમતઓ અિે કમસચારીઓિી અસુરલિત કૃત્યોિી ઓળખ અિે
સુધારણાત્મક ટિયાઓિી સલાહ, સલામતીનુ ં ઓટિટ કરવુ,ં તાલીમ કાયસિમોનુ ં આયોજિ કરવુ ં અિે વયવસામયક
આરોગ્ય અિે સલામતીિે લિતા મવમવધ મુદ્દાઓ પર વયાવસામયક મિષ્ણાતિી સલાહિો સમાવેશ થાય છે .
સલામતી અમધકારી દ્વારા મિષ્ણાંતોિી સહાયથી સલામતી તાલીમ આપવામાં આવી રહી છે . મિયમમત કમસચારીઓ
ઉપરાંત, બધા કોડરાક્ટર અને મજૂર સલામતી પ્રમશિણમાં હાજર રહેશે.
વયવસામયક આરોગ્ય મિરીિણ

સંભમવત વયવસામયક જોખમી કાયસસ્થળો પર મિયમમત દે ખરે ખ રાખવામાં આવી રહી છે . અવાજ, િરમી, ધ ૂળ
અિે જોખમી રસાયણોિા સંપકસ િે કારણે કોઈપણ બીમારીિી વહેલી તકે તપાસ માટે કમસચારીઓિા
આરોગ્યિી મિયમમત મિરીિણ કરવામાં આવે છે .
આ સવેલડસ પ્રોગ્રામમાં ઓટિઓમેરી અિે ફેફસાિા પરીિણોિો પણ સમાવેશ કરવામાં આવશે. વયવસામયક
રોિોિે દૂ ર કરવા માટે કંપિી પાસે એક મવિતવાર વયવસામયક આરોગ્ય વયવસ્થાપિ યોજિા છે .
પ્રોજેક્ટથી થતા ફાયદા (CSR)

CSR પ્રવ ૃમત્તઓ િા પાંચ વષસ માટે બજેટ ફાળવણી રૂપે ૧૬00.00 લાખ રૂમપર્ા ખચય કરવામાાં આવશે. CSR
પ્રવ ૃમત્તઓમાં મશિણ, આરોગ્ય અિે સ્વચ્છતા, માળખાિત મવકાસ, ટકાઉ જીવિમિવાસહ, રમતિમત અિે ્ુવા
મવકાસ અિે પયાસવરણીય પ્રોજેક્ટ વિેરેિો સમાવેશ થાય છે . આ ઉપરાંત, આ પ્રોજેક્ટ મવમવધ પ્રકારિા વેરા,
એક્સાઈઝ િયુટી વિેરે દ્વારા સરકારિી આવકિો ઉમેરો કરશે.
પયાસવરણીય વયવસ્થાપિ યોજિા

પયાસવરણીય સંચાલિ મવભાિ દ્વારા મવમવધ મોમિટટરિંિ પટરમાણોિી મિયમમત દે ખરે ખ રાખવામાં આવી રહી
છે . પયાસવરણીય પ્રભાવોિે ઘટાિવા સ ૂચિો અનુસાર ર્ોગ્ર્ પિલા લેવામાાં આવે છે . કોઈ પણ િમત
અટકાવવા માટે મિયમમત દે ખરે ખ રાખવામાં આવશે. કમસચારીઓિી કામિીરી સુધારવા માટે કંપિી મવમવધ
તાલીમ કાયસિમ હાથ ધરશે. પ્લાડટ િા કામકાજ દરમ્યાિ આવી રહેલા કટોકટીિી પટરસ્સ્થમતઓ સામે લિવા
માટે મિયમમત સમર્ે મવશેષ તાલીમ િોઠવવામાં આવશે.

EPCM માટે ખચસ
પયાસવરણ પ્રદૂ ષણ મિયંત્રણ પિલાં માટે નો ખચય (EPCM) િીચે આપેલા કોષ્ટકમાં છે .
Total 1682.26 377.95
ગ્રીિ બેલ્ટ િેવલપમેડટ

હાલમાાં ૧૭૦ હેક્ટર િેત્રમાં ગ્રીિબેલ્ટ મવકમસત છે . અિે આશરે ૮૪ હેકટરિો મવસ્તાર ગ્રીિ બેલ્ટનો મવકાસ
કરવામાાં આવશે. ત્ર્ારપછી, કુલ ગ્રીિબેલ્ટ મવસ્તાર ૨૫૪ હેક્ટર થશે. કુલ ૧૮૩૫૬૬ છોિ, બાઉડરી રસ્તાિી
સાઈિ, ઓટફસ અિે ઇમારતોિી આસપાસ અિે ખુલ્લી જમીિમાં વ ૃિોનુ ં વાવેતર કરવામાં આવશે.
સમાપન
મોિીફિકેસન પ્રોજેક્ટ કર્ાય પછી પ્લાડટની સુમવધાઓ સ્થામિક પયાસવરણ પર િજીવી અસર કરશે. તેમ છતા
સ ૂલચત પ્રદૂ ષણ મિયંત્રણ, પયાસવરણ વયવસ્થાપિ પિલાઓનો અમલ , બાંધકામ અિે કામિીરીને કારણે
થતી પ્રમતકૂળ અસરોની કાળજી લેવામાાં આવશે. આ પ્રોજેક્ટિા લીધે સામાજજક-આમથિક પાસા પર ઘણા ફાયદા
થશે.
આમ, મિયંત્રણિમ પયાસવરણીય પ્રભાવોિે ધ્યાિમાં રાખીિે, મોિીફિકેસન પ્રોજેક્ટ પ્રદે શ માટે વધુ
ફાયદાકારક રહેશે અિે પ્રાદે મશક, રાજ્ય અિે રાષ્રીય અથસતત્ર
ં માં મિમિતપણે સુધારણા કરશે.

Draft EIA/EMP Report for proposed Modification in Existing Plant by
installing Auxiliary Facilities without increasing Plant Capacity by M/s.
ArcelorMittal Nippon Steel India Limited
Index
Sr. No. Title Page No.
Executive Summary of EIA Report-English
Executive Summary of EIA Report-Gujarati
Tor Compliance
Chapter-1: Introduction
1.1 Background 1-1
1.2 Purpose of The Report 1-4
1.3 Identification of The Project Proponents 1-4
1.4 Brief Description of The Project 1-4
1.5 Need for The Project 1-5
1.6 Demand-Supply Gap 1-7
1.7 Structure of The EIA Report 1-8
1.8 Regulatory Frame Work 1-9
1.9 Show Cause Notices 1-9
Chapter-2: Project Description and Infrastructural Facilities
2.1 Project Description 2-1
2.2 Justification of the Project 2-1
2.3 Location of the Project Site and Surrounding Salient Features 2-1
2.4 Details of major industries within study area (10 Kms Radius) 2-5
2.5 Key Infrastructure Map of Project Site 2-6
2.6 Importance to the Country and The Region 2-6
2.7 Cost of The Project 2-6
2.8 Project Schedule and Implementation 2-8
2.9 Main Phases of The Project 2-9
2.9.1 Pre-Construction Activities 2-9
2.9.2 Construction Activities 2-9
2.9.3 Production Activities / Facility (Existing and Proposed Auxiliaries Facilities) 2-9
2.9.4 Manufacturing Process Existing Units 2-9
2.9.5 Manufacturing process of Proposed Auxiliary Facilities 2-39
2.10 Raw Materials 2-57
2.10.1 Raw Material Consumption 2-57
2.10.2 Quantum Generation Iron Ore from Iron Ore Mines 2-59
2.10.3 Quantum Generation Coal and Coke from Mines 2-60
2.10.4 Quantum Generation fluxes 2-61
2.10.5 Mode of Transportation of raw Materials 2-62
2.10.6 Raw Material Handling 2-62
2.10.7 Raw material substitution or elimination 2-63
2.10.8 System of Coke Quenching Adoption 2-63
2.11 Infrastructure Facilities/ Proposed Infrastructure 2-63
2.11.1 Land 2-63
2.11.2 Power Requirements 2-66
2.11.3 Fuel Requirements 2-68
I-1

2.11.4 Energy Balance Data 2-68
2.11.5 Manpower Requirements 2-68
2.11.6 Water Requirement 2-68
2.11.6.1 Existing Scenario 2-68
2.11.6.2 Proposed Scenario 2-70
2.11.6.3 ZLD Proposal-AMNS Scheme for UF/RO Systems 2-72
2.11.6.4 Plant Wise ETP details 2-74
2.11.6.5 Plant Wise Treatment Methods 2-76
2.11.6.6 Details of Pollution Control Measures (Water) 2-92
2.11.6.7 Final Discharge 2-94
2.11.6.8 Trace Metals in treated water 2-94
2.12 Environmental Effect 2-94
2.12.1 Air Emission 2-94
2.12.1.1 Existing and proposed emission and stack details 2-94
2.12.1.2 Action Plan to reduce the emission 2-102
2.12.1.3 CEMS and Opacity meter 2-104
2.12.2 Noise Environment 2-105
2.12.2.1 Details of Noise Generation in Plant 2-105
2.12.2.2 Mitigation Measures 2-106
2.12.3 Solid and Hazardous Waste Generation 2-106
Chapter-3: Baseline Environmental Status and Description of Environment
3.1 Introduction 3-1
3.2 Period of Monitoring and Area of Study 3-1
3.3 Climate of the Study Area 3-3
3.4 Air Quality & Meteorology 3-3
3.4.1 Data Collection Methodology 3-3
3.4.2 Meteorology 3-3
3.4.3 Temperature Details 3-3
3.4.4 Relative Humidity (RH) 3-3
3.4.5 Rainfall 3-3
3.4.6 Cloud Cover 3-3
3.4.7 Predominant Wind Direction 3-3
3.4.8 Site Specific Micro-Meteorological Data 3-4
3.5 Air Environment 3-5
3.5.1 Ambient Air Quality Monitoring 3-5
3.5.2 Methodology for Ambient Air Quality Monitoring 3-5
3.5.3 Result and Discussion 3-7
3.6 Water Environment 3-8
3.6.1 Physico-Chemical Characteristics of Water 3-12
3.6.1.1 Ground Water 3-12
3.6.1.2 Surface Water 3-12
3.6.1.3 Marine Environment 3-12
I-2

3.7 Geomorphological, Geological, Hydro-Geological Status 3-14
3.7.1 Geomorphology & Drainage 3-14
3.7.2 Soil 3-17
3.7.3 Geology 3-17
3.7.4 Hydrogeology 3-19
3.8 Noise Environment 3-20
3.8.1 Conclusion 3-21
3.8.2 Noise Levels due to Transportation 3-22
3.8.2.1 Conclusion 3-22
3.9 Traffic Study 3-22
3.9.1 Methodology 3-23
3.9.2 Results and Discussions 3-23
3.10 Soil Environment 3-24
3.10.1 Methodology for Soil Monitoring 3-24
3.11 Land Environment 3-26
3.11.1 Method of Data Preparation 3-26
3.11.2 Description of the Land Use / Land Cover Classes 3-26
3.12 Socio - Economic Environment 3-28
3.12.1 Introduction 3-28
3.12.2 Rational for The Study 3-28
3.12.3 Brief Demographic Profile of District 3-28
3.12.4 Objective of Social Impact Assessment 3-29
3.12.5 Approach and Methodology 3-29
3.12.6 Tools and Techniques 3-29
3.12.7 Stakeholders’ Identification 3-29
3.12.8 Findings of Social Impacts and Community Consultations 3-29
3.12.9 Public Consultation 3-32
3.13 Description of the Biological Environment 3-33
3.13.1 Ecological Impact Assessment 3-33
3.13.2 Period of Study 3-34
3.13.3 Methodology 3-34
3.13.4 Biodiversity of Terrestrial Environment 3-35
3.13.4.1 Habitats Description of the Project Site and Its Immediate surroundings 3-35
3.13.4.2 Habitats Description of the Study Area (10 KM) 3-36
3.13.5 Floral Diversity of Study Area 3-36
3.13.5.1 Trees 3-36
3.13.5.2 Shrubs 3-38
3.13.5.3 Herbs 3-38
3.13.5.4 Climbers and Twiners 3-40
3.13.6 Cultivated Plants in the study area 3-41
I-3

3.13.6.1 Major Crops 3-41
3.13.6.2 Minor Crops 3-41
3.13.6.3 Vegetables 3-41
3.13.6.4 Horticulture Practices and Fruit Grown 3-41
3.13.7 Rare and Endangered Flora in the Study Area 3-41
3.13.8 Endemic/Endangered plants of the Study Area 3-42
3.13.9 Status of Forest and their Category in the Study Area 3-43
3.13.10 Faunal Biodiversity of the Study Area 3-44
3.13.10.1 Birds of the Study Area 3-44
3.13.10.2 Butterflies from the Study Area 3-45
3.13.10.3 Herpetofauna 3-46
3.13.10.4 Mammals 3-46
3.13.11 Rare and Endangered Fauna of the Study Area 3-46
3.13.11.1 As per IUCN RED (2020) list 3-46
3.13.11.2 As per Indian Wild Life (Protection) Act, 1972 3-47
3.13.12 Endemic Fauna of the Study Area 3-48
Chapter-4: Anticipated Environmental Impacts & Mitigation Measures
4.1 Identification and Evaluation of Impact 4-1
4.2 Predictions and Evaluation of Impacts 4-1
4.3 Air Environment 4-2
4.3.1 Details of Environmental Impacts 4-2
4.3.2 Mitigation Measures Suggested Based on Air Dispersion Modeling 4-10
4.3.3 Secondary Fugitive Emission & Mitigation Measures 4-11
4.4 Water Environment 4-18
4.4.1 Raw Water Availability 4-18
4.4.2 Construction Phase Impacts and Mitigation Measures 4-18
4.4.3 Operation Phase Impacts and Mitigation Measures 4-18
4.4.4 Impact of Ground Water and its Mitigation Measures 4-18
4.4.5 Execution Plan for Impervious flooring/RCC Flooring in Stock Yards 4-19
4.4.6 Action plan to avoid leaching of materials to the ground water 4-19
4.5 Soil Environment 4-21
4.5.1 Construction Phase Impact and Mitigation Measures 4.21
4.5.2 Operation Phase Impact and Mitigation Measures 4-21
4.5.3 Slag Management Plan 4-23
4.6 Noise Environment 4-23
4.6.1 Construction Phase Impact and Mitigation Measures 4-23
4.6.2 Operation Phase Impact and Mitigation Measures 4-23
4.7 Ecology 4-24
4.8 Infrastructure and Services 4-27
4.8.1 Impact of the Transportation 4-27
4.8.2 Impact on Existing Road Network: 4-27
4.9 Environmental Hazard 4-27
I-4

4.10 Impacts on Occupational Health & Safety 4-27
4.11 Impact on Socio-Economic Aspect 4-27
4.11.1 Positive Impact 4-27
4.12 Reserve Forest, National Parks / Sanctuaries 4-28
4.13 Matrix Representation 4-28
Chapter-5: Environmental Monitoring Program
5.2 Environmental Management Cell 5-1
5.3 Monitoring Schedule and Monitoring Locations and Monitoring Frequency 5-1
5.4 Monitoring Methodologies 5-3
5.5 Reporting and Documentation 5-3
5.6 In-House Laboratory Facility 5-3
Chapter-6: Additional Studies
6.1 Public Consultation/Hearing 6-1
6.2 Philosophy and Methodology of Risk Assessment 6-1
6.3 Objective of the Risk Assessment Study 6-2
6.4 Elements of the RH Study 6-2
6.4.1 Storage and Handling of Hazardous Chemicals 6-2
6.4.2 Toxic Hazards of Substances 6-3
6.4.3 Assessment of Flammability & Explosive Properties 6-3
6.4.3.1 Flammability Hazards of Substances 6-4
6.4.3.2 Explosion Hazards 6-5
6.4.3.3 Corrosion Hazards 6-5
6.4.3.4 Reactivity Hazards 6-6
6.5 Details of Manufacturing Process 6-6
6.5.1 Description of Hazardous Chemicals 6-6
6.6 Raw Materials Storage 6-8
6.7 Risk Scenarios: Quantitative Analysis 6-20
6.7.1 Software Used for Calculations 6-21
6.7.1.1 Vulnerability Analysis 6-21
6.7.1.2 Maximum Credible Accident Scenario 6-21
Dispersion Scenarios of Hazchem - Emergency Releases. Blast Furnace “CO”
6.7.1.3 6-25
Scenarios
6.7.1.4 Dispersion Scenarios of Hazchem- Emergency Releases. Corex “CO” Scenarios 6-45
Dispersion Scenarios of Hazchem - Emergency Releases. “CRM” Ammonia
6.7.1.5 6-76
Scenarios Site Data
Dispersion Scenarios of Hazchem - Emergency Releases. “CRM” Hydrogen
6.7.1.6 6-86
Scenarios
Dispersion Scenarios of Hazchem - Emergency Releases in “Pipe Shop”
6.7.1.7 6-92
Hydrogen Sulfide Gas Release Scenarios
Dispersion Scenarios of Hazchem - Emergency Releases in “COKE OVEN
6.7.1.8 6-98
PLANT” Methane gas Release Scenarios
I-5

6.8 Management of Risk and Health Scenarios 6-100
6.8.1 Risk Assessment & Management 6-100
6.8.2 Health Management (Large Hazard Unit) 6-100
Description of Information or Organizational Systems Used to Carry on
6.9 6-101
Industrial Activity Safety, namely
6.9.1 Maintenance & Inspection Schedule 6-101
6.9.1.1 Planned Maintenance 6-101
6.9.1.2 Unplanned Maintenance 6-101
6.9.2 Schedule Maintenance 6-102
6.10 Guidelines for the Training of Personnel 6-102
6.11 Allocation and Delegation of Responsibility for plant Safety 6-102
6.11.1 Responsibility of Employee’s 6-102
6.11.2 Responsibility of Manager 6-103
6.11.3 Responsibility of Safety Personnel 6-103
6.11.4 Implementations of Safety Procedure 6-103
6.12 Risk Prevention and Risk Mitigation 6-104
6.12.1 Preventive Measures 6-104
6.13 Disaster Management Plan 6-106
6.13.1 Types of Disasters 6-107
6.13.2 On-Site Emergency 6-108
6.13.3 Off-Site Emergency 6-108
6.13.4 Organization set Up Plan 6-111
6.13.4.1 Responsibilities of Key Emergency Personnel - Teams 6-113
6.13.4.2 Communication System 6-117
6.14 Occupational Health and Safety Program- mitigating measures 6-120
6.14.1 Occupational Health center. (OHC) 6-121
6.14.2 HSE Organization 6-122
6.14.3 DOS &DON’TS to be Followed 6-122
Chapter-7: Project Benefits
7.2 Corporate Social Responsibility (CSR) 7-1
7.3 Existing CSR Activity 7-1
7.4 Proposed CSR Activities and Estimated Cost 7-4
7.4.1 CSR Budget 7-5
7.5 Employment Potential 7-6
7.6 Benefits of the Industry 7-6
7.7 Direct Earning Benefits to the Nation and State 7-6
7.8 Other Tangible Benefits 7-6
Chapter-8: Impact Assessment and Environmental Management Plan
8.2 Purpose of Environmental Management Plan 8-1
8.3 Corporate Environmental Policy 8-1
I-6

8.4 Details of Environment Management Plan 8-2
8.4.1 During Construction Phase 8-2
8.4.1.1 Air Environment 8-2
8.4.1.2 Water Environment 8-2
8.4.1.3 Noise Environment 8-2
8.4.1.4 Land Environment 8-3
8.4.1.5 Solid Waste 8-3
8.4.1.6 Ecology 8-3
8.4.1.7 Socio-Economic 8-3
8.4.2 During Operation Phase 8-3
8.4.2.1 Air Environment 8-3
8.4.2.1.1Control and Monitoring of Secondary Fugitive Emissions 8-4
8.4.2.2 Water Environment 8-5
8.4.2.2.1Rain Water Harvesting Scheme 8-5
8.4.2.3 Land Environment 8-9
8.4.2.4 Management of Solid/Hazardous Waste 8-9
8.4.2.5 Noise Environment 8-9
8.4.3 Green Belt Development 8-9
8.4.3.1 Selection of plants for Greenbelts 8-9
8.4.3.2 Roadside Plantation 8-11
8.4.3.3 Guidelines for plantation 8-12
8.4.3.4 Location wise total area under Greenery Development 8-12
8.4.3.5 Action Plan for Greenbelt Details 8-14
8.4.4 Conservation Measures for Peacock /Indian Peafowl and White-rumped Vulture 8-15
8.4.4.1 Peacock /Indian Peafowl 8-15
8.4.4.2 White-rumped Vulture 8-16
8.4.5 Socio-Economic Aspects 8-16
8.4.6 Occupational Health and Safety 8-16
8.4.7 Concept of Waste-Minimization, Recycle/Reuse/Recover Techniques, Energy 8-17
Conservation, And Natural Resource Conservation
8.5 Environmental Management Department 8-18
8.6 Environmental Policy 8-19
8.7 Reporting System to The Directors 8-19
8.8 Budgetary provision for EMP 8-20
Chapter-9: Analysis of Alternatives (Technology & Site)
Chapter-10: Environmental Cost Benefit Analysis
Chapter-11: Summary and Conclusion
11.1 Name of the Project 11-1
11.2 Location of the Project 11-1
11.3 Details of earlier ECs 11-1
11.4 Products and Capacities 11-2
11.5 Project Requirement 11-4
I-7

11.5.1 Land Requirement 11-4
11.5.2 Major Raw Material Requirement 11-5
11.5.3 Water Requirement 11-7
11.5.4 Power Requirement 11-7
11.5.5 Fuel Requirement 11-7
11.5.6 Manpower Requirement 11-8
11.6 Process Description 11-8
11.7 Project Cost 11-10
11.8 Estimated time of Completion 11-10
11.9 Site Selected for the project 11-10
11.10 Baseline Environment 11-10
11.10.1 Ambient Air Quality 11-10
11.10.2 Ground Water Quality Monitoring 11-10
11.10.3 Surface Water Quality Monitoring 11-10
11.10.4 Background Noise Level 11-11
11.10.5 Soil Quality 11-11
11.10.6 Land Use Pattern 11-11
11.10.7 Socio-Economic Study 11-11
11.10.8 Biological Environment 11-11
11.11 Anticipated Environmental Impacts & Mitigation Measures 11-11
11.11.1 Air Environment 11-11
11.11.2 Water Environment 11-12
11.11.3 Noise Environment 11-12
11.11.4 Soil Environment - Solid / Hazardous Waste Management 11-13
11.11.5 Ecological Environment 11-15
11.11.6 Socio-Economic 11-16
11.12 Environmental Monitoring Programme 11-16
11.13 Additional Studies 11-18
11.13.1 Public Hearing 11-18
11.13.2 Risk Assessment 11-18
11.13.3 Occupational Health Monitoring 11-18
11.14 Project Benefits Corporate Social Responsibility (CSR) 11-18
11.15 Environmental Management Plan 11-18
11.15.1 Cost of EPCM 11-18
11.15.2 Green Belt Development 11-18
11.16 Conclusion 11-18
Chapter – 12: Consultant Engaged
I-8
List of Tables
Table No. Title Page No.

1.1 Details of Existing EC’S Granted 1-1
1.2 Implementation status of the existing EC 2016 1-2
1.3 Details of proposed Auxiliary Facilities 1-3
1.4 Need of the proposed Auxiliary Facilities 1-5
1.5 List of Show Cause Notices (SCN) Last Year: 1-9
1.6 List of Notice of Directions (NoD) - Last Year: 1-9
2.1 Surrounding Salient Features and Environmental Setting 2-5
2.2 List of Major Industries within Study Area (10 Kms Radius) 2-5
2.3 Project Cost Break up for the proposed modification 2-7
2.4 Capital Cost and Recurring Cost for EPCM 2-8
2.5 Implementation Schedule 2-8
2.6 Major Raw Materials Requirement 2-57
2.7 Details of Quantum Generation Iron Ore from Iron Ore Mines 2-59
2.8 Trace Element Analysis of Iron Ore 2-59
2.9 Details of Quantum Generation of Coal and Coke from Mines 2-60
2.10(A) Trace Element Analysis of Coal 2-61
2.10(B) Trace Element Analysis of Coke 2-61
2.11 Details of Quantum Generation fluxes 2-62
2.12 Trace Element Analysis of Fluxes 2-62
2.13 (A) Land Use Break up 2-64
2.13 (B) Existing and proposed Auxiliaries facilities 2-64
2.13 (C) Area wise land use breakup 2-66
2.14 Power requirement for existing plant facilities 2-66
2.15 Power requirement for proposed auxiliary plant facilities. 2-67
2.16 Characteristic of Coal 2-68
2.17 Details of Manpower Requirement 2-68
2.18 Characteristics of waste water to be treated 2-72
2.19 The outlet permeate water quality 2-73
2.20 ETP Details 2-74
2.21 Details of Wastewater Generation and Its Management 2-93
2.22 Trace Metal Analysis of three outlets 2-94
2.23 Details of Existing Stacks 2-95
2.24 Details of Proposed Stacks 2-98
2.25 Details of Cost for Action Plan 2-102
2.26 Details of Noise Generation 2-105
2.27 Details of Solid Waste generation 2-106
2.28 Details of Hazardous Waste generation and its management 2-107
3.1 Predominant Wind Direction 3-4
3.2 Site Specific Meteorological Data (1st Oct 2020 to 31st Dec 2020) 3-4
3.3 Details of Ambient Air Quality Monitoring Locations 3-6
I-9

3.4 Ambient Air Quality Status 3-7
3.5 Ambient Air Zn Dust Status 3-8
3.6 Details of Ground and Surface Water Monitoring Locations 3-8
3.7 Baselines Ground Water Quality 3-10
3.8 Baseline Surface Water Qualities 3-11
3.9 Noise Monitoring Stations 3-20
3.10 Background Noise Levels 3-21
3.11 Noise Levels Due to Transportation 3-22
3.12 PCU Levels (Vehicle wise PCU Value) 3-23
3.13 PCU Levels (Nos. of vehicle) Type of vehicle 3-23
3.14 Present Traffic Scenario 3-23
3.15 Level of Service 3-24
3.16 Details of Soil Quality Sampling Locations 3-24
3.17 Physico - Chemicals Characteristics of Soil 3-24
3.18 Areas Statistics of Land Use/Land Cover Map 3-26
3.19 Demography of the Study Area 3-30
3.20 Summary of Public Consultation 3-32
3.21 List of Tree species 3-37
3.22 List of Shrubs 3-38
3.23 List of Herbs 3-39
3.24 List of Climbers and Twiners 3-40
3.25 List of Birds 3-44
3.26 List of Butterflies 3-45
3.27 List of Herpetofauna 3-46
3.28 List of Mammals 3-46
4.1 Details of Emission from Existing stack 4-3
4.2 Details of Emission from Proposed stack 4-5
4.3 Summary of ISCST3 Model Output 4-10
4.4 Maximum Ground Level Concentration 4-10
4.5 Details of stockyards 4-19
4.6 Chemical Characteristic of Solid Waste 4-21
4.7 Slag Management Plan 4-23
4.8 Plant Wise Noise Generation Points and Mitigation Measures 4-24
5.1 Schedule of Environmental Monitoring 5-2
5.2 List of Equipment Available for Monitoring 5-3
6.1 Toxic Effects of Chemical Substances. 6-2
6.2 Damages to Human Life Due to Heat Radiation 6-4
6.3 Effects Due to Incident Radiation Intensity 6-5
6.4 Damage Due to Overpressures 6-5
6.5 Incompatible Storage Recommendations 6-7
6.6 Facilities and Inventory of Hazardous Materials at Various Locations of the 6-9
plant
6.7 Hazardous Chemicals Used. - Raw Materials Bulk in Tank farms & RM 6-17
I - 10

Stores. - Hazard Parameter
6.8 vulnerable zones 6-20
6.9 list of Risk Dispersion Scenarios 6-22
7.1 Proposed CSR budgetary Plan 7-5
8.1 Recommended plant species for green belt development along the boundary of 8-10
as a wind barrier as well as to prevent dust pollution
8.2 Species for Plantation along the roadside 8-11
8.3 Existing Developed Green Belt Details at AMNS 8-12
8.4 Type of Tree & Coverage 8-12
8.5 Proposed Green Belt Area to be developed 8-13
8.6 Type of Tree with ht. & Age 8-13
8.7 Greenbelt Details (Existing) & Proposed Greenbelt Plan 8-14
8.8 Greenbelt Details (Existing) & Proposed Greenbelt Plan 8-14
8.9 Service Cost and Maintenance Cost 8-14
8.10 Break up cost for Environment Pollution Control Measures 8-20
11.1 Surrounding Salient Features and Environmental Setting 11-1
11.2 List of EC Year wise 11-1
11.3 List of Product 11-2
11.4 Details of Land Breakup 11-4
11.5 List of Raw Materials 11-5
11.6 Details of Solid Waste generation and its management 11-13
11.7 Details of Hazardous Waste generation and its management 11-14
12.2 Functional Area Experts Involved in the EIA 12-3
12.3 Laboratory Involved for Baseline Monitoring & Other Analysis 12-3
I - 11
List of Figures
Figure No. Title Page No.

2.1 Detailed map of Surat District Showing Project Location 2-2
2.2 Google Image of Project Site 2-3
2.3 Photographs of Project Site 2-3
2.4 Plant Layout showing Existing Plant Facilities and Proposed Auxiliaries 2-4
Facilities
2.5 Key Infrastructure Features and Settlements 2-6
2.6 Existing Water Balance Diagram 2-69
2.7 Proposed Water Balance Diagram 2-71
2.8 ZLD Scheme of modular UF+RO system (Two Modules) 2-73
3.1 Google Image of Project Site with Study Area 3-2
3.2 Location Map of Project Site with Study Area 3-2
3.3 Wind Rose Diagram 3-5
3.4 Location of Ambient Air Quality Monitoring Stations 3-6
3.5 Locations of Ground Water Sampling Stations 3-9
3.6 Locations of Surface Water Sampling Stations 3-9
3.7 Drainage Plan of 5Km Radius of Study Area 3-15
3.8 Digital Elevation Model of 10 km Radius 3-15
3.9 Drainage map of the Study Area 3-16
3.10 Soil Map of The Surat District Area 3-17
3.11 Geohydrological Map of Surat District 3-18
3.12 Baseline Noise Qualities Monitoring Stations 3-21
3.13 Map of Traffic Survey 3-22
3.14 Locations of Soil Sampling Stations 3-25
3.15 Satellite Imagery of the Study Area 3-27
3.16 Landuse and Landcover Map 3-27
3.17 Study Area Map 3-35
4.1 Spatial distribution of 24-hour average pm conc. (g/m3) 4-9
4.2 Spatial distribution of 24-hour average SO2 conc. (g/m3) 4-9
4.3 Spatial distribution of 24-hour average NOx conc. (g/m3) 4-10
4.4 RCC/Impervious flooring network 4-19
4.5 Drain and retaining wall drawing 4-20
4.6 Drain and retaining wall drawing Oxide yard. 4-20
8.1 Greenbelt Layout for existing and proposed 8-15
8.2 Layout for Infrastructure Facilities for Truck Drivers 8-17
8.3 Hierarchy in EHS 8-18
8.4 Health, Safety and Environment (HSE) Policy 8-19
8.5 Reporting System 8-19
I - 12
Draft EIA/EMP Report for proposed Modification in Existing
Plant by installing Auxiliary Facilities without increasing Plant
Capacity by M/s. ArcelorMittal Nippon Steel India Limited
ToR Compliance
Terms of Reference (TOR) issued by Reconstitute Environmental Appraisal Committee (Industry)
(EAC-(I)) vide MoEF&CC letter No. F. No. J-11011/44/2004-IA II(I) dated 8th February, 2021
Sr. No. Terms of Reference Compliance

Additional TOR
1 No construction activity/infringement will take place in flood It is certified that there is no construction or
plain of Tapi river situated in the vicinity of the project site. The infringement at Tapi flood zone is going to do, as the
flood plain corresponding to HFL of Tapi river shall be depicted auxiliary projects are coming or limited in the existing
and same may be verified by an authority not below the rank of District project site only. Our plant is at notified industrial
Magistrate/Executive Engineer of the State Government estate and from the inception of the project, no flood
water entered in to the plant premises.
Our unit is in Tapi basin and our plant superimposed
on Tapi basin map is enclosed as annexure-25
Flood plain corresponding to HHL is under the review
of authority and immediately on receipt of the signed
document, it will be submitted
2 The PP will raise green belt in 33% of the total project area. This Total AMNS premises is 770 ha,
will include 50 m wide green belt along the boundary of the plant Existing Green belt area 170 ha (22%), Proposed
situated towards the Tapi river Green belt area 84 ha (11 %), total green belt area 254
ha (33%)
Plant Area: 670 ha – Green Belt 183 ha (27 %)
Township Area: 100 ha – Green Belt 71 ha (71 %)
Please refer section 8.4.3 on page no. 8-9 of Chapter 8
3 PM levels from existing and new stacks shall be maintained at The company has prepared elaborate road map for
less than 30 mg/Nm3 except for Coke Oven chimney where it bringing down emissions and for that a budget of
shall be 50 mg/Nm3 Rs.400 Cr with time lines has been approved by the
Board of Directors.
Please refer section 2.12.1.2 on page no. 2-102 of
Chapter 2.
4 Emission from ARP stack shall be less than 10 mg/Nm3 of HC1 ARP stack emission of HCl is currently under 20
mg/nm3. The technology supplier has committed to
bring the stack emission less than 10 mg/nm3 during
actual operations. Still, if it is above 10 mg/nm3 AMNS
will install a scrubber cum agglomerator unit to bring
the emission below 10 mg/nm3
5 Zn dust shall be monitored in AAQ in CRM complex and data Zn dust was monitored in AAQ in CRM complex,
shall be submitted in EIA report details enclosed.
Please refer section 3.5.3 on page no. 3-7 of chapter 3
6 HW generated in CRM shall be disposed of in TSDF HW generated from CRM will be disposed in to TSDF
Please refer section no. 2.12.3 on page no. 2-106 of
Chapter 2
7 Oily sludge from CRM and other mills shall be incinerated Oily sludge will be handed over to rule 9 authorised
recycler.
Chapter 2
8 100 % Solid waste generated shall recycled/reused or sold Generated solid waste is/will be reused for inhouse
consumption as raw material for other plant and some
of the solid waste is/will be sold to Rule 9 authorized
End Users
Chapter 2
9 Treated effluent from various ETPs including BOD plant of Coke 100% Treated effluent is/will be recycled in the plant
ovens shall be recycled and reused inside the steel works
Please refer section 2.11.6 on page no. 2-68 of chapter
2
10 Mangroves survey shall be carried out and study report shall be Mangrove survey has been carried out and found that
furnished no mangrove is present within plant premises

3
11 CRZ mapping of the project site shall be carried out through an Detailed report and CRZ map from IRS (Institute of
M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat. 1-1


authorized agency interalia including HTL/LTL mapping, CRZ Remote Sensing) will be submitted soon.
land classification along with super-imposition of facilities To validate this statement, we have already placed
envisaged in the project Order for obtaining CRZ map (SGC/WO-Let/21-
22/002 dated 12.06.2021). This is one of the agencies
approved by MoEFF&CC to carry out CRZ related
activities.
12 Cumulative impact assessment shall be carried out for the entire This project is modification of the facility by installing
facility within the boundary of the plant complex auxiliary facilities. Plant capacity is not going to
change by this proposal. Please refer section 4.3 on
page no. 4-2 of chapter 4
13 EMPs for social and infrastructure development shall be based on AMNS is doing lot of CSR activity specially in the
the assessment of social needs and the issues raised in public Hazira Village like digital education, medical camp,
hearing social awareness program, road making and Job
opportunity for local peoples.
For the proposed modification project company has
allocated a budget of 1600 lac for CSR activity
Please refer Section 7.4 on page no 7-4 of chapter 7
14 CEMS shall be provided on all process stacks and the signal shall CEMS already provided to existing stacks and will be
be received in plant control room for central control of APCDs installed in proposed stacks also.
installed in the plant Please refer Section 2.12.1.3 on page no 2-104 of
chapter 2
15 All roads in the plant shall be paved and industrial vacuum Internal roads are paved and they are regularly cleaned
cleaners shall be used regularly to clean roads to reduce fugitive through the industrial vacuum cleaner to reduce
emissions fugitive emission.

16 Action plan to reduce the fugitive emissions from the plant shall To reduce the fugitive emission
be furnished • Upgraded Fume Extraction system has been
installed
• Bag house capacity is increased & new filter bags
have been installed.
• Manual water sprinkling is going on, in & around
plant as well as on roads
• Road sweeping machines for effective road
cleaning
17 All stockyards shall be having impervious flooring and shall be AMNS have 4 no.s of stockyards. All are with
equipped with water spray system for dust suppression. Stock RCC/impervious flooring and having water spray
yards shall also have garland drains to trap the run off material system for dust suppression. There is also garland drain
to trap the runoff material.
18 Action plan for rain water harvesting shall be furnished AMNS has developed a rain water harvesting system
by which AMNS is harvesting more than 8,00,000
cubic meters of rainwater in just one calendar year
Please refer Section 8.4.2.2.1 on page no. 8-5 of
chapter 8.
19 Ultralow NOx burner with three stage combustion, flue gas For new CRM 2 we will be using ultra low NOx
recirculation and auto combustion control system shall be used burners to bring down the emission norms. And for
Coke oven we will be using the modern technology to
achieve emission standards.
20 It is requested that the draft EIA Report may be prepared in Noted
accordance with the above mentioned specific ToRs and enclosed
generic ToRs and additional ToRs and thereafter further necessary
action including conduct of public consultation may be taken for
ToR for undertaking EIA study for obtaining Environment
Clearance in accordance with the procedure prescribed under the
EIA Notification, 2006 as amended
21 In accordance with this Ministry's Notification vide S.O. 751 (E) Noted
dated 17.02.2020, the ToRs are valid for a period of four years
from today i.e., 08.02.2021 and will expire on 07.01.2025. There
will be no further extension of validity of ToR
Generic Terms of Reference


1 Executive Summary Complied
2 Introduction
i Details of the EIA Consultant including NABET accreditation EIA Consultant: Shree Green Consultants is accredited
in the metallurgical sector as A category consultant by
QCI-NABET.
Please Refer Chapter –12
ii Information about the project proponent M/s. ArcelorMittal Nippon Steel India Limited is a
joint venture between M/s. ArcelorMittal, one of the
world’s leading steel and mining companies, and M/s
Nippon Steel, Japan’s largest steel producer. Both
ArcelorMittal and Nippon Steel have an excellent track
record of achievements in the capital intensive and
competitive manufacturing sectors.
Please refer Section 1.3 on page no. 1-4 of Chapter 1
iii Importance and benefits of the project The project is beneficial due to generation of more
employment. By this modification AMNS will be able
to achieve production of 9.6 MTPA.
Please refer chapter 7
3 Project Description
i Cost of project and time of completion. Cost of project is Rs. 6413.13 Cr. Detail
implementation plan is enclosed at Section 2.7 on page
no. 2-6, also refer Section 2.8 on page no. 2-8 of
Chapter 2
ii Products with capacities for the proposed project. Production capacity is 9.6 MTPA which will remain
same even after the installation of proposed auxiliary
facilities.
(table 1.2 page no. 1-2)
iii If expansion project, details of existing products with capacities It is modification project without increasing plant
and whether adequate land is available for expansion, reference capacity. All the auxiliary facilities will be coming in
of earlier EC if any. existing land only.
(table 1.2 page no. 1-1)
iv List of raw materials required and their source along with mode Please refer Section 2.10 on page no. 2-57 of Chapter –
of transportation. 2
v Other chemicals and material required with quantities and Please refer Section 6.5.1 on page no. 6-6 of Chapter 6
storage capacities
vi Details of Emission, effluents, hazardous waste generation and Please refer Section 2.12 on page no. 2-94 of Chapter 2
their management.
vii Requirement of water, power, with source of supply, status of Please refer Section 2.11 on page no. 2-63 of Chapter 2
approval, water balance diagram, man-power requirement
(regular and contract)
Viii The Project Proponent shall furnish the requisite documents Please refer Section 2.11.6 on page no. 2-68 of Chapter
from the competent authority in support of drawl of ground 2
water and surface water supply of electricity.
ix Process description along with major equipment’s and Please refer Section 2.9 on page no. 2-9 of Chapter –2
machineries, Process flow sheet (quantitative) from raw
material to products to be provided.
x Hazard identification safety and details of proposed System Please refer Section Chapter 6.
xi Expansion/modernization proposals:
a. Copy of all the environmental clearance(s) including Please refer table 1.1on page 1-1 of chapter 1.
amendments there to obtained for the project from Please refer annexure 24 for the certified EC
MOEF/SEIAA shall be attached as annexure. A certified copy compliance report.
of the latest monitoring Report of the RO of the ministry of
Environment and forests as per circular dated 30th May,2012 on
the status of compliance of conditions stipulated in all the
existing environmental clearances including Amendments shall
be provided. In addition, status of compliance of Consent to
Operate for the ongoing existing operation of the project from
SPCB shall be attached with the EIA-EMP report.
b. In case the existing project has not obtained environmental


clearance, reasons for not taking EC under the provisions of the
EIA Notification 1994 and/or EIA Notification 2006 shall be
provided. Copies of Consent to Establish/No Objection
Certificate and Consent to Operate (in case of units operating
prior to EIA Notification 2006, CTE and CTO of FY 2005-
2006) obtained from the SPCB shall be submitted. Further,
compliance report to the conditions of consents from the SPCB
shall be submitted.
4 Site Details:
i Location of the project site covering village, Taluka/Tehsil, The details regarding location of the project along with
District and State on Indian map of 1:1000,000 scale. the toposheet of the study area, coordinates of the site
ii A toposheet of the study area of radius of 10km and site and downloaded google earth map are furnished.
location on 1:50,000/1: 25,000 scales on an A3/A2 sheet. Please refer Section 2.3 on page no. 2-1 of Chapter 2
iii Co-ordinates (Lat-long) of all four corners of the site.
iv Google map-Earth downloaded of the project site.
v Layout maps indicating existing unit as well as proposed unit The layout plan constituting all the plant facilities,
indicating storage area, plant area, greenbelt area, utilities etc. If storage area and the essential amenities along with the
located within an Industrial area/Estate/Complex, layout of location of the plant is enclosed.
Industrial Area indicating location of unit within the Industrial Please refer Section 2.3 on page no. 2-1 of Chapter 2
area/Estate.
vi Photographs of the proposed and existing (if applicable) plant Plant site is located at Hazira village of Surat District
site. If existing, show photographs of plantation/greenbelt, in in Gujarat and of the total land area 33% is allocated
particular. for green belt.
vii Land use break-up of total land of the project site (identified and All the additional facilities are coming in existing plant
acquired), government/ private - agricultural, forest, wasteland, premises only. AMNS is in Notified Industrial Area
water bodies, settlements, etc shall be included. (not required Please refer Section 2.11.1 on page no. 2-63 of Chapter
for industrial area) 2
viii A list of major industries with name and type within study area Being in Notified Industrial Area, there are many
(10km radius) shall be incorporated. Land use details of the industries within 10 km radius of the AMNS premises.
study area Major industries are listed in
Section 2.4 on page no. 2-5 of Chapter 2
ix Geological features and Geo-hydrological status of the study Detailed Geological and Hydro Geological study has
area shall be included. been conducted.
x Details of Drainage of the project up to 5km radius of study This is modernisation project with instalati0on of
area. If the site is within 1 km radius of any major river, peak auxiliary facilities. Total Production capacity will
and lean season river discharge as well as flood occurrence remain the same even after this project.
frequency based on peak rainfall data of the past 30 years. Please refer Section 3.7 on page no. 3-14 of Chapter 3
Details of Flood Level of the project site and maximum Flood
Level of the river shall also be provided. (mega green field
projects)
xi Status of acquisition of land. If acquisition is not complete, There is no land acquisition is required. All the
stage of the acquisition process and expected time of complete proposed auxiliary facilities are going to come in
possession of the land. existing project site only.
Please refer Section 2.11.1 on page no. 2-63 of Chapter
2
xii R&R details in respect of land in line with state Government This is an existing project situated at Notified
policy Industrial Estate. Hence no R&R study is
recommended.
5 Forest and wildlife related Issues:
i Permission and approval for the use of forest land (forestry Forest Clearance is required only if any forest land is
clearance), if any, and recommendations of the State Forest involved as project site. This is an existing project
Department. (if applicable) situated at Notified Industrial Estate.
ii Land use map based on High resolution satellite imagery (GPS) This is an existing project situated at Notified
of the proposed site delineating the forestland (in case of Industrial Estate with no forest land inside plant
projects involving forest land more than 40ha) premises.
iii Status of Application submitted for obtaining the stage I forestry Forest Clearance is required if any forest land involved
clearance along with latest status shall be submitted. as project site


This is an existing project situated at Notified
Industrial Estate with no forest land inside plant
premises.
iv The projects to be located within 10 km of the National Parks, Wild life Clearance required if any Wild life sanctuary
Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild and National Park located near (within10 km) the
Animals, the project proponent shall submit the map duly project site.
authenticated by Chief Wildlife Warden showing these features This is an existing project situated at Notified
vis-à-vis the project location and the recommendations or Industrial Estate with no Wild life sanctuary and
comments of the Chief Wildlife Warden-thereon National Park located near the project site.
v Wildlife Conservation Plan duly authenticated by the Chief Wild life conservation plan is prepared by Ecology bio
Wildlife Warden of the State Government for conservation of diversity experts and submitted for authentication by
Schedule I fauna, if any exists in the study area chief wildlife warden. Will submit the same
immediately on receipt.
Please refer section 8.4.4 on page no 8-15 of chapter 8
vi Copy of application submitted for clearance under the Wildlife Not Applicable.
(Protection) Act, 1972, to the Standing Committee of the
National Board for Wildlife.
6 Environmental Status
i Determination of atmospheric inversion level at the project site Please refer Section 3.4 on page no. 3-3 of Chapter –3
and site-specific micrometeorological data using temperature,
relative humidity, hourly wind speed and direction and rainfall.
ii AAQ data (except monsoon) at 8 locations for PM10, PM2.5, Please refer section 3.5 on page no. 3-5 of chapter 3
SO2, NOx, CO and other parameters relevant to the project
shall be collected. The monitoring stations shall be based CPCB
guidelines and take into account the predominant wind
direction, population zone and sensitive receptors including
reserved forests.
iii Raw data of all AAQ measurement for 12 weeks of all stations Please refer section 3.5 on page no. 3-5 of chapter 3
as per frequency given in the NAQQM Notification of Nov.
2009 along with - min., max., average and 98% values for each
of the AAQ parameters from data of all AAQ stations should be
provided as an annexure to the EIA Report.
iv Surface water quality of nearby River (100m upstream and Please refer section 3.6 on page no. 3-8 of chapter 3
downstream of discharge point) and other surface drains at eight
locations as per CPCB/MoEF&CC guidelines.
v Whether the site falls near to polluted stretch of river identified No, the site does not fall near to polluted stretch of
by the CPCB/MoEF&CC, if yes give details. river identified by the CPCB/MoEF& CC, the site
located inside the notified industrial area
vi Ground water monitoring at minimum at 8 locations shall be Please refer section 3.6 on page no. 3-8 of chapter 3
included
vii Noise levels monitoring at 8 locations within the study area. Please refer section 3.8 on page no. 3-20 of chapter 3
viii Soil Characteristic as per CPCB guidelines. Please refer section 3.10 on page no. 3-24 of chapter 3
ix Traffic study of the area, type of vehicles, frequency of vehicles Please refer section 3.9 on page no. 3-22 of chapter 3
for transportation of materials, additional traffic due to proposed
project, parking arrangement etc.
x Detailed description of flora and fauna (terrestrial and aquatic) Detailed Conservation plan is prepared and two season
existing in the study area shall be given with special reference to marine study has also conducted.
rare, endemic and endangered species. If Schedule- I fauna are Please refer section 3.13 on page no. 3-33 of chapter 3
found within the study area, a Wildlife Conservation Plan shall
be prepared and furnished.
xi Socio-economic status of the study area. Please refer section 3.12 on page no. 3-28 of chapter 3
7 Impact and Environment Management Plan
i Assessment of ground level concentration of pollutants from the Please refer section 4.3 on page no. 4-2 of chapter 4
stack emission based on site- specific meteorological features.
In case the project is located on a hilly terrain, the AQIP
Modelling shall be done using inputs of the specific terrain
characteristics for determining the potential impacts of the
project on the AAQ. Cumulative impact of all sources of
emissions (including transportation) on the AAQ of the area
shall be assessed. Details of the model used and the input data
used for modelling shall also be provided. The air quality


contours shall be plotted on a location map showing the location
of project site, habitation nearby, sensitive receptors, if any.
ii Water Quality modelling - in case, if the effluent is proposed to 100% ZLD scheme is proposed and please refer
be discharged in to the local drain, then Water Quality Modeling section 2.11.6.2 on page no 2-70 of chapter 2
study should be conducted for the drain water taking into
consideration the upstream and downstream quality of water of
the drain.,
iii Impact of the transport of the raw materials and end products on Please refer section 2.10.6 on page no. 2-62 of chapter
the surrounding environment shall be assessed and provided. In 2
this regard, options for transport of raw materials and finished
products and wastes (large quantities) by rail or rail-cum road
transport or conveyor-cum-rail transport shall be examined.
iv A note on treatment of wastewater from different plant Please refer section 2.11.6 on page no. 2-68 of chapter
operations, extent recycled and reused for different purposes 2
shall be included. Complete scheme of effluent treatment.
Characteristics of untreated and treated effluent to meet the
prescribed standards of discharge under E(P) Rules.
v Details of stack emission and action plan for control of Please refer section 2.12.1 on page no. 2-94 of chapter
emissions to meet standards. 2
vi Measures for fugitive emission control Please refer section 4.3.3 on page 4-11 of chapter 4
vii Details of hazardous waste generation and their storage, Please refer section 2.12.3 on page no. 2-106 of
utilization and management. Copies of MOU regarding chapter 2
utilization of solid and hazardous waste in cement plant shall
also be included. EMP shall include the concept of waste- Please refer section 8.4.7 on page no. 8-17 of chapter 8
minimization, recycle/reuse/recover techniques, Energy
conservation, and natural resource conservation.
viii Proper utilization of fly ash shall be ensured as per Fly Ash From AMNS fly ash is not generated.
Notification, 2009. A detailed plan of action shall be provided.
ix Action plan for the green belt development plan in 33 % area Detailed action plan for greenbelt development and
i.e. land with not less than 1,500 trees per ha. Giving details of maintenance is made. Already we have 22% green belt
species, width of plantation, planning schedule etc. shall be and 11% is will be developed as per the details
included. The green belt shall be around the project boundary enclosed. Please refer section 8.4.3 on page no. 8-9 of
and a scheme for greening of the roads used for the project shall chapter 8
also be incorporated.
x Action plan for rainwater harvesting measures at plant site shall Detailed rain water harvesting plan has been developed
be submitted to harvest rainwater from the roof tops and storm and already implemented in site. Please refer section
water drains to recharge the ground water and also to use for the 8.4.2.2.1 on page no. 8-5 of chapter 8
various activities at the project site to conserve fresh water and
reduce the water requirement from other sources.
xi Total capital cost and recurring cost/annum for environmental Please refer section 2.7 on page 2-6 of Chapter 2
pollution control measures shall be included.
xii Action plan for post-project environmental monitoring shall Please refer section 5.3 on page 5-1 of Chapter 5
be submitted.
xiii Onsite and Offsite Disaster (natural and Man- made) Please refer section 6.13 on page 6-106 of Chapter 6
Preparedness and Emergency Management Plan including Risk
Assessment and damage control. Disaster management plan
should be linked with District Disaster Management Plan.
8 Occupational health:
i Details of existing Occupational & Safety Hazards. What are Please refer section no. 8.4.6 on page no 8-16 of
the exposure levels of hazards and whether they are within chapter 8
Permissible Exposure level (PEL). If these are not within PEL,
what measures the company has adopted to keep them within
PEL so that health of the workers can be preserved,
ii Details of exposure specific health status evaluation of worker. Please refer section no. 8.4.6 on page no 8-16 of
If the workers' health is being evaluated by pre-designed format, chapter 8
chest x rays, Audiometry, Spirometry, Vision testing (Far &
Near vision, colour vision and any other ocular defect) ECG,
during pre-placement and periodical examinations give the
details of the same. Details regarding last month analysed data
of above mentioned parameters as per age, sex, duration of
exposure and department wise.

iii Annual report of health status of workers with special reference
to Occupational Health and Safety.
iv Plan and fund allocation to ensure the occupational health & Please refer section 8.4.6 on page no. 8-16 of chapter
safety of all contract and casual workers 8.
9 Corporate Environment Policy
i Does the company have a well laid down Environment Policy Please refer section 8.6 on page no. 8-19 of chapter 8.
approved by its Board of Directors? If so, it may be detailed in
the EIA report.
ii Does the Environment Policy prescribe for standard operating Please refer section 8.7 on page no. 8-19 of chapter 8.
process / procedures to bring into focus any infringement /
deviation / violation of the environmental or forest norms
/conditions? If so, it may be detailed in the EIA.
iii What is the hierarchical system or Administrative order of the AMNS is headed by the CEO and the board of
company to deal with the environmental issues and for ensuring directors, followed by the vice president and the head
compliance with the environmental clearance conditions? of HSE.
Details of this system may be given.
Please refer section 8.6 on page no. 8-19 of chapter 8.
iv Does the company have system of reporting of non-compliances The company has a well experienced team consisting
/ violations of environmental norms to the Board of Directors of of officers from various departments to co-ordinate the
the company and / or shareholders or stakeholders at large? This activities concerned with management and
reporting mechanism shall be detailed in the EIA report implementation of the environmental control measures.
Head EHS is having direct access to top management
to discuss all non-compliances and violations and take
necessary actions to not to reoccur those.
Please refer section 8.5 on page no. 8-18 of chapter 8.

10 Details regarding infrastructure facilities such as sanitation, fuel,
AMNS provides excellent infrastructural facilities to
restroom etc. to be provided to the labour force during employees as well as labourers, the company gives
construction as well as to the casual workers including truck prima facie importance to sanitation by providing
drivers during operation phase. restrooms to all workers.
8.
11 To Address the Public Hearing issues, provisions contained Noted
under Ministry’s Office Memorandum vide F.No. 22-65/2017-
IA.III dated 30/09/2020 shall be complied.
12 Any litigation pending against the project and/or any Show cause notice received from GPCB has been
direction/order passed by any Court of Law against the project, listed and details of NGT order is also summarised.
if so, details thereof shall also be included. Has the unit received Please refer Section 1.9 of page no. 1-9 of chapter 1.
any notice under the Section 5 of Environment (Protection) Act,
1986 or relevant Sections of Air and Water Acts? If so, details
thereof and compliance/ATR to the notice(s) and present status
of the case.
13 A tabular chart with index for point wise compliance of Complied
above TOR.
14 The ToRs prescribed shall be valid for a period of three year for Noted
submission of the EIA-EMP reports along with Public Hearing
Proceedings (wherever stipulated)
SPECIFIC TERMS OF REFERENCE FOR EIASTUDIES FOR METALLURGICAL INDUSTRIES (FERROUS & NON-
FERROUS)
1 Complete process flow diagram describing each unit, its Please refer section 2.9.4 on page no. 2-10 and section
processes and operations, along with material and energy inputs 2.9.5 on page no 2-39 of chapter 2
& outputs (material and energy balance).
2 Details on blast furnace/ open hearth furnace/ basic oxygen Please refer section 2.9.4 on page no. 2-10 and section
furnace/ladle refining, casting and rolling plants etc. 2.9.5 on page no 2-39 of chapter 2
Details on installation/activation of opacity meters with Proposed installation /activation of opacity meter with
3 recording with proper calibration system recording proper calibration system is under progress
Please refer section 2.12.1.3 on page no. 2-104 of
chapter 2
4 Details on toxic metals including mercury, arsenic and fluoride From the analysis report, it is evident that, No toxic
emissions metals including mercury, arsenic, fluoride etc are
emitted from the stack.


5 Details on stack height requirement for integrated steel All the stacks are installed based on the calculations
with possible emission from the source. The height is
finalised as per CPCB guidelines. Please refer section
2.12.1 on page no. 2-94 of chapter 2
6 Details on ash disposal and management -Non-ferrous metal Not applicable
7 Complete process flow diagram describing production of Not applicable
lead/zinc/copper/ aluminium, etc.
8 Raw materials substitution or elimination Please refer section 2.10 on page no. 2-57 of chapter 2
9 Details on smelting, thermal refining, melting, slag fuming, and Not applicable
Waelz kiln operation
10 Details on Holding and de-gassing of molten metal from Not applicable
primary and secondary aluminum, materials pre-treatment, and
from melting and smelting of secondary aluminium
11 Details on solvent recycling Not applicable
12 Details on precious metals recovery Not applicable
13 Details on composition, generation and utilization of waste/fuel Please refer process description of Coke oven recovery
gases from coke oven plant and their utilization. type on page 2-13 of chapter 2
14 Details on toxic metal content in the waste material and its Detailed analysis report enclosed. Please refer section
composition and end use (particularly of slag). 4.5.2 on page no. 4-21 of chapter 4
15 Trace metals Mercury, arsenic and fluoride emissions in the raw Please refer annexure 23
material.
16 Trace metals in waste material especially slag. Please refer section 2.12.3 on page no. 2-106 of
chapter 2
17 Plan for trace metal recovery Not applicable
18 Trace metals in water Please refer section 2.11.6.8 on page no 2-94 of
chapter 2
ADDITIONAL TORS FOR INTEGRATED STEEL PLANT
1 Iron ore/coal linkage documents along with the status of Please refer section 2.10.2 on page no. 2-59 of chapter
environmental clearance of iron ore and coal mines 2
2 Quantum of production of coal and iron ore from coal & iron Please refer section 2.10.2 on page no. 2-59 of chapter
ore mines and the projects they cater to. Mode of transportation 2
to the plant and its impact
3 For Large ISPs, a 3-D view i.e. DEM (Digital Elevation Model) Please refer section 3.7.1 on page no. 3-15 of chapter
for the area in 10 km radius from the proposal site. MRL details 3.
of project site and RL of nearby sources of water shall be
indicated
4 Recent land use map based on satellite image. High resolution Please refer section 3.11 on page no. 3-26 of chapter 3.
satellite image data having 1m – 5m spatial resolution like quick
bird, Ikonos, IRS P-6 pan sharpened etc. for the 10 km radius
area from proposed site. The same shall be used for land used
/land –cover mapping of the area.
5 PM (PM10 and PM 2.5) present in the ambient air must be Please refer section 3.5.2 on page no. 3-5 of chapter 3.
analysed for source analysis – natural dust/RSPM generated
from plant operations (trace elements) of PM10 to be carried
over.
6 All stock piles will have to be on top of a stable liner to avoid All stock piles will be on top of a stable liner to avoid
leaching of materials to ground water. leaching of materials to ground water
7 Plan for the implementation of the recommendations made for Please refer section 8.7 on page no. 8-19 of chapter 8
the steel plants in the CREP guidelines.
8 Plan for slag utilization Slag is utilizing for road making in the plant premises
9 Plan for utilization of energy in off gases (coke oven, blast Please refer section 2.11.4 on page no. 2-68 of chapter
furnace) 2
10 System of coke quenching adopted with justification. Please refer section 2.10.8 on page no. 2-63 of chapter
2
14 Details of proposed layout clearly demarcating various units Please refer section 2.3 on page no. 2-1 of chapter 2
within the plant
15 Complete process flow diagram describing each unit, its Please refer section 2.9 on page no. 2-9 of chapter 2


processes and operations, along with material and energy inputs
and outputs (material and energy balance)
16 Details on design and manufacturing process for all the units Please refer section 2.9 on page no. 2-9 of chapter 2
17 Details on environmentally sound technologies for recycling of Environmentally sound technologies for the recycling
hazardous materials, as per CPCB Guidelines, may be mentioned and reuse of solid and hazardous waste has been
in case of handling scrap and other recycled materials devised.
Please refer section 2.12.3 on page no. 2-106 of
chapter 2
18 Details on requirement of energy and water along with its source Please refer section 2.11.6 on page no. 2-68 of chapter
and authorization from the concerned department. Location of 2
water intake and outfall points (with coordinates)
19 Details on toxic metal content in the waste material and its Please refer section 2.12.3 on page no. 2-106 of
composition and end use (particularly of slag) chapter 2
20 Details on toxic content (TCLP), composition and end use of Please refer section 2.12.3 on page no. 2-106 of
slag chapter 2

Chapter – 1
Introduction
1.1 Background
M/s. ArcelorMittal Nippon Steel India Limited (hereafter referred as AM/NS India Ltd) is a joint venture
between ArcelorMittal one of the world’s leading steel and mining companies, and Nippon Steel, Japan’s
largest steel producer. AM/NS owns and operates an integrated well-planned, sophisticated and
environment-friendly steel complex at a distance of 27 km (Surat-Hazira road) from Surat City in Gujarat
State. This is the largest single location of flat steel production in India with an annual production capacity
of 9.6 million tons. and supported by a complete infrastructure setup, including captive port, power plant,
lime plant and oxygen plant. The plant's downstream facilities include 1.5 MMTPA plate mill, 0.6 MTPA
pipe mills and 1.2 MMTPA cold rolling complexes.
AM/NS has the statutory Environment Clearances issued by Ministry of Environment & Forests, Govt. of
India. Now the company has decided to propose some modifications in the Hazira facility by installing
Auxiliary Facilities to support the existing facilities to achieve their best without increasing Plant Capacity.
Ministry of Environment, forests and Climate Change has already accorded environmental clearances for
the existing integrated steel plant. Details of Environmental Clearance granted is given in table 1.1.
Table 1.1 Details of Existing EC’S Granted

Year of EC
Granted
capacity 1190 meter
2008
J-11011/714-A/2008-IAII(I) Pellets Plant (4 MMTPA), HBI/DRI (1.85 MMTPA), COREX
*We have not yet achieved 9.6 MTPA (with the proposed modifications, we will be able to achieve 9.6
MTPA by 2025)

Table 1.2 Implementation status of the existing EC 2016

Unit
No. 2016
in 2016 in 2020
Crude Tar (By – TPA 52,200 63,000 1,15,200
Product)
Sulphur (By – TPA 1,700 1,980 3,680
Product)
Product)
5 Air Separation
Oxygen Liquid Nm /hr 2,950
3 500 3,450 2950 in operations
1(EAF) (4Nos.)
Furnace (BoF) (3
Nos.)
(4 EAF& 4LF)
(Lime / Dolime)
& Long Product -
HRC
Wire Rod 0.7 0 0.7
15 Caster Shop
Caster
16 CRM

Sr. Name of Facility Unit As per EC dated 9th March Implementation Status as on Dec, 2020
No. 2016
in 2016 in 2020
Coils/Sheets
Jetty
Based Power Plant
19 Pipe Mill
received from SPCB)
Copy of environmental clearance of 2016 is enclosed as annexure-1
increase in the steelmaking capacity.
Table 1.3 Details of proposed Auxiliary Facilities

15 CRM-2
CR Coils/Sheet 2.2

for Special grades)
Coke oven gas
1.2 Purpose of the Report

The Environmental Impact Assessment (EIA) study has been carried out as a part of the process to obtain
Environmental Clearance for the above-mentioned modification proposed. Environmental Management
Plan (EMP) and Mitigation Plan have been prepared to effectively minimize potential adverse
environmental impacts due to the proposed modification.
The draft EIA/EMP Report have been prepared in line with Terms of Reference (TOR) suggested by
Environmental Appraisal Committee of MoEF&CC.
The overall objective of any EIA exercise is to identify and assess the adverse impacts of a project to the
environment in the planning stage itself, so that necessary mitigation measures can be taken to minimize or
reduce the impact in a cost-effective way. In view of this, the specific objectives of this EIA are as follows:
• To have an in-depth know-how of the project and to identify the probable sources of pollution that
may arise from each stage of the process
• To review current environmental status of the area within 10 km radius of the project site by
collecting the baseline data on the environmental attributes including air, noise, water, land,
ecological, hydro-geological climate and socio-economic environments
• To estimate the impacts of the project on the surrounding environment and mitigation measures
proposed
• To prepare a comprehensive Environmental Management Plan to ensure that the environmental
quality of the area would be preserved
• To formulate a strategy for effective monitoring and identify any deviations in the environmental
quality after the project is operational, which would help in evolving in depth measures.
1.3 Identification of the Project Proponents

M/s. ArcelorMittal Nippon Steel India Limited is a joint venture between M/s. ArcelorMittal, one of the
world’s leading steel and mining companies, and M/s Nippon Steel, Japan’s largest steel producer. Both
ArcelorMittal and Nippon Steel have an excellent track record as well as achievements in the capital
intensive and competitive manufacturing sectors.
ArcelorMittal and Nippon Steel have become leading players in each of their businesses with a focused
approach through integration, incorporation of state of the art technology and innovative in-house research.
AMNS operates an integrated steel complex at Hazira. The complex is one of the largest single location flat
steel producer in India with an annual production capacity of 9.6 million tons.
1.4 Brief description of the Project

AMNS want to add some more facilities at same premises. These facilities are for increasing the efficiency
by modification or replacement of facilities with out increasing plant capacity. In effect these modifications
are planned to achieve the total production capacity.

1.5 Need for the Project

These projects are required now to achieve the total granted capacity, as till date the industry was operating
near about to 6MTPA capacity. Looking to the worldwide demand of steel and the boost imparted by the
new ownership really looking for achieving the maximum capacity possible from the facility. While
evaluating the requirements to achieve the same within the existing facility, some gap analysis has been
done and some projects, which directly have impact on production, environment and sustainability were
identified. And to implement those projects, this proposal has been made to ministry to obtain required
clearances
Table 1.4 Need of the proposed Auxiliary Facilities

EAF/CONARC
7 Blast Furnace Dust Catcher /Dust The blast furnace (BF) process is the most important process in
temperatures

14 Hot metal Pretreatment Station Pretreatment of hot metal. ... Pre-treatment of hot metal is the
Outside Shop (KR Technology) adjustment of the composition and temperature of blast furnace
produced hot metal for optimal operation of the oxygen converter
process
temperature
temperatures.
irrigation use.
three Phases
Phase 1:
Mill (CTCM)


Phase 2:
mill (PLTCM)
(CGL-3)
Phase 3:
1.6 Demand-Supply Gap

Looking to the up-world demand of steel both internationally & domestic and the boost imparted by the
new ownership really looking for achieving the maximum capacity possible from the facility, we intend to
increase the production beyond 6 MTPA as per the margin available in the existing EC. Further Make in
India drive from the Government of India had boosted the requirement of achieving the highest volume of
production from any unit.
We are gradually improving and attain a production of 9.6 MMTPA of Crude steel due to variable product
mix depending on the market demands and price patterns
The applied 21 projects are auxiliary in nature and will help us to de-bottleneck our operations, improve
product mix and reduce cost and achieve the volumes in current market scenario. The CRM lines will
support us to increase the Value-added component of our total production.
Currently about 65-70% of production from Hazira is in form of Hot Rolled (HRC/S/P) with CRM
Complex production in the range of about 18%. When we increase the Crude steel volume the CRM
complex share will reduce initially as our existing lines are already max. out and will increase the HR
product %. The additional CRM complex will help us to initially maintain and later increase the share of
CRM Complex as we increase Crude Steel volume.
Saleable product mix data for augmented production of Crude Steel

We are gradually improving and attain a production of 9.6 MMTPA of Crude steel due to variable product
mix depending on the market demands and price patterns.
The CY20 Actual (in spite of COVID) and CY21 Planned numbers are given below -
(Figures in Thousand TPA)
CY20 Actual CY21 Plan
Liquid Steel 6706 7436
FG 6388 7009
Product wise
HRC/S/P 4373 68% 4592 66%
HRPO 233 4% 294 4%
CR 381 6% 455 6%

GAL 483 8% 540 8%

CR Plant routed 18% 18%
Plate 575 9% 696 10%
Pipe 159 2% 215 3%
Commercial quality 185 3% 217 3%
The applied 21 projects are auxiliary in nature and will help us to de-bottleneck our operations, improve
product mix and reduce cost and achieve the volumes in current market scenario. The CRM lines will
support us to increase the Value-added component of our total production.
Currently about 65-70% of production from Hazira is in form of Hot Rolled (HRC/S/P) with CRM
Complex production in the range of about 18%. When we increase the Crude steel volume the CRM
complex share will reduce initially as our existing lines are already max. out and will increase the HR
product %. The additional CRM complex will help us to initially maintain and later increase the share of
CRM Complex as we increase Crude Steel volume.
(Figures in Thousand TPA)

CY21 Plan CY24 CY25
CRM Line 1289 1300 1300
New CRM 400 1350
1289 1700 2650
Total FG 7009 8600 8600
% CRM 18% 20% 31%
1.7 Structure of the EIA Report

Environment Impact Assessment (EIA) and Environmental Management Plan (EMP) report is based on the
guidelines of the Ministry of Environment, Forests & Climate Change (MoEF&CC) and Central Pollution
Control Board (CPCB). It incorporates the following.
• Chapter 1 is an Introduction to the Industry, purpose of the report, information of project proponent
and regulatory frame work.
• Chapter 2 presents a Description of Project and Infrastructure facilities including industrial and
environmental aspects of M/s. AMNS India Limited during operation phase activities as well as
manufacturing process details of proposed product. This chapter also gives information about project
location, raw material storage and handling, water and wastewater quantitative and qualitative details,
treatment of industrial and domestic effluent, details of air pollution and its control system, type and
quantity of hazardous waste generation and its management, details of utilities etc. for the existing as
well as proposed modification of the unit.
• Chapter 3 covers Baseline Environmental Status including meteorological details, Identification of
baseline status of Environmental components of the surrounding area covering air, water, noise and
land environment, study of land use pattern, ecological and socio-economic environment giving
details about District Surat as well as the study area.
• Chapter 4 deals with Identification and Prediction of Impact, which provides quantification of
significant impacts of the proposed replacement activities on various environmental components.
Evaluation of the proposed pollution control facilities has been presented.
• Chapter 5 describes Environment Monitoring Plan to be adopted.
• Chapter 6 gives the information of Public Hearing and additional studies like Risk Analysis and
Disaster Management Plan that is adopted by the company.
• Chapter 7 gives the benefits of the projects.

• Chapter 8 describes Environment Management Plan (EMP) to be adopted for mitigation of anticipated
adverse impacts if any and to ensure acceptable impacts.
• Chapter 9 gives the summary and conclusion of the report.
• Chapter 10 gives the information of the consultant.
1.8 Regulatory Frame Work
Environment clearance application for Modification in Existing Plant by installing Auxiliary Facilities
without increasing Plant Capacity for Steel Making in the Form-I along with Prefeasibility report to
MoEF&CC (Ministry of Environment, Forest and Climate Change) was submitted on 24th Dec 2020 and
TOR meeting was held on 19th January, 2021.
The EIA and EMP Report has been prepared in line with Terms of Reference (TOR) issued by Reconstitute
Environmental Appraisal Committee (Industry) (EAC-(I)) vide MoEF&CC letter No. F. No. J-
11011/44/2004-IA II(I) dated 8th February, 2021 enclosed as Annexure-2. The compliance of Terms of
Reference (regulatory scoping carried out as per TOR).
1.9 Show Cause Notices

The details of show cause notices of last year given in table 1.5. Notice of Directions (NoD) is given in
table 1.6
Table 1.5 List of Show Cause Notices (SCN) Last Year

Show cause Notice Under Reason Compliance Done
no. & date Section
SCN-551312 Air Act Looking to IR Observation dusting was observed at Compliance report
Dated 16/01/2020 ground level due to truck movement on dry roads. submitted to GPCB.
Also SPM = 247 mg/Nm3 (limit - 60 mg/Nm3) in the

ambient sampling done at the terrace of the plant.
Table 1.6 List of Notice of Directions (NoD) - Last Year

Sr Notice of Under Reason Compliance
No. Direction & Date Section Done
1 GPCB/CCA- Air Act 1) Brown Coloured dusting was observed from Compliance
SRT-1190(3) / SMP-2 furnace. report submitted
ID-14186/561688 2) Dusting was observed in the bottom line feeding to GPCB.
dated 09.06.2020 area of Stock house.
3) Haphazard storage of fly ash was found in corex-
1 plant area.
4) Analysis report of sample collected from Stack
attached to stock House- Coal Line 1 of corex
plant shows PM – 371 mg/Nm3 (Limit – 150
mg/Nm3)
5) Analysis report of ambient air sample shows
PM10 – 292.67 mg/Nm3 which is higher than
permissible limits.
2 GPCB/CCA- Air Act 1) Brownish Fugitive emission from Corex and Compliance
SRT- SMP-II plant and accumulation of dust (Reddish report submitted
1190(5)/ID_1418 particulate matter) on leaf of trees. to GPCB.
6/572184 dated 2) Heavy Dusting due vehicular movement in plant
04.11.2020 premises.
3) Result of AAQM sample i.e Particulate matter- 307
mg/Nm3 is exceeding the permissible limit.
3 GPCB/CCA- Water Act 1) Unit is discharging generated wastewater having Compliance
SRT- minor flow & pH @2 to 4 from central laboratory report submitted

Sr Notice of Under Reason Compliance

No. Direction & Date Section Done
1190(5)/ID_1418 located in Corex Plant in to nearby storm water to GPCB.
6/572186 dated drain within factory premises.
04.11.2020 2) Unit is discharging treated wastewater in to storm
water drain which is ultimately goes to estuary of
river tapi which violates the CC&A condition i.e.
Zero liquid discharge outside the factory premises.
3) In SMP-II plant, ETP sludge (@ 300 MT) is
stored in open land & accumulation of sludge on
land in haphazard manner near clarifier area.
4) Accumulation of sludge in haphazard manner near
sludge drying bed.
5) Provided hazardous waste storage area seems to
be inadequate in capacity with the actual
generation of the unit and roof of the storage area
is damaged.
6) Unit has stored huge quantum of granulated slag
on open land near jetty.
7) There is no mentioning of Fuel/Raw material i.e.
Blending Coal in obtained EC issued in march
2016 w r to proposal.
8) Unit has proposed to use blended coal which is
not a authorized fuel.
9) Unit has proposed to sell tar sludge to outside
agency. The receptor details of the same is not
submitted.
4 GPCB/CCA- Air Act 1. Fugitive emission in the plant and road side due Compliance
SRT-340(15)/ID- to vehicular movement as well as heavy dust report submitted
20680/587088 deposition on the factory shed is observed. to GPCB.
dated 31.03.2021 2. Dust deposition on leaves of trees is observed at
various locations.
3. General housekeeping is observed very poor in
the plant area and water sprinkling is not carried
out regularly.
NOTE: ROSHNI B. PATEL VS. UOI & ORS (O.A. NO. 27 OF 2020 (WZ))
Background & Present Status
The applicant in the captioned matter has approached the Hon’ble National Green Tribunal (“NGT”)
regarding the alleged dumping of hazardous waste by Hazira Container Freight Station Private Limited
(“HCFS”) and ArcelorMittal Nippon Steel India Limited (“AMNS”).
The NGT on 4th August 2020 issued notice to the various respondents in the captioned matter and has
directed the respondents to file their replies. AMNS has accordingly already filed a detailed reply denying
the various allegations made in the captioned matter and has also clarified the factual position as detailed
hereafter.
Response by AMNS
1. Land presently bearing survey no. 261 is not owned by AMNS
a. It has been falsely alleged in the Application filed by the Applicant before the NGT that AMNS is
disposing of hazardous waste on a land bearing survey no. 261 owned by AMNS which is adjacent to
the land of HCFS and that the aforementioned land falls within Coastal Regulation Zone (“CRZ”).
b. Land presently bearing survey no. 261 which is adjacent to the land of HCFS is not owned by AMNS
and hence, AMNS is not disposing of any hazardous waste on the aforementioned land.

c. AMNS owned the earlier land bearing survey no. 261 which has been subsequently numbered as
survey no. 83 and this land presently bearing survey no. 83 owned by AMNS is located within the
premise of the Plant. Therefore, AMNS has nothing to do with land bearing survey no. 261.
2. Environmental compliance by AMNS

a. AMNS is an environmentally conscious company and it has been making all possible efforts to
operate in harmony with the environment. AMNS is operating in compliance with the regulations and
conditions imposed by or under existing laws in India.
b. AMNS has been undertaking several programs / activities / initiatives for the benefit of people
residing in and around Hazira as a part of its Corporate Social Responsibility (“CSR”) initiatives.
3. Disposal of hazardous waste

a. AMNS neither owns the land presently bearing survey no. 261 which is adjacent to the land of HCFS
as falsely alleged by the Applicant nor is it disposing of any hazardous waste on the aforementioned
land.
b. AMNS has been ensuring that the hazardous waste generated at the Plant is disposed of in
compliance with the applicable laws and conditions imposed on AMNS by relevant regulatory
authorities. Details of hazardous waste generated at the Plant and its disposal by AMNS is shown in
the table below:
Sr. Particulars Disposal/recycling

No.
1. Chemical sludge from waste Disposal at GPCB approved TSDF site.
water treatment
2. Used or spent oil Sent to registered re-refiner.
3. Empty barrels / Containers / Liners contaminated Sent to registered re-refiner.
with hazardous chemicals / waste
4. Zinc Dross Sent to authorised recycler.
5. Iron slag Being recycled internally in the Blast Furnace,
Corex and also being used for construction of
internal plant roads and village roads.
6. Granulated slag Being sold to authorised personnel/agencies.
7. Fly ash There is no generation of fly ash from the
Plant.
c. There is no fly ash generation from the Plant of AMNS.
d. AMNS procures power pursuant to a power purchase agreement entered into by AMNS (“PPA”),
which is very much essential for the seamless operation of its Plant. As per the terms of the PPA,
AMNS is being supplied with fly ash generated from the power plant and the same is thereafter in a
compliant manner sold to third parties who inter alia undertake to comply with all the applicable
environmental compliances in this regard.
e. The Applicant in its Application before the NGT has created an illusion that fly ash is a hazardous
waste, however, it is to be noted that fly ash is excluded from the category of hazardous wastes as per
the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016.
4. HCFS requested for waste material from AMNS by promising compliance with environmental
laws
a. HCFS has been requesting AMNS for providing waste material to them for developing or reclaiming
their land and has stated in its letters that they take responsibility for complying with Statutory
Environment Acts / Rules / Norms in this regard.
5. Allegations raised against AMNS are vague and cryptic

a. The Applicant in the Application before the NGT has made whimsical, vague and cryptic allegations
against AMNS without supplying any specific proof or acceptable material to substantiate the
allegations.

b. Applicant has not placed any material on record to substantiate the allegation that AMNS is disposing
of hazardous waste on a land bearing survey no. 261 which is adjacent to the land of HCFS.
c. It is submitted that one of the grounds raised by the Applicant in its Application is the violation of the
Wildlife (Protection) Act, 1972. AMNS denies violation of the Wildlife (Protection) Act, 1972.
d. No cause of action against AMNS is disclosed in the Application and the applicant is trying to obtain
relief by misleading the NGT.
GPCB ACTION TAKEN REPORT

GPCB is Respondent No. 5 in the case before the NGT. GPCB has submitted its Action Taken Report and
in the said report, GPCB has stated that AMNS plant was visited by GPCB on 03.09.2020 and one of the
salient features of the inspection report is that at present, no dumping / storage of the fly ash / slag /
hazardous waste is observed on the land bearing survey no. 261.

Chapter – 2
Project Description and Infrastructural Facilities
2.1 Project Description
M/s. ArcelorMittal Nippon Steel India Limited (hereafter referred as AM/NS India Ltd) is a joint venture
between ArcelorMittal one of the world’s leading steel and mining companies, and Nippon Steel, Japan’s
largest steel producer. AM/NS owns and operates an integrated well-planned, sophisticated and
environment-friendly steel complex at a distance of 27 km (Surat-Hazira-road) from Surat City in Gujarat
State. This is the largest single location of flat steel production in India with an annual production capacity
of 9.6 million tons. and supported by a complete infrastructure setup, including captive port, power plant,
lime plant and oxygen plant. The plant's downstream facilities include plate mill, pipe mills and cold rolling
complexes.
AM/NS has the statutory Environment Clearances issued by Ministry of Environment & Forests, Govt. of
India. Now the company has decided to propose some modifications in the Hazira facility by installing
Auxiliary Facilities to support the existing facilities to achieve their best without increasing Plant Capacity.
2.2 Justification of the Project

These projects are required now to achieve the total granted capacity, as till date the industry was operating
near about to 6.0 MTPA capacity. Looking to the worldwide demand of steel and the boost imparted by the
new ownership really looking for achieving the maximum capacity possible from the facility. While
evaluating the requirements to achieve the same within the existing facility, some gap analysis has been
done and some projects, which directly have impact on production, environment and sustainability were
identified. And to implement those projects, this proposal has been made to ministry to obtain required
clearances.
2.3 Location of the Project Site and Surrounding Salient Features

Location Map, Google Image, Photographs of Project Site and Detailed Layout Map of the project is shown
in figure-2.1, figure-2.2, figure-2.3 and figure-2.4 respectively. A location detail of the site is given below.
The surrounding salient features and Environmental Setting are given in table 2.1

b) Village : Hazira
d) District : Surat
e) State : Gujarat

Figure 2.1 Detailed map of Surat District Showing Project Location

Figure 2.2 Google Image of Project Site
Figure 2.3 Photographs of Project Site
CRM complex AMNS House
Water Reservoir within project site CRM Plant

Internal Road within plant premises
Figure 2.4 Plant Layout showing Existing Plant Facilities and Proposed Auxiliary Facilities

Table 2.1 Surrounding Salient Features and Environmental Setting

Headquarter
2.4 Details of Major Industries within study area (10 kms radius)
Hazira is one of the major ports of India and the most important element of Surat Metropolitan Region.
The town is known as the industrial hub of India and is located on the bank of the Tapti River, two
kilometer away from the Arabian Sea. A base for major industrial and shipping facilities like Kribhco,
Shell, Larsen & Toubro , NTPC , ONGC, GAIL, Gujarat State Petroleum Corporation, UltraTech
Cement and Hazira Manufacturing Division (HMD) of Reliance Industries, EBTL, Adani Hazira port etc.
the list of major industries within study area given in following table 2.2.
Table 2.2 List of Major Industries within Study Area (10 KMs RADIUS)
Sr. No. Industry Name Type Distance and direction
1 Kribhco Ltd. Chemical Fertilizers 2 km North - East
Isolated storage & handling of hazardous
2 Shell India 3 km North - East
chemicals
3 Larsen & Toubro Ltd. (L&T) Heavy engineering unit 1 km North - East
4 NTPC Thermal power plant 4 km North - East
5 ONGC Petro-chemical complexes 10 km North - East
6 GAIL 6 km North - East
chemicals
7 GSPC Petro-chemical complexes 5 km North - East
8 UltraTech Cement Cement plant 4.5 km North - East
Petrochemical based processing (processes other
9 Reliance Industries than cracking & reformation and not covered 4 km North - East
under the complexes)
10 Adani Hazira Port Port 3 km South -West
11 IBP Hazira Terminal 10 km North-East
chemicals
Krishak Bharati Cooperative
12 Chemical fertilizers 8.6 km North -East
Ltd. (KRIBHCO)
Gujarat State Energy
13 Thermal power plant 5.9 km North-East
Generation Ltd. (GSEG)
14 Cairn energy Isolated storage & handling of hazardous 5.8 km North

Sr. No. Industry Name Type Distance and direction

chemicals
15 ABG Ship Yard Ship breaking and building 10 km North-East
16 The industry is inside the hazira notified industrial estate and hence surrounded by number of industries
2.5 Key Infrastructure Map of Project Site

A key Infrastructure map showing major features of study area covering 10 kms radius from the project site
is presented in following figure 2.5.
Figure 2.5 Key Infrastructure Features and Settlements
2.6 Importance to the Country and the region

The Proposed modification project of the industry will be beneficial to the region. The company will bring
new job opportunities for the local people. They will, therefore, become economically stronger. Following
are the key benefits of the project.
• Project will generate direct as well as indirect employment. The positive impact includes enhanced
direct employment for technical / administrative works and indirect employment opportunities for
transporters of raw material and finished goods.
• Project proponent currently performing CSR activities up to 2.5% of project cost which will uplift
the socio-economic status of nearby villages.
2.7 Cost of the Project

The total cost of the proposed modification would be approx. Rs. 6413.13 Crores. It includes Engineering
Procurement and construction cost. Detailed project cost breakup is given in table 2.3. Capital cost for
environmental pollution control measures will be around cost 1682.26 Cr. The cost breakup is given in the
following table 2.4

Table 2.3 Project Cost Break up for the proposed modification

Sr. Proposed
Facility Unit Engg. Procurement Construction Total
No. capacity
Coal briquetting plant - (1000
1 TPD 1,000.00 0 6 16 22
TPD)
BF - PCI Project - Pulverised
2 T/HR 80 0 40 26 66
coal
Lime Kiln (500 TPD) - Lime & MT/
3 15,000.00 - 33.78 6.7 40.48
Dolime Month
Rotary Kiln (200 TPD) - MT
4 6,000.00 3.12 22.5 4.38 30
Calcined Lime /Month
Blast Furnace Dust Catcher/Dust
5 TPD 150 0 1.5 1.07 2.57
Separation unit - 150 TPD
Acid Regeneration Plant - 100
6 KL/Day 100 0.8 20.9 6 27.7
KL & Pickling line - 3
BF Slag Grinding Mill (BOO) -
7 TPD 50 0 1 0.93 1.93
50 TPD
New Cooling Towers For
Mod 1 & 2 M3/HR 3,900.00 - 3 - 3
8
Mod 3 & 4 M3/HR 5,300.00 - 3 - 3
Mod 5 & 6 M3/HR 2,000.00 - 0.75 - 0.75
Slag conditioning & Metal
9 TPD 7,500.00 16.2 0 10.8 27
recovery plant
Thick plate Normalizing TO/YEA
10 15,000.00 - 3 1.5 4.5
Furnace R
TO/YEA 300,000.0
11 Shot Blasting Machine 1.2 8 1.6 10.8
R 0
3X500
12 VD Cooling Tower M3/HR 0.03 1.67 0.3 2
M3/HR
3X1065
13 RHD Tower M3/HR 0 2.16 0.2 2.36
M3/HR
Water Treatment plant for 500 2X500
14 M3/HR 0 10 20 30
MW CCPP M3/HR
CRM - 2 - - - 5940
Hot Rolled Pickled Coils/Sheets 3.2 - - - -
15 CR Coils/Sheets 2.2 - - - -
MTPA
Galvanised Coils/Sheets 1 - - - -
Annealing Coils/Sheets 1 - - - -
Ladle Furnace - Existing Liquid
16 steel 4.6 MTPA (Standby LF-5 _ _ - 32.64 6.44 39.08
for special grades)
SMP-1 Fume extraction system
17 _ _ 0.25 25.85 6.08 32.18
upgradation
Mod 4 Additional VPSA
18 toUtilize Corax Gas and going _ _ - - - 66.1
Forward Coke Oven gas
Hotmetal pretreatment station
19 _ _ - - - 12
Outside shop (KR Technology)
Tank Farm-2 With
20 interconnection between Pkl-3 & _ _ - - - 8
ARP-2
Additional ladle Furnace (LF7) -
21 MTPA _ 33.18 8.5 41.68
Standby for Special Grades
Total 6413.13

Table 2.4 Capital Cost and Recurring Cost for EPCM

Total 1682.26 377.95
2.8 Project Schedule and Implementation

Implementation of project within a pre-defined time frame is a significant factor for the success of a project.
Judicious implementation may save on numerous costs like interest, administrative overheads and helps to
realize the goals as per pre- defined objectives.
The implementation of the project will encompass foremost activities like preparation of specification /
drawings, issue of tenders, receipt of quotations, scrutiny of tenders, placing of orders, civil & structural
construction, delivery & erection of equipment, test trial runs of various items of equipment and
commissioning of the plant & equipment. Completion of the project will take place after getting the
necessary clearances from concerned authorities. The Implementation schedule for the proposed
modification is given in table 2.5
Table 2.5 Implementation Schedule

Months
Units
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
Coal briquetting Plant - (1000 TPD)
BF – PCI Project- Pulverized coal
Lime Kiln (500 TPD) - Lime and
Dolime
Rotary Kiln (200 TPD) - Calcined
Lime
Blast Furnace Dust Catcher /Dust
separation unit-150 TPD
Acid Regeneration Plant - 100 KL
& Pickling Line-3
BF slag grinding mill (BOO) - 50
TPD
New Cooling towers
Slag Conditioning & Metal
Recovery plant
Thick Plate Normalizing Furnace
Shot blasting machine
VD Cooling Tower
RHD Cooling Tower
Water Treatment Plant for 500 MW
CCPP
CRM-2 inclusive of CGL#3,
PLTCM, CGL#4 and C-GAL.
Ladle furnace - Existing Liquid
Steel 4.6 MTPA (Standby LF-5 for
Special grades)
SMP-1 furnace – existing liquid
steel 4.6 MTPA (Stand by LF-5 for
Special grade)
Mod 4 additional VPSA to utilize

Corex gas and going forward Coke

oven gas
Hot metal Pretreatment Station
Outside Shop (KR Technology)
Tank Farm-2 with interconnection
between PKL-3 & ARP-2
Additional Ladle Furnace (LF7) –
Standby for Special grades
2.9 Main Phases of the Project

2.9.1 Pre-Construction Activities
As the proposed modification project site is located in Hazira, Surat and well connected with road, rail and
sea. and it is near to Surat city. There is no need to construct any approach road for site access. No
significant pre-construction activities are anticipated.
2.9.2 Construction Activities

Construction activities will take place within the existing premises for proposed auxiliary facilities
mentioned above in phase wise manner and Construction shall be undertaken only after obtaining all the
statutory clearances:
2.9.3 Production Activities / Facility (Existing and Proposed Auxiliary facilities)

There is no enhancement in the production capacity by the installation of proposed Auxiliary facilities. The
capacity of existing plant facility and proposed auxiliary facilities is discussed in table 1.2 and 1.3
respectively of chapter 1.
2.9.4 Manufacturing Process Existing Units

E-1 HBI Plant (DRI Mod. I to VI)
Process Description
Lump ores and pellets from various sources are brought to the site by large ships, which anchor at outer
anchorage. Lump ores and pellets are basically iron oxide with 65-69 % Fe content. Natural gas, which
mainly consists of Methane, is reformed in presence of catalysts in Reformer. The cracked Natural gas
consisting of Carbon Monoxide and Hydrogen at a temperature of 900 °C is fed into shaft furnace from the
bottom. The oxide coming from top and reducing gas coming from the bottom reacts with each other.
Carbon Monoxide and Hydrogen having more affinity to Iron than oxygen, depletes oxygen from Iron
oxide thereby producing Sponge Iron. There is no intermediate phase of liquefaction involved in this
reduction. Therefore, the process is also called as Direct Reduction Iron (DRI).
DRI formed has a tendency of getting oxidized and is fire hazardous. To prevent this they are compressed
in Briquetting machine and produce a compact Hot Briquette Iron, which doesn't react with atmospheric air
and is easy to handle. Iron ore fines generated during the process is being presently sent to Pelletisation
Plant to convert the same into pellets which in turn being utilized as a raw material in HBI plant.

Flow Diagram of HBI Plant
E-2 Blast Furnace

Process Description
In the Blast Furnaces (BF) liquid iron (popularly termed as ‘Hot Metal’) is produced by the process of
reduction at high temperature from raw materials like iron ore, base mix, sinter, coke, fluxes (limestone /
quartzite), etc. &also air blast / O2. In blast furnace the process is also known as “Counter current process”
as solid raw material is being charged from the top and hot air is being blown from bottom. During the
process the impurities are removed in the form of slag and hot metal is produced. Coal is being injected to
reduce consumption of main fuel coke which is a cost reduction measure. Liquid metal and slag are being
separated in the area known as cast house. The liquid Hot Metal is transported in Hot Metal Ladles to the
Steel Melting Shops (SMS) for the production of steel.
Sometimes the Hot Metal is poured in the Pig Casting Machine (PCM) to produce Pig Iron. Slag produced
is granulated by high pressure water jets in the Cast House itself.
Sometimes the Hot Metal is poured in the Pig Casting Machine (PCM) to produce Pig Iron. Slag produced
is granulated by high pressure water jets in the Cast House itself or sent to Slag Dumping in the Slag Pots.
• Furnace Proper: In the Furnace Hot Metal (along with slag) is processed from the raw materials.
• Cast House: In the Cast House, Hot Metal & slag are tapped from the Furnace tap hole and after
flowing through a system of refractory lined troughs / runners flow into Hot Metal Ladles and slag
goes to granulation plant or dry pit.
• Stoves: Stoves heat the air blast provided by Turbo Blowers to the Blast Furnaces through the
Tuyeres.
• Raw material storage and Raw Material Charging Section: In this there are designated bunkers for
raw materials transported from yard / Sintering Plant (SP) / Raw Materials Handling Plant (RMHP)
by conveyors.
• Gas Cleaning Plant (GCP): The blast furnace gas (BFG) generated in the BF is cleaned through a
series of steps before transporting it to the BFG Holder.
• Slag Granulation Plant (SGP) / Dry pit: During the process of iron making, the impurities are
fluxed and removed as slag. The hot liquid slag is made into slag granules by means of high-
pressure water jets in the Slag Granulation Plant in the Cast House itself. If the slag is not
granulated in SGP, it is poured in the dry pit.
• Pig Casting Machine (PCM): Sometimes when there is poor off take of Hot Metal by SMS or if the
Hot Metal chemistry is very adverse, Hot Metal is taken to this section for casting into Pig Iron.
• Pulvarised coal Injection: In this section coal is pulvarised to fine dust in mills and injected in the
furnace.
Process flow Diagram of Blast Furnace
E-3 Sinter Plant:

Process Description
Sintering process is developed mainly to utilize under size of lump ore called iron ore fines; which
otherwise, could not be charged directly in blast furnace. In order to conserve these, otherwise waste
material, they are compacted together and made into lumps by a process known as sintering. Sintering is
defined as the agglomeration of the Iron ore fines (generally <8 mm) by incipient fusion of fine mineral
particles with heat produced by burning of coke breeze, uniformly distributed in raw mix bed. During the
sintering process, iron ore fine particles agglomerate into a porous compact heterogeneous lumpy mass
called SINTER by incipient fusion caused by the heat produced during the combustion of the solid fuel
within the moving bed of loosely particles.
The coke at the top of the blend is ignited by gas burners, that can be fueled by coke oven gas, blast furnace
gas, or natural gas. As the sinter bed moves, air is sucked from the top through the mixture, enabling
combustion through the entire layer and complete sintering – where the temperatures may reach 1300 –
1480oC. At the end of the strand, the material is cooled by air and finished sinter is size-screened.
As per given burden, raw materials are collected on a common conveyor from the respective bunkers
through weigh feeders and then mixed homogeneously in mixing drums (primary & secondary mixing
drums) by adding required water (7 to 8 %) and then feed on sinter machine. Generally, raw mix bed height
is 550 mm and is adjusted based on quality of the raw material. The bed in running (motion) condition is
taken to ignition front. The raw mix undergoes through the ignition furnace and there is a negative suction
from bottom. As soon as suction takes place, hot products of combustion are sucked through the bed and
transfer its heat to the next layer of the bed keeping it ready for the combustion. These flue gases are
let out from chimney through ESP. After completion of the sintering process, sinter cake will be
crushed and screened after discharge from the machine. Sinter having size > 5 mm will go to the cooler
and then it will go to BF. Sinter with size < 5 mm size fines will be re-cycled in the process.

Process Flow Diagram of Sinter Plant
E-4 Coke Oven Recovery Type:

Process Description
Major Design Features of Oven Plant

Sr. No. Description Unit Values
1. Utility requirement
Circulating water including Coke Dry quenching (CDQ) m3/h 25,290
Make up water m3/h 750
Power requirement
Maximum Demand for Coke oven plant MVA 26
Annual Energy Consumption for Coke oven Plant MU 175
Power generation from Coke dry Quenching Power plant MW 38
2A Production - Coke
BF Coke(25-80mm) t/yr 2,295,000
Nut coke(10-25 mm) t/yr 89,250
Coke Breeze (less than 10 mm) t/yr 165,750
2B By product
Crude tar t/yr 119,000
Sulphur t/yr 3,740
Crude Benzol t/yr 34,460
3. Coke oven gas generation (@340m3/TDCC) Nm3/h 131,960
4. Waste generation
Tar sludge t/yr 570
Biological Oxygen Demand (DBO) sludge t/yr 538
Waste water generation (COB+CDQ) m3/h 156
The major operation involved in the coke oven plants are

a) Coal handling plant
b) Coke oven Battery & Machines
c) Coke sorting plant
a) Coal Handling Plant

Coal transportation from stock yard to pre-crusher
Coal will be transported from existing coal stock yard to top of the crusher house through coal conveying
system.

Coal blending and crushing

Discharge of pre-crusher / bypass chute will be conveyed to blending silo building and will be fed to pre-
identified silo through conveyor fitted with tripper car to locate silo feeding. In blending bin different
quality of coals will be blended according to the blending ratio determined by coal proportioning test, and
to ensure the blended coal is able to be converted into qualified coke.
All transfer houses will be considered with suitable DFDS (Dry Fog De-dusting system) system whereas
storage yard will be envisaged with water spraying system to negotiate pollution control in operating zone.
Proper hoisting and handling facilities will be considered in each transfer houses and buildings for
maintenance & repair.
b) Coke Oven Battery & Machines
The Coke oven battery shall be stamp charged, by-products partial recovery type, twin flue, under-jet,
regenerative design with fireclay, high alumina and silica construction.
Process Description on Coke oven plant

Crushed coal from coal handling plant is transferred into surge bins through coal conveyors. Coal is then
charged into the coal box of SCP machine through conveyor for making coal cake. The supporting plate at
the bottom of stamping box of Stamping Charging Pushing machine takes the coal cake inside the oven
through the pusher side opening of the oven and withdraws the plate leaving the cake inside.
Coal cake will undergo through high temperature carbonization at 950~1050°C. After designed coking
period, ready coke will be pushed by pusher device of Pusher machine through coke guiding grid into Coke
bucket and then transferred by Loco car to CDQ for dry quenching. Cooled coke from CDQ will be
discharged to conveyor, which ultimately transfers to coke route conveyors. After CDQ, cooled coke will
be transferred to conveyor belt and finally conveyed to coke sorting plant.
The raw gas produced during carbonization goes through gas off take system and converge into gas
collecting main. In goosenecks and gas collecting main, ammonia liquor is sprayed on the raw gas to bring
down gas temperature from ~800°C to around 80°C and then the gas passes on to by-product plant through
tar box and suction main.
Cleaned Coke oven gas/ BF gas for heating is received in coke oven battery from outside main pipeline,
going through gas main, gas pre-heater/ regenerator of battery, and gas branch pipe into each combustion
chamber, mixing and burning in the combustion chamber with air preheated from the regenerative chamber.
Due to partial waste gas recirculation, the gas and air lengthens the flame, rendering vertical heating more
even and efficient. The burning flue gas temperature can reach 1200°C-1300°C. After burning, the waste
gas goes through crossover hole, vertical flue channel, and will have heat exchange in regenerator chamber
with checker bricks and then goes through waste gas flues and finally gets discharged from chimney to
atmosphere through a refractory lined concrete Chimney of 145 m height. Regenerators serve the purpose
of recovering waste heat from the exit flue gas and utilizing in heating the combustion air/fuel. This reduces
the exit flue gas temperature and help in keeping surrounding temperature low.
Coke Oven Machine
Number of Oven machines and other major units considered for 2.55 MTPA stamp charged coke oven
batteries are listed below:
Details of Major Units Coke Oven Plant
Sr. No. Description Quantity
1 Stamping Charging Pushing machine 4
2 De-dusting coke guide car 4
3 Charging Gas Transfer car (CGT car) 4
4 Electric locomotive 4
5 Hydraulic reversing machine 4

6a Wet Quenching tower 2

6b Coke dry Quenching system 2
7 Coke bucket carriage 4
8 Dry quenching buckets 4
Main characteristics of oven machines are:

Stamping Charging Pushing (SCP) machine:
The SCP is a two-spot machine that means first spot for opening the door of oven and pushing out coke,
second spot for charging the coal cake and again the first spot for closing the oven door. 5-2 series for
pushing has been considered under revised capacity. The coal from surge bin is fed to coal bin on SCP
through two belt conveyors. The stamping system of SCP machine consists of 4 groups of 6 nos. hammer
stamping machine and 2 groups of 4 nos. hammer stamping machine. The 6 groups of stamping machines
are connected with horizontal pins and position of them is interchangeable. By the application of hammers
coal cake is formed. Once the coal cake is made the machine moves to assigned oven for charging the cake
inside the oven.
When the coke inside the oven is fully carbonized and is ready for pushing, the SCP machine comes at
“pushing position” and pusher side door is opened by the door manipulator. Door cleaning can start at this
position. Then the wedges of the counter pressure device are applied to transfer the horizontal force
occurring during pushing to the foundation of machine tracks. After getting the ‘release signal’ from the co-
ordination PLC that the coke guide and quenching car are ready at specified position, the coke is pushed out
of the oven by means of the pushing device of SCP machine.
Charging Gas Transfer Car (CGT)

When the moist coal cake at atmospheric temperature is charged into the hot oven there will be immediate
generation of huge quantity of dust and gases. In order to treat these gases and prevent them from escaping
into the atmosphere and creating pollution, the Charging gas transfer (CGT) car is provided. Working of
CGT car is very simple. Suction is created by the high-pressure ammonia liquor aspiration system in the
goose neck of the oven to be charged and in the gooseneck of adjacent oven where the gas is to be
transferred. This suction draws the charging gases into the GCM and then to by-products plant. To connect
the oven to be charged with the transfer ovens the U-tubes of the CGT car is used. To ensure proper gas
tightness both ends of the U-tubes are dipped into water caps of the Water sealing system provided
at/around the suction hole at the oven top. This will greatly reduce the emission during charging of the coal
cake. Provision will be made in the car for opening/ closing of stand pipe cap, valve box isolation, injection
of ammonia liquor in goose neck and stand pipe & goose neck cleaning.
De-dusting Coke Guide Car

Ready coke shall be guided through coke guide car’s coke guide grate into coke bucket of coke bucket
carriage. Coke guide car will open and close the coke side door of the oven according to the pushing
schedule and arrangement to clean the door and the door frame. It will have provision of sucking & routing
pushing emission particles to pushing emission control system with ground dedusting facilities.
Coke bucket carriage and Loco

Coke bucket of coke bucket carriage shall receive hot coke from oven through coke guide car and take it to
wet quenching tower / CDQ. Effective volume of the hot coke carriage shall meet the maximum volume of
coke from one oven. The loco will have the facility to accommodate rotating bucket for taking coke to CDQ
chamber.
Hydraulic Reversing Machine

Hydraulic Reversing Machine shall include hydraulic station, Coke Oven gas cylinder, waste gas (Mixed
gas) cylinder, electrical system and stroke indicator, etc. Hydraulic station and reversing system working
environment shall be explosion proof area. All electrical elements will be selected taking into account
explosion proof requirement. The function of the reversing system is to reverse the heating sequence after a
pre-fixed reversal time from odd to even vertical flue burning of fuel gas and vice versa. The reversal
system drive is hydraulically driven. However, provision for manual operation will be available in case of
emergency. There will be provision of interlocking with PLC or Automation control signal, which will
ensure stoppage of heating the battery if the heating gas pressure in cellar goes below 50 mm WC.
Pushing Ground De-dusting (Emission Control) Station

When red hot coke is pushed from oven, hot flue gas and coke dust are generated which pollute the
environment. To combat above two ground-based pushing emission control systems have been considered
to suit the 4 x 55 coke oven batteries.
Emission generated during pushing shall be collected and cleaned in a ground-based coke pushing de-
dusting station. Pushing de-dusting system is composed of three parts: the large size dust hood provided in
the coke guide car; the pipeline laid on the ground, regenerative cooler, impulse bag type de-dusting
machine, silencer, ventilation machine set, chimney, etc., these unit are used for extinguishing the flue gas
and final purifying
Flue Gas Discharge

Two chimneys shall be provided for four batteries. The height of chimneys will be about 145 m. Chimney
discharge shall be compliant to environment regulations.
Quenching Station
We will start the coke oven plant with Wet Quenching system. However, we are envisaging installing a
Coke dry quenching (CDQ) plant under “Clean Development Mechanism” or some other arrangement
which not only will further improve the environment, huge quantity of sensible heat from hot coke shall be
recovered for power generation and shall improve the coke quality substantially.
This facility being a closed circuit, greatly reduces the pollution in surrounding area.
Auxiliary Facilities
The following auxiliary facilities are envisaged
• The coke oven batteries shall have service benches on both pusher and coke sides. Intermediate
benches and end benches shall be provided which shall have maintenance facilities.
• Oven door maintenance station shall have facilities for change of knife edges, components and
brick lining. Also, there will be an emergency coal hopper at the end of battery to take care of
spillage arising out of breakage of coal cake.
• One pilot oven shall have the advantage of checking the economical coal blend mix before charging
to battery.
• A spillage coal conveyor shall be installed at the pusher side service platform to convey spillage
into spillage coal bin.
Coke Dry Quenching Plant (CDQ)

Two nos. of Coke Dry Quenching Plant have been envisaged. The capacity of each dry quenching plant
shall be of approx. 170 TPH.
Main features of the CDQ facility

Coke bucket shall be of rotating type in order to have better size distribution of coke in the bucket as well as
in cooling chamber. This also improves thermal efficiency of the chamber. The operation of the crane such
as lifting, travelling will be remote – controlled in the CDQ operation control room.
Charging facility & cooling chamber
Coke charging facility shall have bell distributor to help in reducing the segregation of coke grain size
inside the chamber. Also, at the bottom of the chamber shall have blasting device to enable coke for
uniform descending. With these facilities will improve thermal efficiency and outlet coke shall have
temperature within the limits.

Discharging equipment
Coke discharging equipment shall ensure continuous and uniform discharge & maintaining the stable
operation without leak of the gas from the chamber. Under the voltage & frequency fluctuation the system
shall continue to run stable by considering necessary special control units to nullify the fluctuation of the
above parameters. Similarly, it shall satisfy the safety and environmental requirements of noise as well as
particulate matters etc.
Gas circulating equipment:

The design of circulation fan shall ensure to give lengthy life without getting breakdown and stalling the
whole CDQ operation. Outlet gas of the chambers shall be free from combustibles. Otherwise, there may be
chance of explosion. This shall be ensured by keeping provision of free air addition in the chamber, finally
uniform composition & oxidized atmosphere of the gas enters subsequent equipment. The design shall
ensure dust free gas before entering into the boiler by installing necessary dust catchers of multi-cyclone
type dust catcher in the circulating gas before entering into the boiler. Similar system shall be considered
before entering the gas into circulating blower to minimize coke fines enter into fan blades and damage.
High Pressure Boiler

The boiler shall be designed that it produces steam of constant pressure and constant temperature. The
boiler & associated steam piping with valves shall be designed, manufactured and inspected in accordance
with Indian Boiler Regulation. While designing boiler tubes consideration shall be taken that circulating gas
high abrasive coke dust does not damage tubes. So, necessary wear preventing measured shall be
considered in designing the tubes to increase the life of the boiler. Natural circulation of water and effective
utilization of the heat available with circulating gas shall be considered, to enable to give compact system
with most economical in both fixed and operating cost.
De-dusting facilities: Dust extraction system along with bag filter and cyclone shall be installed in the dry
quenching plant to meet the emission levels as per the Indian government stipulated norms while charging
and discharging of coke oven. The coke dust, coke breeze extracted during CDQ operation from de-dusting
system & dust catchers shall be conveyed for proper use.
Others
One coke bucket repair station with all necessary equipment for carrying out bucket repair has been
envisaged. One power plant (with combined steam generation) has been envisaged with extraction turbine.
Extraction steam can be used in coke oven and by – product plant.
By – Products Plant
By-products facilities will be designed to remove the impurities like tar, ammonia, hydrogen Sulphide and
crude Benzole in by-product plant from Coke Oven Gas with simultaneous recovery of some of the
valuable primary products like crude tar, and crude Benzole.
With a view to keep the capital cost of the project low and techno-economically viable the by-products
plant will be designed for removal of impurities from coke oven gas with subsequent recovery of essential
by-products like crude tar and crude Benzole.
Cleaned coke oven gas from by-products plant is used in coke oven heating and surplus gas is used as a fuel
for substitute of natural gas. Hence it is essentially required that the gas should be cleaned from all
corrosive and clogging elements. Because of the corrosive nature of ammonia, its removal from coke oven
gas is a necessity in By-product plants. Crude tar and crude Benzole produced in the by-products plant will
be sold. The surplus coke oven gas after battery heating in coke oven complex will be utilized as a fuel for
substitute of natural gas.
The major units of the by-product plant envisaged are given below:
1. Gas Condensing Blowing section
2. Ammonia / H2S scrubbing section

3. De-acidification section
4. Claus plant
5. Crude Benzole removal unit
6. Tar storage area and loading facility.
7. Flare stack
8. BOD plant with RO process
9. Utilities facilities
Technological Parameters
The design yield figure of by-products plant under capacity of 2.55 MTPA based on the yield figures, as
given below.
Process description
Gas condensing Blowing section
Gas from coke oven battery will flow to a down-comer from where it will be sucked by exhauster through
the primary gas coolers and Electrical tar precipitators (ETP). The gas will be cooled in the primary gas
coolers by re-circulation of cooling water & chilled water and tar will be condensed. The gas will be further
purified from residual tar in the electrostatic tar precipitator. Flushing liquor and tar from gas collecting
main, together with tar and sludge from down comer will be delivered to decanters for settling of tar &
sludge from flushing liquor to get clarified liquor, tar and sludge.
The tar sludge generated from tar decanter will be mixed with the coal blend before feeding it to batteries.
Condensate pump house will consist of pumps for pumping of flushing liquor, gas condensate and tar to
intermediate tanks, setting tanks. The primary gas coolers will be indirect horizontal tube type having two
sections. In the top section, the gas will be cooled with re-circulated cooling water from primary cooling
towers whereas in the bottom section chilled water will be used. The gas will be cooled to about 200-220 C
which will facilitate removal of crude Benzole to a greater extent than if cooled with cooling water only.
This will reduce downstream operational problems as well as reduce the load on downstream processing
units.
The gas from Primary cooler will enter the ETPs. The ETPs will be conventional tubular type and the
electrodes will be of stainless steel. Exhausters will be electrically driven centrifugal blower type and will
have stand-by arrangement. Decanters will be provided with longitudinal scrapper chain mechanism for
sludge removal from Tar.
Removal of H2S with Cracking of Ammonia and Recovery of Sulphur

After the gas exhauster, the COG is directed to H2S /NH3 scrubbing system. There are two separate
scrubbing towers for NH3 and H2S. Coke Oven Gas enters H2S scrubber followed by NH3 scrubber. Lean
solutions obtained from stripping columns shall be used as Absorbent for these towers. H2S & NH3 free
coke oven gas at a temperature of 24–25°C can be used as fuel gas by consumer.
The H2S & NH3 enriched liquor from both the scrubbers goes to stripping section where the enriched liquor
is steam-stripped. Excess flushing liquor from gas condensation plant also enters to top of the Ammonia
stripper & caustic soda is added to the same stripper from middle part for removal of fixed Ammonia salt.
The major portion of lean liquor coming from Ammonia stripper is reused in NH 3 scrubber (as scrubbing
liquor) & remaining part is sent to an effluent treatment plant.
The H2S free lean liquor from H2S stripper is sent to H2S scrubber as a scrubbing medium.
The vapour containing mainly H2S, NH3 & HCN comes out from H2S stripper goes to NH3 Cracking Unit
followed by Sulphur recovery unit.

Claus Plant
The H2S/ NH3 vapour are led to the burner system of catalytic reactor operating at sub–stoichiometrical
combustion condition at a proper temperature for reaction; a certain ratio of H2S is burnt to SO2. In the
catalyst bed of catalytic oven reactor NH3 and HCN compounds of vapour are cracked. The secondary air is
also supplied in the downstream of catalytic bed to adjust the stoichiometric ratio of H2S/ SO 2 for the
reaction in Clause Reactor for Sulphur recovery.
Gas leaving from Catalytic Oven Reactor is around 1100°C which is cooled by a waste heat boiler where
steam can be generated. After cooling the vapours enter Reactor-I where H2S/SO2 converted to elemental
Sulphur in presence of catalyst. After Reactor-I the process gas is directed via Sulphur condenser. The
Reactor - II is same as Reactor-I where final conversion of H2S to Sulphur takes place.
After Reactor-II, process gas is again passed through another sulphur condenser. In both sulphur
condensers, process gas is cooled & liquid sulphur is precipitated. After second sulphur condenser the
gaseous effluent is fed to inlet of PGC as tail gas.
The liquid sulphur is collected from waste heat boiler & sulphur condenser and then collected in sulphur
sealing pot. Then it is discharged into sulphur drain tank to sulphur storage tank. The liquid sulphur may be
sent to sulphur solidification unit where solid sulphur pellet is formed (purity>99.5%)
Benzol recovery unit

Benzol scrubbing
In Benzol scrubbing units, there are two sets of Benzol scrubbing columns, one working and other one
stand by., Rich oil pump will be solar oil or wash oil for Benzol scrubbing column.
Crude Benzol stripping

In Crude Benzol stripping units, there are two sets of crude Benzol stripping columns, one working and
other one stand by. The debenzolized units are located in the middle of this area, the heat exchanging device
is located in the same area, the pumps are located underground. There are two tube furnaces, one working
and one stand by.
Two Nos of crude Benzol tanks are there with auxiliary facility of loading and dispatch of crude Benzol and
firefighting system as well as monitoring of crude Benzol concentration in the area.
Wash oil consumed in the system is made up from fresh wash oil tank in existing oil depot into lean oil
system periodically.
Tar storage area and loading facility

In this unit 4 tar storage tanks are provided, storage capacity for 20 days’ tar production, which are used to
receive tar from the tar-ammonia liquor separating system and to regularly transport outside by tank car.
Two NaOH tank and two Wash oil tanks will be considered in oil depot.
Wash oil transported by truck is self-dumped into wash oil un-loading tank from which it is pumped with
wash oil un-loading pump into wash oil tank and then regularly sent to crude Benzole distillation unit.
NaOH transported by truck is self-dumped into NaOH un-loading tank from which it is pumped with NaOH
un-loading pump into NaOH tank and then regularly sent to deacidifier and ammonia stripper unit.
Flare stack
The flare is a last line of defence in the safe emergency release system in coke oven plant. It uses to dispose
of unused / excess gases from coke oven plant. The flare provides a means of safe disposal of gas from its
facilities, by burning them under controlled conditions such that adjacent equipment or personnel are not
exposed to hazards, and at the same time obeying the environmental regulation of pollution control and
public relations requirements.

Two flare stacks shall be considered to flare the Coke oven gases.
BOD (Biological Oxygen Demand) plant

BOD plant for Coke oven Battery, By-product plant and CDQ plant shall be considered. Waste water
treatment (BOD) will be installed with addition of RO Process, NANO filter, Ultra filter etc. 80% of the
treated water will be recycling back as a process water and 20% water will be used for control Cooling of
slag. Slag will be store in a concrete open storage yard having inclination in one side of the yard so that
whatever water is not evaporated during cooling of slag will be put in the pit and reuse again so that nothing
will go to the soil. The concrete tank will be design in such a way that nothing will go in to the soil.
Water discharge from BOD plant would have provision of treatment with RO process.
The outlet water quality from BOD will meet the standards/parameters specified as given below:
(Limiting concentration in mg/l, except for pH)

pH : 6.0 – 8.5
Suspended solids : 100
BOD, 3 days at 270C : 30
COD : 100
Oil and grease : 10
Ammonical nitrogen as N : 50
Cyanide (as CN-) : 0.2
Phenol : 1.0
Coke Sorting Plant

Plant & equipment of coke sorting plant will be designed to meet the requirement of coke production. Coke
sorting system will consist of coke cutting and sizing process to make coke suitable for Blast Furnace and
Sinter Plants.
Coke cutting and screening

The purpose of coke cutting is to adjust the coke grain. Coke carried after quenching will go first through a
magnetic separator and will be delivered into coke cutting and screening station. After screening by
vibrating screen, (+) 80mm coke will be cut by coke cutter, (-) 80mm coke will be given onto the belt
conveyor directly by chute below the vibrating screen. There is a by-pass chute besides cutter, when do not
need to be cut, coke will be sent directly onto the belt conveyor below coke cutter by the by-pass chute.
After passing through cutting station, coke will be sent into coke screening station by belt conveyors. After
screening by two kinds of vibrating screens, coke will be classified into three grades of 25-80mm, 10-
25mm and 0-10mm. Each kind of coke will be stored in respective bunker.
The fraction +25 to 80 mm will have a direct feeding facility to Blast furnace from coke screen room. The -
25mm to +10mm fraction shall be conveyed to BF & -10mm fraction shall be conveyed to Sinter plants. A
coke yard would be developed where three sizes of coke will be stored after coke screening building. This
coke yard will consist of transfer houses, traveling trippers, conveyors etc.

Process Flow Diagram Along with Mass Balance of 2.55 MTPA Coke Oven Plant
E-5 Air Separation Unit

Process Description
Air Compression, Pre-cooling and Frontend Purification
Process air is filtered by a filter system and compressed to the required process pressure by a multistage air
turbo compressor. The compressor shall be provided with suitable anti surge control to protect the
compressor. The compressed air is cooled in the after cooler with cooling water and then further cooled in a
direct contact air cooler (DCAC) against chilled water from the evaporative cooler.
Contaminants such as water vapour, CO2 and potentially hazardous hydrocarbons are adsorbed from the air
while passing through an adsorber vessel filled with sieve material. The dual adsorbers are regenerated by
waste nitrogen gas from the rectification unit. During the heating cycle the regeneration gas is heated in an
electric gas heater and desorbs water and CO2 from the molecular sieve. During the cooling cycle the
adsorbents are cooled with dry waste nitrogen gas. After the completion of the regeneration sequence, the

adsorber are pressurised before being switched over to adsorption. The regeneration heater will be provided
with 20% spare heater elements. The heater construction will allow replacement of failed element
assemblies with minimum disruption. Any failed element can be individually replaced and whole bank need
not be replaced.
The process air downstream of the molecular sieve station is divided into different streams. One passes
directly the main heat exchanger where it is partially cooled against returning products. Another part is
further compressed by means of two blowers in series which are driven by expansion turbines providing the
required cold power for the process. This pressurised stream passes finally as well through the main
exchanger where it is further cooled while boiling the outgoing internally compressed streams of oxygen
and nitrogen, which in turn are evaporated and warmed up. After leaving the heat exchanger this air stream
is depressurised and fed into the pressure column.
Air Separation
In the pressure column the air is pre-separated into pure nitrogen at the top and into an oxygen rich liquid at
the bottom. The liquid nitrogen provides the required reflux for rectification by condensation in the main
evaporator/condenser against boiling oxygen from the sump of the low-pressure column.
Part of this liquid nitrogen serves as reflux for the pressure column, a minor part passes through the sub
cooler and is transferred to a liquid nitrogen storage tank) as product (LIN). A further part is compressed in
the liquid nitrogen internal compression pump, split into high pressure and (after let down) low pressure
streams, which are vaporised and warmed up in the main exchanger against boosted air, leaving as HP
GAN and LP GAN product.
In the low-pressure column, the final separation takes place into pure oxygen, as a bottom product and
waste nitrogen at the top. Liquefied air withdrawn from the pressure column is used as oxygen feed, being
sub cooled in the sub cooler before the expansion into the low-pressure column Liquid oxygen is withdrawn
from the sump of the low-pressure column and is then pumped the to the required gaseous product pressure
by the internal compression pumps. The compressed liquid stream is separated and part let down to low
pressure before both streams are evaporated and warmed up in the main heat exchanger against boosted air
(see description above), leaving the cold box as high-pressure oxygen (HP GOX) and low-pressure oxygen
(LP GOX). Part of the liquid oxygen can be transferred to the liquid storage tank upon demand.
The waste nitrogen gas from the top of the low-pressure column is warmed in the sub cooler and in the
main heat exchanger and finally fed to the evaporation cooler for water chilling and as heated gas in the
molecular sieve absorber for regeneration purposes.
Argon Recovery by Rectification

In the crude argon column, the oxygen is removed by means of cryogenic rectification. Part of the argon
enriched gas from the low-pressure column is used as a feed for the crude argon column. Reflux for the crude
argon columns is provided by condensing the main part of the oxygen free crude argon in heat exchange, against
oxygen enriched liquid, in the top condenser. Part of the oxygen free crude argon yielding at the top of the crude
argon column is withdrawn and fed into the pure argon column. The oxygen rich liquid collected in the bottom
of the crude argon column is fed back to the low-pressure column by the LOX reflux pump.
In the pure argon column with condenser and evaporator the remaining nitrogen content is separated by
means of cryogenic rectification. Part of the top gas is vented to atmosphere in order to purge the removed
nitrogen from the column.
Pure liquid argon is withdrawn as product (LAR) from the sump of the pure argon column. This is passed to
the argon storage tank. Part of the liquid argon from the tank is compressed in the LAR transfer pumps for
delivery to the pressurised cold converters. The liquid argon from the cold converters is passed to
atmospheric vaporisers to provide gaseous argon at 20 bar (g) pressure.

Cooling Water System

Cooling water system shall be provided with the interconnecting feed and return water piping, cooling
water pumps, cooling tower and side stream filtration system.
Storage tanks & Back-Up system

Existing Storage facilities shall be utilized for storage of liquid products from the proposed ASU.
Process Flow Diagram of ASU
E-6 Steel Melt Shop-1 (EAF 4 No.)

Process Description
The process completes in Single Step:
Arcing: One Electrode is brought down and Current is passed through 4 Bottom Electrodes & One top
Electrode to produce arc. HDRI thorough Vessel / CDRI/HBI through Conveyors / Scrap Through Bucket
is feeded w.r.t. input power supply to maintain the bath temp.
It has the flexibility to use the charge-mix in many combinations.
Process sequence in EAF process
• Hot heel killing – Deoxidation of hot heel to subside the reaction.

• HDRI through Vessel / CDRI/HBI through Conveyors / Scrap through Bucket (Metallic) is feeded.
The required quantity is being charged on Bucket / Continuous basis into the furnace.
• Side lance oxygen Injection [Decarburization, desiliconisation & dephosphorization) – During
Feeding Metallic into the Furnace, the oxygen is injected through 4 Lances as per the SOPs which
reacts with the impurities in the steel to form corresponding oxides and will be removed after
further reacting with flux
• Flux addition – Due to exothermic chemical reactions the steel is getting heated which is controlled
by the addition of Metallic. Flux (Lime & Dolime) are feeded to remove the impurities.
• Sample & Temperature measurement– During process the sample is analyzed and temperature is
measured to control the process.
• Deslagging – A part of the slag generated during steel making reaction is drained out into slag pot
from time to time.
• Arcing – Arcing is carried out by One Top graphite electrode & 4 Bottom Electrodes.

• Material addition (Metallic , Flux & coke) – During arcing, Metallic is added at a required feed rate
w.r.t. the input power. Flux is added to remove the impurities and coke is added to maintain foamy
slag.
• Oxygen Injection – During arcing, Oxygen is injected from side lances to remove the impurities.
• End of Arcing – When the required bath weight, tapping temperature and target steel analysis is
achieved the arcing is stopped.
• Tapping– The liquid steel is poured from EAF into ladle through EBT. A part of alloying addition
is added during tapping to facilitate the process.
The liquid steel is tapped into the teeming ladle placed on a self-propelled steel ladle transfer car and moved
into the crane take over position for transportation to the ladle furnace.
E-8 Steel Melt Shop -2

As above
The Twin Shell Conarc furnace is a combination of converter and electric arc furnace where in various
charge mixes consisting of hot metal, DRI and scrap can be processed to produce good quality steel. Conarc
furnace is designed to use large percentage of hot metal than 30 to 80%. It is basically a twin shell operation
comprising operating in converter mode by the oxygen lancing in one shell and arcing mode in the other
shell at a time. Suitable arrangement is made to have a separate top lance similar to basic oxygen converter
for each shell and a common electrode gantry to serve any of the shell like a conventional arc furnace. To
enable oxygen lancing during arcing period, side wall mounted oxygen lance as well as door lance will be
provided. The typical cycle time consists of set of activities - blowing phase and arcing phase. As soon as
the blowing phase is completed in one shell, the arcing phase should be over in the other furnace.
A hot sheet of 25 to 30 tonne from the previous heat is retained in the furnace. Hot metal is poured into the
furnace through slag door using a launder. Use of hot metal saves electric energy, reduces melting time,
saves electrodes and improves overall economics of the plant. Oxygen is blown using roof mounted
supersonic oxygen lances. Depending on the proportion of hot metal in the charge mix, the blowing period
may vary from 30 to 55 min approximately. DRI is charged into the furnace through mechanized system of
overhead bins, vibro feeders, conveyors, chutes. Lime is continuously fed during the blowing period and
resulting slag is flushed out. When the bath carbon is about 0.06%, the blowing is stopped and then arcing
period commences.
During this period, DRI along with lime is continuously charged to reduce high FeO in slag as well as to
achieve foamy slag formation, coke injector is done at low bath carbon. The tap to tap time is about 74 min
for each shell with the proposed charge mix. However, the actual tap to tap time will vary depending upon
the casting time per ladle and heat delivery cycle from CONARC furnace. As soon as the charge is melted,
bath sample is taken and the steel temperature is adjusted and the steel is tapped into a pre – heated ladle
placed on the ladle transfer car below the furnace tap hole. The preheat temperature of the steel ladle should
be in the range of 1000 – 11000C.
Predetermined quantity of ferro-alloys and de-oxidizers are dosed into the ladle during tapping and the inert
gas bubbling is started in ladle to properly mix the additives and to homogenize the temperature. After
tapping of the furnace, EBT is closed, furnace walls and banks are inspected again and if necessary
gunned/fettled. The furnace is then ready to commence the next melting operation. About 25 – 30 t of liquid
steel is left in the furnace as hot steel for subsequent heat. CONRAC furnace slag is flushed into slag pot
placed below the slag door from where it is disposed of using road transport. Entire operation of the
CONARC furnace is controlled with level – II automation. Furnace and gases generated during furnace
operation are continuously extracted and cleaned.

Process Flow Diagram
E-9 Corex Plant

Process Description
In the COREX process, which produces hot metal of the blast furnace quality, all metallurgical work is
carried out in two separate process reactors, i.e., the reduction shaft and the melter gasifier.
The major charge materials in Corex plant consist of non-Coking coal, Iron Ore pellets, coke and additives.
Non coaking coal received in the plant will be blended in the raw material yard and sent to drying plant.
Dried coal will be sent into Corex plant. Additives and coke also be sent from raw material yard to Corex
plant bin.
Pellets are first charged in the reduction shaft via a lock hopper system where they are reduced to direct
reduced iron (DRI) by the reduction gas moving in counter flow. Discharge screws convey the DRI from
the reduction shaft into the melter gasifier where final reduction and melting takes place in addition to all
other metallurgical and slag reactions. Hot metal and slag tapping are then carried out as in conventional
blast furnace practice. Non – coking coal is directly charged into the melter gasifier via a lock hopper
system. Due to the high temperatures predominating in the dome of the melter gasifier (in excess of 1000
oc), then higher hydrocarbons released from the coal during devolatilization are immediately dissociated to
carbon monoxide and hydrogen. Undesirable by – products such as tars and phenols, etc. are destroyed and
therefore do not get released to the atmosphere. Combustion with oxygen injected into the melter gasifier
through tuyere results in the generation of a highly efficient reduction gas.
The reduction gas emerging from the melter gasifier mainly consists of CO and H2 laden with fine coal, ash
and iron dust. This dust is largely removed from the gas stream in a hot gas cyclone and is then recycled in
the process by burning with the oxygen. The reduction gas temperature is adjusted to its optimum working
range between 800 oc and 850 oc with the addition of cooling gas. After leaving the hot gas cyclone the
reduction gas is then blown into the reduction shaft via a bustle, reducing the iron oxide in counter flow.

The top gas is subsequently cooled and cleaned in a scrubber, after which it is available as a rich export gas
with a net calorific value of approx. 1970 Kcal / Nm3 suitable for a wide range of applications. However, in
the proposed project, Corex export gas will be utilized for production of DRI after CO2 adsorption, and
surplus amount for heating and power generation.
Corex gas usage in HBI / DRI:

The Corex gas is used as fuel for Reformer burner (GCV as 2050 Kcal / Nm3). 40 % of spent gas from
shaft furnace (Top gas) is treated for CO2 removal. This CO2 free gas is mixed with balance 60% Top gas
and natural gas and preheated before being fed to reformer. Hence the H2 / CO ratio of this gas, existing the
reformer, is 1.6 and is required only 1600 Nm3 / ton of production. The available reducing gas is
approximately 350,000 NCMH. The switching of corex gas with top gas going to CO2 removal system
gives two advantages. First is we get favorable H2 / CO ratio. The second is that we need to remove low
percentage of CO2 of Top gas as compared to high percentage in corex gas.
Reduction of the Iron Ore

In the DR furnace the high temperature reducing gas carries out reduction of the iron ore and carbon is
added to the reduced iron.
Reducing gas injected to the furnace is comprised of primarily H2 and CO. The reductants to oxidants ratio
in the reducing gas is typically in the 10.5 to 1 (ten point five to one) or higher range. Reductants being H2
+ CO while the oxidants are H2O and CO2. Other gases present in small amounts are N2 and CH4. The H2
/ CO ratio is controlled by adjusting the steam / carbon ratio of the feed gas upstream of the reformer.
The ratio of H2 / CO in the reformer product gas stream is maintained at approximately 1.55 to 1 (one point
five to one) for the purpose of catalyst protection. In the event the H2 / CO ratio is higher the system
becomes less efficient. In the event the ratio is less than 1.55 to 1, there is a strong potential for deposition
of carbon in the catalyst. Such depositions limit the reformer capacity causing a loss of production and can
cause physical damage to the reformer tubes.
All reducing gas / natural gas fed to the DRI furnace, after reacting with the oxide feed, exits the furnace
through the top gas off take and driven through a water curtain venture for cleaning / cooling and then to a
packed bed scrubber (water) where it is further conditioned for process requirements. Refractory selected
for extreme conditions and wear liners are employed in the top gas duct.
Natural Gas is injected at various points in the furnace, a fraction of which reacts with the hot iron. The
amount of natural gas added plus any volume expansion of the gas stream due to the reactions is either
forced up through the furnace burden to the top gas off take.
The scrubber design and operating conditions are critical. In the event the scrubber packing becomes
plugged it is necessary to operate at less than optimum conditions or even to stop the plant to allow removal
of sludge from the packing.
Downstream of the scrubber the process gas is spilt into two streams:
1. Process gas which is compressed for re – circulation through the reformer.
2. Top gas fuel which is sent to the CO2 removal system for removal of CO2.

E-10 Lime Plant (Lime or Dolime)

Process Description
The shafts of the kiln have semicircular cross section. The two shafts are connected by a channel at certain-
height. The shafts have an outer shell of steel plating. The kiln is lined with suitable refractory material in
the burning zone (calcining zone) and cooling zone. The preheating zone is lined mainly with fireclay
bricks. After a period of operation, a thin crust of dust deposited on the refractory will contribute
considerably to the protection of the brickwork against abrasion.
The kiln demands constants throughput. During each inversion, a measured amount of stone is charged into
shaft, which, in the next cycle, will act as a regenerator. In this way, there is the lowest gas temperature and
consequently, the maximum recovery of heat. The weight of the charge remains constant independent of the
kiln output. The number of charges per hour and duration of the heating period are controlled. At nominal
output, the kiln is charged every 12 minutes. At a lower output, the interval can be longer.
The charging system consists of a hopper placed above the kiln in the middle of two shafts. The hopper has
two outlets; each equipped with a hydraulically operated valve. A belt conveyor feeds the hopper and
charges a batch into the hopper. The stone from hopper will be fed to the appropriate valve.
The calcinated lime shall be continuously discharged from both shafts via discharged tables located below.
The rate of discharge is present for constant discharge from below the cooling zone of both shafts.
The discharge tables extract the calcined lime from inside the kiln and the lime falls into the small
discharges hoppers located underneath the discharge tables to collect the calcined lime during the 12
minutes (approx.) burning period.
Due to the high pressure inside the kiln, these hoppers are sealed off from the atmosphere by airtight
hydraulically operated flaps. During each inversion action when shafts are without pressure, these
hydraulically operated flaps are opened and the burnt lime drops into the pressure free reception hopper.
Cooling air is fed into the discharge hoppers from where it reaches the kiln passing through the lime
situated on the discharge tables.
The periodical reversing of the heating from one shaft to another required reversing devices for fuel,
combustion air and waste gas. The fuel supply shall be reversed by means of special hydraulically operated
valves. Combustion air and waste gas are also reversed by means of double acting hydraulic cylinder

operated flaps. Cooling air however, flows continuously into both shafts. The inversion process is
controlled automatically through automation program
E-11 CPP
Process Description
Natural gas fired gas turbine unit of 20 MW capacity is maintained as black start facility with DG set power
supported auxiliaries. One unit of Steam turbine of 11 MW power also with steam from HBI modules’ flue
gas heat recovery steam generator (boiler), which is supplied to a condensing type, a non-reheat steam
turbine through steam piping. Thus, M/s AMNS India have a gas turbine and a steam turbine at CPP of 31
MW total power generation capacity. The process does not involve direct use of water. Water is mainly
used for cooling operations, which is recycled.
Natural gas being a very clean fuel does not cause any air pollution due to combustion. As can be seen from
the analysis report of flue gas emission all the parameters like particulate matter, sulphur dioxide and oxides
of nitrogen are well within the tolerance limits specified by the GPCB.
E-12 Plate Mill

Process Description
Slabs will be transported by overhead crane and placed onto the RHF approach table. From there the slabs
will be transported via the roller table onto the RHF entry table. Once the slabs have been correctly aligned
the slab charging device will lift the slabs and place them down on the RHF skids. A maximum of two slabs
can be charged into the RHF in one cycle, side by side, to give a double row in the RHF.
The RHF is a walking beam type; the slabs are lifted and walked forwards on each cycle of the RHF. The
RHF is split into two zones, initially the slabs are heated up to the required temperature in the heating zone,
the slabs then pass through a second, soaking zone. The soaking zone allows the slabs to achieve a constant
temperature throught the volume prior to RHF dropout. Once the slabs reach the exit end of the RHF they
will be at the correct temperature with a homogenous temperature profile. When the mill is ready to receive
the next slab the RHF door will open and the exit discharge device will lift the slab out of the RHF and
place it down on the RHF exit table. The discharge device is split into two to enable a single slab to be
lifted out from the double row in the RHF. The slabs are dropped out of the RHF at an appropriate time to
ensure the minimal gap time at the mill is maintained.
Once the slabs have been placed on the RHF exit table they will be transported via a roller table into a
primary descaling unit (PDS). During the re – heating process the slabs will develop an oxide layer (scale),
which if not removed, will be rolled into the surface of the product causing surface defects and reduced
product quality. In order to ensure optimum product quality the slabs are descaled to remove the oxide
layer. The process of scale removal, in brief consists of a combination of mechanical impact and the
explosive effect of water being superheated at the interface of the oxide and steel. Therefore sufficient
impact energy is required to crack the oxide layer and sufficient water volume is required to enter the cracks
to the interface and explode the scale off.
The PDS unit consists of four headers (two top, two bottom) with nozzle jets delivering water at high
pressure and suitable flows. Two of the headers are operational and two of the headers are standby headers,
although both can be used simultaneously if required. The headers are enclosed in a descaler hood to
contain the water and scale. Once the slabs are descaled, they are transported to the mill area via roller
table.
In mill stand area briefly the equipment comprises, a turnable either side of the mill stand, a modern four
high mill stand with automatic gauge control cylinders (AGC), work roll bending and quick work roll
change facilities.
Slabs arriving at the entry turn table from the PDS are either rolled directly into the mill bite for the first
pass of the rolling schedule or if required turned prior to entering the roll bite.
Slab turning serves three purposes: The main purpose is to develop product width from a slab, which cannot
be cast at the full required width. Plates are turned and rolled out for width, before being turned back and
rolled out to the final length. The second purpose for plate turning is to improve the homogeneity of the
slab by rolling the microstructure in different directions this improves the micro structural texture of the
plates and consequently improves final plate properties. The final purpose is to give a benefit in product
yield correct use of a plate turning strategy results in improved square ness of the rolled plate length,
reducing the requirements for plate trimming and thereby improving the productivity of the plant. Generally
known as plan view Rolling (PVR).
Although the PDS is effective at removing the primary scale built up during the re – heating process,
secondary scale will reform between the PDS and the mill and also between consecutive passes on the mill,
until the piece temperature has dropped sufficiently. To avoid secondary scale being rolled into the plate
surface the mill is equipped with secondary descaling headers on the mill stand. The secondary descaling
system is used on the ingoing passes and in the same way as the PDS delivers sufficient volume of water at
high pressure onto the product.
When the hot plate from the mill is passed through the laminar cooling system, stress can be set up in the
plate, which lead to buckling of the plate. The hot leveler relieves these stresses by a sequence of reversals
above the yield point of the material. The hot leveler processes the rolled plate length up to a maximum
gauge of 100 mm under load.
In front of the cooling banks, a hot plate marker is located. This is intended for marking plates of gauges
above 50 mm, which will be taken off onto cooling bed of the heavy plate cooling transfer device. Plates
being processed on the shear lines will be marked on the shear lines. The walking beam type cooling beds
are designed to allow the plates to cool as they are slowly transported from one end of the bed to the other.
The cooling beds are designed such that either bed can be used for any of the product.
From the ultrasonic testing area, the plates are transferred via roller table to the static crop shear. The
purpose of this shear is to divide rolled plate lengths into lengths approximately equal to the final plate
length. This has advantage of improving yield from the side trim shear by reducing the effect of camber in
the rolled product. The shear is also capable of taking head and tail crops if required.
Once the product has been processed on the static crop shear, as required it will be transported to the double
side trim shear (DSTS) and slitting shear. The double side trim shear is capable of cutting material up to 50
mm thick.
Working in tandem with the DSTS, the slitting shear can be used to divide a rolled plate along its length to
produce plate lengths with a minimum width of 900 mm.

Once plates have been side trimmed, they are transported by roller table to the divide shear. At this stage, if
required, a sample piece can be cut. Once the reference cut is made the plate is moved forwards to cut the
first final plate length. If multiple final plate lengths are produced then the last cut is a tail end cut on the
last piece. A plate marker & stamper is provided after the divide shear to mark or stamp each final plate
with a unique identification mark.
At the end of the shear line a plate pre – piler is provided for piling individual plates. The plate stacker can
pile a maximum of 5 plates or to 50 mm high, whichever is the lower value.
The stacker consists of a lifting device to lift individual plates up to a set of electromagnets; each plate is
lifted in turn until a complete pile is made. Once the pile is complete the lifting device rises to support the
pile and then lowers the pile back down to the roller table. The pile is then transported to the dispatch area.
For the anticipated product mix, the major part of quality plates can be produced without the use of a cold
leveler, which is the case in numerous plate mills. However, as the requirements for tight flatness tolerances
are constantly increasing. VAI recommend the installation of such equipment. This would be located on a
parallel line after the plate marker in the shear line, with a plate transfer to move the plates to the cold
leveler.
Heavy plate with gauges above 50 mm cannot be processed on the shear lines, which have a maximum
cutting capability of 50 mm. Plates above this gauge will therefore be transferred onto the heavy plate
cooling bed. Once the plates are at the exit of the transfer they will be lifted and placed on cooling grids to
cool to ambient temperature. Once cooled, these plates can be stacked in the storage area and then
processed through the flame cutting machine as required.
For enhancing the product quality and to cater high quality plate market, thin plates are further processed
through thin plate heat treatment line. Heat treat line consists of normalizing line (normalizing furnace) and
hardening line (Austentising furnace, quenching box and tempering furnace).
As per heat treatment requirement plates are transferred to heat treatment area, where all the plates are
processed through in line shot blasting machine. The shot blasted plates are then lifted by hi speed piler
depiler crane and placed on two heat treatment line as per requirement. Plates are centered with the help of
lifting and centering device.
In the normalizing line the plate is heat treated for removal of internal stress by heating and then cooling it
in normal atmosphere The Normalizing furnace is roller hearth type furnace of 70mtr in length. Natural gas
is used as fuel for heating the plates up to 980·C through Self recuperative radiant tube burner (indirect
heating). Here nitrogen act as protective atmosphere. The hot plate out from furnace is then cooled in the
atmospheric temperature to get the desired mechanical properties.
In the Hardening line the plate is first heated to elevated temperature around 980·C in Austentising furnace
then it is cooled in very quick time with the help of water sprayer in Quenching box the plate out from
quenching box is the heated to 750·C in tempering furnace. Afterward the plate is cooled in atmospheric
temperature.
The Austentising furnace is also roller hearth type furnace of 43.5 mtr in length. Natural gas is used as fuel
for heating the plates up to 980·C through Self recuperative radiant tube burner (indirect heating). Here
nitrogen act as protective atmosphere. The quenching furnace is roller type furnace of 26.22 mtr length,
here water sprayer is used to cool the plates quickly. For this furnace is divided in three zones, high
pressure, medium pressure and low-pressure zones, the plate is first pass-through high-pressure zone where
the cooling rate is high after that the plate is taken to low pressure zone where plate is cooled slowly. The
plate out from quenching furnace is taken to tempering furnace which is also roller hearth type furnace of
64 mtr in length. Natural gas is used as fuel for heating the plates up to 750·C through direct heating.

The pales out from both heat treatment lines are then sent to piler station where it is piled and stacked as per
the requirement.
E-14 Hot Rolling mill

Process Description
In metalworking, rolling is a metal forming process in which metal stock is passed through one or more
pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to impart a desired mechanical
property. The concept is similar to the rolling of dough. Rolling is classified according to the temperature of
the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is
known as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process
is known as cold rolling. In terms of usage, hot rolling processes more tonnage than any other
manufacturing process, and cold rolling processes the most tonnage out of all cold working processes. Roll
stands holding pairs of rolls are grouped together into rolling mills that can quickly process metal,
typically steel, into products such as structural steel (I-beams, angle stock, channel stock), bar stock,
and rails. Most steel mills have rolling mill divisions that convert the semi-finished casting products into
finished products.
In rolling mills, intermediate steel products are given their final shape and dimension in a series of shaping
and finishing operations. Most of the slabs are heated in reheating furnaces and rolled into final shape in
hot– or cold–rolling or finishing mills. While some products (e.g., reinforcement bars, steel plates) only
require hot-rolling, some others may require both hot– and cold–rolling (steel for cars and white-goods).
Mechanical forces for cold rolling will create much more force and energy needs, while hot rolling happens
much faster with less forces; however, there are significant energy costs to heat the metal to near eutectic
temperatures in large integrated steel plants, the hot strip rolling process is the third largest user of energy
after iron and steel making
In any hot rolling operation, the reheating furnace is a critical factor to determine end-product quality, as
well as the total costs of the operation. Energy use in a reheating furnace depends on production factors
(e.g., stock, steel type), operational factors (e.g. scheduling), and design features. Based on seven sites,

average total primary energy requirement of 1.2 GJ/t-cast steel is reported for hot rolling. According to IEA
(2007), globally, typical hot rolling energy needs are 2 – 2.4 GJ/t. Upgrading existing furnaces will be
another way of harvesting energy savings.
Typical hot rolling mill consists of a reheat furnace, sizing press, roughing mill, finishing mill, runout table
and coiler. Among these components, the finishing mill, which is composed of two work rolls (WRs), and
two backup rolls (BURs) supporting them, has a major influence on the dimensional accuracy of the slab
thickness. During hot finish rolling, the ideal symmetry boundary conditions between the upper and lower
rolls cannot always be guaranteed because of the complex interactions between the mill stands. Various
asymmetrical working conditions such as the pass schedule, differences in WR radii, angular speed
differentials of the WRs, strip temperature distribution, friction, tension, looper angle and entrance angle
can induce a non- uniform deformation behaviour in the deformation zone and consequently lead to a front-
end curvature (FEC), that is, turn-up/down. Turn-up makes bite by the WRs in the next stand difficult,
whereas turn-down causes severe damage to the rolling table.
HSM Capabilities
• Capacity : 3.6 MTPA
Product Dimensions
• Thickness : 1.6 – 20 mm
• Width : 760 – 2000 mm
• Weight : up to 30 T
• Specific Weight : up to 18.5 Kg/mm
• Inner Diameter : 740 +/- 40 mm
• Outer Diameter : 1930 mm Max

E-15 CSP Mill

Process Description
Product Mix:
• Coil Thickness Range 1.0 – 20 mm
:
• Coil Width range 930 – 1680 mm
:
• Coil Weight :
up to 32 T
• Specific Coil Weight :
up to 20.5 Kg/mm
• Grades feasible :
Low Carbon, Medium & High Carbon,
High Strength Low Alloy (HSLA)
The thin slab from Caster directly enters and heated in Tunnel Furnace. At the Exit of Tunnel Furnace,
slabs run over a roller table equipped with side guides through a Hydraulic Emergency Cutting Device and
a High Pressure Descaler.
After descaling, the thin slab passes through 7 (seven) Mill stands where it is rolled down to specified final
thickness.

At the exit of finishing mill, Online X-ray gauges for thickness & profile measurement and one width
measurement gauge are housed in Measuring house.
The strips are cooled under laminar bank of water before coiling in down coiler. Prior to handling in the
yard, the coils are strapped, weighed and marked online.
E-16 CRM
Pickling Line
Pickling is the one of the main essential activity of cold rolling & galvanizing process. CRM Complex has
one pickling line with capacity of 0.6 MMTPA and one is proposed with the capacity of 0.8 MMTPA. The
main objective of pickling is to remove the scales on the surface of the Hot Rolled Coil.
Process description
In this process the strip, emerging from entry section enters Pickling section consisting of three tanks
separated by squeeze roll stand. The Pickling tanks are shallow granite troughs specially designed to
support and guide the strip during all phases of operation. Hot dilute Hydrochloric Acid (HCl) is circulated
in each of the section from individual recirculation tanks through heat exchangers to make up the lost heat
during the process.
When the strip passes through the pickling tanks in the presence of HCl, oxide layers on the strip will get
dissolved in the acid and the strip emerging from the pickling tank passes through the rinse concentrate tank
where hot water is circulated from a collection tank and sprayed on the strip.
The strip emerging from the rinse concentrate chamber passes through a five-stage hot rinse section where
rinse water is cascaded from exit side chamber to entry side chamber through simple overflow system. Acid
carried over along the strip will be cleaned in this rinse section and finally acid and oxide free strip will
enter the drier. Waste pickle liquor from existing as well as proposed pickling line will be taken to Acid
Regeneration Plant (ARP), where acid is regenerated and reuse in the system.
Due to heat contained in the strip, carry over water duly squeezed dries quickly. The dry strip is oiled and
wound under the tension on the re-coiler and this coil is known as Hot Rolled Pickled Coil.
The hot acid evolves certain number of fumes. These fumes are sucked from the tanks with high-pressure
suction blower and passed through to a water-scrubbing tower where they are washed to clean the HCl
fumes. The pickling tanks, rinse tanks and acid recirculation tanks are connected to the system to ensure
that no acid & acid fumes escape into the atmosphere. The final emission from the scrubbing tower will be
less than the GPCB norms, 20 mg/Nm3 of HCl - stringent norms given by GPCB though EPA Norms
would be 35 mg/Nm3 - and is released through a stack to the atmosphere.
Cold Rolling
CRM Complex has two Cold Rolling Mill. A reversing mill (6-HI Combination Reversible UC Mills
supplied by Hitachi, Japan) with capacity of 0.2 MMTPA which exists and a tandem mill (4-HI Tandem

Mill supplied by VAI) with capacity of 1.0 MMTPA. The main objective of cold rolling is to achieve lower
thickness with better tolerance, better shape and surface on the material.
Process description
The 6 Hi UCM single stand combination reversible mill is used for the cold reduction of low carbon hot
rolled pickled material and the temper rolling of the cold rolled annealed material. The manufacture &
supplier of this mill is Hitachi Ltd. Tokyo, Japan. The brief description of the both processes is as below.
The cold reduction process is such that the Hot Rolled Pickled Coil (Free from any type of Oxidizes Scale)
is elongated in length - wise direction to obtain the desired thickness under the compressive load and
tensions. This cold reduction process is carried out under the constant roll gap mode to ensure the uniform
output thickness.
The head end of hot rolled pickled coil is threaded from Pay off Reel (POR) to Delivery Tension Reel
(DTR) than after gripping & wrapping in the DTR, the load and tension are applied as per the reduction
schedule than the actual reduction in the thickness will achieve by elongating the strip length. This process
is called the cold reduction & this step is named as the 1st pass. Once the entire coil length is elongated than
the tail end will thread to the Entry tension Reel (ETR) and again the same process is applied in the
reversed direction. The step is named as 2nd pass. Based on the input & out put material, this no. of passes
may vary.
Temper Rolling Process

Temper rolling is the similar type of cold reduction process but the reduction is much less than the cold
rolling and it is the ounces pass through process. The cold rolled annealed material is load on the entry
tension reel & head end will thread to the DTR than load and the tension will apply and the temper rolling
will carry out. This Temper rolling process is carrying out under the constant roll force mode to ensure the
uniform properties of output material.
Galvanizing Process
CRM Complex has one Galvanizing line with capacity of 0.33 MMTPA and another with capacity of 0.17
MMTPA, which is proposed. Galvanizing is a process of zinc coating on CR or HR.
Process description
As the name implies, hot-dip coating involves the application of a molten coating onto the surface of steel
sheet in a continuous process. That is, the steel sheet is passed as a continuous ribbon, through a bath of
molten metal at speeds up to 600 feet per minute. In the molten-metal bath, the steel strip reacts (alloys)
with the molten metal to bond the coating onto the strip surface. As the strip emerges from the molten bath,
it drags out excess metal, much like when an object is pulled rapidly from a container of water. Using a gas
wiping process, a controlled amount (thickness) of coating, usually expressed as weight (mass) of coating
per unit area, is allowed to remain on the strip surface.
The incoming steel is most often “full-hard” sheet coming directly from a cold reduction mill. The cold
reduction mill is used to decrease the thickness of the hot-rolled pickled strip to the desired thickness. The
cold rolling process makes the steel very hard with limited formability. For heavier sheet thickness, the
product may be entered into the coating line directly after hot rolling and pickling. In either case, the sheet
is uncoiled and welded to the tail end of the coil ahead of it in the processing line. Then, it is cleaned in a
process that typically uses an alkaline liquid combined with brushing. From the cleaning section, the strip
passes into the heating (annealing) furnace to soften the full-hard strip and impart the desired strength and
formability to the steel.
In the annealing furnace, the strip is maintained under a reducing gas atmosphere to remove any vestiges of
oxides on the steel surface. The gas atmosphere is composed of hydrogen and nitrogen. This oxides-
reduction step, iron oxide being converted to iron by reaction with the hydrogen, is very important to obtain
complete wetting of the steel surface during the short time that it is immersed into the coating bath.

The exit end of the furnace is connected directly to the molten coating bath by a “snout” to prevent any air
from re-oxidizing the heated steel strip before it reacting and alloying with the molten coating metal. In the
coating bath, the strip passes around a submerged roll and then exits the bath in a vertical direction. At the
exit point, a set of gas knives (usually high-pressure air), wipe off excess molten metal, leaving behind a
closely controlled thickness of molten metal.
The coating is then cooled to allow the metal to freeze on the steel surface. Freezing of the coating, or
solidification, has to be accomplished before the strip contacts another roll to avoid transferring the coating
onto the roll. Thus, coating-process lines usually have a high tower above the coating bath, perhaps as high
as 200 feet on some of the newer lines.
Galvanneal is produced from galvanized by reheating the coated sheet above the wiping knives to alloy the
zinc with the iron in the steel.
After cooling to close to room temperature, the strip feeds into the exit end equipment -temper mill, tension
leveller, chemical treatment section, oilier, and then is recoiled on an exit-end mandrel.
The continuous strip is sheared at the weld that was made at the entry end of the line to remove the weld as
well as to maintain coil-to-coil identity.
Batch Annealing Furnace and Skin Pass Mill:

CRM Complex will have Batch Annealing Furnaces (BAF) and one Skin Pass Mill (SPM). Annealing is a
heat treatment process to relieve the stresses from the material during cold rolling and refine the grain
structure for better mechanical properties. Skin passing is done to improve mechanical property and provide
the customer specific surface finish on the strip. A variety of qualities can be produced as per the
customer’s specification.
Some finishing lines like slitting and cut to length would be installed to provide the customers the slit coils
or sheet form as per their requirements.
Electrolytic Cleaning Line:

CRM Complex have one Electrolytic Cleaning line of 0.4 MMTPA. The alkaline cleaning of cold rolled
coils by the use of high current density will ensure very clean surface of the strip before annealing. Total oil
and dirt content will not exceed 10 mg/M2/Side (max) after cleaning.
Coil Inspection and Finishing Line:

CRM Complex have one inspection cum slitting line, one slitting line and one shearing line of 12500 tons,
7500 tons and 7500 tons respectively. In the inspection & slitting line, the CR coils will be inspected for
various defects before final dispatch. This line will also have the facility to slit the coil based on customer
specifications.
In the shearing (cut-to-length) line the coil will be cut to desired length for dispatches in sheet form.

E-17 Waste Heat Recovery Power Plant

Process Description
The Power Plant is based on heat Recovery from the exhaust flue gases which are coming out from the four
modules of HBI Plant. For this purpose, the power plant is provided with one common heat recovery steam
generator (HRSG). The HRSG is provided with induced draft fan and stack. The ID fan creates the
necessary draft required for the flue gas from tap off point up to fan inlet.
Now these gases are mixed in the mixing chamber and from there they are passed on into HRSG Boiler.
From the opposite side of the flow of waste gas, water is passed into the boiler in the LP Economizer. The
water passes through LP Economizer, which increases the temperature of water and then it is passed on to
the LP evaporator which converts the high temperature water into steam. Then it goes to the LP Super
heater, where this LP Steam is superheated and passed on to the turbine at the required temperature and
pressure.
Nearly 2/3 amount of total flow of water is passed on to the IP Economizer and then to the IP Evaporator
and to the IP Super heater, where the steam gets converted to the IP steam and then it is passed on to the
turbine at required temperature and pressure.
Now these IP and LP steam generated from the HRSG will be expanded in the steam turbine which helps to
rotate the rotor of the turbine. This turbine is coupled to the generator with the help of gear box and thus the
generator produces the electrical energy. (Siemens Steam turbine capacity 18.4 MW and Generator capacity
25 MVA)
The steam gives up its heat energy in rotating the turbine and thus the low temperature steam coming out
from the turbine is passed on to the condenser where it gets converted into hot water. This hot water is
again re circulated and fed to the boiler with the help of boiler feed pump. Thus, the cycle of the conversion
of mechanical energy into electrical energy goes on.

E-18 Pipe Mill

Process Description
AMNS Pipe mill comprises one unit for Longitudinal Submerged Arc Welded (LSAW) Pipe with capacity
of 3,30,000 TPA; conventional type Helical Submerged Arc Welded (HSAW) pipe unit of capacity 3,00000
TPA. Each of these units produces pipes in the length up to 12.2 meters. These facilities are augmented by
external coating unit of capacity 2 million SqMtr and an internal coating facility of capacity 1 million
SqMtr. The USP of the plant lies in the integration with the raw material producing steel plant and plate
mill at the operating level. This provides us with the ultimate control on the quality of the raw material and
in turn very strong process control throughout the manufacturing process (Ore to Finished Pipe) from a
customer point of view.
The three plants are equipped with state-of-the-art latest generation equipment sourced from globally
recognized suppliers namely GE Inspection System, Urhan & Schull (Lincoln), Iprolem Romania,
Socotherm Italy, Initech Korea, YSD China etc. This equipment enables AMNS to service the customers
with the most stringent specifications. The steel pipe complex has a capacity of 3,00,000 TPA of spiral
welded pipe and 3,25,000 TPA of LSAW pipe along with suitable coating facilities.
LSAW Pipe Mill

Hot Rolled plates, after inspection are subjected to Ultrasonic testing followed by edge milling operation to
precise width and adequate double bevel. The plate is rolled in a 3roll bending machine, followed by post-
Bending to impart the required edge profile to the bent plate and subsequently the plate is tack-welded at
root using Gas Metal Arc Welding process. The welded pipe is washed and then transferred to the end
facing machine to make the pipe ready for inspection and testing. Various tests as per applicable standards
are carried out on the pipe viz. Real-Time Radiography (RTR), Hydro-static testing. Ultra-sonic testing, X-
ray/RTR. Visual & dimensional inspection and mechanical and chemical testing.

Spiral Pipe Mill

Hot Rolled Coil is first inspected for any lamination using the Ultrasonic Testing Equipment. It is then
mounted on the de-coiler & is fed through a series of rollers to flatten and level it, followed by beveling at
both the edges. The beveled coil is then fed by drive rollers to the formation table where the pipe is formed
& followed immediately by inside welding. Then outside welding is performed and transferred to beveling
machine. The finished pipe is then tested by hydro tester as well as other non-destructive testing machine to
ensure that all pipes attain desired quality levels Coating Line
In the multi-layer coating process pipes are blast cleaned and covered with a composed coating of three or
more individual layers viz. fusion bonded epoxy coating or anti-corrosion layer followed by an adhesive
layer and the top layer which provides the mechanical protection to the pipe. Depending on the pipe
diameter, grit blasting is either accomplished by the air blast method or by a blast turbine. The lining is
done by means of airless liquid spray coats (cold- or hot applied) or by Fusion Bonded Epoxy (FBE).
Coal tar Enamel coating begins by the pipe being shot blasted to required standard. A synthetic primer is
then applied on the steel surface a primer application station, depending upon the production planning
control. The pipe is then flooded with hot melted coal tar. Instantly after the initial flooding, the pipe is
wrapped with a fiber glass inner wrap. The pipe is then covered by a wrap of reinforced outer wrap. The
pipe is then water quenched and is ready for final inspection.
The details of which are as below:
Coal Tar Enamel Coating of 1,500,000 Sq. M

Layer PE Coating of 2,000,000 Sq. M
Liquid Epoxy ID Coating of 1,000,000 Sq. M
Configuration of Pipe Mill Division Plants
Flow Diagram of L-SAW

Process Flow Diagram of H-SAW PLANT
2.9.5 Manufacturing process of Proposed Auxiliary Facilities

P-1 Coal briquetting Plant
Process Description
The coal fines will be conveyed from raw material handling screen house to briquetting site by conveyor.
The fines will be stored in storage silo. From silo the fines will be feed to fines drying unit & after drying of
coal fines it will go in another storage silo. From this silo fines will so to mixer unit where fines will mix
with starch and polymer. After mixing mines will go in briquetting machine where fines will be converted
into briquettes. This briquette will go to dyer for removal of moisture. After dryer briquettes will be
screened and feed to briquette charging system. The fines generated in the process will go back directly in
mixer for recycling.
The design basis of Coal Briquetting Plant is given below.

Description Units Values
Coal fines dryer 2 25 TPH
Coal fines mixer 2 25 TPH
Briquetting press 2 25 TPH
Briquette dryer 2 25 TPH

P-2 BF – PCI Project

Process Description
The blast furnace is equipped with pulverized coal injection facility, which substitutes a part of
metallurgical coke charged to the blast furnace. The coal injection unit is designed for a capacity of 150
Kg/THM to achieve an injection rate of 250Kg/THM, a system of 80 Tons per of hour is required. With this
facility the present/ existing system will be kept as standby unit and will be operated at the time of 80TPH
system maintenances.

P-3 Lime Kiln (500 TPD)-Lime & Dolime

Process Description
Lime stone and raw dolomite of size 40-80 mm will be charged into shaft kiln for calcinations. The
undersized limestone/ dolomite less than 40 mm in the charge shall be separated out before feeding to the
kiln. Limestone and dolomite will be subjected to calcinations at temp. 950 oC – 1150 OC to achieve burnt
reactive lime / dolime.
P-4 Rotary Kiln (200TPD)- Calcinate lime

Process Description
Rotary kiln is suitable for calcination of 6-40mm size limestone chips. Calcined lime producing through
this is highly calcined (LOI<3%) and very useful in LF & EAF also. Daily generation of Limestone chips is
average around 350 MT which can be converted into lime. 0-6mm limestone fines as well 0-6mm lime
fines can be used in sinter.

P-5 Blast Furnace Dust catcher/Dust separation unit-150 TPD

Process Description
Abstract The off-gas discharged from a blast furnace is de-dusted in a first stage by a dust catcher or a
cyclone. The separated dust consists mainly of iron and coke. Therefore, most of this dust is recycled in the
sinter plant.
P-6 Acid Regeneration Plant – 100 KL & Pickling line 3

Process Description
Gas Cooling and Pre-concentration
The waste acid is pumped continuously from the pickling plant to the acid storage.
From the storage tank the waste acid is transferred into the separator of the pre-concentrator. A circulation
circuit transfers the waste acid from the separator to the venturi of the pre-concentrator. In this venturi the
hot gases from the roaster come in contact with the circulated liquid. While the liquid is heated and
concentrated, the heat of the roast gas is recovered by evaporating part of its volume. Simultaneously, the
gas stream is cooled from approx. 850 °C to approx. 95 °C and is de dusted. This interaction results in
droplets which are segregated from the gas stream in the separator.
The liquid level in the separator is controlled via addition of waste acid where the concentrate density is
controlled by feeding of water.

Thermal Process:
The concentrated solution is fed to the reactor via an acid lance, which keeps the temperature in the free-
board constant at 850°C. The burner system is located in the bottom of the roaster. It comprises a multitude
of nozzles. The turbulence air is blown by the combustion air blower into the air boxes from where the air is
fed via burner nozzles into the roaster. Inside the nozzles, the fuel gas is mixed with air.
The proper combustion takes place in the fluidized bed. The combustion renders both the energy required
for evaporation and for the roasting reaction. The combustion gas serves also for fluidizing the oxide in the
fluid bed.
The roasting of the waste acid is according to the following chemical equation:
2 FeCl2 + 2 H2O + ½ O2 Fe2O3 + 4 HCl

2 FeCl3 + 3 H2O Fe2O3 + 6 HCl
The temperature within the roaster is controlled via the amount of concentrated waste acid added and is
kept constant due to excellent mixture of gas and particles over the entire bed. The oxide produced forms
layers (onion structure) on the existing particles. The roasting gases consisting of the hydrogen chloride
(HCl), water vapor and the combustion gases exit via the top of the roaster and pass through a cyclone
separator which removes part of the iron oxide (Fe2O3). This cyclone oxide is fed back into the roaster.
After leaving the roaster and the cyclone the hot gases are directed into the preconcentrator. Oxide
Conveying / Storage The iron oxide granulates produced in the roaster are transported with a pneumatic air
lift (the discharge amount can be easily adjusted by regulating air flow) and are guided to a horizontal
conveyor with a cooling jacket followed by a spiral screw conveyor to transport them vertically to an
intermediate storage bin, by this the oxide pellets are cooled to below 100°C.
A small part of the oxide is milled in an oxide crusher and used for better particle formation in the reactor.
Absorption
Downstream of the pre-concentrator the cooled roast gas enters the absorption column. Wash water is
sprayed onto the top of the packing to produce hydrochloric acid by adiabatic counter-current absorption.
The regenerated acid leaves the bottom of the absorber and flows to the regenerated acid storage tank.
Exhaust Gas Cleaning

After the absorber the roast gas enters the exhaust gas cleaning stage, which consists of: Exhaust gas
venturi scrubber In this scrubber the gases come in contact with circulated rinse water from the pickling line
and wash water from the exhaust gas fan in order to remove HCl and dust from the gas stream. This
interaction results in droplets which are segregated from the gas stream in the separator. A portion of the
liquid in the venturi circulation is fed to the top of the absorption column.
Exhaust gas fan

The gas is conveyed through the plant by the variable-speed exhaust gas fan which controls the negative
pressure in the plant. The impeller of the fan is sprayed with water for additional scrubbing of the exhaust
gases. A drop separator is installed downstream of the fan. The separated liquid is accumulated in the
collecting tank.
Collecting tank
Rinse water from the pickling line and liquids from the exhaust gas cleaning section are accumulated in the
collecting tank and fed as absorption liquid to the top of the absorption column.
Packing gas scrubber Further downstream the exhaust gases enter a column scrubber which is charged with
industrial water to further remove hydrogen chloride (HCl). The gas streams through a drop separator and
then exits the PLANT via a stack.

Tank Farm
Waste acid and rinse water are supplied to the tank farm of the PLANT by the pumps of the pickling line.
Regenerated acid is supplied to the pickling line by the regenerated acid pumps of the ARP. Fresh acid is
supplied into the fresh acid tank by truck discharge.
Plant Operation
Process data such as temperatures, pressures and flows are shown on the monitor in the control room with
necessary operating parameters controlled by the PLC system. Start-up, controlling and shutdown of the
plant are performed via the HMI while alarms and malfunctions are recorded in a separate alarm protocol.
The operator can easily check the operating conditions of the PLANT from the control room. Start-up and
shutdown of the ARP can be performed at any time. To start the ARP the roaster is first heated by the
burners. When the proper temperature is reached, water is charged to the pre-concentrator circuit which in
turn flows to the roaster. When thermally balanced operation is reached, the ARP is switched from water to
acid operation and the regeneration process starts. For shutdown, the ARP is switched back to water
operation for removal of HCl gas before being shut down completely.
Pickling Line
Process Description
Typically processes two out of every three coils produced at the Hot Mill. Its primary function is to remove
the thin layer of oxidized iron, or scale, that forms on the surface of the steel at the temperatures employed
during hot rolling. The unit is capable of pickling 1.4 million tons per year of steel up to ¼” thick and 62”
wide. This includes all Cold Roll and Galvanize products, as well as Pickled purchased by customers who
desire a surface quality more conducive to painting or plating.
Scale itself is chemically very similar to rust, being made up of iron and oxygen bonded together in various
molecular arrangements. Like rust, scale develops at the steel’s surface where the iron is exposed to air,
except that it forms at higher temperatures such as those used during hot rolling. The scale layer grows
deeper into the steel over time at a rate that increases rapidly as the temperature rises; for instance, slabs
exit the reheat furnace at the Hot Mill with a layer of scale up to 1/8” thick.

P-7 BF slag Grinding mill (BOO) – 50 TPD

Process Description
Grinding of cement and/or granulated blast-furnace slag – Material separation in the filter. The cement
components are ground, dried, and classified in the Pfeiffer vertical roller mill. When grinding granulated
blast-furnace slag, the iron particles contained in the slag can be discharged.

P-8 New Cooling tower for Mode 1 to Mod 6

Process Description
Cooling towers are a special type of heat exchanger that allows water and air to come in contact with each
other to lower the temperature of the hot water. During this process, small volumes of water evaporate,
lowering the temperature of the water that's being circulated throughout the cooling tower
P-9 Slag Conditioning & Metal Recovery plant

A slag conditioner containing MgO, carbon or a filler and a binder is mixed and formed under pressure to
produce aggregates which can have the form of a briquette. The slag conditioner is used to improve the
operating performance and refractory life in steel melting furnaces.
Materials recovery plant, also known as materials reclamation facility or materials recycling facility, solid-
waste management plant that processes recyclable materials to sell to manufacturers as raw materials for
new products. Materials recovery plants are generally classified as either “clean” or “dirty,” depending on
whether the facility handles materials that are mixed with other municipal waste. Materials recovery plants
play an important role in reducing the waste stream, the demand for raw materials, and pollution associated
with the manufacturing of new products.
A clean Materials recovery plant takes in commingled recyclable materials that have been separated from
municipal solid waste, usually by individual citizens or businesses before curb side trash collection.
Although some clean facilities are single stream (i.e., all of the recyclable materials are mixed together),
many are dual stream, or source-separated, which means that they receive one stream of mixed paper and
one of other materials such as glass, nonferrous metals, and plastics. The recyclables are sorted and then
prepared for market. Nonrecyclable or contaminated materials are separated out, but they generally amount
to less than 10 percent of the total stream of waste taken in by a clean facility.
At our Metal Recovery Plant, a crushing and magnet separation process is used to recover the metal
contained in iron and steelmaking slag. This can then be effectively reused in the steelmaking process.
Metal recovery plants use a series of conveyers that carry recyclable materials over sorting screens or other
mechanisms that divide the materials. As single-stream recycling becomes more common, more facilities
are designed to accept and separate various types of recyclable materials. Automated systems can sort a
number of materials simultaneously, such as paper, cardboard, aluminium, plastic, and glass, using such
tools as magnets and ultraviolet optical scanners. The mechanized process is augmented by workers who
sort items by hand.
Once the materials have been sorted, they are melted, shredded, or pulped to prepare them for recycling.
Glass is often pulverized and melted for use into new glass objects, although some facilities offer bottle
reclamation, in which bottles are sterilized for reuse. Shredding is used to prepare plastic, metal, and paper
for processing, and pulping converts paper products into a slurry that can be made again into paper. In
salvaging, a product is stripped of valuable components, such as the removal of lead from car batteries.
Processed materials are then shipped to facilities that specialize in using recycled goods for manufacturing.
P-10 Thick Plate Normalizing Furnace

Process Description
Normalizing is a ferritic heat treatment process that is used to make a iron based alloy steel more ductile
and tough. This is achieved after the part(s) have been subjected to thermal hardening processes.
Normalizing involves heating the steel to an elevated temperature, followed by slow cooling to room
temperature. The heating and slow cooling changes the microstructure of the steel. This reduces the
hardness of the steel and will increases its ductility.
Normalizing is performed when another process has decreased ductility and increased hardness of machine
steel parts. Normalizing reforms, the microstructure into more ductile structures. This makes the metal more

formable, more machinable, and reduces residual stress within the material that could lead to unexpected
failure.
This process involves heating a material to an elevated temperature and then allowing it to cool back to
room temperature by exposing it to room temperature air after it is heated. This heating and slow cooling
alters the microstructure of the metal which in turn reduces its hardness and increases its ductility.
P-11 Shot Blasting Machine

Process Description
As part of this technique of blasting, a controlled stream of abrasive shot material is propelled towards the
metallic or steel surface that needs to be shot blasted with. There is a blast wheel that is located at the heart
of the machine. As soon as the rotation of the wheel starts, the metallic abrasives or the shot media are
channelized towards its centre. From this position onwards, the abrasives are accelerated and hurled into the
direction of the surface which is being prepared for finishing. After the completion of this process, the
contaminants as well as the media make a rebound into a separation system which contains the dust
collection system. Just like the name suggests, the dust collector is responsible for collecting or for
removing the media that is pulverized, contaminants or dust. The remaining media gets recycled by
returning it to the storage hopper where the particles can be kept for using them in the future.

P12-VD Cooling Tower

Process Description
A cooling tower is a heat rejection device that rejects waste heat to the atmosphere through the cooling of a
coolant stream, usually a water stream to a lower temperature. Cooling towers may either use the
evaporation of water to remove process heat and cool the working fluid to near the wet-bulb air temperature
or, in the case of closed-circuit cooling towers or dry cooling towers, rely solely on air to cool the working
fluid to near the dry-bulb air temperature using radiators
Common applications include cooling the circulating water used in oil refineries, petrochemical and other
chemical plants, thermal power stations, nuclear power stations and HVAC systems for cooling buildings.
The classification is based on the type of air induction into the tower: the main types of cooling towers are
natural draft and induced draft cooling towers.
Cooling towers vary in size from small roof-top units to very large hyperboloid structures (as in the
adjacent image) that can be up to 200 metres (660 ft) tall and 100 metres (330 ft) in diameter, or rectangular
structures that can be over 40 metres (130 ft) tall and 80 metres (260 ft) long. The hyperboloid cooling
towers are often associated with nuclear power plants, [1] although they are also used in some coal-fired
plants and to some extent in some large chemical and other industrial plants. Although these large towers
are very prominent, the vast majority of cooling towers are much smaller, including many units installed on
or near buildings to discharge heat from air conditioning
P13 RHD Cooling Tower

Process Description
An RHD or HVAC (heating, ventilating, and air conditioning) cooling tower is used to dispose of ("reject")
unwanted heat from a chiller. Water-cooled chillers are normally more energy efficient than air-cooled
chillers due to heat rejection to tower water at or near wet-bulb temperatures.
A cooling tower cools down water that gets over heated by industrial equipment and processes. When the
air and water come together, a small volume of water evaporates, creating an action of cooling. The colder
water gets pumped back to the process/equipment that absorbs heat or the condenser
P14 - Water Treatment Plant for 500 MW CCPP

Process Description
Sedimentation or settling is the simple process in which particles that are heavier than water settle to the
bottom of a container in which the suspension is held, or through which the suspension flows. On the basis
of the concentration of particles and the tendency of particles to interact, four types of settling behaviour
can be distinguished: discrete particle settling, flocculent settling, hindered (also called zone settling) and
compression settling.
Raw Water Raw water p/p

Clarifloculator Clarified tank
house
3 3 3
650m /hr 2 x 500 m /hr 4000 m
Softening Plant PSF
5x200 m3/hr
3
3 x 500 m /hr
New Facility Make up water
Natural gas Flue gas Steam
GTG-1/2/3 HRSG-1/2/3 STG-1/2 IDCT Forebay
1,00,000m3/hr STG-1/2
O/L
Condensor
CWP
GT cooling water
system
Softening water i/p
DM water
3
150 m /day Make up water
P-15 CRM-2
Process Description
AM/NS manufacturing facilities at Hazira comprises of iron making, steel making, and downstream
facilities including cold rolling mill, galvanizing, pre-coated facility, steel processing, an extra wide plate
mill and a pipe mill. In a series of continuous improvement plan and based on finishing strategy, AM/NS
Hazira has planned to upgrade existing facilities and install new facilities in CRM#2 area in following three
Phases:
Phase 1:
Upgradation of existing Continuous Tandem Cold Rolling Mill (CTCM)
New one (1) number continuous galvanizing line #4 for (ZnMg) coating (CGL-4)
New one (1) number coil inspection cum repair line #1.
New one (1) numbers coil packaging line #1
Necessary Utility & auxiliary facilities required for the above mentioned facilities
Phase 2:
New one (1) number Pickling line coupled with tandem cold mill (PLTCM)
New one (1) number Acid Regeneration Plant #3 (ARP-3)
New one (1) Effluent Treatment Plant (ETP)
New one (1) number continuous galvanizing line #3 for GA (CGL-3)
New one (1) number coil inspection cum repair line #2.
New one (1) number coil packaging line #2.
New roll grinding & roll texturing machines
Necessary Utility & auxiliary facilities required for the above mentioned facilities.
Phase 3:
New one (1) number continuous pickling line #4 (PKL-4)
New one (1) number Acid Regeneration Plant #4 (ARP-4)
New one (1) number continuous annealing line (CAL)
New one (1) number coil inspection cum repair line #3
New one (1) number coil packaging line #3
Necessary Utility & auxiliary facilities required for the above-mentioned facilities

PLTCM Pickling line and Tandem Cold Roll Mill

Pickling is the process is in line with 5 stand cold rolling Mill. CRM-2 Complex will have this process of
capacity of 2.0 MMTPA. The main objective of pickled the coil is to remove the scales on the surface of the
Hot Rolled Coil and then move the material to 5 stand cold roll mill for further process.
Process description:
In this process the strip, emerging from entry section enters Pickling section consisting of three tanks
separated by squeeze roll stand. The Pickling tanks are shallow granite troughs specially designed to
support and guide the strip during all phases of operation. Hot dilute Hydrochloric Acid (HCl) is circulated
in each of the section from individual recirculation tanks through heat exchangers to make up the lost heat
during the process.
When the strip passes through the pickling tanks in the presence of HCl, oxide layers on the strip will get
dissolved in the acid and the strip emerging from the pickling tank passes through the rinse concentrate tank
where hot water is circulated from a collection tank and sprayed on the strip.
The strip emerging from the rinse concentrate chamber passes through a five-stage hot rinse section where
rinse water is cascaded from exit side chamber to entry side chamber through simple overflow system. Acid
carried over along the strip will be cleaned in this rinse section and finally acid and oxide free strip will
enter the drier. Waste pickle liquor from existing as well as proposed pickling line will be taken to Acid
Regeneration Plant (ARP), where acid is regenerated and reuse in the system.
Due to heat contained in the strip, carry over water duly squeezed dries quickly. The dry strip is oiled and
wound under the tension on the re-coiler and this coil is known as Hot Rolled Pickled Coil.
The hot acid evolves certain amount of fumes. These fumes are sucked from the tanks with high-pressure
suction blower and passed through to a water-scrubbing tower where they are washed to clean the HCl
fumes. The pickling tanks, rinse tanks and acid recirculation tanks are connected to the system to ensure
that no acid & acid fumes escape into the atmosphere. The final emission from the scrubbing tower will be
less than the GPCB norms, 10 mg/Nm3 of HCl - stringent norms given by GPCB though EPA Norms
would be 30 mg/Nm3 - and is released through a stack to the atmosphere.
Tandem Cold Rolling

CRM Complex has Five stand Cold Rolling Mill will have a capacity of 2.0 MMTPA. The main objective
of cold rolling is to achieve lower thickness with better tolerance, better shape and surface on the material.
Galvanizing Process #4 & 3 and CALGAL (Continuous annealing cum mix Galvanizing line)
CRM Complex-2 has proposed two Galvanizing line of each capacity of 0.5 MMTPA. The CGL #4 will
produce commercial grade Galvanizing and CGL #4 will produce Automotive grade Galvanizing. The
CALGAL will having capacity of 1 MMTPA. Galvanizing is a process of zinc / magnilise coating on CR
or HR.
Process description:
As the name implies, hot-dip coating involves the application of a molten coating onto the surface of steel
sheet in a continuous process. That is, the steel sheet is passed as a continuous ribbon, through a bath of
molten metal at speeds up to 180 meter per minute. In the molten-metal bath, the steel strip reacts (alloys)
with the molten metal to bond the coating onto the strip surface. As the strip emerges from the molten bath,
it drags out excess metal, much like when an object is pulled rapidly from a container of water. Using a gas
wiping process, a controlled amount (thickness) of coating, usually expressed as weight (mass) of coating
per unit area, is allowed to remain on the strip surface.
The incoming steel is most often “full-hard” sheet coming directly from a cold reduction mill. The cold
reduction mill is used to decrease the thickness of the hot-rolled pickled strip to the desired thickness. The
cold rolling process makes the steel very hard with limited formability. For heavier sheet thickness, the

product may be entered into the coating line directly after hot rolling and pickling. In either case, the sheet
is uncoiled and welded to the tail end of the coil ahead of it in the processing line. Then, it is cleaned in a
process that typically uses an alkaline liquid combined with brushing. From the cleaning section, the strip
passes into the heating (annealing) furnace to soften the full-hard strip and impart the desired strength and
formability to the steel.
In the annealing furnace, the strip is maintained under a reducing gas atmosphere to remove any vestiges of
oxides on the steel surface. The gas atmosphere is composed of hydrogen and nitrogen. This oxides-
reduction step, iron oxide being converted to iron by reaction with the hydrogen, is very important to obtain
complete wetting of the steel surface during the short time that it is immersed into the coating bath.
The exit end of the furnace is connected directly to the molten coating bath by a “snout” to prevent any air
from re-oxidizing the heated steel strip before it reacting and alloying with the molten coating metal. In the
coating bath, the strip passes around a submerged roll and then exits the bath in a vertical direction. At the
exit point, a set of gas knives (usually high-pressure air), wipe off excess molten metal, leaving behind a
closely controlled thickness of molten metal.
The coating is then cooled to allow the metal to freeze on the steel surface. Freezing of the coating, or
solidification, has to be accomplished before the strip contacts another roll to avoid transferring the coating
onto the roll. Thus, coating-process lines usually have a high tower above the coating bath, perhaps as high
as 200 feet on some of the newer lines.
Galvanneal is produced from galvanized by reheating the coated sheet above the wiping knives to alloy the
zinc with the iron in the steel.
After cooling to close to room temperature, the strip feeds into the exit end equipment -temper mill, tension
leveller, chemical treatment section, oilier, and then is recoiled on an exit-end mandrel.
The continuous strip is sheared at the weld that was made at the entry end of the line to remove the weld as
well as to maintain coil-to-coil identity.
The CALGAL is process is same as above but having facility to produce annealing material as well as
Galvanizing material as per customer requirement
Coil Inspection and Finishing Line:

CRM-2 Complex will have one inspection cum edge slitting line of capacity 0.35MMTPA. In this the CR
coils will be inspected for various defects before final dispatch. This line will also have the facility to slit
the edge of coil based on customer specifications

P-16 Ladle Furnace – Existing Liquid Steel 4.6 MTPA (Standby LF-5 for Special Grades)
Process Description
A Ladle Furnace is used to relieve the primary melter of most secondary refining operations, and its
primary functions are:
• Reheating of liquid steel through electric power conducted by graphite electrodes
• Homogenization of steel temperature and chemistry through inert gas (Ar) stirring
• Formation of a slag layer (By adding Lime/ Dolime) that protects refractory from arc damage,
concentrates and transfers heat to the liquid steel, trap inclusions and metal oxides, and provide the
means for desulphurization.
Secondary functions that can be included with a ladle furnace are:
• Alloy additions (Like Mn, Ti, Mo, V, B etc.) to provide bulk or trim chemical control
• Cored wire addition (CaFé/ CaSi) for trimming or morphology control
• Provide a means for de-oxidation (by adding C or Al or Si)
• Provide a means for deep desulphurization
• Provide a means for de-phosphorization
• Act as a buffer for downstream steelmaking equipment

P-17 SMP-1 Fume Extraction System upgradation

Process Description
Steel Making Plant1 at AMNS India Currently operates 4 DC Electrical Arc Furnace (EAF). Each EAF has
dedicated Primary Fume Extraction system which captures the Fumes generated during the Steel melting
process. To capture the secondary fumes and dust generated during the charging, Tapping and De-slagging
operation, Secondary Fume extraction system is provided which is common for EAF1,2 and 3 however
EAF4 has dedicated secondary fume extraction system. This project will increase the capacity of common
Secondary Fume Extraction system (for EAF1,2 and 3) to achieve cleaner shop condition and also address
P-18 Mod 4 Additional VPSA to utilize Corex Gas and going forward Coke Oven Gas
Process Description
Air from a Blower is first cooled in an Aftercooler to reduce its moisture content and condensed moisture is
separated in Moisture Separator. The cooled air passes through a tower containing an adsorbent which has
the property to separate oxygen from the air resulting in a gas contains 93% oxygen (balance being argon &
nitrogen) coming out as product gas. To ensure continuous flow of product gas, the other Tower is
simultaneously regenerated by extracting the gases adsorbed in the previous cycle by a Vacuum Pump.
Automatic operation is achieved by opening & closing the valves in a preset sequence by using a PLC.
Major application of this oxygen is for enrichment of combustion air used in fuel fired furnaces & kilns.
Since the oxygen is produced onsite, it is a flexible, efficient and cost-effective technology that can help

you save costs by lowering fuel usage, improve quality and also reduce emissions. Oxygen enrichment is
beneficial in all high temp manufacturing processes used in glass, ferrous & non-ferrous metals, cement,
ceramic tiles, sanitary ware, insulators, gasification of coal, coke, biomass, etc.
P-19 Hot Metal Pre Treatment station outside shope (KR technology)
Process Description
Hot metal pretreatment is a process performed on hot metal after the tapping of a BF (blast furnace) and
before decarburization in a BOF (basic oxygen furnace). In most cases, this process lowers the impurity
content of the hot metal. The advantage of this process originally was the cost reduction.
Hot metal pretreatment is a process performed on hot metal after the tapping of a BF (blast furnace) and
before decarburization in a BOF (basic oxygen furnace). In most cases, this process lowers the impurity
content of the hot metal. Hot metal desulfurization, desiliconization, and dephosphorization are all
processes that are included in this category. Among the various reactions that take place, desulfurization
plays the most important role in hot metal pretreatment. This process was first used in the 1960s, and at
present, desulfurization is the only hot metal pretreatment used in most steelmaking shops, except in some
eastern Asian countries. The use of hot metal dephosphorization began in the 1980s in Japan. The
advantage of this process originally was the cost reduction. Recently, when combined with the recycling of
decarburization slag, it has also made reduced slag generation possible, which is another advantage. Hot
metal desiliconization was developed to adjust the slag volume in order to minimize the cost of refining. In
this chapter, we first explain the fundamentals of each type of reaction in terms of the thermodynamics and
kinetics involved, and then we introduce an example of each process

P-20 Tank Farm -2 with Interconnection between PKL-3 and ARP-2

Process Description
Waste acid and rinse water are supplied to the tank farm of the PLANT by the pumps of the pickling line.
Regenerated acid is supplied to the pickling line by the regenerated acid pumps of the ARP. Fresh acid is
supplied into the fresh acid tank by truck discharge.
P-21 Additional Ladle Furnace (LF7)

Process Description
A ladle furnace is used to relieve the primary process of steel making of many of the secondary refining
operations. Reheating of liquid steel by electric power which is conducted by graphite electrodes.
Homogenization of steel temperature and chemistry through inert gas rinsing.

2.10 Raw Materials

2.10.1 Raw Material Consumption
Raw material consumption details are given in table 2.6.
Table 2.6 Major Raw Materials Requirement

Existing Units
Mod. I to VI)
Flux 140 KT 140 KT
1480 KT
External fines
as per
requirement
Flux
external)
(Recovery Type)
Lime 271 KT 271 KT
(Note: Scrap
can be replaced
by HBI/DRI)
Lime 300 KT 300 KT
(Note: Ideal
mix.,In case of
lower hot metal,
additional HBI,
CDRI required
Coke: 355 KT, 355 KT,
Coal: 2900 KT 2900 KT
(Lime/ Dolime)
(Lime/ Dolime)
11 CPP - - -
Product -HRC


(CSP Casters INI)
16 CRM-1 HRC 1500 KT 0.0 2000 KT
Existing Jetty
Recovery Based
Power Plant
HRC 300 KT 300 KT
Plant - (1000 TPD)
Pulverized coal
TPD) - Lime and
Dolime
TPD) - Calcined
Lime
Catcher /Dust
separation unit-150
TPD
Plant - 100 KL &
Pickling Line-3
TPD
towers (Mod 1 to
Mod 6)
plant
Normalizing KTPH
Furnace
machine plates:
Tower
Plant for 500 MW
CCPP
Special grades)
CPC 850 TPA 850 TPA
17 SMP-1 fume - -

Extraction System
upgradation
VPSA to utilize
Corex gas and
going forward Coke
oven gas
Pretreatment
Station Outside
Shop (KR
Technology)
interconnection
between PKL-3 &
ARP-2
grades Aluminium
CPC 850 TPA 850 TPA
2.10.2 Quantum Generation Iron Ore from Iron Ore Mines

The details of Quantum Generation Iron Ore from Iron Ore Mines are given in table 2.7. The characteristics
(Trace Elements) of iron ore is given in table 2.8. the linkages of iron ore are enclosed as annexure 3
Table 2.7 Details of Quantum Generation Iron Ore from Iron Ore Mines
Sr. No. Name of Contract Capacity Supply to
AMNS
1 Thakurani Iron Ore Mines of 5.5 MTPA 5.5 MTPA
AMNS(Captive)
2 OMC limited 9.12 MTPA 4.84 MTPA
3 NMDC Limited, 309 Ha 1.30 MTPA
4 Serajuddin & Co., Odisha EX Mines 2,00,000 MT Spot
only (Balda Iron Ore Block). purchasing
Table-2.8 Trace Element Analysis of Iron Ore

Sr. No. Parameters Unit Result
1 Arsenic mg/L Not Detected
2 Cadmium mg/L 0.08
3 Lead mg/L 0.12
4 Mercury mg/L Not Detected
5 Antimony mg/L Not Detected
6 Copper mg/L 0.21
7 Nickel mg/L 0.43
8 Zinc mg/L 0.36
9 Fluoride mg/L 0.13
10 Cyanide mg/L Not Detected
11 Chromium mg/L Not Detected
12 Moisture (H2O) % 7.98
13 Iron (Fe) % 63.8
14 Silica (SiO2) % 2.67
15 Alumina (Al2O3) % 2.49
16 LOI % 2.99
2.10.3 Quantum Generation Coal and Coke from Mines

The details of Quantum Generation Coal and Coke from mines are given in table 2.9. The characteristics
(Trace Elements) of Coal and Coke is given in table 2.10 (A) and 2.10 (B). The linkages of Coal and Coke
enclosed as annexure 4. The Coal and Iron ore are purchased from traders based on the COA submitted by
them.
Table 2.9 Details of Quantum Generation of Coal and Coke from Mines
Sr. Suppliers Origin Cargo Tonnage Validity Reference File Name Remarks
No. Page No
1 Balta Gmbh Poland Low Ash 740000 April Master Balta Contract
Metallurgical MT +/- 2016 to Contract Pg Balta Addendum
Coke 25- 10% 31st No 2 For No 8
80mm 40000 Dec Validity.
Low Ash MT +/- 2030 Addendum
Metallurgical 10% No 8 Pg 2 For
Coke 10- Revised
50mm Validity till
Dec 2030
Addendum
No 8 Pg 3 For
Tonnages
2 Anglo South Steam Coal 1360000 April Page No 1 Anglo Contract further
American African MT +/- 2020 to For Tonnage CY 20 extension
Marketing 10 % 31st and Delivery Anglo Addendum in
Limited April Period process
Singapore 2021
3 Anglo South Steam Coal 920000 May Page No 1 Anglo Contract Contract
American African MT +/- 2021 to For Tonnage CY 21 Finalized
Marketing 10% Dec and Delivery Under
Limited 2021 Period Sign Off
Singapore
4 Avani Russian PCI Coal 560000 August Page No 3 Avani Contract 1 Contract
Resources MT +/- 2020 - For Tonnage & Avani Contract Finalized
PTE Ltd 10% Mar and Delivery 2 Under
2021 Sign Off
5 Glencore Russian PCI Coal 80000 April Page No 1 Glencore Contract further
International MT +/- 2021 For Tonnage extension
AG 10% and Delivery in
Period process
6 KRU Russian PCI Coal 2780000 June & Page No 7 KRU J Contract &
Overseas MT +/- Sept For Tonnage KRU Confirmation
Ltd 10% 2021 to and Delivery
Dec
2024
7 Adityaa Indonesia Steam Non- 300000 May 21 Addendum 1- Aditya Contract &
Energy Coking Coal MT (+/- to Page1 Aditya Addendum
Resources )10% July'21
PTE Ltd
8 Pt. Bayan Indonesia Steam Non- 660000 June 21 Business Pt Bayan Business Contract
Resources Coking Coal MT (+/- To Confirmation- Confirmation Finalized
TBK )10% April'22 Page-2 Under
Sign Off

Table 2.10 (A) Trace Element Analysis of Coal

2 Cadmium mg/L Not Detected
3 Lead mg/L Not Detected
6 Copper mg/L 0.07
7 Nickel mg/L 0.42
8 Zinc mg/L 0.33
12 Total moisture (ARB) % 29
13 Ash (ARB) % 2.0
14 Sulphur % 0.20
15 Volatile Matter (ADB) % 42 Approx.
16 Carbon % 72
17 Gross Calorific Value kcal/kg 4700
18 Hydrogen % 5
19 Nitrogen % 1
Table-2.10 (B) Trace Element Analysis of Coke

Sr. No. Parameters Unit Results
2 Cadmium mg/L 0.04
3 Lead mg/L 0.86
6 Copper mg/L 0.65
7 Nickel mg/L 0.32
8 Zinc mg/L 1.86
12 Total moisture % Above 6
13 Ash % Above 12.0
14 Volatile % Above 1.3
15 Sulphur % Above 0.65
16 Phosphorous % Above 0.07
17 CSR % Below 60.0
18 CRI % Above 30.0
2.10.4 Quantum Generation fluxes

The details of Quantum Generation fluxes mines are given in table 2.11. The characteristics (Trace
Elements) of fluxes given in table 2.12. The linkages of fluxes enclosed as annexure 5

Table 2.11 Details of Quantum Generation fluxes

Sr. No. Name of Contract Supply to AMNS
1 Stevin Rock Lime Stone 1.14 MMT
Dolomite 0.9 MMT
2 Riddhi Siddhi Lime Stone 0.2 MMT
3 Oman Quarries Dolomite 0.2 MMT
Table 2.12 Trace Element Analysis of Fluxes

Sr. No. Parameters Unit Results
2 Cadmium mg/L 0.03
3 Lead mg/L 0.54
4 Mercury mg/L Not detected
6 Copper mg/L 0.08
7 Nickel mg/L 0.12
8 Zinc mg/L Not Detected
2.10.5 Mode of Transportation of raw Materials

The bulk Raw material required for the plant is be brought by ships and unloaded by ship to jetty
conveyors. These conveyors in turn move to storage yard. The RM is transported from yard to different
plants is by series of conveyors.
The coke produced shall be routed through cutting and sizing units from coke oven. Prime grade coke from
this unit will be transported to Blast furnace by conveyor and other fractions shall be stored in bunker, from
where coke shall be transported to other consumers by trucks. The by-products produced and chemicals
required shall be transported by road vehicles.
The internal transportation of materials like refractory, store materials shall be by plant vehicles. All the
materials will be covered during transportation through trucks to the site. The raw material Coal by road
and rail transportation causes fugitive emission due to spillage strict adherence to closed mode of
transportation is recommendation
2.10.6 Raw Material Handling

Raw material handling is the unloading, and storage of materials in yards and reclaiming and supply of the
material’s different consumers. The system is composed of yards, conveyors, transportation vehicles and
equipment.
Raw Material Handling System (RMHS) Overview

• Unloading of materials (Coal/Coke/Pellet/Limestone/dolomite) from Jetty to MH and RMHS
Yards.
• Feeding Material to Blast Furnace, Corex, SMP and LCP
Unloading of Material
• Jetty unloading route with max capacity of 2750 TPH
• Four coal yards with 300000 MT capacity.
• Two Coke yards with 120000 MT capacity.
• Oxide Yard with 1200000 MT capacity.
• Flux Yard with 200000 MT capacity.

Stacking/storage/feeding of material
• Coal is stacked at a height of 8m and minimum of 5m gap is maintained between two coal heaps.
• Regular water sprinkling is being done for cooling and dust suppression in 320000 MT capacity
coal yards.
• All 4 Coal yards are provided by Fire hydrant line.
• As per the requirement of Corex plant Coal is being reclaimed to Coal house bunkers through
Conveyor route.
• All other materials like pellets, coke, flux etc. are unloaded in respective yards and reclaimed as per
requirement
• All the yards are mechanized for stacking and reclaiming of materials.
2.10.7 Raw material substitution or elimination

To meet the metallurgical coke requirement for Blast Furnace-Corex-Sinter plant units, a coke oven plant
has been envisaged. The nominal capacity of the coke oven complex has been considered of 2.55 MTPA.
By constructing this coke oven, good quality of coke can be produced for Blast furnace and procurement of
coke may be stopped.
For this coke oven plant different grades of coal shall be purchased. Around 3.7 MTPA of various varieties
of coal shall be required for production of 2.55 MTPA of coke.
2.10.8 System of Coke Quenching Adoption

Hot coke from coke oven (1000 to 10500C) is transported to CDQ facility in bucket carriage, pulled by an
electric locomotive. The hot coke in the bucket is lifted by crane to the top of the chamber, and dumped into
the pre-chamber by the charging facility. The hot coke drops through the cooling chamber, exchanging the
heat with the circulating cooling gas introduced from below. It cooled (below 2000C) and released through
the discharging device. Circulating gas, heated to about 9500C in the cooling chamber, is passed through
the primary dust catcher to remove coarse dust, and then supplied to the boiler. The boiler uses the heat
energy to generate steam that can be used effectively in the power plant to generate the power. The
circulating gas, heat transferred to about 1700C by the time it reaches the boiler outlet, is passed through
the secondary dust catcher to remove the fine dust particles, then passed to the circulating lower, where it is
pressurized for resupply to the cooling chamber.
Advantage of CDQ
• Effect on energy saving. Sensible heat of red hot coke is recovered as steam which can be utilised
for electric power generation and as other heat source.
• Effect of reduction of carbon dioxide emission. Practically no carbon dioxide is emitted during
power generation.
• Reduction of dust emission compared with wet quenching, environment of steel works improved
due to non-emission of quenching steam with toxic gases from coke ovens and non-emission of
dust particles from coke whereas.
• Increase in coke strength compared to wet quenching. Environment of plant is improved due to
non-emission of quenching steam with toxic gases from coke ovens and non-emission of dust
particles from coke wharfs.
• The absence of moisture in the product coke. Along with its enhanced strength, contributes to the
stable operation of the blast furnace.
2.11 Infrastructure Facilities/ Proposed Infrastructure

2.11.1 Land
Existing land 770 ha will be utilized for the proposed modification project i.e no additional land is required.
the land use breakup is given table 2.13 (A), (B) and (C).

Table-2.13 (A) Land Use Break up

Sr. No. Division Facility Area in Ha
1 Division A - HRC Division Existing units 270.29
Plant Includes: HBI Mod I – V, Lime Plant A, Electric
Arc Furnace (SMP1), Caster, HSM, Service Centre,
CRM, Oxygen Plant, CPP-31 MW, Waste Heat Recovery
based power plant 25 MW, Existing Jetty- 1190 Mtrs
Proposed Modification Units 29.71
VD Cooling Tower
RHD Cooling Tower
Water Treatment Plant for 525 MW CCPP
CRM-2 (Hot Rolled Pickled Coils/Sheets, CR
Coils/Sheets, Galvanised, Coils/Sheets, Annealing
Coils/Sheets)
Ladle furnace - Existing Liquid Steel 4.6 MTPA (Standby
LF-5 for Special grades)
SMP-1 fume Extraction System upgradation
Mod 4 additional VPSA to utilize Corex gas and going
forward Coke oven gas
Tank Farm-2 with interconnection between PKL-3 &
ARP-2
2 Division B- Conarc Existing units 238.54
Division Plant Includes: HBI Mod VI, Corex, Blast Furnace &
Sinter Plant, Lime Plant B, Steel Melt Shop (SMP-2),
Caster, CSP & Hot Rolling Mill
Coal briquetting Plant - (1000 TPD)
BF – PCI Project- Pulverized coal
Lime Kiln (500 TPD) - Lime and Dolime
Blast Furnace Dust Catcher /Dust separation unit-150
TPD
BF slag grinding mill (BOO) - 50 TPD
Slag Conditioning & Metal Recovery plant
Additional Ladle Furnace (LF7) – Standby for Special
grades
Hot metal Pretreatment Station Outside Shop (KR
Technology)
3 Division C – Pipe mill (H-Saw, L-Saw, Coating Plant) 20
Division
4 Division D – Plate Mill Existing Units 109.89
Division Plate Mill
Thick Plate Normalizing Furnace
Shot blasting machine
5 Township 100
Total area of AMNS premises 770
Table-2.13 (B) Existing and proposed Auxiliaries facilities

Sr. Existing Area Proposed Area Total Area
Name of Unit
No. (Ha.) (Ha.) (Ha)
1 Blast Furnace-1 20.3897 0 20.3897
2 Sinter plant 5.1872 0 5.1872
3 HBI Modules 1 to 4 16.8599 0 16.8599
4 CPP 1 1.8365 0 1.8365
5 Bhander Power plant 15.3127 0 15.3127
6 CRRS/PCM/Mixer 5.7778 0 5.7778

Sr. Existing Area Proposed Area Total Area

Name of Unit
No. (Ha.) (Ha.) (Ha)
7 Lime plant 1(kiln 1 to 4)/Ferro Alloy Storage 9.4045 0 9.4045
8 MRRS 1 6.1906 0 6.1906
9 SMP 1& Scrap/FES/Slag Dump/Utilities 35.1696 0 35.1696
10 HSM & Water System 14.3411 0 14.3411
11 CRM 1 & Service Centre 20.0996 0 20.0996
12 Oxygen Plant 2.8002 0 2.8002
13 Plate Mill 24.4210 0 24.4210
14 DRI Modules 5 & 6 23.2470 0 23.2470
15 Corex Plant 1 & 2 25.2852 0 25.2852
16 SMP 2 /CSP & Utilities 45.8749 0 45.8749
17 Lime plant -2 (Kiln 5 to 8) 2.9444 0 2.9444
18 MRSS-2 11.8957 0 11.8957
19 Raw Material Handling System 14.5067 0 14.5067
20 Coal Storage yard 17.4661 0 17.4661
21 Coalyard 3.0382 0 3.0382
22 Oxide yard 14.7430 0 14.7430
23 Truck/Trailer Parking area 14.4615 0 14.4615
24 Coal briquetting Plant - (1000 TPD) 0 0.4800 0.4800
25 BF – PCI Project- Pulverized coal 0 0.1457 0.1457
26 Lime Kiln (500 TPD) - Lime and Dolime 0 0.1040 0.1040
27 Rotary Kiln (200 TPD) - Calcined Lime 0 0.3355 0.3355
28 Blast Furnace Dust Catcher /Dust separation 0
0.3196 0.3196
unit-150 TPD
29 Acid Regeneration Plant - 100 KL & Pickling 0
0.6938 0.6938
Line-3
30 BF slag grinding mill (BOO) - 50 TPD 0 0.1600 0.1600
31 New Cooling towers (Mod 1 to Mod 6) 0 0.1230 0.1230
32 Slag Conditioning & Metal Recovery plant 0 0.0335 0.0335
33 Thick Plate Normalizing Furnace 0 0.0630 0.0630
34 Shot blasting machine 0 0.0505 0.0505
35 VD Cooling Tower 0 0.0180 0.0180
36 RHD Cooling Tower 0 0.0225 0.0225
37 Water Treatment Plant for 500 MW CCPP 0 0.8423 0.8423
38 CRM-2 (Hot Rolled Pickled Coils/Sheets, 0
CR Coils/Sheets, Galvanised, Coils/Sheets, 27.1760 27.1760
Annealing Coils/Sheets)
39 Ladle furnace - Existing Liquid Steel 4.6 0
0.1041 0.1041
MTPA (Standby LF-5 for Special grades)
40 SMP-1 fume Extraction System upgradation 0 0.2150 0.2150
41 Mod 4 additional VPSA to utilize Corex gas 0
0.1450 0.1450
and going forward Coke oven gas
42 Hot metal Pretreatment Station Outside Shop 0
0.1100 0.1100
(KR Technology)
43 Tank Farm-2 with interconnection between 0
0.1036 0.1036
PKL-3 & ARP-2
44 Additional Ladle Furnace (LF7) – Standby 0
0.1280 0.1280
for Special grades
Total 351.2531 31.3731 382.6262

Table-2.13 (C) Area wise land use breakup

4 Admin area 15.00
7 Open Area 25.00
12 OHC area 4.00
Total 770.00
Infrastructure facilities such as rest room, sanitation facility will be provided in all the plant for the workers.
A separate area having facilities like truck parking, canteen/dining, rest room, wash room, first aid,
communication facility, ATM, safety training center, studio etc. is allocated for truck drivers.
All the facilities for the truck drivers has been demarcated in the layout provided in Figure 2.4.
2.11.2 Power Requirements

additional (337 MW) will be availed from 400 KV- PSOCL (National Grid). NOC from electricity
department is enclosed as annexure 6. DG sets existing plant (28 nos.) & proposed plant (5 nos.) will be in
operation during power failure.
Table 2.14 Power requirement for existing plant facilities

Sr. No. Name of Plant Unit Status of Existing Units Power in MW
1 HBI Plant MTPA Mod I to VI “7.83” in 120.00
(DRI Mod. I to VI) operation
2 Blast Furnace MTPA “2.04” in operations 15.00
3 Sinter Plant MTPA “1.48” in operations 9.00
4 Coke Oven (Recovery Type) 0.00
Gross Coke MTPA Under construction 0.00
Crude Tar (By –Product) TPA
Sulphur (By –Product) TPA
Crude Benzol (By-Product) TPA
Naphthalene TPA
5 Air Separation 130.00
Oxygen Gaseous Nm3/hr “3,60,544” in operations 0.00
Oxygen Liquid “2950” in operations 0.00
Nitrogen “1,19,944” in operations 0.00
Argon “3,470” in operations 0.00
6 Steel Melt Shop-1(EAF) MTPA “4.6” in operations 400.00

Sr. No. Name of Plant Unit Status of Existing Units Power in MW

(4Nos.)
7 Steel Melt Shop-2 MTPA “5.0” in operations 160.00
(4 EAF& 4LF)
8 Corex Plant (2 Nos.) MTPA “1.7” in operations 15.00
9 Lime Plant MTPA “0.93” in operations 4.00
(Lime/ Dolime)
10 CPP MW 31 In operations 0.00
MW 525 In operations 0.00
11 Plate Mill MTPA In operations 35.00
12 Pellet Plant MTPA Not yet established 0.00
13 CSP, Hot Rolling Mill & Long Product - MTPA In operations 80.00
HRC
Rebar Not yet established 0.00
Wire Rod
14 Caster Shop
Slab From Slab Caster MTPA In operations 20.00
Billets From Billet Caster MTPA Not yet established 0.00
15 CRM
Hot Rolled Pickled Coils/Sheets MTPA In operations (Consent To 30.00
CR Coils/Sheet operate received from
Galvanized Coils/Sheets SPCB)
Coated Sheets/Coil
Any Other Lines
16 Extension of Existing Jetty Meters In operations 0.00
17 Waste Heat Recovery Based Power Plant MW “25” in operations 0.00
18 Pipe Mill
H Saw Pipes MTPA In operations 5.00
L Saw Pipes MTPA (Consent To Operate
received from SPCB)
Coating Plant MTPA
19 Aux 15.00
Total 1038.00
Table 2.15 Power requirement for proposed auxiliary plant facilities.

Sr. No. Name of Plant Power in MW
1 Coal Briquetting plant 3.25
2 BF – PCI 2.66
3 Acid regeneration plant 0.61
4 Lime Kiln (500 TPD) - Lime & Dolime 16.0
5 Rotary Kiln (200 TPD) - Calcined Lime 0.52
6 BF Slag Grinding Mill (BOO) - 50 TPD 0.25
7 CRM-2 85.00
8 SMP-1 Fume extraction system upgradation 6.6
9 Additional ladle Furnace (LF7) - Standby for Special 10.11
Grades
Total 125.00
Unit Wise Power Requirement

Power Requirement MW
Existing plant facility 1038
Proposed Auxiliary facilities 125
Total Required power 1163

2.11.3 Fuel Requirements

Coal, Coke & NG will be used as a fuel. The characteristics of coal is given in the table 2.16. The coal
linkages documents are enclosed as annexure 4.
Table 2.16 Characteristic of Coal

1 Total moisture (ARB) % 29
2 Ash (ARB) % 2.0
3 Sulphur % 0.20
4 Volatile Matter (ADB) % 42 Approx.
5 Carbon % 72
6 Gross Calorific Value kcal/kg 4700
7 Hydrogen % 5
8 Nitrogen % 1
2.11.4 Energy Balance Data

Energy balance data is given in annexure-7.
2.11.5 Manpower Requirements

The manpower requirement after proposed modification will be 15270 nos. Details of manpower is given in
table-2.17.
Table-2.17 Details of Manpower Requirement

Existing Plant Proposed Auxiliary Total
Category
facility Plant facility
Managerial Staff 2800 380 3180
Skilled / Semi Skilled - Direct 4900 620 5520
Skilled / Semi Skilled - Indirect 4400 580 4980
Unskilled / Labour-Indirect 1400 190 1590
Total 13500 1770 15270
2.11.6 Water requirement

2.11.6.1 Existing Scenario
being sourced from the Tapi river. The water intake permission from the Narmada Water Resources Water
Supply and Kalpsar Department Division Surat, permission letter is enclosed as annexure 8.
AMNS has two reservoirs with 360,000.00 m3 and 180,000.00 m3 capacities.
The plant wise water requirement is shown in the water balance diagram given in figure 2.6.

Figure 2.6 Existing Water balance Diagram

The balance effluent water is used as follows
Area of use m3/day

Horticulture 254
As makeup to Corex 1&2 plants 1188
Coal and lime dust suppression 5373
Sprinkling in Raw material yard 621
Treated water discharge in Tapi Estuary 5003
2.11.6.2 Proposed scenario

river.

Figure 2.7 Proposed Water Balance Diagram
Road Map for Meeting Norms of Effluent as Per Water Act, 1974
Parameters Statutory Action
Norms Plan
PH 6.5 to 8.5 There is a common action plan made to
Temperature 40º C ensure that the total water going out of
Colour (pt. co. scale) in units 100 units AMNS premises meet the statutory norms.
For the same, a CAPEX for RO plants at 3
Suspended solids 100 mg/l
different locations has been finalized. The
Oil and grease 10 mg/l approximate cost is expected to be in the
Phenolic compounds 1 mg/l range of Rs. 60 Crores.
Sulphides 2 mg/l
Ammonical Nitrogen 50 mg/l
Total Chromium 2 mg/l

Hexavalent chromium 0.1 mg/l

BOD (5 days at 20º C) 30 mg/l
COD 100 mg/l
Cyanides 0.2 mg/l
Fluorides 1.5 mg/l
Arsenic 0.2 mg/l
Lead 0.1 mg/l
Copper 2 mg/l
Nickel 3 mg/l
Zinc 5 mg/l
Total Dissolved Solids 2100 mg/l
Chloride 600 mg/l
Sulphate 1000 mg/l
Bio-Assay Test 90% survival of fish after 96
hours in 100% effluent
To confirm to GPCB norms for Zero discharge AMNS has already spent Rs 17.5 Cr for installation and
implementation of treatment scheme at the site. The construction work is under progress and will be
completed by March 2022.
2.11.6.3 ZLD Proposal-AMNS Scheme for UF/RO systems

For the proposing the ZLD scheme the quality of feeding waste water are given in table 2.18
Table 2.18 Characteristics of waste water to be treated

Sr. No. Parameter Unit Feed waste water
1 TSS Mg/l 30-40
2 Turbidity NTU 30-40
3 Ca as CaCO3 mg/l 320
4 Mg mg/l 171
5 Cl mg/l 389
6 SiO2 mg/l 42
7 TDS mg/l 2906
8 pH 8.5
9 COD mg/l 42.96
10 BOD mg/l 17.12
11 OIL / GREASE mg/l 3.5
12 PAC mg/l Not Detected
This water is a mix of discharge of all the cooling towers. The blowdown of all the cooling towers is
brought to the central facility directly via pipes that have been laid. The facility that has been constructed
for the treatment of this effluent is as figure 2.8.

Figure 2.8 ZLD Scheme of modular UF+RO system (Two Modules)
The effluent water shall be brought via pipes laid into an equalization cum neutralizing chamber. This water
shall be pumped through a reaction tank to a HRSCC clarifier. The clarified water shall be stored in a
properly sized sump. This clarified water then shall be pumped to a bank of Multigrain filters. This process
shall eliminate and balance pH, TSS, COD, BOD, and turbidity.
The outlet of the Multigrain filters would become inlet to a bank of Ultrafiltration units. The outlet of the
ultrafiltration unit would be pumped to a 3-stage RO system. The permeate of the 3-stage RO system shall
be pumped back into the plant as makeup while the RO Reject shall be fed to a brackish sea-membrane
single stage RO system wherein 50% of 3-stage reject water shall again be recovered and is separately
pumped back into the plant as part of the makeup.
At all locations, proper chemical dosing of various chemicals is done to get the desired results. The sludge
formed at each interval is fed back into a sludge tank so as to pump it to a set of filter presses wherein
sludge is removed as dry form to be transported out of the boundary via trucks. The sludge will be disposed
to approved TSDF site. The parameters of outlet permeate treated water is given in table 2.19
Table 2.19 The outlet permeate water quality

RO permeate quality
Parameter Value
pH 6 – 6.5
TDS [ppm] <75
Chlorides [ppm] < 35
The RO Reject will be disposed to TSDF.

2.11.6.4 Plant Wise ETP details

The details of plant wise ETPs are given in table 2.20
Table 2.20 ETP Details

Inlet Outlet
Recycled
ETP Location ETP Inlet ETP Outlet Flow(M3 Flow Plant Scheme
water used
/hr.) (M3/hr.)
Corex ETP pH 8.12 pH 8.1 125 125 Slag Collection tank→ Flocculant
Total 270 TDS (ppm) 280 quenching for treatment Treated water
Alkalinity SMP2 sump→Final Outlet
Chloride 190 Chloride(pp 400
(ppm) m)
Total 230 Total 380
Hardness Hardness
Conductivity 1265 Conductivity 2205
(ms/cm)
TSS (ppm) 120 TSS (ppm) 30
HSM ETP pH 8.01 pH 7.95 10 10 Reused as Collection thickener→
Total 176 Total 180 make up in Flocculant treatment Makeup
Alkalinity Alkalinity direct cooling to direct system
Chloride(pp 278 Chloride(pp 280 circuit
m) m)
Total 298 Total 310
Hardness Hardness
(ms/cm) (ms/cm)
TSS (ppm) 800 TSS(ppm) 30
CSP MILL pH 8.1 pH 8 150 150 Reused as Collection thickener→
ETP Total 125 TDS (ppm) 130 part of make Flocculant
Alkalinity up in fire treatment→DMF→Makeup to
Chloride(pp 270 Chloride(pp 280 water circuit Different stream
m) m) as well as
process water
Total 395 Total 395
circuits
Hardness Hardness
(ms/cm) (ms/cm)
TSS (ppm) 1200 TSS (ppm) 18
Plate Mill ETP pH 8.1 pH 8.1 10 10 Re used back
in to the Collection → HRF treatment
Total 230 Total 228 DCW Circuit Clarifier → Treated water
Alkalinity Alkalinity as part of tank
Chloride(pp 220 Chloride(pp 210 make up
m) m)
Total 210 Total 208
Hardness Hardness
(ms/cm) (ms/cm)
TSS(ppm) 48 TSS(ppm) 20
CRM Acidic pH 1.3 pH- 7.55 40 40 The final Acidic Stream: - Collection
ETP Stream TDS - 15385 outlet treated tank→pH Correction with
Chloride 15604 Chloride - 7000 water is Lime addition→ Flocculant
(ppm) COD - 87 mixed with treatment→HRSCC→pH
TDS (ppm) 24380 TSS - 36 the existing Correction Drain
Fe (ppm) 6129 O&G -1.4 blowdowns of
Fe- 1.2 various Oily Alkali Stream: - pH
Acid 0.48 TSS-36 cooling Correction Flocculant
Concentratio Total Hardness-7117 towers to treatment→DAF→Aeration1
n (%) reduce the →Clarifier1→Aeration2→Cla
COD (ppm) 601 TDS and rifier2→Drain

Inlet Outlet
Recycled
water used
/hr.) (M3/hr.)
Oily pH 5.25 chloride
Stream levels before
Chloride 562 being
(ppm) discharged
TDS (ppm) 673 into Tapi
Oil (ppm) 235 Estuary
COD (ppm) 6118

Alkali pH 11.21
Stream
Chloride 672
(ppm)
TDS (ppm) 771
Oil (ppm) 13812
COD (ppm) 1069
ETP For Coke Phenol 500 Phenol 80 80 Coke Collection tank→ Anaerobic
oven and by (mg/l) (mg/l) ≤0.5 quenching Tank Aerobic Tank Mixing
product plant Cyanide 25 Cyanide and reaction tank Coagulation
(mg/l) (mg/l) ≤0.2 Settling Tank →Final Outlet
COD (mg/l) ≤3500 COD (mg/l)
≤200
NH3-N 100 NH3-N
(mg/l) (mg/l) ≤15
oils ≤50 Oils
≤5
Suspended Suspended 70
solids solids
Ph 8.5 Ph 8.5
ETP HBI Mod pH 7.2 pH 7.88 3200 3200 Treated Water Feed Tank→ Clarifloculator
1 to 6 from Mod → Sludge Ponds Oil Skimmer
Temperature 65 Temperature 29.9 5&6 used as Outlet
, oC , oC make up in
SS, mg/l 800- SS, mg/l 30 corex Plant
1200
ppm Treated Water
Oil & Oil & 5.6 from Mod
Grease, mg/l Grease, mg/l 1&4 used as
BOD, mg/l BOD, mg/l 12 make up in
blast
COD, mg/l COD, mg/l 68 furnace
Iron, mg/l Iron, mg/l 0.58
Total Cr., Total Cr., ND*
mg/l mg/l
Hexa. Cr., Hexa. Cr., ND*
mg/l mg/l
Copper, mg/l Copper, mg/l ND*
Sulphides, Sulphides, ND*
mg/l mg/l
Fluoride, Fluoride, 0.47
mg/l mg/l
Zinc, mg/l Zinc, mg/l 0.098
Cyanide, Cyanide, ND*
mg/l mg/l
Lead, mg/l Lead, mg/l ND*

Inlet Outlet
Recycled
water used
/hr.) (M3/hr.)
Nickel, mg/l Nickel, mg/l ND*
Ammonical Ammonical 10.8
Nitrogen, Nitrogen,
mg/l mg/l
Phenolic Phenolic ND*
Compounds, Compounds,
mg/l mg/l
Colour, Co- Colour, Co- 30
Pt unit Pt unit
2.11.6.5 Plant Wise Treatment Methods
CRM ETP
T-3 T-4
Acidic effluent
sump Neutralizer# Neutralizer# Thicken
1 2 er
Sludge
Filter press
Sump
Clear
Final Outlet Water HRSCC
Tank (Clarifier)
(CWT Tank)
ALKALI EFFLUENT & OILY EFFLUENT TREATMENT PLANT SCHEME
Aeration
Collection Tank# 1
Oily Sump DAF
Effluent
Sump Flash
Mixture TPI
Alkali TPI
Neutralizer Clarifier
Sump# A
Sludge Sump #1
Alkali
Sump# B
Clear Water Aeration

Final Outlet Tank (CWT Clarifier Tank# 2
Tank) #2
Acidic Waste Water Inlet Parameters

Parameters Acidic Stream Inlet
Flow 26 m3/hr.
pH 1.30
CHLORIDE 15604
TDS (ppm) 24380
Fe(ppm) 6129
Acid Concentration (%) 0.48
COD (ppm) 601

Acidic Waste Treatment

The treatment Scheme suggested for the Acidic rinse, waste from Acid sump, Acid Spillage & Waste Pickle
Liquor is as follows:
Combined rinse and acidic water are collected in acid waste collection Sump. The collected effluent is then
pumped to neutralization tank for further treatment.
Flash mixer & Flocculator-The equalized effluent is neutralized using alkali (Lime) depending on the pH
of the effluent to remove the heavy metals from the effluent. The neutralized effluent would be pumped to
Thickener for separation of suspended solids & precipitate heavy metals before treatment in Aeration tank.
Thickener- Thickener is designed to remove suspended particles from water
High-Rate Solids Contact Clarifier (HRSCC)-Neutralised effluents is feed into a High-Rate Solid
Contact Clarifier (HRSCC) for removal of Suspended Solids.
Clear Water Tank (CWT Tank)-The clarified effluent from the HRSCC is collected in Clear water tank
& maintain the pH between 6.5 to 8.5.
Alkaline & Oil Emulsion Effluent Treatment

Parameters Oily Stream Inlet Alkali Stream Inlet
pH 5.25 11.21
Chloride 562 672
TDS (ppm) 673 771
COD (ppm) 6118 13812
Oil (ppm) 235 1069
The treatment Scheme suggested for the Oil Emulsion and alkaline effluent separately is as follows:
A) Primary Treatment: For removal of oil and grease along with coarse settable impurities and associated
BOD and COD there along. 1. TPI 2. DAF (Common)
B) Secondary treatment (Biological Treatment): For removal of dissolved organics and associated BOD
and COD there along. 1. Two stage Activated Sludge Process. The Detailed Technical Description is given
below
Alkaline Waste-Effluent from ECL & SPM stream is feed to TPI-I to remove free floating oil after pH
correction. Alkaline dump storage tank is provided to take care of dump waste during maintenance period.
Oil emulsion effluent: -Effluents from CRM # 1 & CRM # 2 are feed to TPI – II to remove floating oil
after pH correction.
A) Primary Treatment
TPI Oil Separator-It removes floating oil from system water.
Dissolved Air Flotation-The Dissolved Air Flotation (DAF) is designed to separate oil and suspended
solids by flotation. This is accomplished by addition of air, in the form of fine bubbles, to the wastewater.
The rising bubbles adhere to or are trapped in the waste particle structure and carry them to the surface
where these are removed automatically.
B) Secondary Treatment
Aeration Tank-The effluent from the Alkaline & Oil collection sump will be taken first into Conventional
Aeration followed by Extended Aeration Tank (AT) where soluble organics are degraded aerobically by
microorganisms and then to conventional aeration system. In order to ensure required population of bacteria

in AT, i.e., Mixed Liquor Suspended Solids (MLSS) and also part of the settled sludge from Clarifier is
recirculating back to aeration tank.
Secondary Clarifier-The Mixed Liquor from Aeration tank enters the central well of secondary clarifier
for separation of sludge and liquid. The clarifier is a sedimentation tank with mechanism where settled
solids get scrapped at the clarifier floor and collected in the central well. A part of sludge from the clarifier
centre well is recirculated back to AT while the balanced is sent to sludge handling facility for disposal.
Final Outlet Treated Water Parameters

CRM ETP Final Outlet
pH 7.55
Chloride 7000
TDS (ppm) 15385
COD (ppm) 87
O&G (ppm) 1.4
Fe (ppm) 1.2
TSS (ppm) 36
Total Hardness 7117
The final outlet treated water is mixed with the existing blowdowns of various cooling towers to reduce the TDS and
chloride levels before being discharged into Tapi Estuary. The final quality of the water that is discharged is as given
below.
Sr. No. Test Parameters Unit Result Limit

1 Flow m3/day 2280 6000
2 Ph Value ˗˗ 8.1 6.50-8.50
3 Temperature ˚C 30.1 40
4 Total Suspended Solids mg/L 68 100
5 Oil & Grease mg/L 5.8 10
6 BOD (3 Days @ 27 ˚C) mg/L 14 30
7 COD mg/L 62 100
8 Iron as Fe mg/L 0.45 ˗
9 Total Chromium as Cr+3 mg/L Not Detected 2
10 Hexavalent Chromium as Cr+6 mg/L Not Detected 0.1
11 Copper as Cu mg/L Not Detected 2
12 Sulphide as S mg/L Not Detected 2
13 Fluoride as F mg/L 0.5 1.5
14 Zinc nas Z mg/L 0.44 5
15 Cyanide as CN mg/L Not Detected 0.2
16 Lead as Pb mg/L Not Detected 0.1
17 Nickel as Ni mg/L Not Detected 3
18 Ammonical Nitrogen as NH3 mg/L 6.9 50
Phenolic Compounds AS
19 mg/L Not Detected 1
C6H5OH
20 Colour Co-pt 50 100
90% survival of fish
Not
21 Bio-assay test ˗˗ after 96 hours in
Specified
100% effluent.

Plate mill ETP
BACKWASH FLASH
HRF WATER MIXTURE CARIFIER FILTER PRESS
SUMP
TREATED
SYSTEM WATER
MAKEUP & TANK
BACKWASH
ETP Treatment
The treatment Scheme suggested for the HRF Backwash effluent treatment.
Flash mixer- The equalized effluent is neutralized using PAC & Flocculent to remove the suspended solids
from the effluent.
Clarifier-Thickener is designed to remove suspended particles from water.

Treated water Tank-Collection of treated water & then pump out to SST.
Filter Press-Underflow of Clarifier is feed in filter press for removal of sludge.
Inlet and outlet Waste Water Parameters

Parameters Inlet Outlet
pH 8.1 8.1
Total Alkalinity(ppm) 230 228
Total Hardness 210 208
Chloride 220 210
Conductivity(ms/cm) 1550 1530
TSS (ppm) 48 20
The final outlet is reused back into the DCW circuit as part of make-up.
Corex ETP
COREX PROCESS BLOWDOWN WATER
HRT
OVERFLOW
(MOD 5&6) TREATED
FLASH CLARIFIER
WATER
MIXTURE
BLOWDOWN TANK
& BACKWASH
WATER


pH 8.12 8.1
Total Alkalinity (ppm) 270 280
Total Hardness (ppm) 230 380
Chloride (ppm) 190 400
TSS (ppm) 120 30
Outlet water Hardness and chloride are increasing as Corex blowdown water mixing in thickener.
ETP Treatment
The treatment Scheme suggested for the HRF Backwash effluent treatment.
Flash mixer-The equalized effluent is neutralized using PAC & Flocculent to remove the suspended solids
from the effluent
Clarifier-Thickener is a circular RCC reactor provided mechanism for scraping precipitated suspended
particles.
Treated water Tank-Treated water has collected in Treated water tank.
The final water is used in slag quenching for SMP2
CSP MILL ETP
FLASH MIXTURE
DBS SUMP
SLURRY
PIT
FILTER PRESS
CLARIFIER A CLARIFIER B
PSF
Backwash CLEAR OILY WATER
DMF WATER
and system SUMP
makeup SUMP
Treatment Scheme
DBS SUMP- Collect all backwash water in sump.
Flash mixer-The equalized effluent is neutralized using PAC & Flocculent to remove the suspended solids
from the effluent
Clarifier-Thickener is a circular RCC reactor provided mechanism for scraping precipitated suspended
particles.
Oily water sump- remove oil from Outlet water.
Clear water sump- Treated water collected in sump
DMF- Remove TSS from Clear water through continuous recirculation
The final outlet water is reused as part of makeup in fire water circuit as well as process water
circuits.


pH 8.10 8.00
Chloride 270 280
TSS (ppm) 1200 18
HSM ETP
DBS SUMP 15 Dia 13.5 Dia

Thickener Thickener
Filter press Underflow 13.5 Dia

Thickener
Direct
system
makeup

Inlet Outlet
pH 8.01 7.95
Chloride 278 280
TSS (ppm) 800 30
Sump- collect all backwash water in sump

15dia thickener a&b- working as primary clarifier. It removes suspended particles
13.5 dia thickener- working as secondary clarifier. It removes suspended particles. Outlet of clarifier use
as system makeup.
The final outlet water is reused as make up in direct cooling circuit.

Waste Water Treatment Plant for Coke Oven & by Product Plant
WWTP (Waste Water Treatment Plant) is a facility to be used for treatment of phenol cyanide
containing waste water from COB and BPP, by using a new process of A/A/O (Anaerobic, Anoxic, Oxic)
and double membrane. During degradation of NH3-N in the coking wastewater, other pollutants such
as COD can also be degraded. The wastewater goes through secondary sedimentation tank into
biochemical treatment, which mainly includes mixing & reacting tank, and coagulation sedimentation
tank. The effluent after coagulation sedimentation can be discharged out.

Phenol mg/l 500 0.5
Cyanide mg/l 25 0.2
COD mg/l 3500 200
NH3-N mg/l 100 15
Oils 50 5
SS 700 70
pH 8-9 6.5 – 7.5
Treatment Method
This WWTP is mainly used for treatment of the phenol-cyanide containing wastewater from coke making
and by-products units, which is composed of pre-treatment unit, biochemical treatment unit and sludge
treatment with details below
Pre-Treatment
The pre-treatment unit is to be built mainly to remove the oils containing in the wastewater, which is
composed of deoiling tank by gravity, deoiling by flotation and water quality and volume adjusting
facilities, etc. for preparing an appropriate incoming environment for downstream biochemical
treatment.

Deoiling tank by gravity

Wastewater enters the deoiling tank where the heavy oil settles down the bottom of the tank by gravity
and will be periodically transported by truck. The deoiling tank has two lines in parallel. The outlet water
from deoiling tank goes into adjusting tank
Adjustment Tank
The adjustment tank is mainly used for the internal adjustment for coke making wastewater. In case of
unstable biochemical treatment or system failure, the inlet water will enter the adjustment tank for
temporary storage until normal operation of the system
Deoiling by floatation equipment

Deoiling by flotation equipment is mainly used for removal of the emulsified oil in the wastewater.
Cavitation flotation process is adopted in this design. The outlet water from the deoiling tank enters the
flotation suction well and pumped to reaction tank where PAC will be dosed to generate a big flocs unit
and then delivered to CAF (Cavitations Air Flotation). Tiny air bubbles will be generated to carry the
flocs unit and emulsified oil up to the surface of CAF. The surface oils will be scrapped to oil collecting
duct and discharged to oil residue sump
Oil residue Tank

The floating oil mixing liquid and light oil mixing liquid from the flotation device and deoiling tank will
enter oil residue tank where the oil separates from the water due to different specific gravity. The
separated water will be recycled to the system. When the oil in tank reaches a certain level, it will be
pumped and transported out by tank car
Biochemical treatment
The main purpose is to degrade the poisonous substance in the coke making wastewater by
biochemical reaction of the microbe (active sludge) to reduce the COD in the wastewater. The
biochemical treatment unit is mainly composed of anaerobic tank, anoxic tank, aerobic tank, secondary
settling tank, sludge reflux facilities, blower, dosing devices and de-foaming facility, etc
Anaerobic tank
The anaerobic tank is a rectangular shaped reinforcement water tank. Rotating distributors are used for
water distribution to avoid stream cut-off. To maintain phosphor supply and appropriate water
temperature, the suction well is equipped with steam tracing
Anoxic Tank
Anoxic tank is one of critical part of the biochemical treatment unit where the organics in the wastewater
is used as carbon source and energy for de-nitrification and NOT-N in the reflux is used as oxygen
source for de-nitrification. In this philosophy, de-nitrification reaction can be carried out with the bio
membrane on the packing and pollutants such as NH3-N, COD can be partly removed and degraded
NO3 - + 5H+→NO2 - + 2 H2O+ OH

NO2 - + 3H+→1.5N2 + 2H2O+ OH-
Aerobic Tank
The outlet water from anoxic tank flows into the aerobic tank for mixing after lifted by sludge pump to
degrade the organics in the wastewater. The biochemical reaction of the microbe occurs in the aerobic tank
where the NH3-N is oxidized to NOT-N, i.e. the phenol, cyanide and sulfur cyanide, etc. will be further
degraded. The aerobic tank is equipped with micro diffuser. The air duct is normally made of stainless steel.
The blower outlet is equipped with air filter. In general, the retention time for de-phenolization in the
aerobic tank is less than 8 hours and that for cyanide and sulphur cyanide removal is more than 16 hours.
When the inlet water COD is around 1200 ～1800mg/L, the retention time should be around 24～36h. The
outlet COD after the biochemical treatment can drop down below 50mg/L. In bio-denitrification process,

the denitrification reaction is fast. Nitrification reaction plays a critical role in the de-nitrification. Thus, the
microbe in the active sludge of the aerobic tank must be provided with a sound environment.
NH3 : 30-50 mg/l

COD : 80-100 mg/l
BOD : 10-20 mg/l
Phenol : 1.1-1.5 mg/l
HCN : 0.1 – 0.2 mg/l
Secondary settling Tank

The secondary settling tank is equipped with one set sludge scraper. The mixed liquid from aerobic tank
enters the inlet of secondary settling tank and then is evenly distributed to the setting area where the active
sludge settles down and flows through outlet pipe to the reflux wastewater tank for further treatment. The
settled active sludge at the bottom will be scraped out to the sludge collecting sump and then pressurized by
pump to inlet water distribution tank of the aerobic tank for increasing the sludge concentration.
Post Coagulation Treatment

Part of outlet water from secondary settling tank returns to the anoxic section and the remaining part enters
the mixing section of mixing reaction tank where PFS or flocculent DM301 and PAM, etc. will be mixed
with the wastewater to form bigger flocculent structure for easier separation from water. The mixing tank is
a rectangular shaped reinforcement water tank, equipped with agitator for a better mixing normally for 1
minute mixing the reaction tank is a rectangular shaped reinforcement water tank, equipped with mixer, the
reaction time is about 30 minutes.
Sludge Treatment
The sludge treatment system normally consists of sludge thickener, sludge-lifting pump, belt type
dehydrator. Sludge treatment system sludge thickener is to primarily dewater the sludge containing 99.5%
water and then to prepare sludge cake of 70~80% water through belt type dehydrator. Coagulation settling
tank discharges flocculent sludge and secondary settling tank discharge excessive sludge, both will be
pumped to sludge thickening tank for primary dewatering. The sludge in thickening tank has water about
97~98％, which will be pumped to belt type dehydrator and dosed with PAM for a better dewatering. The
dewatered sludge cake is discharged to the sludge storage tank and then transported out by truck. The
thickening tank and belt type dehydrator can work intermittently according to the sludge amount.
HBI Plant

At HBI, there are three water circuits: machinery cooling water, clean water system and contaminated water
system. As all the three circuits are Open water system, the blowdown is required to maintain the water
quality. The require blowdown from machinery & clean water system is being done to the contaminated
water circuit.
The contaminated water circuit is used for direct cleaning and cooling of the process gas at venturi
scrubbers to remove the dust carried along the gases from shaft furnace. Also, the users of contaminated
water circuit are the dust collection systems of the plant to avoid dust emissions to the atmospheres while
handing and transportation of product.
The return water of contaminated water circuits from plant equipment (Top gas scrubber, cooling gas
scrubber, dust collection system etc.) is feed to the clarifier / thickener for removing the suspended solids
and overflow clean water is collected at the process water sumps for its reuse again after cooling with the
help of cooling towers.
The main purpose of treatment /processing at clarifier is to remove the Suspended solids in return process
contaminated water, having suspended solids in the range of 800 ppm-1200 ppm. After clarification,
suspended solid in clarifier overflow water reduces in the range of 25 to 36 ppm. The underflow water of
clarifier is pumped to sludge ponds for settling and clean water /overflow water from sludge pond is again
feed to the clarifier.
The diameter of clarifier is 32 meters with the inlet water flow rates of approximately 3200 m3/hour. The
overflow water from clarifier having suspended solids content in the range of 25 to 35 ppm is recycle back
to the process circuit. There are total 4 numbers of clarifiers in HBI/DRI plant: one each for Modules 1&2
and Modules 3&4, an individual clarifier for Module 5& 6. Anionic polyacrylamide dosing as flocculants is
used to enhance the performance of clarifier.
At Module 5&6, High rate Thicker (HRT) is available for processing the underflow water from Mod 5 & 6
clarifiers and underflow of HRT is pumped to sludge ponds and return water /overflow water from sludge
pond is feed to HRT. The overflow water from HRT is collected in a sump and either pump back to the
clarifier of Mod 5 & 6 or pump to the SMP 2 sump for its usage at slag cooling. The quantity of water
diverted for the slag cooling purpose is substantiated the requirement of the blowdown from contaminated
process water circuit of Mod 5 & 6. So, presently there is no effluent discharge from Mod 5&6 area.
Similarly, at Module 1-4 area, partial quantity of blowdown water (approx. 40% of the total blowdown
quantity) from contaminated process water circuit is pumped to the Blast Furnace area for its usage for slag
cooling and slag granulation unit.


HBI: Unit I – IV (2 nos. of clarifiers, one each for Mod-1&2 & Mod 3&4)
Inlet outlet
Standard Specified
Parameter Parameters Parameters
by GPCB
To Clarifier (Effluent)
Flow rates 2850 m3/hour 1352* m3/day 5000
pH 7.2 7.88 6.50 - 8.50
Temperature, oC 65 29.9 40
SS, mg/l 800-1200 ppm 30 100
Oil & Grease, mg/l 8 5.6 10
BOD, mg/l 26 12 30
COD, mg/l 88 68 100
Iron, mg/l 1 0.58 -
Total Cr., mg/l ND ND 2
Hexa. Cr., mg/l ND ND 0.1
Copper, mg/l ND ND 2
Sulphides, mg/l ND ND 2
Fluoride, mg/l 0.6 0.47 1.5
Zinc, mg/l 0.25 0.098 5
Cyanide, mg/l ND ND 0.2
Lead, mg/l ND ND 0.1
Nickel, mg/l ND ND 3
Ammonical Nitrogen, mg/l 15 10.8 50
Phenolic Compounds, mg/l ND ND 1
Colour, Co-Pt unit 66 30 100
* Total generation of effluent is 2252 m3/day. 900 m3/day is pumped to Blast Furnace

HBI: Unit V & VI (2 Nos. of clarifier, each for Mod 5 & 6)
Standard
Parameter Inlet Parameters to clarifier Outlet Parameters (Effluent) Specified by
GPCB
Flow rates 3200 m3/hour 0** m3/day 3275
pH 7.2 7.88 6.50 - 8.50
Temperature, oC 65 29.9 40
SS, mg/l 800-1200 ppm 30 100
Oil & Grease, mg/l 8 5.6 10
BOD, mg/l 38 12 30
COD, mg/l 150 68 100
Iron, mg/l 1.2 0.58 -
Total Cr., mg/l ND ND 2
Hexa. Cr., mg/l ND ND 0.1
Copper, mg/l ND ND 2
Sulphides, mg/l ND ND 0.5
Fluorides, mg/l 0.87 0.47 1.5
Zinc, mg/l 0.1 0.098 5
Cyanide, mg/l ND ND 0.2
Lead, mg/l ND ND 0.1
Nickel, mg/l ND ND 3
Ammonical Nitrogen, mg/l 18 10.8 50
Phenolic Compounds, mg/l ND ND 1
Arsenic, mg/l 0.08 ND 0.2
Chloride, mg/l ND ND 600
Sulphate, mg/l ND ND 20
Colour, Co-Pt unit ND ND 100
** Pumped to SMP-2 & COREX 1 &2
CRM 2
The CRM-2 project shall be implemented in three phases (Phase-I, II & III). The following types of water
are involved in CRM-2 project:
- Industrial grade water
- Demineralized water
- Indirect cooling water
- Emergency water
- Drinking water
- Fire water
- Waste water/effluents
Industrial grade water: This water will be sourced from existing raw water treatment plant near HRC
reservoir. This water will be used for makeup in cooling tower, input to demineralization plant and to fulfil
the requirement of service water for various production units under CRM-2 expansion in three phases. The
requirement of industrial grade water is indicated in Table-1 for three phases.
Demineralized water: There will be new demineralization water plant for generation of demineralized
water. Industrial grade water will be supplied as input to Demineralization plant. Demineralized water will
be used in production units as well as in hydrogen plant and boiler unit. Reject from Demineralization plant
will be mixed with treated effluent and it will be supplied for slag quenching. Three demineralization plants
for three phases shall be installed based on requirement.
Indirect cooling water: Industrial cooling water shall be supplied to the process consumers. Hot return
water from process consumers will be cooled in an induced draft cooling tower. Thereafter, it will be
pumped back to the circuit. Recirculation system will be equipped with auto backwash strainer at common
delivery header to improve water quality. Industrial water shall be added as make up for compensation of
evaporation & drift losses in the cooling tower and blowdown from the circuit.
Separate dedicated recirculation system will be installed for different phases. Pump house along with
pumps, auto backwash strainer, cooling tower cells will be expanded/added as per requirement in phase-II
and phase-III.
Emergency water: To protect furnace, emergency water will be provided from emergency overhead tank
(EOHT). Tank shall be filled up by diesel engine operated pump located at recirculating water pump house.
Based on process requirement in different phases, diesel engine pump shall be installed.
Drinking water: Drinking water shall be available from plant existing network for all the phases. Network
shall be extended as per requirement in different phases.
Fire water: Fire water requirement for phase-I shall be sourced from existing plant fire water network.
However, new fire water pumping system shall be installed during phase-II and phase-III implementation.
Industrial grade and cooling tower blowdown water shall be used during filling of fire water reservoir
Waste water/effluents: The major waste water/effluents shall be generated after CRM 2 project
implementation.
- Process effluents
- Blow down from cooling tower
- Reject water from Demineralization Plant
Table-2 represents the phase wise various types of effluents generation and expected quality
Water requirement and wastewater generation

Sr. Area Recirculating Emergency Industrial Grade Total Total DM Wastewater
No. Water Water Make up water Industrial Water Generation,
Requirement, Requirement, Requirement, M3/Hr. Grade Make Requirement, M3/Hr.
M3/Hr M3/Hr. Cooling Process Up Water M3/Hr
Tower Make Make up Requirement,
Up M3/Hr
Phase-I
1 CGL#4 - 500 ktpa 1500 300 - 11 11 12 8.7
2 Inspection cum 10 - - - - - -
trimming line -
200 ktpa
3 Packaging line - 10 - - - - - -
18-20 coils /hr
4 Compressed air 150 - - - - - -
station
5 Hydrogen plant 20 - - - - 0.25 -
6 Boiler - - - - - 9.75 -
7 DM Plant - - - 28 28 - 6
8 Recirculating - - 38 - 38 - 15
water system
Total (Phase-I) 1690 300 38 39 77 22 29.7
Phase-II
1 CGL#3 - 500 ktpa 1500 300 - 11 11 12 8.7
2 PLTCM - 2.2 2300 - - 26 26 9 26
MTPA
3 ARP - 12 kL/hr 100 - - 10 10 12 Incl. with
PLTCM
figure
trimming line -
200 ktpa
5 Packaging line - 10 - - - - - -
18-20 coil /hr
6 Roll shop 25 - - - - - -
station
8 Hydrogen plant 30 - - - - 0.4 -
9 Boiler - - - - - 34 -
10 DM Plant - - - 86 86 - 19
11 Recirculating - - 93 - 93 - 37
water system
Total (Phase-II) 4200 300 93 133 226 67.4 90.7
Phase-III
1 Mixed CAL - 1 2350 500 - 20 20 20 17.5
MTPA
trimming line -
200 ktpa
3 Packaging line - 10 - - - - - -
18-20 coil /hr
station
5 Hydrogen plant 45 - - - - 0.6 -
6 DM Plant - - - 26 26 - 6
7 Recirculating - - 55 - 55 - 22
water system
Total (Phase-III) 2490 500 55 46 101 20.6 45.5

Sr. Area Recirculating Emergency Industrial Grade Total Total DM Wastewater

No. Water Water Make up water Industrial Water Generation,
Requirement, Requirement, Requirement, M3/Hr. Grade Make Requirement, M3/Hr.
M3/Hr M3/Hr. Cooling Process Up Water M3/Hr
Tower Make Make up Requirement,
Up M3/Hr
Total (Phase- I + II + 8380 1100 186 218 404 110 165.9
III)
Phase wise various types of wastewater generation and expected quality

Type of Unit Flow Expected Quality Quality shall be achieved
Effluents Phase-I Phase-II Phase-III after treatment
Chrome m3/month 5 5 10 Chromate: 30 ppm (max.), pH: 6.5 to 8.5

effluent Zn fines: 300 ppm (max.), SS: 100 ppm
Phosphate: 20 g/l (max.), O&G: 10 ppm
Fluorides: 10 g/l (max.) TDS: 2100 ppm
Contaminated m3/hr 3.1 3.1 6.2 Oil & Grease: 0.1 g/l Hexavalent Cr: 0.1 ppm
DM water + Zn (max.), BOD: 30 ppm
dross Zn fines: 1000 PPM COD: 100 ppm
(max.), Temperature: 40 deg C
Fe fines: 1000 mg/l Phenolic compounds: 1 mg/lit
(max.), Sulphides: 2 mg/lit
COD: 30 - 50 g/l Ammoniacal nitrogen: 50
Zn fines: 100 PPM (max.), mg/lit
Dirty fines: 50 ppm Zn: 1 mg/lit
(max.), Percent Sodium: 60
Alkaline m3/month 4000 4000 8000 Oil & Grease: 3.5 g/l
effluent (max.),
NaOH: 30 g/l (max.),
Fe fines: 2500 mg/l
(max.),
Dirty fines: 100 ppm
(max.),
Phosphates: 10 g/l (max.)
Acidic effluent m3/hr - 21 - pH: 2.3
Chloride: 8040 mg/lit
Fe: 7592 mg/lit
Oily effluent m3/hr - 5 - BOD: 3500 mg/lit
COD: 32000 mg/lit
O&G: 300-2000 mg/lit
TSS: 500 mg/lit
Blow down m3/hr 15 37 22 pH: 8.27
from cooling Conductivity: 1400 µS/cm
tower TH as CaCO3: 417 ppm
C: 175 ppm
Turbidity: 14 NTU
Reject water m3/hr 6 19 6 Conductivity: 2300 µS/cm
from
Deminerali-
zation Plant
Description of Process Effluent Treatment Plant

Effluent treatment plant (ETP) in Phase-I the following type of effluents shall be generated from Phase-I
production unit
- Chrome effluent
- Contaminated DM water and Zn dross
- Alkaline effluent
The schematic diagram of proposed ETP for phase-I is attached.

Chrome effluent treatment: Chrome waste shall be collected in RCC tank i.e. Chrome effluent collection
sump. The effluent generation being very less, will be treated in batch mode. The effluent shall be pumped

from collection sump to the chrome reaction tank where Sulfuric acid, SBS and NaOH shall be added. After
sufficient reaction time, mass shall be pumped to filter press. Cake generated from filter press shall be
dumped in designated area. Filtrate water from filter press shall be transferred to thickener feed tank for
further treatment. However, the outlet water quality of ETP shall follow the GPCB stipulations.
As the chrome waste effluent generation is very less and periodic, the capacity of chrome wastewater
treatment plant shall be selected in such a way that the same treatment plant shall be used for Phase-II and
Phase-III.
Contaminated DM water and Zn dross treatment: For such type of waste water treatment, new
treatment line is considered in Phase-I. Contaminated DM water and Zn dross waste water shall be
collected in a RCC collection sump from where it will be pumped to Tilted Plate Interceptor (TPI) oil
separator for removal of floating oil. Overflow from TPI shall go to flocculation tank and underflow shall
go to sludge storage tank. In flocculation tank, coagulant shall be added. Then, it shall be pumped to high-
rate solid contact clarifier (HRSCC). Overflow from HRSCC shall be connected to flocculation tank (before
dissolved air flotation, DAF unit) of alkaline wastewater treatment line for further treatment and underflow
shall be routed to sludge storage tank. From sludge storage tank, sludge shall be pumped to filter press.
Cake generated from filter press shall be dumped in designated area. Filtrate water from filter press shall be
transferred to thickener feed tank for further treatment. However, the outlet water quality of ETP shall
follow the GPCB stipulations.
Alkaline effluent treatment: For alkaline effluent treatment, new treatment line is considered in Phase-I.
Alkaline effluent shall be collected in a RCC collection sump from where it will be pumped to pH
correction tank in which HCl and de-oiling polymer shall be added. Then the effluent shall be passed
through TPI for oil removal. Overflow from TPI shall be discharged to flocculation tank and underflow
shall be discharged to sludge storage tank. Flocculation tank and subsequent treatment units shall be
designed to consider volume of overflow from HRSCC (contaminated DM water and Zn dross treatment)
and alkaline effluent. From flocculation tank, the effluent shall be pumped to dissolve air floatation unit
(DAF) for removal of oil and suspended solids. Overflow from DAF shall go to aeration tank and
underflow shall go to sludge storage tank. Aeration tank (stage 1 &2) shall be installed for degradation of
organics aerobically by micro-organism. The Mixed Liquor from respective aeration tank shall enter the
secondary clarifier for separation of sludge and liquid. A part of sludge from the clarifier shall be
recirculated back to aeration tank while the excess sludge shall be sent to sludge storage tank.
The clear water from the clarifier shall overflow uniformly over the peripheral launder and feed to chlorine
contact tank for chlorination. From chlorination tank, clear water shall be sent to treated effluent collection
sump. In treated water collection sump, blowdown water from cooling tower and reject water from
demineralization plant shall be added. Mixed water from treated water collection sump shall be pumped for
slag quenching.
Sludge from TPI, DAF and both secondary clarifiers shall be collected in sludge storage tank and then it
shall be pumped to filter press. Filtrate from filter press shall be discharged to thickener feed tank for
further treatment in the main treatment line and cake shall be dumped to designated area for further use.
Effluent treatment plant (ETP) in Phase-II: The following type of effluents shall be generated from
Phase-II production units:
- Chrome effluent
- Alkaline effluent
- Oily effluent
- Acidic effluent
The schematic diagram of proposed ETP for phase-II is attached.

Chrome effluent treatment: Chrome effluent shall be treated in treatment plant which shall be installed in
Phase-I as the chrome waste effluent generation is very less and periodic.
Contaminated DM water and Zn dross treatment: For phase-II requirement, a new treatment line shall
be installed in Phase-II. Process is same as mentioned above under phase-I.
Alkaline effluent treatment: To cater phase-II requirement, a new treatment line shall be installed in
Phase-II. Process is same as mentioned above under phase-I. In this treatment scheme, additionally oily
effluent after pH correction and floating oil removal in TPI shall be added in the alkali oily wastewater tank
for further treatment.
Oily effluent treatment: Oily effluent shall be collected in a RCC collection sump from where it will be
pumped to pH correction tank in which HCl and de-oiling polymer shall be added. Then the effluent shall
be passed through TPI for oil removal. Overflow from TPI shall be discharged to flocculation tank of alkali
waste treatment line for further treatment and underflow shall be discharged to sludge storage tank common
with alkaline treatment line.
Acidic effluent treatment: Combined rinse and acidic water shall be collected in acid wastewater
collection Sump. The collected effluent shall then be pumped to neutralization tank for correction of pH
where in alkali (Lime/NaOH) shall be dosed. The neutralized effluent shall be discharged to a thickener by
gravity for separation of suspended solids & precipitate heavy metals. Then overflow from thickener shall
be routed to HRSCC by gravity and underflow shall be discharged to sludge sump (common with alkaline
effluent). In HRSCC, polymer shall be dosed. Overflow from HRSCC shall be send to pH correction tank
for neutralization using HCl and underflow to common sludge sump. After pH correction tank, effluent
shall be passed through media filter to arrest very fines and filtered water collected in common treated
effluent collection sump.
In treated water collection sump, blowdown water from cooling tower and reject water from
demineralization plant for phase-II shall be added. Mixed water from treated water collection sump shall be
pumped for slag quenching.
Effluent treatment plant (ETP) in Phase-III: The following type of effluents shall be generated from
Phase-III production unit
- Chrome effluent
- Alkaline effluent
The schematic diagram of proposed ETP for phase-II is attached.
Chrome effluent treatment: Chrome effluent shall be treated in treatment plant which shall be installed in
Phase-I as the chrome waste effluent generation is very less and periodic.
Contaminated DM water and Zn dross treatment: For phase-III requirement, a new treatment line shall
be installed in Phase-III. Process is same as mentioned above under phase-I.
Alkaline effluent treatment: To cater phase-III requirement, a new treatment line shall be installed in
Phase-III. Process is same as mentioned above under phase-I.
Finally treated effluent from phase-III ETP, blowdown water from cooling tower and reject water from
demineralization plant for phase-III shall be collected in a treated effluent collection sump and mixed water
shall be pumped for slag quenching.
Notes:
• Sewage generated in all the phases shall be collected by tanker from respective septic tank and shall
be discharged to existing sewage treatment plant.

• Industrial grade makes up water shall be available from existing water treatment plant (Near HRC
reservoir area). However, existing treatment units/pumping units may require augmentation to get
make up water for Phase-II & Phase-III.
Photographs of ETP
2.11.6.6 Details of Pollution Control Measures (Water)

Water cleansing, recycling and reuse measures are already installed by AMNS. The table depicts below all
the equipment that have been erected and are working to ensure proper treatment of the effluent.
Sr. No. Plant Name Pollution control system Installation detail Capital cost in cr.
1 Corex Recirculation system Corex pumps 1.14
2 Corex filters 0.10
3 Corex cooling towers 4.00
4 Corex heat exchangers 1.20
5 Corex pump houses 4.48
6 Corex cooling towers 15.39
(construction)
7 Corex clarifiers 18.33
8 Corex scrubbers 1.63
9 ETP ETP 1.50
10 ETP civil 2.34
11 ETP structural 0.19
12 Sludge Sludge granulation 15.00
13 Handling/granulation Decanters 1.00
14 Sludge ponds 6.48
16 SGP ponds 5.76
17 SGP cooling tower 0.72
19 ASU ASU pump house 2.21
20 ASU cooling tower 5.80
21 SMP & CSP Conarc 1 cooling system conarc 2 Re circulation pumps 20.00
22 cooling system CSP caster cooling Cooling towers 12.00
23 system INI caster cooling system Heat exchangers 16.00
24 CSP mill cooling system Pressure sand filters 30.00
25 Chlorine dosing system 2.00
Sr. No. Plant Name Pollution control system Installation detail Capital cost in cr.
26 Acid dosing system 0.50
27 Effluent treatment plant 4.00
28 Scale pits 15.00
29 Secondary settling 7.00
Tanks
30 Fin fan coolers 5.00
31 Filter press 0.50
32 Oil skimmers 0.35
33 Sewage treatment plant 0.50
34 Pump houses 15.00
35 Electrical 10.00
36 Piping &structural 50.00
37 DRI Recirculation system Clarifier 4.31
38 Classifier 0.20
39 Cooling tower 5.15
40 Cw dosing system 0.16
41 Top gas scrubber 1.48
42 Cooling gas scrubber 1.02
43 BF Recirculation system Thickners 3.50
44 Settling tank 6.50
45 Sludge separation 7.00
System
46 Cooling towers 8.50
Total 312.93
As seen, more than Rs. 312.93 Crores have been spent. Apart from this the following also has been done.
We first embarked on reducing the water consumption across each plant to the maximum extent possible.
Thus, despite being the only integrated steel major to go under NCLT for over 2 years and thus with
minimal CAPEX, we have managed to reduce our freshwater consumption by over 14.7% Y-o-Y along
with 8% increase in production
Division wise wastewater generation and its management is given in table 2.21.
Table 2.21 Details of Wastewater Generation and Its Management

Quantity (m3/day)
Division Plant Name Existing Wastewater Management
Proposed Total
HRC Division HBI 1-4 129 0 129 Recovery through UF/RO Plant, RO Reject
SMP1/LP-A 2004 0 2004 will be utilized for slag quenching and for
HSM 1209 0 1209 sprinkling on various raw materials
SC/CRM 380 0 380 storage.
Oxygen Plants 1142 0 1142
25MW PP/CPP1 621 0 621
Jetty 0 0 0
Conarc 3085 0 3085
Division
Plate Division 535 0 535
Pipe Division 0 0 0
Coke Oven 0 6000 6000
CRM 2 0 3984 3984

2.11.6.7 Final Discharge

As has been proposed, the total wastewater shall be recirculated for reuse in various plants as makeup after
the installation of both the UF/RO treatment facilities. The RO reject will be disposed to TSDF.
There are three STPs to treat domestic effluent generated from plant and residence. One with a capacity 480
KLD inside plant premises and two nos. inside the township with capacities of 1000 KLD and 600 KLD.
STP treated water will be used for gardening purpose.
2.11.6.8 Trace Metals in treated water

Monthly manual monitoring is being done for Trace metals by Third Party approved by NABL &
Recognized by MoEF&CC, New Delhi under Sec. 12 of Environmental Protection Act-1986 and reports
are being sent to GPCB & MoEF&CC. Trace Metal Analysis of three outlets is given in table 2.22.
Table 2.22 Trace Metal Analysis of three outlets

Sr. No. Parameter Unit Outlet 1 Outlet 2 Outlet 3 GPCB Norms
1 pH value - 8.16 7.95 7.49 6.50-8.50
2 Temperature C 31.3 30.6 30 40
3 Total Suspended Solids mg/L 49 56 56 100
4 Oil & Grease mg/L 6.1 4.9 7.2 10
5 BOD mg/L 15 11 12 30
6 COD mg/L 49 58 60 100
7 Iron mg/L 0.27 0.38 0.54 -
8 Total Chromium mg/L ND ND ND 2.0
9 Hexavalent Chromium mg/L ND ND ND 0.1
10 Copper mg/L ND ND ND 2.0
11 Sulphide mg/L ND ND ND 0.5
12 Fluoride mg/L 0.55 0.65 0.52 1.5
13 Zinc mg/L 0.084 ND 0.62 5.0
14 Cyanide mg/L ND ND ND 0.2
15 Lead mg/L ND ND ND 0.1
16 Nickel mg/L ND ND ND 3.0
17 Ammonical Nitrogen mg/L 6.3 7.7 6.9 50
18 Phenolic compounds mg/L ND ND ND 1.0
19 Arsenic mg/L ND ND ND 0.2
20 Chloride mg/L - - 98.9 600
21 Sulphate mg/L 180 55 36 1000
22 Colour Co-pt 40 50 50 100
2.12 Environmental Effect

Proposed activities comprise preparation of raw materials, agglomeration of fines in sinter plant, feeding of
burden to blast furnace, manufacturing of coke in coke ovens, conversion of liquid iron to steel, Making
and shaping of steel, granulation of slag, recovery of chemicals in by-product plant etc. All the above-
mentioned processes add to air, water, solid waste and noise pollution.
2.12.1 Air Emission

2.12.1.1 Existing and proposed emission and stack details
Major sources of air emission Flue gas emission and process emission in the steel making industries. Stack
are attached to the various units and fugitive dust from the raw material handling areas.
Details of existing and proposed stack along with pollutants and pollution control device are given in table
2.23 and 2.24 respectively.

Table 2.23 Details of Existing Stacks

Stack Stack
Sr. Name of Permissible limits Permissible limit as
Stack Name Height Dia. APCM
No. Plant GPCB per TOR
(M) (M)
HRC Division
1 HRC Boiler of HRC Plant 30 1.25 Adequate stack height PM : 50 mg/Nm3 PM : 30 mg/Nm3
SO2 : 100 ppm SO2 : 100 ppm
NOx : 50 ppm NOx : 50 ppm
2 HRC Heat Recovery Steam 60 3.36 Adequate stack height PM : 10 mg/Nm3 PM : 30 mg/Nm3
Generator (HRSG) – 31 SO2 :10 ppm SO2 :10 ppm
MW NOx : 80 ppm NOx : 80 ppm
3 HRC Reheating Furnace-I 88.5 4.017 Adequate stack height PM : 100 mg/Nm3 PM : 30 mg/Nm3
SO2: 40 ppm SO2: 40 ppm
4 HRC Reheating Furnace-II 88.5 4.017 Adequate stack height PM : 150 mg/Nm3 PM : 30 mg/Nm3
5 HRC Electric Arc Furnace I & 45 4 FES System 1& 2 with PM: 80 mg/Nm3 PM: 30 mg/Nm3
II Bag Filter
6 HRC Electric Arc Furnace III 45 5.7 FES System with Bag PM: 80 mg/Nm3 PM: 30 mg/Nm3
Filter
7 HRC Electric Arc Furnace IV 45 5.8 FES System with Bag PM : 80 mg/Nm3 PM : 30 mg/Nm3
Filter
8 HRC Normalizing Furnace 30 1.6 Adequate stack height PM : 80 mg/Nm3 PM : 30 mg/Nm3
9 CRM Boiler No.1&2 of CRM 30 1.4 Adequate stack height PM : 50 mg/Nm3 PM : 30 mg/Nm3
SO2 : 100 ppm SO2 : 100 ppm
10 CRM Batch Annealing Furnace 20 0.7 Adequate stack height PM : 50 mg/Nm3 PM : 30 mg/Nm3
(BAF) SO2 : 100 ppm SO2 : 100 ppm
11 CRM Heat Recovery Steam 60 5 - PM : 150 mg/Nm3 PM : 30 mg/Nm3
Generator (HRSG) – 25 SO2 : 50 ppm SO2 : 50 ppm
MW NOx : 190 ppm NOx : 190 ppm
12 HBI Reformer cum 30 3.7 Venturi Scrubber PM : 50 mg/Nm3 PM : 30 mg/Nm3
Recuperator- I
Recuperator- II
Recuperator- III
Recuperator- IV
Recuperator-V
17 HBI Process Dust Collection 20 0.9 Venture Scrubber + PM : 40 mg/Nm3 PM : 30 mg/Nm3
System (PDCS) - I Hydro Cyclone
System (PDCS) – II Hydro Cyclone
System (PDCS) – III Hydro Cyclone
System (PDCS) – IV Hydro Cyclone
System (PDCS) – V Hydro Cyclone
22 Lime Kiln – I 45 1.061 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
23 Lime Kiln – II 45 1.061 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
24 Lime Kiln – III 45 1.061 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
25 Lime Kiln – IV 45 1.061 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
26 CRM HCl Scrubber attached to 25 1.2 HCL Scrubber HCL: 20 mg/Nm3 HCL: 20 mg/Nm3
Pickling operation - Line
1
27 CRM HCL Scrubber attached to 25 1.2 HCL Scrubber HCL: 20 mg/Nm3 HCL: 20 mg/Nm3
Pickling operation - Line
2

Stack Stack
(M) (M)
28 CRM HCL Fume Scrubber 25 0.6 HCL Scrubber HCL: 20 mg/Nm3 HCL: 10 mg/Nm3
attached to Acid
Regeneration Plant (ARP)
29 CRM Fume Extraction System 30 2 FES System SO2: 40 mg/Nm3 SO2: 40 mg/Nm3
Attached to Cold Rolling NOx : 25mg/Nm3 NOx : 25mg/Nm3
Mill - Line 1
30 CRM Fume Extraction System 30 2 FES System SO2: 40 mg/Nm3 SO2: 40 mg/Nm3
Attached to Cold Rolling NOx : 25mg/Nm3 NOx : 25mg/Nm3
Mill - Line 2
31 CRM Gas Scrubber attached to 30 0.6 Gas Scrubber SO2: 40 mg/Nm3 SO2: 40 mg/Nm3
Galvanizing operation - NOx : 25mg/Nm3 NOx : 25mg/Nm3
Line 1
32 CRM Gas Scrubber attached to 20 0.6 Gas Scrubber SO2: 40 mg/Nm3 SO2: 40 mg/Nm3
Galvanizing operation - NOx : 25mg/Nm3 NOx : 25mg/Nm3
Line 2
33 CRM Pickling Line 3 30 0.8 Water Scrubber HCl: 20 mg/Nm3 HCl: 20 mg/Nm3
Conarc Division
34 Blast Stove and Fume 75 6.3 Fume Extraction System PM: 150 mg/Nm3 PM: 30 mg/Nm3
Furnace Extraction (FES) with Bag filter SO2: 100 ppm SO2: 100 ppm
(BF)/ Cyclone (Dust NOx: 50 ppm NOx: 50 ppm
Suppression System)
35 Blast Stock House 45 5 De-dusting system with PM: 150 mg/Nm3 PM: 30 mg/Nm3
Furnace Bag filter SO2: 100 ppm SO2: 100 ppm
NOx: 50 ppm NOx: 50 ppm
36 Blast Turbo blower / Boiler 1 & 100 4 Adequate stack height PM: 150 mg/Nm3 PM: 30 mg/Nm3
Furnace 2 SO2: 100 ppm SO2: 100 ppm
37 Blast Slag Granulation Plant 70 - Air Vents to slag - -
Furnace granulation vessel only
during tapping
38 Blast Hot Metal Transfer / 45 5.5 FES System with Bag PM: 150 mg/Nm3 PM: 30 mg/Nm3
Furnace Fumes Exhaust (Cast filter SO2: 100 ppm SO2: 100 ppm
House) NOx: 50 ppm NOx: 50 ppm
39 Sinter Sinter plant process stack 30 4.5 ESP PM: 150 mg/Nm3 PM: 30 mg/Nm3
Plant (De-dusting) SO2: 100 ppm SO2: 100 ppm
40 Sinter Sinter plant process stack 60 3 ESP PM: 150 mg/Nm3 PM: 30 mg/Nm3
Plant (Waste gas) SO2: 100 ppm SO2: 100 ppm
41 Conarc FES (Fume Extraction 45 5.7 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
Plant System - Conarc 1.1) SO2: 100 ppm SO2: 100 ppm
42 Conarc FES (Fume Extraction 45 6.13 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
43 Conarc FES (Fume Extraction 45 7.2 Bag Filter PM: 150 mg/Nm3 One stack combined
Plant System - Conarc 2.1) SO2: 100 ppm installed for Conarc
NOx: 50 ppm 2.1 & 2.2
Conarc FES (Fume Extraction 45 7.2 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
44 CSP Tunnel Furnace – A Stack 60 2.1 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
1 SO2 : 100 ppm SO2 : 100 ppm
2 SO2 : 100 ppm SO2 : 100 ppm
3 SO2 : 100 ppm SO2 : 100 ppm
47 CSP Tunnel Furnace – B Stack 60 2.2 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
1 SO2 : 100 ppm SO2 : 100 ppm

Stack Stack
(M) (M)
2 SO2 : 100 ppm SO2 : 100 ppm
3 SO2 : 100 ppm SO2 : 100 ppm
50 CSP Tunnel Furnace – C Stack 60 1.93 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
1 SO2 : 100 ppm SO2 : 100 ppm
2 SO2 : 100 ppm SO2 : 100 ppm
3 SO2 : 100 ppm SO2 : 100 ppm
53 Blast Gas Flare 50 4 Only Flaring of excess - -
Furnace BF Gas
54 Blast Pulverized Coal Injection 50 - De-dusting system with PM: 150 mg/Nm3 PM: 30 mg/Nm3
Furnace Bag filter
55 Blast De – dusting for mixer 50 4.1 De-dusting system with PM: 150 mg/Nm3 PM: 30 mg/Nm3
Furnace Bag filter
56 HBI Reformer cum 40 4.31 Venturi Scrubber PM : 150 mg/Nm3 PM: 30 mg/Nm3
Recuperator -VI
57 HBI Process Dust Collection 20 0.7 Dust collection scrubber PM : 150 mg/Nm3 PM: 30 mg/Nm3
System (PDCS) - VI
58 HBI Junction House – 23 30 0.7 Dust collection scrubber
PM : 150 mg/Nm3 PM: 30 mg/Nm3
59 HBI Junction House – 24 30 0.7 Dust collection scrubber
PM : 150 mg/Nm3 PM: 30 mg/Nm3
60 Corex FES of Cast House 1 30 4.2 Bag Filter PM : 150 mg/Nm3 PM: 30 mg/Nm3
61 Corex FES of Cast House 2 30 4.2 Bag Filter PM : 150 mg/Nm3 PM: 30 mg/Nm3
62 Corex Gas Flare – 1 30 2.4 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
SO2 : 100 ppm SO2 : 100 ppm
63 Corex Gas Flare - 2 30 2.4 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
SO2 : 100 ppm SO2 : 100 ppm
64 Corex FES Stock house oxide 30 1.9 Bag Filter with De- PM : 150 mg/Nm3 PM: 30 mg/Nm3
line -1 dusting system
65 Corex FES Stock house oxide 30 1.9 Bag Filter with De- PM : 150 mg/Nm3 PM: 30 mg/Nm3
line- 2 dusting system
66 Corex FES Stock house Coal 30 1.9 Bag Filter with De- PM : 150 mg/Nm3 PM: 30 mg/Nm3
67 Corex FES Stock house Coal 30 1.9 Bag Filter with De- PM : 150 mg/Nm3 PM: 30 mg/Nm3
68 Corex De – dusting Coal Drying 30 2.3 Bag Filter with De- PM : 150 mg/Nm3 PM: 30 mg/Nm3
line no - 123 dusting system
71 Corex De – dusting Coal 30 1.388 Bag Filter with De- PM : 150 mg/Nm3 PM: 30 mg/Nm3
Transportation - 1 dusting system
Transportation - 2 dusting system
Blending dusting system
74 Lime Kiln – V 45 1.2 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
75 Lime Kiln – VI 45 1.2 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
76 Lime Kiln – VII 45 1.2 Bag Filter PM: 150 mg/Nm3 PM: 30 mg/Nm3
Plate Mill Division
77 Plate RHF 1 & 2 106 3.64 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3

Stack Stack
(M) (M)
Mill SO2 : 100 ppm SO2 : 100 ppm
78 Plate Normalizing Furnace 1 30 1.7 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
79 Plate Normalizing Furnace 2 30 1.7 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
80 Plate Austinizing Furnace 1 30 1.6 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
81 Plate Austinizing Furnace 2 30 1.6 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
82 Plate Tempering Furnace 30 1.42 Adequate stack Height PM : 150 mg/Nm3 PM : 30 mg/Nm3
83 Plate Cold leveler De – dusting 30 1.4 Bag Filter PM : 150 mg/Nm3 PM: 30 mg/Nm3
Mill system
Pipe Mill Division
84 Pipe Mill De-dusting Blower 1 30 0.64 Bag Filter PM : 150 mg/Nm3 PM: 30 mg/Nm3
Bhander Power Plant
88 CPP – HRSG - 1 65 - Low NOx Generating PM : 10 mg/Nm3 PM : 30 mg/Nm3
525 MW Burners SO2 : 10 ppm SO2 : 100 ppm
91 CPP – GT-1 30 - Low NOx Generating PM : 10 mg/Nm3 PM : 30 mg/Nm3
Table 2.24 Details of Proposed Stacks

Stack
Name of Stack Permissible limit
Sr. No. Stack Name Height APCM
Plant Dia. (M) as per TOR
(M)
1 HRC Boiler-VDVOD 30 1.25 Adequate stack height PM : 30 mg/Nm3
SO2 : 100 ppm
NOx : 50 ppm
2 HRC Stack for Coal Feeding 20 0.5 Water scrubber PM: 30 mg/Nm3
(Ferro Alloy Store) Adequate stack height
3 HRC Caster 1 : Steam Fan 35 1.4 - -
Exhaust
Exhaust
Exhaust-01

Stack
(M)
Exhaust-02
7 HRC Gas Turbine – 31 MW 30 2.5 Adequate stack height PM : 30 mg/Nm3
SO2 : 100 ppm
NOx : 50 ppm
8 HBI Process Dust Collection 20 0.7 Venturi Scrubber PM: 30 mg/Nm3
System - DRI
9 HBI Module 2 Process Dust 60 1 Water Scrubber PM: 30 mg/Nm3
Collection Bubbler
10 HBI Module 2 Hot DRI Surge 30 0.5 Water Scrubber PM: 30 mg/Nm3
Bin Bubbler
Collection Bubbler
Bin Bubbler
Collection Bubbler
Bin Bubbler
Collection Bubbler
Bin Bubbler
17 HBI Turbo Expander Heater 20 0.5 - PM : 30 mg/Nm3
Stack SO2 : 100 ppm
NOx : 50 ppm
18 CRM Chromic Dryer Blower - 30 0.5 - SO2: 40 mg/Nm3
01 for Galvanizing Line 1 NOx : 25mg/Nm3
19 CRM Chromic Dryer Blower - 20 0.5 - SO2: 40 mg/Nm3
02 for Galvanizing Line 2 NOx : 25mg/Nm3
20 CRM Alloy Furnace Fume Vent 30 0.2 - SO2: 40 mg/Nm3
Common Facility for NOx : 25mg/Nm3
Galvanizing Line 1&2
21 CRM Hot Skin Pass Mill Vent 20 0.5 Water Scrubber SO2: 40 mg/Nm3
NOx : 25mg/Nm3
22 CRM PKL-3 (Boiler) 32 0.5 Adequate stack height PM : 30 mg/Nm3
SO2 : 100 ppm
NOx : 50 ppm
23 Lime Kiln 1&2 Feeding and 30 0.5 Bag Filter PM: 30 mg/Nm3
Storage
Storage
Storage
Storage
Storage
Storage
Storage
30 Lime DE System for Kiln 5 & 6 25 0.7 Bag Filter PM: 30 mg/Nm3
Feeding
Stack
(M)
Feeding
Product Junction House
PJH-1
Product Junction House
PJH-3
34 Lime Kiln – VIII 55 1.2 Bag Filter PM: 30 mg/Nm3
35 Blast Slag Granulation Plant 70 Air Vents to slag
Furnace (SGP-2) granulation vessel only
during tapping.
36 Sinter Plant Product Bag Filter 36 1.45 Bag Filter PM : 30 mg/Nm3
SO2 : 100 ppm
NOx : 50 ppm
37 Sinter Plant Mixer Bag Filter 40 2 Bag Filter PM : 30 mg/Nm3
SO2 : 100 ppm
NOx : 50 ppm
38 Sinter Plant Cooler Stack 35 3.4 - PM : 30 mg/Nm3
39 Sinter Plant Mixing Drum Steam Vent 20 2 - -
40 Conarc Plant Boiler-RHTOB 32 1.55 - PM : 30 mg/Nm3
SO2 : 100 ppm
NOx : 50 ppm
41 Conarc Plant CSP Caster 1 : Steam Fan 60 1.2 - -
Exhaust
Exhaust
Exhaust
44 Conarc Plant INI Caster : Steam Fan 30 1.2 - -
Exhaust
45 Corex Corex 1 Tower Top De- 30 0.5 De-dusting System PM: 30 mg/Nm3
dusting
46 Corex Corex 2 Tower Top De- 30 0.5 De-dusting System PM: 30 mg/Nm3
dusting
47 Corex Corex 1 Slag Granulation 30 1 - -
Plant (SGP)
48 Corex Corex 2 Slag Granulation 30 1 - -
Plant (SGP)
49 Pipe Mill Smoke Unit - Extruder 15 0.95 Screen Filter PM: 30 mg/Nm3
Fume Stack (Coating
Plant)
50 Pipe Mill Epoxy Booth Stack 15 0.5 Screen Filter PM: 30 mg/Nm3
(Coating Plant)
51 Pipe Mill De-dusting Blower 1 32 0.5 Bag-Filter PM: 30 mg/Nm3
(New Coating Plant)
52 Pipe Mill De-dusting Blower 2 32 0.5 Bag-Filter PM: 30 mg/Nm3
(New Coating Plant)
53 Pipe Mill De-dusting Blower (New - 0.7 Bag-Filter Vent is there stack
Coating Plant) to be installed
PM: 30 mg/Nm3
54 Pipe Mill Epoxy Stack Vent (New 20 0.5 Screen Filter PM: 30 mg/Nm3
Coating Plant)
55 Pipe Mill Smoke Unit - Suction 12 0.65 - PM: 30 mg/Nm3
Blower (H-Saw 1)

Stack
(M)
56 MH ECR1 CSH - Wet Coal Screen 25 0.7 Bag Filter PM: 30 mg/Nm3
House
57 MH ECR1 OSS - Oxide Screen 25 0.7 Bag Filter PM: 30 mg/Nm3
House
58 MH ECR1 NJH 22 - CC25 Head End 25 0.7 Cyclone Separator PM: 30 mg/Nm3
59 MH ECR1 JH23 - CC115 Tail End 25 0.7 Cyclone Separator PM: 30 mg/Nm3
60 MH ECR1 JH9A - CC 27, 28 Head 25 0.7 Cyclone Separator PM: 30 mg/Nm3
End
61 MH BF NJH-10 : GJ3 Conveyor 20 0.5 Bag Filter PM: 30 mg/Nm3
for Handling BF Coke
62 MH BF NT-20-A: BF1 Conveyor 20 0.5 Bag Filter PM: 30 mg/Nm3
for Handling BF Sinter
Feeding.
63 MH BF NT20-1-NC47 Conveyor 20 0.5 Bag Filter PM: 30 mg/Nm3
for Handling Oxide to BF
64 MH Jetty Junction House JH3A : 20 0.5 Bag Filter PM: 30 mg/Nm3
Coal Feeding to Corex
65 MH Jetty Junction House JH4A : 20 0.5 Bag Filter PM: 30 mg/Nm3
Coal Feeding to Corex
66 MH Plant B Junction House 2 20 0.5 Bag Filter PM: 30 mg/Nm3
67 Coal Dust Extraction System of 30 1.2 Bag Filter with De- PM: 30 mg/Nm3
Briquetting Rotary drier dusting system
Plant
68 Acid HCL Fume Scrubber 35 1.2 Adequate height stack HCL < 10
Regeneration attached to Acid mg/Nm³
Plant -100 Regeneration Plant (ARP)
KL
69 BF slag Chimney 5-8 m 600 – Adequate height stack SOx – 100
grinding mill 750 mm mg/Nm3
(BOO) - 50 NOx – 50
TPD mg/Nm3
70 Lime Rotary Kiln 30 1 - PM: 30 mg/Nm3
71 Lime Kiln silo Dedusting 10 1 - PM: 30 mg/Nm3
system
72 Lime Limestone silo Dedusting 10 1 - PM: 30 mg/Nm3
system
73 Thick Plate Thick plate Normalizing 30 1.2 at Adequate height stack PM: 30 mg/Nm3
Normalizing Chimney Top
Furnace
74 SMP-1 EAF Secondary Emission 45 6.5 Yes, this Project itself is PM: 30 mg/Nm3
Control System for pollution control of
the SMP1 Shop
75 CRM-2 Pickling Section 25 1.2 HCl Scrubber HCL: 20 mg/Nm3
76 CRM-2 Pickling Section 30 1.2 Water Scrubber HCL: 20 mg/Nm3
77 CRM-2 Acid Regeneration Plant 25 0.6 HCl Scrubber HCL: 10 mg/Nm3
78 CRM-2 Tandem Mill Section in 30 0.6 Fog Exhaust System
PLTCM
79 CRM-2 Furnace of Galvanizing 30 0.6 Gas Scrubber PM : 30 mg/Nm3
Lines (CGL#3 & CGL#4) SO2 : 100 ppm
and Annealing Lines NOx : 50 ppm
80 Coal Dust Extraction System of 30 1.2 Bag Filter with De- PM: 30 mg/Nm3
Briquetting Rotary drier dusting system
Plant
81 Coal Dust Extraction system 21 2.5 Bag Filter with De- PM: 30 mg/Nm3

Stack
(M)
Briquetting for transfer points of belt dusting system
Plant conveyors
82 Coke Oven Battery chimney - 1 125 5 Adequate stack height PM : 50 mg/Nm3
Plant SO2 : 100 ppm
NOx : 50 ppm
83 Coke Oven Battery chimney - 2 125 5 Adequate stack height PM : 50 mg/Nm3
Plant SO2 : 100 ppm
NOx : 50 ppm
84 Coke Oven Coke pushing ground de- 125 5.13 Bag Filter PM : 50 mg/Nm3
Plant dusting chimney SO2 : 100 ppm
NOx : 50 ppm
85 Coke Oven Environmental de-dusting 125 5.13 Bag Filter PM : 50 mg/Nm3
Plant system stack for CDQ SO2 : 100 ppm
NOx : 50 ppm
86 Coke Oven Battery chimney – 1 & 2 145 5 Adequate stack height PM : 50 mg/Nm3
Plant-2 SO2 : 100 ppm
NOx : 50 ppm
87 Coke Oven Coke pushing side de- 30 2.5 Bag Filter PM : 50 mg/Nm3
Plant-2 dusting chimney SO2 : 100 ppm
NOx : 50 ppm
88 Coke Oven Coke pushing ground de- 30 2.5 Bag Filter PM : 50 mg/Nm3
Plant-2 dusting chimney SO2 : 100 ppm
NOx : 50 ppm
89 Coke Oven Environmental de-dusting 50 1.8 Bag Filter PM : 50 mg/Nm3
Plant-2 system stack for CDQ SO2 : 100 ppm
NOx : 50 ppm
2.12.1.2 Action Plan to reduce the emission

In the existing scenario all the emission like PM, SO2 and NOx, from stack are found to be within the
GPCB prescribed standard. The analysis report of last six month is enclosed as annexure 9. To achieve the
PM level < 30 mg/Nm3 in the existing stack and for proposed, the company will execute action plan which
is given in table 2.25.
Table 2.25 Details of Cost for Action Plan

Sr. Budgetary Cost Target
Plant Action Plan
No. (Rs. In Cr) Date
1 Steel Making ▪ Conarc 2 RABH Bag Replacement 2.4311 Completed
Plant – 2 (SMP-2)▪ Bellow Replacement in C1, C2, C3 & C4 4.3362
Jun-22
Compartment
▪ LRF - Impeller and casing replacement. 2.8004 Jun-22
▪ Conarc Phase-2 de-dusting capability study - Jun-22
▪ Off line/ On line Launder Lancing de-dusting - Jun-22
▪ Damper fixing in HMPS & Linear Actuator 0.7415
Jun-22
replacement in LF & Canopy
2 Lime Plant – 2 ▪ Kiln 5 & 6 - Replacement of all filter bags and cages. 0.55 Completed
(LP-2) ▪ Project for installation of 11 DE Systems covering all 35
Oct-22
drop points
3 Corex ▪ Installation of retainer wall in de-dusting silo 0.55 Completed
▪ Skid Steer for cleaning in tower and stock house 0.25
Completed
surrounding area
▪ Provision of additional bin at JH-24 and JH-25 0.5 Mar-22
▪ Super Sucker Installation for road and Conveyor 0.40
Jun-22
bottom area cleaning
▪ Wind Screen Installation in between CDP /ASU 0.2 Jan-22


Plant Action Plan
▪ Concrete Flooring at Coal De-dusting, Skip feeding 0.15
Mar-22
and Stock house junction house area
▪ Bag replacement in Coal de-dusting system in stage 1.49
wise & Rectification of purging system and Jan-22
pneumatic conveying system.
▪ Dedusting Coal Blending station - Need to refurbish 0.7
Jun-22
entire system.
4 Steel Making ▪ FES upgradation Project Implementation 72 Jun-23
Plant – 1 ▪ Skull Cutting process fume gas capture system 6
Jun-23
(SMP-1) Installation
▪ 35 mt level Ventilation project implementation 8 Jun-22
▪ Super Sucker Machine Installation at MFS and 4
Dec-22
CRANE level
▪ Mobile Super Sucker Machine Procurement 2 Dec-22
▪ Mechanized and regular conveyor Scrappers 2
Dec-22
Changing in all of the belt conveyor
▪ Complete cleaning / painting and restoration of the 4
Dec-22
SMP-1 structures and floor
▪ Slag Yard – Cooling Pond and water recycling system 6
-
Installation
5 Lime Plant – 1 ▪ Kiln 1 & 2 – Replacement of Bag House 1.25
Jun-21
(LP-1)
6 Sinter Plant ▪ Complete Revamping for the Dedusting Network 4
Jun-22
‘ with upgradation of the Fan
▪ Concrete Flooring for proper & Timely Cleaning. 1.5 Jun-22
▪ Maintenance of Roads & Floors with Mechanized 0.75
-
Housekeeping
▪ Wind Fencing Installation for Sinter Plant. 4 Jun-22
▪ Pneumatic Dust handling system Installation for 6.5
eliminating very Micro-fines dust handling in Jun-22
Conveying system.
▪ Provision of CO monitoring system 0.3 Jun-22
▪ Upgradation of WG ESP system 46 Jun-22
7 Blast Furnace ▪ Wind fence Installation around stock house 0.0673 Jun-22
▪ Mechanized house-keeping for BF internal road and 0.75
Jun-22
shop floor
▪ Concreting of Boiler and Stock house road. 0.86 Jun-22
▪ Concreting at stock house area. 0.75 Jun-22
▪ Stock House Bag Filters Installation 0.75 Jun-22
▪ Stock House Modification in Oxide & Coke route De- 5.8
dusting and Additional de-dusting system Installation Jun-21
for Tripper Level.
▪ Hot metal Transfer/Fumes Exhaust (Cast House) 10
Jun-22
Installation
▪ Cast House Bag Filters Installation 0.749 Completed
▪ PCI Bag Filters Installation 0.2902 Completed
▪ De-dusting for mixer additional suction point for 0.9
Apr-22
ladle lancing and revamping of existing system
8 Hot Briquetted Provision of Drain & RCC Road
Iron (HBI) ▪ From Mod 1 clarifier to HBI stores 0.42 Jun-22
▪ From Mod 1 Local emergency to HBI workshop 0.42 Jun-22
▪ From Mod 2 HDRI loading station to NG station 0.42 Jun-22
▪ From Mod 3 HDRI loading station to pump house 0.42 Jun-22
Provision of RCC road
▪ From Mod6 VPSA to Mod5/6 oxide screen house 0.29 Completed
▪ From SMP2 main road to Siddhi building 0.29 Completed


Plant Action Plan
9 Cold Rolling Mill▪ New scrubber system, FRP structure to be installed 1
Jun-22
(CRM) for Chimney support.
▪ Acid treatment from ARP plant 3.36 Jun-22
▪ PKL3 New Chimney Installation with FRP structure. 0.5 Jun-22
10 Material ▪ Provision of RCC Flooring at HBI, Sinter & BF 1.0176
Jun-22
Handling Material Handling Area
(MH) ▪ Installation of 10m high Wind Fence Cladding system 5.33
Jun-22
along periphery (Coke & Coal Yard 1 to 6)
▪ Concrete flooring for all yards 1-6 37.2 Jun-23
▪ Fire water system all around the yard 2.33 May-22
▪ Retention wall all around the yard 1.74 Nov-22
▪ Water sprinklers all around the yard 5.5 Nov-22
▪ Installation of Wind Fence Cladding system along 4
periphery of Lime Plant 1 and Coke & Coal Shed in Jun-22
front of BF & Sinter.
▪ Installation of Dust Collection System (SMP1 & SMP 5
Nov-22
2 MH areas)
▪ Provision of Dust Spillage Controls at Mod 5-6 MH 0.5
Nov-22
Yard & Sludge Pond Areas
▪ Installation of Water Sprinkling System at Mod 5-6 0.20
Jun-22
Oxide & Product Fines areas
▪ Provision of RCC Flooring at MH Areas in Corex 0.75 Jun-22
▪ Provision of Dust Cleaning & Disposal Systems at 1.5
MH Yard near Lime plant 2, MH areas in Lime Plant Jun-22
2, Junction House No. 23 & 24
▪ Installation of Dust Collection System at MH areas 12.5
Nov-22
junction houses - 10 numbers
11 Pipe Mill ▪ Installation of Dust collector System + Chimney at 0.5
Completed
De-Dusting Blower-7
12 Admin ▪ Truck Mounted Road sweeper – 04 Nos. 2.4 Completed
▪ Installation of New Ozone System & New Pump 0.225 Completed
▪ Development of 734262 Sqm. Green Belt. 6.53 Jun-23
13 Utilities ▪ Recycling & Reuse of Effluent Water through 60.08
May-23
Reverse Osmosis (RO) Project Implementation
Total Cost (Rs. In Cr) 393.7383
2.12.1.3 CEMS and Opacity meter

CEMS has been installed on all process stacks and signal are being received in plant control room for
central control of APCDs installed in the plant. CEMS will be provided to the all-proposed stack.
Further for proposed projects, installation /activation of opacity meters with recording with proper
calibration system will be done.
Sr. No. Particulars Nos.

1 Online Stack Analyzers - PM 72
2 Online Stack Analyzers - SO2 - NOx 06
3 Effluent Quality Monitoring Systems (EQMS) 03
(i) Effluent Outlet 1 – HRC Division
(ii) Effluent Outlet 2 – Plate Mill Division
(iii) Effluent Outlet 3 – Conarc Division
4 Continuous Ambient Air Quality Monitoring Stations (CAAQMS) 04
(i) East Direction
(ii) West Direction
(iii) North Direction
(iv) South Direction

Installation & Commissioning of following Online Stack Analyzers are under progress.
Sr. No. Particulars Nos.

1 Flow, Temperature & Pressure Analyzers 86
2 CO Analyzers (Blast Furnace) 06
3 O2 Analyzers 54
4 PM Analyzers 11
5 SO2 & NOX Analyzers (Kiln, Hot & Cold Rolling Mills) 48
2.12.2 Noise Environment

2.12.2.1 Details of Noise Generation in Plant
level.
plant operation. Plant wise Noise generation details is given in table 2.26
Table 2.26 Details of Noise Generation

Sr. Point of Outlet Parameters
Plant
No. Generation Noise (dba)
1 HBI Plant (DRI Mod. I to VI) Rotating 65.6
2 Blast Furnace equipment, 64.6
3 Sinter Plant Plant 71.5
machineries and
4 Coke Oven (Recovery Type) 67.2
other plant
5 Air Separation facility 71.4
6 Steel Melt Shop-1 (EAF) (4Nos.) 70.5
7 Basic Oxygen Furnace (BoF) (3Nos.) 65.2 (oxygen plant)
8 Steel Melt Shop-2 (4 EAF& 4LF) 72.0
9 Corex Plant (2 Nos.) 70.3
10 Lime Plant (Lime/ Dolime) 66.2
11 CPP 62.6
12 Plate Mill 69.4
14 CSP, Hot Rolling Mill & Long Product -HRC 70.4
15 Caster Shop 71.0
16 CRM-1 66.2
18 Waste Heat Recovery Based Power Plant 60.3
19 Pipe Mill 67.7
20 Coal briquetting Plant - (1000 TPD) 70.2
21 BF – PCI Project- Pulverized coal 72.0
22 Ladle furnace - Existing Liquid Steel 4.6 MTPA (Standby LF-5 72.5
for Special grades)
23 Lime Kiln (500 TPD) - Lime and Dolime 60.3
24 Rotary Kiln (200 TPD) - Calcined Lime 66.2
25 Additional Ladle Furnace (LF7) – Standby for Special grades 60.3
26 Blast Furnace Dust Catcher /Dust separation unit-150 TPD 70.5
27 Acid Regeneration Plant - 100 KL & Pickling Line-3 69.2
28 Tank Farm-2 with interconnection between PKL-3 & ARP-2 70.0
29 BF slag grinding mill (BOO) - 50 TPD 60.3
30 New Cooling towers 60.3
Sr. Point of Outlet Parameters

Plant
No. Generation Noise (dba)
31 Mod 4 additional VPSA to utilize Corex gas and going forward 71.5
Coke oven gas
32 Slag Conditioning & Metal Recovery plant 60.3
33 Hot metal Pretreatment Station Outside Shop (KR Technology) 60.3
34 Thick Plate Normalizing Furnace 68.5
35 Shot blasting machine 73.2
36 VD Cooling Tower 69.7
37 RHD Cooling Tower 70.4
38 Water Treatment Plant for 500 MW CCPP 72.1
39 CRM-2 66.2
2.12.2.2 Mitigation Measures

Following mitigation measures is/will be adopted.
• Mufflers, silencers are/will be provided
• Anti-vibration pad for equipment with high vibration are/will be used
• Use of PPEs like earmuff and earplugs
• Housing / casing to all noise generating machines
• Green belt development at plant boundary
2.12.3 Solid and Hazardous Waste Generation

Details of plant wise solid waste generation and hazardous waste generation along with their management
are given in table-2.27 and 2.28 respectively. A copy of MOU between AMNS and solid/hazardous waste
handling vendor is attached as annexure 10.
Table 2.27 Details of Solid Waste generation

Fines
1 Pellet Fines 902
Corex
4 Mill Scale 150
/ CSP
palletization
palletization
Material.
Material.
Slag
Granulated Slag
(IM)
sub base material
13 SMP I & II Steel Slag 1651
material


villagers
sub base material
De Spherization
(HMDP) Slag
Dust and Sludge

machine
sinter plant
activities
22 BF BF Dust 52
Refractories
High Alumina
30 SMP I & II 2
Grog
Coal Fines
Non-PCI Corex
coal fines
Table 2.28 Details of Hazardous Waste generation and its management

modification
(TPA)
Micropelletization
Vendors.

modification
(TPA)
Sludge)
Drums vendor.
CHWIF.

approved TSDF site.
approved TSDF site
batteries
wool TSDF site
/Year
Vendor.
TSDF site
TSDF site

modification
(TPA)
Reuse-Recycling Measures of Major Solid / Hazardous Waste At AMNS:

Sr. No. By-Product / Hazardous Waste Name End Use
1 Pellet Fines Sinter Plant
2 BF Return Fines Sinter Plant
3 Mill Scale Sinter Plant + BF
4 Lime Stone Fines / Dolomite Fines Usage in BF / Corex / Sinter
5 Lime Fines CRM ETP/Sinter Plant
6 Dolime Fines Sinter plant
7 FES Dust
8 ETP Sludge Reuse through Micro-palletization in Sinter Plant
9 HBI Sludge Pond Fines
10 Corex Sludge Micro Palletization through SAP (Sludge Agglomeration
Plant) and usage in Sinter plant.
11 HBI QT Fines Usage in SMP through Ferrous Briquetting
12 DRI Cyclone Dust
13 Slag 1) Recycle in Internal Plants (Sinter, BF and Corex).
2) NHAI Road Making
3) Project Site development.
4) Internal Plant area development.
5) Tetrapod making for Shore protection.
6) Used as Ballast in railway track.
7) Road making in Mukhymantri Gram Sadak Yogena.
8) Internal Plant Road making.
Reuse of CRM ETP Sludge for Micro Pellets Production:

The sludge has micron-size particles only. The physical form is sticky and wet, which takes a long time to
get dried to the core. In a semi dried state, it cannot be handled through sinter plant hopper because of
clogging problems. Once fully dry, it is highly prone to create dust nuisance.
A process to pelletize partially dried ETP sludge into small sized nodules (called micro-pellets) of size 1 to
3 mm has been developed in Drum Pelletizer. The sludge needs to be mixed with FES dust and lime fines
for absorbing the oil and moisture and then to be fed into Drum Pelletizer. Drum Pelletizer is a simple
rotating drum with water spraying nozzles, scrapper plate and an exit dam. The dam helps increasing
retention time and promotes Palletization. Based on the findings, we have put up a facility in the ETP
Sludge dumping area to convert ETP Sludge in micro-pellet and being transported to Sinter Plant and being
consumed there.

Chapter – 3
Baseline Environmental Status and Description of Environment
3.1 Introduction
In order to assess the impacts due to proposed modification project on surrounding environment, the first
step is to assess the existing environmental conditions. Since assessing an environment is not a one-day
task, for assessment usually three months’ period is taken to arrive at meaningful results. Monsoon season
is avoided owing to the instability in the environmental condition.
Air, water, soil, land and its utilization, noise, geology, hydrology, ecology and biodiversity constitute a
major part of environment management, the present status of each has been described here and the
components are selected based on the significance of impacts. The human aspect of environment is also
essential to be considered and for this purpose the existing socio-economic environment is also assessed.
The assessment is done as per the “Terms of Reference” (TOR) issued by the expert appraisal committee
for specific project. TOR for the project was allotted by EAC of MoEF&CC New Delhi.
To prepare EIA report in line with the issued TOR, SGC FAEs/Team members along with Empanelled
experts monitoring team from own Laboratory visited the location and selected the study area to monitor
the environmental parameters and in accordance with the Guidelines for EIA, issued by the Ministry of
Environment, Forests and Climate Change, Government of India. The components of the study taken into
consideration were:
• Air Quality and Meteorology

• Air Environment
• Noise Environment
• Land Environment
• Water Environment
• Biological Environment
• Socio-economic Environment
• Solid and Hazardous Waste
• Risk Assessment
• Land Use
• Hydrogeology
• Geology
3.2 Period of Monitoring and Area of Study

The baseline environmental quality was assessed during the period October 1st, 2020 to December 31st,
2020 in a study area of 10 km radial distance from the project site. Google Image of study area and
topographic map are given in figure 3.1 & 3.2 respectively.

Figure 3.1 Google Image of Project Site with Study Area
Figure 3.2 Location Map of Project Site with Study Area

3.3 Climate of the Study Area

Surat hosts a tropical savanna climate moderated strongly by the Arabian Sea. The summer begins in early
March and lasts till June. April and May are the hottest months, the average maximum temperature being
37 °C (99 °F). Monsoons begin by late June and the city receives about 1,200 millimeters (47 in) of rain by
the end of September, with the average maximum being 32 °C (90 °F) during those months. During
October and November, the city witnesses the retreat of monsoon and the return of soaring temperatures till
late November. Winter starts in December and ends by late February, with average temperatures of around
23 °C (73 °F).
3.4 Air Quality & Meteorology

3.4.1 Data Collection Methodology
The baseline information on micro-meteorology, ambient air quality, water quality, ambient noise levels,
soil quality and floristic descriptions are drawn from the actual site data analyzed by Shree Green
Environmental Laboratories. The FAE‟s (AQ and AP) were involved in selection of monitoring locations
and data collection. Long term meteorological data recorded at the nearest IMD station –Surat was also
collected. A copy of the long-term Climatological data is enclosed as annexure 11. Apart from these, the
secondary data has been collected from Census Handbook, Revenue Records, Statistical Department, Soil
Survey and Land Use Organization, District Industries Centre, Forest Department, Central Ground Water
Authority, etc.
3.4.2 Meteorology
Dispersion of Air borne pollutants is largely influenced by atmospheric motion. Knowledge of these
motions, whose range is scaled from turbulent diffusion to long-range transport by weather systems. It is
essential to simulate such dispersion and analyze the quality of impacts of air pollution on the environment.
The purpose of EIA is to determine whether average concentrations are likely to be encountered at fixed
locations (Known as the receptor), due to the given sources (locations and rates of emission known), under
idealized atmospheric conditions. It is imperative that one should work under idealized conditions and all
analysis pertaining to air turbulence and ambient air or noise pollution should be done considering the best
expected meteorological conditions. Essential care was taken to ensure that the weather station is installed
within a distance of six times the height of nearest vertical terrain elements (house, trees etc.) and at a
height of 10m from the average ground level of the fetched area.
3.4.3 Temperature Details

The monthly maximum and minimum temperatures recorded on-site during the aforesaid monitoring period
varied between 13.0 – 39.0 °C. It could be observed that, the pattern of data recorded on-site generally
matches with the past data of IMD.
3.4.4 Relative Humidity (RH)

The monthly minimum and maximum relative humidity recorded onsite during the said monitoring period
showed a variation in the range of 16 % to 84 %.
3.4.5 Rainfall
No rainfall episode was witnessed during the entire baseline monitoring season.
3.4.6 Cloud Cover

The area remains cloudy between the months of June - September, which is the active period of the
monsoon season. Generally, cloud cover ranges from 6 to 7 OKTAS during monsoon season.
3.4.7 Predominant Wind Direction

Pre dominant wind direction is shown in table 3.1.

Table 3.1 Predominant Wind Direction
Month Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
First Highest
Morning NE NE NE SW SW SW SW SW SW SE NE NE
Evening NW NW NW SW SW SW SW SW SW SW NW NW
Second Highest
Morning N N SE NW W W W W W NE SE E
Evening NE SW SW NW W S W W W, NW NW NE NE
Third Highest
E,
Morning NW NW NW SE S, NW S, SE S CALM NW E N
CALM
Evening N NE W W S W S S S NE, W N, E N
As per Indian Meteorological Department (IMD), Long Term Climatological Tables, 1961-1990 the
predominant wind direction during the study period post monsoon season is observed to be from NE to SW
direction.
3.4.8 Site Specific Micro-Meteorological Data

Site-specific mean meteorological data is given in table 3.2 and the wind rose diagram processed using the
aremod software based on data collected at site is shown in figure 3.3. The wind rose diagram reveals that
the wind was blowing predominantly from the NE direction during the monitoring period.
Table 3.2 Site Specific Meteorological Data (1st Oct 2020 to 31st Dec 2020)
Months
Meteorological Parameter st nd
1 Month 2 Month 3rd Month
o
Temperature ( C)
Min. 20.0 18.0 13.0
Max. 39.0 38.0 36.0
Avg. 30.9 25.7 22.6
Relative Humidity (%)
Min. 25.0 23.0 16.0
Max. 83.0 84.0 80.0
Avg. 56.0 50.4 48.7
Wind Speed (km/h)
Min. 0.0 0.0 0.0
Max. 9.1 9.9 16.9
Avg. 3.1 3.7 4.1
Predominant wind direction Blowing from NE

Figure 3.3 Wind Rose Diagram
3.5 Air Environment

3.5.1 Ambient Air Quality Monitoring
The baseline information encompasses the data regarding ambient air quality with respect to the study area
of 10 km radius around the contract area. The various sources of air pollution in the region are- dust rising
from unpaved roads, domestic fuel burning, vehicular traffic, agricultural activities and operation of other
industries etc. The prime objective of baseline air quality monitoring is to assess the existing air quality of
the area. This will also aid in assessing the conformity to standards of the ambient air quality during the
operations.
The baseline status of the ambient air quality has been assessed through scientifically designed ambient air
quality network. The design of monitoring network in the air quality surveillance program is based on the
following considerations:
 Topography / terrain of the study area

 Regional synoptic scale climatologically normal
 Densely populated areas within the region
 Location of surrounding industries
 Representation of regional background
 Representation of valid cross-sectional distribution in downwind direction
3.5.2 Methodology for Ambient Air Quality Monitoring

The ambient air quality monitoring was carried out for a period of 3 months in accordance with the
guidelines of Central Pollution Control Board, IS 5182 and National Ambient Air Quality Standards
(NAAQS) of CPCB of November 2009 is enclosed as annexure 12. Ambient Air Quality Monitoring
(AAQM) was carried out at eight locations during Post monsoon season from 1st October 2020 to 31st
December 2020 for analyzing parameters such as Particulate Matter (PM10 & PM2.5), Sulphur Dioxide
(SO2), Oxides of Nitrogen (NOx), Carbon Monoxide (CO) Total Hydrocarbon (THC), Lead (Pb), and Non-
Methane Hydro Carbon (NMHC). Sampling locations were selected from the study area of 10 km radial
distance around the project site. The locations of the different stations with respect to its distance and
direction from project site are given in table 3.3 and figure 3.4 respectively.
The values for mentioned concentrations of various pollutants at all the monitoring locations were
processed for different statistical parameters like arithmetic mean, minimum concentration, and maximum
concentration and percentile values. The baseline levels of pollutants are expressed in terms of various
statistical parameters as given in tables 3.4.
Table 3.3 Details of Ambient Air Quality Monitoring Locations

Sr. Bearing W.R.T. Approximate radial Distance Type of
Name of Village
No. Project Site from Project Site (KM) Area
1. Project site (A1) - - Industrial
2. Hazira (A2) S 1.5 Residential
3. Nand Niketan (A3) N 2.0 Residential
4. MRSS Building (A4) W 1.3 Industrial
5. Sunvali (A5) NNW 3.7 Residential
6. Vanta (A6) NEE 8.4 Residential
7. Mora (A7) N 7.0 Residential
8. Dumas (A8) E 6.0 Residential
Figure 3.4 Location of Ambient Air Quality Monitoring Stations

Table 3.4 Ambient Air Quality Status

Parameters
Sr. Sampling
- PM10 PM2.5 SO2 NOx CO THC NMHC Lead
No. Location
(µg/m3) (µg/m3) (µg/m3) (µg/m3) (mg/m3) (ppm) (ppm) (µg/m3)
Min. 72.6 37.1 25.86 31.42 0.52 1.84 1.47
Project site Max. 124.85 63.7 41.52 43.72 0.91 3.91 3.71
1. BDL
(A1) Avg. 95.64 49.48 32.27 38.05 0.70 2.81 2.51
98th Per. 122.85 63.648 39.17 43.35 0.89 3.88 3.68
Min. 81.90 32.9 29.3 35.1 0.61 2.21 2.05 0.00
Max. 127.00 67.9 42.2 48.3 0.91 4.52 4.42 0.50
2. Hazira (A2)
Avg. 99.46 48.48 34.57 42.44 0.76 3.38 3.24 0.23
th
98 Per. 123.36 65.04 41.05 48.14 0.90 4.51 4.40 0.47
Min. 62.80 28.51 22.40 30.22 0.73 3.18 3.20
Nand Niketan Max. 84.23 36.10 31.95 40.10 1.21 5.63 5.24
3. BDL
(A3) Avg. 73.26 32.74 26.69 35.12 1.00 4.00 4.00
98th Per. 83.82 36.05 31.8 39.75 1.20 5.58 5.21
Min. 58.34 22.41 14.10 20.04 BDL BDL BDL
MRSS Max. 69.33 28.46 26.31 27.30 BDL BDL BDL
4. BDL
Building (A4) Avg. 64.97 25.45 17.31 23.69 BDL BDL BDL
98th Per. 68.91 28.14 22.80 27.21 BDL BDL BDL
Min. 43.12 20.21 15.24 20.50 0.10 0.10 0.18
Max. 66.22 30.64 29.77 31.52 0.44 0.73 0.51
5. Sunvali (A5) BDL
Avg. 58.97 27.28 18.92 27.99 0.27 0.43 0.34
98th Per. 65.71 30.23 25.27 31.46 0.42 0.72 0.51
Min. 54.29 22.15 12.44 16.11 BDL BDL BDL
Max. 67.45 27.89 17.86 22.57 BDL BDL BDL
6. Vanta (A6) BDL
Avg. 60.44 25.00 14.77 19.06 BDL BDL BDL
98th Per. 67.28 27.68 17.63 22.27 BDL BDL BDL
Min. 65.31 28.45 20.15 28.12 0.1 BDL BDL
Max. 76.41 32.74 24.71 36.32 0.54 BDL BDL
7. Mora (A7) BDL
Avg. 70.88 30.33 22.30 32.20 0.33 BDL BDL
98th Per. 76.20 32.36 24.62 35.87 0.52 BDL BDL
Min. 57.23 25.63 17.44 27.51 0.22 0.21 0.23
Max. 71.42 31.56 25.25 34.52 0.73 0.91 0.8
8. Dumas (A8) BDL
Avg. 63.91 29.07 21.16 31.17 0.47 0.51 0.54
98th Per. 70.83 31.29 25.13 34.47 0.72 0.89 0.80
NAAQM Standards 100 60 80 80 4 - - 1
Source: Shree Green Environmental Laboratories, Surat.
3.5.3 Result and Discussion

Zn dust was monitored in the CRM complex and results are shown in table 3.5

Table 3.5 Ambient Air Zn Dust Status

Sr. No. Sampling Location Zn Dust (µg/m3)
1. CRM Complex 0.25
The test reports for ambient air Zn dust is enclosed as annexure 13.
The values of all the parameters were found within the stipulated standard of CPCB, except PM10 value
only at two monitoring locations i.e. project site and Hazira village, which are due to industrial activity and
vehicular transportation.
3.6 Water Environment

The Quality of ground water was studied by collecting eight water samples from hand pumps, tube wells in
surrounding villages. Sampling points were decided using Google image and field survey. Standard
procedures were followed for the sampling and analysis of physico–chemical parameters of water.
Sampling location of ground water and surface water is given in table 3.6. Location map of the sampling
station is given in figure 3.5 and 3.6. The results of ground water and surface water is given in table 3.7 and
3.8 respectively.
Table 3.6 Details of Ground and Surface Water Monitoring Locations
Approx. Radial Distance from Bearing

Sr. No. Sampling Locations
Project Site (KM) W. R.T. Project Site
Ground Water Monitoring Locations
1. Hazira (GW1) 1.8 SW
2. Gundardi (GW2) 1.7 NW
3. Sunvali (GW3) 4.6 NNW
4. Suvali Gam (GW4) 7.0 NNW
5. Rajgari (GW5) 8.6 N
6. Mora (GW6) 7.8 NNW
7. Vanta (GW7) 8.7 ENE
8. Dumas (GW8) 5.2 E
Surface Water Monitoring Locations
9. Nr. Project Site (SW1) 0 --
10. Hazira (SW2) 1.13 SSW
11. Sunvali (SW3) 6.3 N
12. Suvali Gam (SW4) 6.6 NNW
13. Rajgari (SW5) 8.3 NNE
14. Nr. GSEG Colony- Tapi River (SW6) 4.8 NNE
15. Mora Tekra (SW7) 7.7 N
16. Dumas (SW8) 5.5 E
GW= Ground water, SW= Surface water

Figure 3.5 Locations of Ground Water Sampling Stations
Figure 3.6 Locations of Surface Water Sampling Stations

Table 3.7 Baselines Ground Water Quality

Locations
Gundardi
Sr.
Rajgari
Sunvali
Dumas
(GW1)
(GW2)
(GW3)
(GW4)
(GW5)
(GW6)
(GW7)
(GW8)
Hazira
Suvali
Vanta
Mora
Parameters Unit
Gam
No.
1. pH at 25 oC pH Unit 7.42 7.28 7.37 7.61 7.19 7.08 7.14 7.11

oC
2. Conductivity at 25 mS/cm 1.911 1.321 1.592 1.817 1.163 0.874 1.004 0.912
3. Temperature °C 24 24 25 25 25 24 26 25
4. Turbidity NTU <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0 <1.0
Total Dissolved Solid at
5. mg/L 1251 864 1039 1174 749 561 661 587
180 oC
6. Total Alkalinity mg/L 430 420 425 450 410 390 400 410
7. Total Hardness mg/L 510 500 510 530 490 450 485 470
8. Calcium mg/L 108 98.2 102.2 116.23 90.18 60.12 86.17 80.16
9. Magnesium mg/L 63.2 62.0 62.0 58.3 64.4 72.9 65.6 65.6
10. Chloride mg/L 302 202 252 280 174 130 162 144
11. Sulphate mg/L 72.7 50.6 57.4 65.9 43.8 29.7 37.9 33.1
12. Nitrate mg/L 8.13 3.81 5.02 6.54 2.17 1.59 2.02 1.84
13. Ammonical Nitrogen mg/L <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
14. Iron mg/L 0.21 0.12 0.13 0.17 0.1 <0.1 <0.1 <0.1
15. COD mg/L 12 <5 <5 8 <5 <5 <5 <5
16. BOD (3 Days at 27°C) mg/L <5 <5 <5 <5 <5 <5 <5 <5
17. Dissolved Oxygen mg/L 5.9 5.8 5.2 5.5 5.1 5.7 5.0 5.3
18. Cyanide mg/L NIL NIL NIL NIL NIL NIL NIL NIL
Pt. Co.
19. Color <5 <5 <5 <5 <5 <5 <5 <5
Scale
20. Flouride mg/L 2.13 0.97 1.23 1.97 0.63 0.57 0.51 0.42
21. Phenolic Compound mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
22. Boron mg/L <0.25 <0.25 <0.25 <0.25 <0.25 <0.25 <0.25 <0.25
23. Copper mg/L <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025
24. Manganese mg/L <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05
25. Zinc mg/L <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
26. Arsenic mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
27. Cadmium mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
28. Total Chromium mg/L <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025
29. Lead mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
30. Mercury mg/L <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005
31. Nickel mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
MPN/100
32. Total Coliform Absent Absent Absent Absent Absent Absent Absent Absent
ml
MPN/100
33. Escherichia coli Absent Absent Absent Absent Absent Absent Absent Absent
ml
Source: Shreegreen Environmental Laboratories, Surat

Table 3.8 Baseline Surface Water Qualities

Locations
Nr. Gseg Colony -

Tapi River (SW6)
Nr. Project Site
Mora Tekra
Suvali Gam
Sr.
Rajgari
Sunvali
Dumas
Hazira
(SW1)
(SW2)
(SW3)
(SW4)
(SW5)
(SW7)
(SW8)
Parameters Unit
No.
1. pH at 25 oC pH Unit 7.12 7.78 7.81 7.67 7.59 7.63 8.62 8.29

2. Conductivity at 25 °C mS/cm 0.639 1.061 1.204 0.712 0.802 0.871 2.004 1.837
3. Temperature °C 24 25 26 26 27 26 27 26
4. Turbidity NTU 4 9 15 5 5 6 31 24
5. Total Dissolved Solid at
mg/L 391 641 728 439 502 527 1214 1109
180 oC
6. Total Alkalinity mg/L 280 300 320 340 290 310 360 345
7. Total Hardness mg/L 60 80 100 65 75 85 160 120
8. Calcium mg/L 10.02 16.03 20.04 12.02 14.03 16.03 28.06 22.04
9. Magnesium mg/L 8.51 9.72 12.15 8.51 9.72 10.94 21.87 15.8
10. Chloride mg/L 74.0 142 140 92.0 108 122 248 222
11. Sulphate mg/L 15.3 25.11 37.19 17.9 18.1 21.3 61.3 48.9
12. Nitrate mg/L 4.37 11.72 13.60 6.71 7.41 8.32 18.60 15.20
13. Ammonical Nitrogen mg/L <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2
14. Iron mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
15. COD mg/L 8.1 24.2 28.2 12.1 16.1 20.2 40.3 36.3
16. BOD (3 Days at 27°C) mg/L <5 10.33 13.54 <5 6.23 8.35 19.88 17.42
17. Dissolved Oxygen (DO) mg/L 5.1 4.8 4.6 4.9 4.1 4.7 4.4 4.5
18. Cyanide mg/L NIL NIL NIL NIL NIL NIL NIL NIL
19. Pt. Co.
Color <5 <5 <5 <5 <5 <5 <5 <5
Scale
20. Flouride mg/L 0.39 0.21 0.19 0.48 0.54 0.62 0.83 0.76
21. Phenolic Compound mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
22. Boron mg/L <0.25 <0.25 <0.25 <0.25 <0.25 <0.25 <0.25 <0.25
23. Copper mg/L <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025
24. Manganese mg/L <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05
25. Zinc mg/L <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5
26. Arsenic mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
27. Cadmium mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
28. Total Chromium mg/L <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025
29. Lead mg/L <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1
30. Mercury mg/L <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005
31. Nickel mg/L <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01
MPN/100
32. Total Coliform <1.8 <1.8 <1.8 <1.8 <1.8 <1.8 <1.8 <1.8
ml
MPN/100
33. Escherichia coli <1.8 <1.8 <1.8 <1.8 <1.8 <1.8 <1.8 <1.8
ml
Source: Shreegreen Environmental laboratories, Surat.

3.6.1 Physico-Chemical Characteristics of Water

3.6.1.1 Ground Water
3.6.1.2 Surface Water

samples.
3.6.1.3 Marine Environment

Tapi River
The Tapi River is the second largest west-flowing river and the sixth largest river in the Indian Peninsula. It
originates from Multai in Betul district in Madhya Pradesh at an elevation of 752 m, having a length of 724
km, and falls into the Arabian Sea slightly beyond Surat city limits. Majority of the higher order tributaries,
such as Panzara, Purna and Girna join the Tapi River from the south. The total drainage area of the Tapi
River is 65,145 km2, out of which 9,804 km2, 51,504 km2 and 3,837 km2 lie in Madhya Pradesh,
Maharashtra and Gujarat respectively. The basin is elongated in shape, with a maximum length (i.e. 687
km) extending from east to west and maximum width (210 km) extending from north to south. The average
channel gradient of the Tapi River is 0.001. Surat city is located in the delta region of the Tapi River and
has a history of frequent flooding. The Tapi Basin is divided into three sub basins, namely the upper Tapi
Basin (up to Hathnur), the middle Tapi Basin (from Hathnur to Gighade) and the lower Tapi Basin (from
Gighade to the sea). This last 190 km portion of river Tapi lies in Gujarat. After passing through Satpura
hills on right banks and Satmala on left bank in Khandesh area of Maharashtra, it enters the Surat district of
Gujarat.
Estuarine Environment
Going by the definition of Fair Bridge (1980), An estuary is defined as “An inlet of the sea reaching into a
river valley as far the upper limit of tidal rise, normally diverging into three sectors namely, (a) a marine or
lower estuary in free connection with the open sea, (b) a middle estuary, subject to strong salt and fresh
water mixing and (c) an upper or fluvial estuary, characterized by fresh water but subjected to daily tidal
action. An Estuary is also characterized by two opposing current systems, the unidirectional stream current
and oscillating tidal current, which meet and exert considerable and complicated effects upon
sedimentation, water mixing and other physical and biological features of estuary.”
An estuary is normally associated with a pronounced tidal regime, with the tide moving up and down twice
daily. The tidal movement prevents the settlement of mud in the center of the estuary but permits the
marginal depositions. This leads to the formation of extensive mud flats on either side. The pressure of the
tides does however influence the development of tidal currents up and down the Tapi estuary over a
considerable distance up to Weir cum cause way.
To evaluate the marine ecosystem in the Tapi Estuary within the close proximity to the of M/s
ArcelorMittal Nippon Steel India Ltd, sampling had been conducted at 10 sampling Locations.
The treated effluent generated by AM/NS India Ltd is discharged into Tapi estuary. Monitoring results of
the study conducted in March, 2020 and Oct 2020 revealed anthropogenic pressure in Estuary.
During the selection of sampling locations maximum care was taken to get the representative sampling of
plankton communities and benthic communities of Tapi estuary as well as the baseline Physico Chemical

data to interpret the impact due to the activities of project premises and cumulative impact of other activity
in Tapi estuary.
The chlorophyll-a in the sampling stations showed a variation from 0.834-3.90 mg/M3 during High tide
period.
The phytoplankton community of the sub surface water near the project site can be classified mainly four
groups, Blue green algae, Diatoms, Green algae and Dinoflagellates. The blue green algae were represented
by one genus Pediastrum sp., while Diatoms were represented by 14 genera belonging to 3 classes, 9
orders, and 12 families. Dinoflagellates were represented by 2 genera, comprising 1 class, 2 orders and 2
families. Phytoplankton population of the sampling stations at the sub surface layer was varying from 171-
300 units/ L (171-300X103 units/m3) during high tide period. The phytoplankton populations was found to
be varying in the range of 110-148 units/ L (110-148X103 units/m3) during high tide period along 10
selected sampling stations at the sub surface layer in Tapi estuary.
Zooplankton community was represented by six groups of planktons; Tintinids, Rotifers, Nematodes,
Copepods, Decapods and larval forms. Among these, holoplankton of this region; Copoepods were the most
dominant and diverse group among zooplanktons followed by Rotifers. During this sampling run the
Nauplius Larvae was also observed as a major group in the plankton population at all the sampling
locations. Trachophore larvae of Polychaete and Cyphonautes larvae of Bryozoa were observed in its
various growing stages. The zooplankton density was varying from 78-107 No/L during High tide and 107-
130 No/L. The zooplankton density was observed to be varying from 110-148 No/L the during high tide
and 110-148 No/L during low tide.
Margalef’s diversity index (Species Richness)S of phytoplankton communities was varying from. 3.07-
3.501, Shannon-Wiener’s Index (H) of phytoplankton communities was in the range of 0.9684 - 1.196
(H'(log10)) between 10 selected sampling stations and Simpson diversity index (1D) of phytoplankton
communities was below 0.9 at all sampling stations except few varying from 0.812 – 1.256.
Margalef’s diversity index (Species Richness) S of zooplankton population was varying from. 3.204- 3.984,
Shannon-Wiener’s Index (H) of zooplankton was in the range of 1.084 - 1.256 (H'(log10)) and Simpson
diversity index (1-D) of Zooplankton population was above 0.9 at all sampling stations and varying from
0.9081- 0.9456 between 10 selected sampling stations.
The texture of the sediment from the sampling station was found to be sandy. Hence, the numerical
abundance of the benthic fauna was very low. The faunal population mainly consisted of few Polychaete
worms. Benthic fauna in sub tidal region was varying from 0-69 /m2.
Low species plankton diversity suggests a relatively few successful species in this habitat. The environment
is quite stressful with relatively few ecological niches and only a few organisms are really well adapted to
this environment. Any change in the environment would probably have quite serious effects. Tapi estuary is
has relatively few ecological niches and only very few opportunist organisms are well adapted to this
environment and thrive better than other species.
The Tapi estuary is normally associated with a pronounced tidal regime, with tide moving up and down
twice daily. This creates an environment with varying salinity condition thereby creating a stressful
environment for the aquatic organisms. The tidal movement prevents the settlement of the mud in the
center of the estuary but permits the marginal depositions. This leads to the formation of extensive mud
flats on both sides. The pressure of the tides does however influence the development of tidal currents up
and down the Tapi estuary over a considerable distance up to Weir cum cause way. This tidal section
receives number of untreated sewage outlets on its both sides. These organic pollutants will robe the life-
giving oxygen from the aquatic system during its microbial decomposition.
The detailed Marine report is enclosed as Annexure 14.

3.7 Geomorphological, Geological, Hydro-Geological Status

This brief report deals with the field observations carried out for geological study, hydrogeological
inventory and to ascertain nature & behavior of subsurface formation such as topsoil nature, subsurface
strata/persistence of unconsolidated formations below ground level for study purpose for Modification in
Existing Plant by Installing Auxiliary Facilities without Increasing Plant Capacity at ArcelorMittal Nippon
Steel India Ltd., Hazira Industrial area, Hazira, district-Surat (Guj.). Geomorphological, geological and
hydrogeological inventory of the area was carried out and all possible technical details were collected from
the studied area as well as surrounding area.
Location:
The studied area lies about 27 km west of Surat city station, AMNS steel plant located at north of village
Hazira and NH-6 connected to Surat. Geographical position of the area is latitude N210645.2 &
longitude E723906.7 taken from nearby environment laboratory of AMNS Steel, Hazira. The area is near
Magdalla local port. This area comes under restricted coastal zone as per Survey of India, this area falls in
46C/12 (F43M12), and lies on sheet no. 24 of Geological & Mineral Atlas of India by Geological Survey of
India.
3.7.1 Geomorphology & Drainage

Based on the general elevation, slope and landscape configuration in the terrain, the studied area falls in the
mud flat region and some part of it towards Gulf of Khambhat consist of coastal sand dune of western
coastal region. The area is surrounded by water from three sides. The topography is almost flat to semi flat.
In survey of India no elevation has been marked in study area due to sea shore. As per geomorphological
study, low lying area is towards north, north west, south west, south and southern eastern, it means surface
water flow is towards these directions and ultimately merges in Gulf of Khambhat and surface flow of
southern eastern, eastern and northern eastern is towards Tapi river which also ultimately confluences in
Gulf of Khambhat. There are no elevations been shown in Survey of India Sheet no. 46C/12 (F43M12) at
AMNS plant study area. As per Garmin GPS, maximum height of the area is 19m at coordinate
N210534.8 & E723838.4, contours elevations range 19m-4m from MSL measured and minimum
height were observed at N211032.0 & E724303.5. All measurements were taken by Garmin GPS vista
cx. Tapi river trends northeast to south west in eastern periphery of studied area and confluences into Gulf
of Khambhat. High water line & low water line marked as per Survey of India sheet plan enclosed in Plate.
Fairly dense jungle as Reserved Forest is in south west of AMNS Steel plant area or west of Hazira village.
Regional study indicates dendritic drainage pattern of the area. The thick brownish black medium to fine
grain silty saline clay with sand and gravels layer spreads almost throughout area. In low lying area
thickness becomes more which does not exceed over 1.50 m from ground level varying from place to place
and below this there is unconsolidated formation persisting upto 30m or more; than basalt rock formation
persisting at deeper depth. Drainage map of the study area is shown in figure 3.7
The Tapi is the major river which passes through the central parts of the district and flows towards the west.
The river is perennial in nature. It originates in Madhya Pradesh near Betul and has about 62225 sq. Km. of
catchment area. The average width of the river upstream of Kathor bridge in about 500m. Downstream of
the bridge the average being about 700m. Pickup weir was constructed on the Tapi River in 1954 at
Kakarapar about 56km west of Surat. Ukai dam, constructed in 1965, is situated about 25km upstream of
Kakarapar weir. The area is surrounded from three sides by water. The topography of the study area is
almost flat to semi flat. The MRL of the project site is around 8-10 m and RL of nearby river is 0-1 m from
MSL. A map of Digital Elevation Model (DEM) of 10 KM radius from the project site is given in figure
3.8.

Figure 3.7 Drainage Plan of 5Km Radius of Study Area
Figure 3.8 Digital Elevation Model of 10 km Radius

As per geomorphologic study, low lying area is towards North West, West, South West, South and
Southern Eastern Area. It means surface water flow is generally towards north west, west, southwest and
south i.e. towards Arabian sea and surface flow of southern eastern, eastern and northern eastern is towards
Tapi river which it ultimately confluence to Arabian sea. So, the regional water flow direction is towards
sea area, maximum height of the area is 19m from MSL measured at coordinate N21 0 05’ 34.8” and E720
38’ 38.4” and minimum height were observed at N210 10’ 32.0” and E720 43’ 03.5”. Tapi River trends
northeast to southwest in eastern periphery of studied area and confluences into Arabian Sea. Drainage map
of the study area is shown in figure-3.9.
Figure 3.9 Drainage map of the Study Area
(Source: Survey of India Toposheet and Google Image)

3.7.2 Soil
The area belongs to soil of older & younger tidal flats deposit of western coast of marine environment,
which is fine, clayey, montmorillonite soil with loamy soils, hence is inferior in quality which is almost
saline (khar) soil. The quality of soil is more deteriorated towards coastal plains. Thickness of topsoil is
adequate in the area. Topsoil persists up to a depth of 0.75m to 1.50m below ground level with and without
silt. Mud cracks were reported at Suvali village N210946.8 & E723840.8. Suvali village area has
good quality of soil rather than nearby AMNS Steel area, hence agriculture is the major occupation of the
people in the village area. Marginal quality of soil was also reported along the coordinates N210851.3 &
E723822.3. The deposition of saline sea sand and undulations reported due to low/high tide in the area.
In coastal region, the soil varies from being deep to very deep in thickness dark and grey to black in color.
The texture is clay loam to silty loam. The area is affected by tide as well as leaching of salts from land at
higher elevation forming saline alkali soils. The content of clay in this soil is high and permeability is low
(mud flats).
Most of the down area and nalla area is covered with mixed good brownish muddy and yellow brown
topsoil. Density of plantation in the surrounding area is low due to saline soil and tidal effects/shallow
saline water. Soil map of the Surat district is given in figure 3.10
Figure 3.10 Soil Map of The Surat District Area
3.7.3 Geology
Geological formation of the area belongs to Holocene age. According to study, geological formations of
older tidal flat and younger tidal flat deposits of marine environment were observed in and around studied
area. The area is Marshy. Deeper lithology of the studied area mainly contains basalt of upper Cretaceous to
Eocene age. No rocky outcrops/ rock formations have been reported at shallow to moderate depth. Good
mud deposits were observed towards sea bank area. Dunes of blown sand abundant in coastal areas fluvio-
marine deposits abundant in tidal flats and estuaries.
The formations exposed in and around the study area as GSI 1988-
As per mentioned unit 11 in GSI plate-
Lithology – older tidal flat deposit
Formation- Rann clay formation
Age- Holocene
Environment- Marine

Lithology – unconsolidated formation (clay/silt/kankar/sand/gravel/ boulders)

As per mentioned unit 14 b in GSI plate-
Lithology – Tidal flat deposit
Formation- Mahuva formation
Age- Holocene
Environment- Marine
As per mentioned unit 13 in GSI plate-
Lithology – Coastal dune deposits
Age- Holocene
Environment- Marine
As per mentioned unit 14 c in GSI plate-
Lithology – Shoal deposit
Age- Holocene
Environment- Marine
The eastern area towards Surat occupied by the rock types belongs to the Deccan volcanic of upper
Cretaceous to Eocene age and sediments of tertiary and quaternary period. The Deccan volcanic comprises
of basalt flows. Basalt is locally capped by laterite belonging to Salod formation (palaeocene) towards
Surat. Geological map of Surat District is given in figure 3.11
Geotechnical Studies:
As per GSI 1995 geotechnical map data indicates the area information as follows-
IIb2a :-
Morpholgic /morphotectonic units :- Coastal plain
Engineering Provinces :- Coastal sediments
Formation :- Unconsolidated sand with/without clay, silt
Permeability :- Cumulative high
Bearing Capacity :- Low
Compressive strength :- (1-2 kg/cm2)
Foundation Characteristics :- Poor
Fault plain has been reported by GSI nearby area which trends NE-SW.
Seismic Zone:
The area falls in the moderate risk zone of seismic zonetion to limit of III seismicity zone (ISI). Earthquake
epicenter in south west of Surat has been reported by GSI towards coastal bank. The studied area belongs to
Alluvial –fill along intracratonic linear depressions. The Bouger Gravity Anomaly varies between 0 to +10
m Gal.
Figure 3.11 Geological Map of Surat District

3.7.4 Hydrogeology
The study area almost covered by Alluvium. This aquifer can broadly be demarcated into two zones namely
newer alluvium and older alluvium. The newer alluvium is present along the river courses and comprises
fine to coarse grained sand trap wash with cay intercalations. The sand is unconsolidated but shows some
degree of cohesion at places. Water levels are in general deeper in newer alluvium. Older alluvium is
present in inter river plains and comprises sand, clay, kankar, gravel and silt. The ground water occurs
mostly under unconfined conditions but at places semi-confined conditions are also observed, probably due
to presence of clay lenses.
The depths of the wells in alluvium generally range from 3.0 to 30.0m with some of the wells having bores
down to 50m below bottom of the wells. The maximum number of wells, about 80% is 5 to 20m deep.
Depths to water levels in the wells range from 0.5 to 15m bgl about 90% wells shows water levels less than
10m bgl. Yields of the dug wells and dug-cum- bored wells range between 100 and 450 m3/day.
In village Gunladi & old Gunladi, village Kacchi basti and other area no open well/ no bore well/no
hanpump exist so total water supply is by AMNS Steel Ltd. Quality of groundwater is not good. So water
supply in nearby villages Gunladi, Hazira etc. is by AMNS Steel Ltd. Handpump and open well water is
mainly used for domestic household purpose. In Gunladi village three to four wells have been reported;
these are almost non yielding. In year 2014 due to tidal effects saline water accumulated in open wells and
groundwater quality of wells gets more deteriorated. Other wise 10 years back groundwater quality was
good in this area. So, some habitation migrated to Surat city.
Calyex/ Manually drilled bore wells of the area indicates drilled depth of 15m -20m; no consolidated
formation/rock has been reported in the area. So, casing pipe has been lowered upto deeper depth. Deeper
quality of groundwater is more deteriorated in this area so no deeper borewells have been drilled in the area.
Generalized transmissivity values of district as per CGWB ranges in between 104-2965 m2/day with saline
& marginal quality of groundwater in and surrounding study area.
Suvali & juna Suvali village has good quality as compared to other nearby area so villagers are using
groundwater for agriculture use. Deepest well of the area is having depth around 9m but deeper quality of
borewells water is not of good quality so, in this area open wells are yielding and agriculture is done by
open wells only. In Suvali village numbers of individual bore wells are yielding in houses and used for
domestic purpose.
Groundwater quality towards Mora village is also not so good and is of marginal quality. Open well at
Raigir bus stand is saline so even shallow open wells are abandoned and wells are non-yielding. Bore wells
of depth 15m to 30m depth are low yielding with marginal quality being used up for agriculture purpose. In
Raigir area groundwater quality is also not good so almost all surrounding open wells of the area are
abandoned and old govt. water supply system fulfills the marginal drinking water quality. Open wells water
is for domestic purpose. Mora Tekra village area has slightly deeper water level of 4.70m depth open well
which has been recorded dry in the area at coordinates N211041.5 & E723927.8. In Mora village
Reliance water supply fulfills drinking water problems of villagers. High TDS water quality has been
recorded from the area. Towards sea shore quality of groundwater becomes more saline while towards other
side quality of groundwater is slightly better. Jateshwar Tirth Dham Bawadi area near bus stand Mora Tekra
village has saline water quality; water supply is by Reliance. Nava Kawas village area no bore wells/open
wells are yielding water due to water quality and water supply is by Kribco Gujarat state company.
Groundwater quality in the studied area is highly saline (brackish to saline) and not good for cultivation
purpose, saline to marginal far from coastal banks. The ground water in the area having total dissolved salts
varies from 1200ppm to thousands so this quality of water is not suitable for domestic, drinking as well as
industrial purpose. So water supply in industrial area as well as in domestic area is by government from
Tapti River basin and all individual villages has its own underground and overhead storage tanks for
villagers water supply through pipe line. Almost all villages of studied area where quality is not drinkable
are facilitated by individual village base RO system. Some of the villages use packed RO water daily for

drinking use. In some villages water supply is fulfilled by tankers. Villagers are using own private
tubewell/open well water for domestic uses. Deeper ground water quality is more saline than upper
horizons. The depth of groundwater level is ranging between 0.80m to 9m, which depends on topography as
well coastal bank distance. However, in tube wells it varies from 18m to 25m. The average rise in water
level between pre monsoon and post monsoon period is about 2m to 6m. The litho unit comprises of older
and younger tidal flat deposits. The general direction of groundwater flow towards is in north east to south
east or towards Tapti then confluence to Arabian Sea. All nallas confluence into Tapti River & lastly
merges in Gulf of Khambhat. Number of open wells and bore wells are abandoned due to quality problem
and almost all farmers nearby proposed area depends on rains. So, the area is not suitable except Suvali
village/ localized fresh water pockets.
As the slope is low, runoff becomes less and as a result the seep rate increases as per flat topographical
condition of the area, water seeps poorly through top brown black soil (also through good mud cracks
reported at E723840.8 & N210946.8) with few silts below that kankar concentration /yellow sticky
non permeable clay/silt with gravel/ sand over 20m depth below ground level and lowering of casing (blind
& slotted) upto drilled depth. Quality of ground water deteriorates with deeper depth so maximum depth of
bore well in the area is generally 30m.
However, there is a chance that excessive withdrawal water from tube wells may result from salinity ingress
which may deteriorate the ground water quality particularly in area adjoining the sea coast. It is therefore,
recommended that rate discharge from these areas may be maintained in such a way that
relationship/cushion between fresh and saline water may not be disturbed.
Hydrogeological setup indicates that alluvium forms a good potential aquifer in northern part of studied
area. Generally, wells depth ranges from 4m to 16m and shallow bore wells ranging from 15m to 30m in
the area. The utilization of groundwater resources is limited due to quality issue. Numbers of bore wells in
surrounding villages of AMNS Steel are abandoned due to highly saline quality. Depth to water level map
of pre monsoon & post monsoon of Surat district as per CGWB -
3.8 Noise Environment

The noise analysis within the study area was carried out using sound level meter. The monitoring locations
are given in table 3.9 and location map is given in figure 3.12
Table 3.9 Noise Monitoring Stations

Sr. Approximate Radial Bearing W.R.T. Project
Name of Village
No. Distance from Project Site Site
1. Project site (N1) 0 --
2. Hazira (N2) 1.8 SW
3. Nand Niketan Village (N3) 2.4 N
4. MRSS Building (N4) 1.7 NW
5. Sunvali (N5) 4.6 NNW
6. Vanta (N6) 8.7 ENE
7. Mora (N7) 8.6 N
8. Dumas (N8) 5.2 E

Figure 3.12 Baseline Noise Qualities Monitoring Stations
Table 3.10 Background Noise Levels

Noise Level (Leq) in dBA Noise Level (Leq) in dBA
Sr. Category of
Location (Day time) (06:00 to (Night time) (21:00 to
No. Area
21:00 hrs.) 06:00 hrs.)
1. Project site (N1) Industrial 41.0 - 65.0 45.0 - 51.0
2. Hazira (N2) Residential 51.0 - 65.0 42.0 - 46.0
3. Nand Niketan Village (N3) Residential 45.0 - 59.0 40.0 - 44.0
4. MRSS Building (N4) Industrial 53.0 – 62.0 42.0 – 47.0
5. Sunvali (N5) Residential 42.0 - 59.0 39.0 - 41.0
6. Vanta (N6) Residential 44.0 – 56.0 42.0 – 54.0
7. Mora (N7) Residential 41.0 - 59.0 38.0 - 46.0
8. Dumas (N8) Residential 45.0 – 63.0 37.0 – 42.0
Source: Shreegreen Environmental Laboratories, Surat.
3.8.1 Conclusion
Ambient noise levels monitoring was done at day as well as night time. The results are given in table 3.10.
At Industrial area maximum noise levels recorded during the day time 65.0 Leq dB(A) and during night
time 51.0 Leq dB(A).
area are well within the prescribed limits as prescribed by the CPCB.

3.8.2 Noise Levels due to Transportation

Noise levels were also measured at two different locations. The observed noise level is stipulated in table-
3.11.
Table 3.11 Noise Levels Due to Transportation

Sr. Noise Level (Leq) in dBA (Day Noise Level (Leq) in dBA (Night
Location
No. time) (0600 to 2100 hrs.) time) (2100 to 0600 hrs.)
1. Nand Niketan (NT1) 68.0 – 72.0 58.0 – 63.0
2. Mora Village (NT2) 49.0 – 63.0 44.0 – 52.0
3.8.2.1 Conclusion
The communities close to the project site are not exposed to major noise sources. The commercial activities
and transport apart from natural sources contribute to community noise levels. The noise levels close to
project site were low and within the stipulated standards of CPCB for the respective designated areas.
3.9 Traffic Study

NH-6 is 0.5 km in E direction from project site, hence traffic density study was conducted at NH-6
Connecting Surat to Hazira. Location of survey is given in figure 3.13.
Figure-3.13 Map of Traffic Survey

3.9.1 Methodology
Vehicular Count
The vehicles moving in both the directions were counted continuously for 24 hours at one location. The
vehicles were counted every hour and recorded under respective category. The maximum traffic count in an
hour is termed as peak hour traffic.
Categorization of Traffic
The vehicles were categorized under various heads like heavy motor vehicles such as buses, trucks and
tankers (10 wheelers), light motor vehicles (cars, jeeps), three wheelers (auto rickshaws, 3-wheel tempo,
Bicycles etc.) two wheelers (scooters, motor cycles etc.).
3.9.2 Results and Discussions

The summary of daily traffic density in terms of PCU for the locations were monitored during the study
period is summarized below and % of composition of the vehicles is given below. It was observed that the
cars/jeeps and trucks/buses form the major volume of the traffic. The overall total traffic PCU of this road is
minimal. The present level of traffic in terms of Passenger Car Units (PCU) at these locations as per the
conversion factors stipulated by Indian Road Congress (IRC) is presented below.
The present level of traffic has been converted to Passenger Car Units (PCU) at this location as per the
conversion factors stipulated by Indian Road Congress (IRC). The Passenger Car Unit (PCU) recorded at
the selected traffic location, which is towards Surat Hazira road is about 12228.0 PCU.
Table 3.12 PCU Levels (Vehicle wise PCU Value)

Sr. No. Types of Vehicles PCU
1 Cycle 0.5
2 Motor Cycle or Scooter 0.5
3 Passenger Car/Jeep/Van, goods auto rickshaw or passenger Auto-rickshaw 1.0
4 Agricultural Tractor, Light Commercial Vehicle, Mini Bus 1.5
5 Two and Three Axle Truck, Bus 3.0
6 Multi Axle Trucks, Tractor with Trolley 4.5
7 Others (Bullock Cart) 6.0
Table 3.13 PCU Levels (Nos. of vehicle)

Numbers of Numbers of
Type of vehicle PCU PCU
Vehicle Vehicle
Cycle 120 60 180 90
Motor Cycle or Scooter 756 378 1342 671
Goods auto rickshaw or passenger Auto-
80 80 134 134
rickshaw
Passenger Car/Jeep/Van, 236 354 843 1264.5
Agricultural Tractor, Light Commercial
25 75 54 162
Vehicle, Mini Bus
Two and Three Axle Truck, Bus 225 675 1420 4260
Multi Axle Trucks, Tractor with Trolley 13 58.5 46 207
Others (Bullock Cart) 0 0
Total 1471 1680.5 4264 6788.5
Table 3.14 Present Traffic Scenario

Type of vehicle Existing Traffic Scenario and Level of Services
Road Type Surat to Hazira to Surat (2+2 lane)
Capacity as per IRC (PCU’s /day) 12500
Existing total volume in a day (Nos.) 8469
Existing volume / capacity ratio 0.68
Level of Service D ‘Fair’

Table 3.15 Level of Service

Sr. No Existing volume / capacity ratio Level of Service
1 0.0 to 0.2 A Excellent
2 0.2 to 0.4 “B” (Very good)
3 0.4 to 0.6 “C” (Good)
4 0.6 to 0.8 “D” (Fair)
5 0.8 to 1.0 “E” (Poor)
3.10 Soil Environment

3.10.1 Methodology for Soil Monitoring
Soil type and its fertility of an area are essential to plan for cropping. Soils are primarily derived from
parent rocks. The color, texture and mineral content are normally used to classify the soils. The information
on soils has been collected from various secondary sources and also through primary soil sampling analysis
of which is described in this section.
For studying the soil profile of the region, 8 locations were selected to assess the existing soil conditions
around the contract area representing various land use conditions. The concentrations of physical and
chemical parameters were determined.
The sampling locations have been finalized with the following objectives:
• To determine the baseline soil characteristics of the study area; and
• To determine the impact of industrialization on soil characteristics.
Soil monitoring station details are given in table 3.16 and location map is given in figure 3.14. Soil
monitoring results are given table 3.17
Table 3.16 Details of Soil Quality Sampling Locations

Sr. Approximate Radial Distance Bearing
Sampling Location
No. from Project Site (KM) W.R.T. Project Site
1. Project site (S1) 0 --
2. Hazira (S2) 1.8 SW
3. Nand Niketan Village (S3) 2.4 N
4. Mora (S4) 1.7 NW
5. Sunvali (S5) 4.6 NNW
6. Vanta (S6) 8.7 ENE
7. Rajgari (S7) 8.3 NNE
8. Dumas (S8) 5.2 E
Table 3.17 Physico-Chemicals Characteristics of Soil

Nand
Sr. Project Hazira Mora Sunvali Vanta Rajgari Dumas
Parameters Unit Niketan
No. Site (S1) (S2) (S4) (S5) (S6) (S7) (S8)
(S3)
1 pH at 25°C pH Unit 8.37 8.11 8.56 7.51 6.84 7.04 6.91 7.87
2 Conductivity mS/cm 2.871 2.305 3.011 1.911 1.532 1.801 1.784 1.932
3 Bulk Density g/cc 1.59 1.86 1.74 1.32 1.12 1.24 1.08 1.46
4 Porosity % 51 53 39 58 63 59 64 52
5 Organic Carbon % 1.96 2.05 1.82 3.54 3.09 2.16 2.81 2.48
6 Calcium mg/kg 101 138 127 144 163 201 153 187
7 Magnesium mg/kg 25.4 38.7 31.1 50.1 52.2 72.4 48.9 61.9
8 Cation Exchange Capacity mEq/100g 30.6 34.1 31.9 32.1 35.2 46.1 34.8 38.9
9 Sodium Absorption Ratio % 1.27 1.13 1.08 2.42 2.61 3.04 2.53 2.74

Nand
Sr. Project Hazira Mora Sunvali Vanta Rajgari Dumas
Parameters Unit Niketan
No. Site (S1) (S2) (S4) (S5) (S6) (S7) (S8)
(S3)
10 Available Nitrogen % 2.41 2.66 2.21 4.08 3.81 3.53 2.91 3.44
11 Available Phosphorus mg/kg 40.2 32.5 38.9 66.8 53.9 101 83.4 97.6
12 Moisture % 5.89 10.4 13.8 6.02 9.52 13.4 3.87 5.01
13 Water holding capacity % 55 52 61 41 33 38 31 47
14 Permeability cm/Hr 3.4 3.9 2.9 4.3 4.8 4.5 5.1 3.7
15 Particle Size
Sand % 50 14 21 25 71 15 69 22
Clay % 23 53 42 42 11 53 8.2 38
Silt % 27 33 37 33 18 32 22.8 40
Sandy
Sandy Sandy Clay
16 Soil Texture Class - Clay Clay Clay Clay Clay
Loam Loam Loam
Loam
17 Sodium mg/Kg 27.4 21.9 31.2 20.6 14.9 19.7 17.1 19.9
18 Potassium mg/Kg 40.5 38.1 43.6 33.8 22.3 29.6 27.1 35.2
Figure 3.14 Locations of Soil Sampling Stations
3.10.2 Conclusion

3.11 Land Environment

3.11.1 Method of Data Preparation
Information of land use and land cover is important for many planning and management act the land use
and the land cover determines the infiltration capacity. Barren surfaces are poor retainers of water as
compared to grasslands and forests, which not only hold water for longer periods on the surface, but at the
same time allow it to percolate down.
Field Verification
Field verification involved collection, verification and record of the different surface features that create
specific spectral signatures / image expressions on FCC. In the study area, doubtful areas identified in
course of interpretation of imagery is systematically listed and transferred on to the corresponding SOI
topographical maps for ground verification. In addition to these, traverse routes were planned with
reference to SOI topographical maps to verify interpreted LU/LC classes in such a manner that all the
different classes are covered by at least 5 sampling areas, evenly distributed in the area.
Ground truth details involving LU/LC classes and other ancillary information about crop growth stage,
exposed soils, landform, nature and type of land degradation are recorded and the different land use classes
are taken. Satellite image and landuse map of study area is given in figure 3.15 and 3.16 respectively.
3.11.2 Description of the Land Use / Land Cover Classes

It is defined as an area of human settlements composed of houses, commercial complex, transport,
communication lines, utilities, services, places of worships, recreational areas, industries etc. Depending
upon the nature and type of utilities and size of habitations, residential areas are classified as villages, towns
and cities. The use of land in 10 km radius from the proposed modification project site is given in table
3.18.
Table 3.18 Areas Statistics of Land Use/Land Cover Map

Sr. No. Land use Class Area in Ha Area in %
1 Agriculture 1681.00 5.3
2 Airport 284.04 0.9
3 Arabian Sea 15090.38 48.0
4 Mangrove Forest 784.88 2.5
5 Industrial Area 2814.92 8.9
6 Aqua Farms 1047.41 3.3
7 Mangrove Nursery 929.20 3.0
8 Mud 2204.92 7.0
9 Port 348.54 1.1
10 Settlements 915.48 2.9
11 Scrubland 2905.95 9.2
12 Waterbody 2399.35 7.6
13 Water Park 59.08 0.2
TOTAL 31465.13 100

Figure 3.15 Satellite Imagery of the Study Area
Figure 3.16 Landuse and Landcover Map

3.12 Socio - Economic Environment

The current situation of the PIA is represented by the findings of the socioeconomic study for assessing the
impact of the proposed modification project on local residents presents the current situation of the PIA,
perception and priorities of the local population regarding industrialization around them.
Scope of Work
• Use of secondary data from census, statistical handbooks, topo sheets, health records and relevant
official records available with the Government agencies
• Develop, field test and modify tools for the study using proportionate, sampling method
• Assessment of social impacts of this development project
• Identify direct and indirect impacts due to the proposed project
• To identify and quantify qualitative impact, mitigation and management plan
• Suggest Corporate Environment Responsibility (CER) activities to the company as per
requirements or based on field inference
• Preparing write up for the EIA report
Applicable Regulations
The following regulations/policies and their amendments thereof have been consulted during preparation of
the Report.
• Right to Fair Compensation and Transparency in Land Acquisition, Rehabilitation and
Resettlement Act, 2013 and its subsequent amendments
• Right to Fair Compensation and Transparency in Land Acquisition, Rehabilitation and
Resettlement (Gujarat Amendment) Act, 2016 and its subsequent amendments.
• Corporate Environment Responsibility Policy, 2018
3.12.1 Introduction
Development projects are usually people friendly and the human environment is given prime importance in
the process of project preparation and operation. The components of human environment are
socioeconomic traits, livelihood pattern, possession and assets, available basic services, infrastructure,
quality of life, culture, value systems, social relationships, etc. In-depth investigation of these variables in
the Project Influence Area (PIA) helps in gauging the prevalent situation and assessing prospective impact
of the proposed expansion/Project. This in turn, enables the industry to plan suitable mitigation measures
and extend social support to the residents of the PIA, this facilitates in making the project sustainable.
3.12.2 Rational for The Study

M/s Arcelor Mittal Nippon Steel (AMNS) India has proposed modernization of their steel plant at Hajira.
Under the proposed modification, a Social Impact Assessment (SIA) of AMNS has been carried out in the
PIA, as a part of the Environmental Impact Assessment (EIA).
3.12.3 Brief Demographic Profile of District

In 2011, Surat District had a population of 6,081,322 with a sex ratio of 787 which is much below the
average national sex ratio, the reason behind this is the immigration of male workers in industries. There
was change of 42.24 percent in the population compared to population as per 2001.Population density in the
district in 2011 was 1,337 people per sq. km. Average literacy rate in the district in 2011 was 85.53; male
and female literacy rate was 89.56 and 80.37 respectively. Surat is one of the fastest developing cities of
Asia.
Development in Hazira has been phenomenal. Currently it is home to several major corporate houses,
including Essar Steel India Limited, Reliance, L&T, NTPC, KRIBHCO, ONGC, GAIL, IOC, HPCL,
BPCL, IBP Oil and Gas Major; Shell has recently started its LNG terminal here;
Several other multinational companies have evinced interest and are likely to set up industries in Hazira in
the next two to three years. Investment’s worth of billions of rupees has been made in the area in various
industries and the amount is likely to escalate with many more corporate sectors eyeing the region, it is
expected that Hazira will soon become the hub of industrial activities in the State.
3.12.4 Objective of Social Impact Assessment

Usually, such projects advantage the local people in several ways, such as- i) local accessibility to the
produces, ii) career prospect in the project, iii) opportunity for improving quality of life through income
generation and infrastructure development. However, the project may also affect the local inhabitants
negatively by land acquisition, displacement, resettlement and rehabilitation (R&R) and certain other social
implications relating to public health, gender issues, child labor, enhancing social evils, etc. Therefore, an
attempt to mitigate those negative impacts needs to be undertaken by the Project authority. This social
study, has therefore been conducted with the aim to understand the existing situation and the probable
socioeconomic impact of the proposed project in a comprehensive manner.
The information collected for SIA will also serve as baseline data and will be useful for future monitoring
and evaluations of human environment and social development. Explicit consideration of social aspects of
development has therefore, been undertaken be addressing issues such as poverty reduction, and enhancing
the role of women in development as major priorities. A larger importance has also been given to people’s
perception and priorities.
3.12.5 Approach and Methodology

Firstly, a detailed desk review of available reports and documents like the Primary Census Abstract, 2011
and socioeconomic context of the project was undertaken to grasp the existing situation. The, District map,
and other relevant websites were also consulted.
Secondly, based on the secondary data, locations within the radial coverage of 10 kilometers (aerial) from
the proposed expansion Project area were identified. Two zones were demarcated- a) Core Zone- enlisted
villages- Hajira and Mora- close to the Project.
b) Buffer Zone- enlisted villages beyond the Core Zone and up to 10 km from the site.
There are only 15 locations in the PIA as this is already an industrial area and a considerable portion of the
10 km is in the sea.
3.12.6 Tools and Techniques

The tools used for this study were- Checklist, Questionnaire and Discussion Guide for Public Consultation
is enclosed as annexure 15.
3.12.7 Stakeholders’ Identification

For efficient planning a thorough identification of stakeholders, appropriate consultation and participation
of affected people in decision making process are of prime importance. This helps the stakeholders in
understanding the project objectives and needs; and in communicating their expectations, apprehensions,
willingness, affordability, views and preferences. It ensures an increased participation of people facilitating
better acceptance of the project. Stakeholders' consultation was done during social impact assessment at the
project locations and nearby villages within 10 km radius of the proposed project, the result of the same has
been presented later in the Peoples’ Perception section. Mitigation measures have been planned based on
findings of this social impact assessment report.
3.12.8 Findings of Social Impacts and Community Consultations

The findings of desk review, socioeconomic survey and various consultations at community level are
presented below:
Population: The total population of fourteen villages as indicated by the secondary source has increased
from 63,477 to 1, 01,120 over a period of 10 years from 2001 to 2011. The decadal population growth rate
in the sub-district is - 60.9 percent.

Table 3.19 Demography of the Study Area

Sr. Location Gram Sub- District 2011 2021
No. Panchayat District Total Population Male Female Population
Households
1 Damka Damka Choryasi Surat 1331 5,604 3,118 2,486 3,126
2 Bhatlai Bhatlai 1,144 4,066 2,786 1,280 4082
3 Rajgari Rajgari 318 1,300 716 584 1305
4 Limla Limla 926 3,683 1,922 1,761 3697
5 Kavas Kavas 1,602 6,500 4,108 2,392 32,605
6 Hajira Hajira 4,443 16,724 12,840 3,844 16788
7 Hajira INA Hajira INA 5,562 3375 2187 5583
8 Mora Mora 3,802 13,924 11,115 2,809 13977
9 Sunvali Sunvali 975 4,165 2,308 1,857 4181
10 Vanta Gaviyer 195 244 146 98 127
11 Gaviyer Gaviyer 562 2,585 1,743 842 2,744
12 Kandi faliya Kadifaliya 211 971 478 493 975
13 Dumas Dumas 796 7224 3,727 3,497 7252
14 Sultanabad Sultanabad 1,570 3,661 1,853 1,808 4,125
15 Bhimpor Bhimpor 3,636 7,862 4018 3844 7892
Total Population 21,511 84,075 54,253 29,822 66,955
* Projection of the population is based on the decadal growth rate of Chorasi Taluka
Project Location
The area under assessment is mainly rural. The project site is located at Hajira Industrial belt in Choryasi
Taluka of Surat District in Gujarat State. This District is around 5.8 km in south-west direction. There are
about 17 cold storage industries and some other companies like metallurgical industries, brick
manufacturing industries and other industries in the surrounding. Surat is one of the fastest developing
cities of Asia. The nearest city forms the project site is Surat around 23 km in east direction.
The Area Profile

In 2011, the District of Surat had population of 6,081,322 of which male and female were 3,402,224 and
2,679,098 respectively. In 2001 census, Surat had a population of 4,275,540 of which males were
2,362,072 and remaining 1,913,468 were females. There was change of 42.24 percent in the population
compared to population as per 2001. The decadal population growth rate in the sub-district is -60.9 percent
2001 to 2011.
The initial provisional data released by census India 2011, shows that density of Surat District for 2011 is
1,337 people per sq. km. Surat District administers 4,549 square kilometers of areas. Literacy rate in rural
areas of Surat District is 76.92 % as per census data 2011. Gender wise, male and female literacy stood at
82.76 and 70.60 percent respectively. Average literacy rate of Surat in 2011 was 85.53% compared to
77.62% in 2001. Male and female literacy was 89.56% and 80.37% respectively. With regards to Sex
Ratio in Surat, it stood at 787 per 1000 male. The average national sex ratio in India is 940 as per latest
reports of Census 2011; child sex ratio in Surat District was 813 in 2011 census. According to the census
for the year 2011, child sex ratio is 835 compared to figure of 859 of 2001 census data. As per census,
20.3% of the population of Surat District lives in the rural areas.
The Field Data

All villages considered for sampling under the PIA represented a mix of Hindus, Muslims and some other
groups. Gujarati and Hindi are the predominant languages here. The respondents are residing here for 2
yeas to 35+ years; many are staying since their birth. More than 91% reside in nuclear families. In the
surveyed households 44.3% of the family members are women, i.e. the sex ratio is 796. Of all, more than
85% of the people have finished their school level, about 10% have completed college education and the
rest have studied up to post-graduation.
The locality has a wide range of occupational arenas- many (about 85%) work in the surrounding industries.
But most of them are deployed through contractors on temporary basis. The respondents acknowledge the
contribution of these industries in their work life. They pointed out that job opportunity has increased due
to the presence of these industries. One person works as teacher, the rest work for agriculture/farming,
animal husbandry, dairy, fishing, health, handicrafts, government and private jobs, petty business transport,
and so on. Farming is negligible here. Monthly income falls in the range of ₹5,000 to ₹40,000 and mean
monthly income is ₹18,652 and mean savings is ₹5,969.
When non-economic parameters are considered, it was found that most (97%) of the households possess
television and gas connection; about 84% have ration card. Of all 71% have refrigerator. All have
cellphones, more than 62% have cycle, 72+% have two wheelers, 30% have water purifier, 38% possess
computer, more than 21% have car, about 14% have air conditioner, 11% have washing machine and about
42% have some music system. This picture does not rank the residents as poverty-stricken.
Majority have their own individual house; a larger number reside in rented/company provided
accommodation. About 90% of the houses are pucca in nature with basic amenities. The PIA has income
opportunities due to the development of industries around. Therefore, there has been remarkable in-
migration in this location. The respondents have reported no death in the last one year.
Infrastructure
It has been assessed that in the PIA all locations are having almost all basic services and infrastructural
facilities like, local government, drinking water, sanitation, drainage, solid waste management, primary
health care, anganwadi centre, educational facility, vocational training, roads, electricity, street lights, bank,
post office, road, transportation facility, dairy, etc. All the respondents have house connection for water
supply; about 20% use dug well and more than 31% use public hand pump and the rest use other sources,
like public stand post. Water is being supplied through tankers during dry time. Except four respondents,
all have sanitary latrine in house, those four goes for open defecation. Except one, all enjoy electric
connection at home.
Government Schemes and Services

Within the PIA there are various programs being implemented by the Government. People have the facility
of a public distribution system, Integrated Child Development Services (ICDS) scheme operational-
anganwadi centers are present in all villages and are focusing on the issues of mother and childcare.
People’s Perception
Enquiring about their opinion regarding the industry, about 81% of the respondents were neutral in their
response and 18% were positive. About 66% mentioned that the project has proved beneficial for them. As
an explanation, they mentioned that the Project provides them with job opportunities and provision for
infrastructure development. A quarter had negative response and their logic behind was environmental
pollution leading to poor yield of crop and other associated hazards. According to them pollution of the air
and water is worsening, and its consequences are dust, effect on land, poor crop, dermatological and
breathing problems, reduced migratory birds, death of fish, etc. The extent of Pollution often escalates due
to the release of wastewater to the sea by many industries in the locality.
Residents of the PIA are well aware of the ongoing activities in the area. Many identify this project to be
one having a positive impact in their lives. Through this project they mainly expect employment generation
and improvement in basic services and infrastructures facilities. They also anticipate that it will boost the
overall development of the area and improve their quality of life.
Most people reported environmental pollution in their locality. Many surrounding industries have provided
their contributions towards adopting measures to reduce pollution. However, people expressed that major
problem is air pollution especially at night time and crops get affected as a consequence. The companies in
the area are active in providing services under their corporate responsibility activities in several areas for
local area development

3.12.9 Public Consultation

Local people are well aware of the activities proceeding in the area. They perceive this project positively.
Through this project they are expecting a larger employment generation and an improvement in the basic
services and infrastructures. They also expect that it will boost the overall development of the area and
improve their quality of life. Details of public consultation is presented in following table-3.21.
Table 3.20 Summary of Public Consultation

Location Date and People’s Views Names of the Photographs
Time Participants
Hajira 24.11.2020 The participants mentioned that 6 members
12:05 pm their main occupation is related
to fishery. But due to industrial
pollution their work is almost
come to a standstill.
For several years the AMNS has
been operating Lok Vikash
Kendra for women
Mora 25.11.2020 People complained about 1. Birju Kumar

environmental pollution due to 2. Narendra Bhai
industries. At the same time they 3. Guddu Bhai
admitted that there is increased
job opportunity in the area.
Kavas 26.11.2020 The participants were aware 1. Anju

about the upcoming industry. 2. Daksha
They mentioned about local 3. Varsha
developments and job 4. Damyanti
opportunity with the 5.Seema
industrialization of the PIA. 6.Urmila
7. Pooja
8. Meenakshi
9. Neelam
10. Shweta
Hajira 27.11.2020 A group of women were doing 1. Sushila

03:30 pm embroidery work in sari. None 2. Sheetal
of them knew about the 3. Rekha
upcoming project; only they 4. Champa
knew about the existing facility 5. Meena
of AMNS. 6. Sheela
7. Savita
Some women used to go for
fishing but now they have
stopped because some dead fishes
are found in the pond, which are
not edible. Some of the women
were collecting scrap but now
they have stopped after the
surrounding industries are set up.
According to them, the common
illnesses that they suffer are
related to skin problem and hair
loss.

Location Date and People’s Views Names of the Photographs

Time Participants
They are bothered about safety of
their children because children
cannot play on the roadside in the
village due to heavy traffic.
In the village water and

electricity supply were found
good. They expressed that these
industries are not beneficial.
Hajira 27.11.2020 A group of people were talking 1. Santosh Kumar
04: 10 PM tea at the small tea stall. Most of 2. Om Prakash Singh
them shifted here from the other 3. Laxman Singh
state (UP and Bihar) and working 4. Anil Kumar
in nearby industries (EBTL and 5. Dheeraj Singh
AMNS). The group members are 6. Sanjay Kumar
aware of environmental pollution 7. Om Prakash Saho
load. Some of the members 8. Munna Yadav
knew about the upcoming 9. Shubham Patel
project. They wanted permanent 10. Swamideen Saho
job instead of contractual job.
The group was happy to know

about the upcoming project for
infrastructure development and
expected employment
opportunity. Due to lockdown of
last year, many villagers lost their
job. They were uninterested in
the conversation due to excess
heat and current corona situation.
3.12.10 Conclusion
The Modification project by AMNS India Ltd will initiate direct and indirect positive impacts on the lives
of the surveyed area. Respondents across different socio-economic groups, age, gender and locations have
pronounced that the concerned industry will be beneficial for them and it will boost their quality of life
owing to larger employment opportunities and also by reflecting a positive change. The Company is
practicing their Corporate Social Responsibility (CSR) to improve their quality of life.
3.13 Description of the Biological Environment

3.13.1 Ecological Impact Assessment
Ecological Impact Assessment (EcIA) is used to predict and evaluate the impacts of development activities
on ecosystems and their components, thereby providing the information needed to ensure that ecological
issues are given full and proper consideration in development planning. Environmental impact assessment
(EIA) has emerged as a key to sustainable development by integrating social, economic and environmental
issues in many countries. EcIA has a major part to play as a component of EIA but also has other potential
applications in environmental planning and management.
Ecological Impact Assessment provides a comprehensive review of the EcIA process and summarizes the
ecological theories and tools that can be used to understand, explain and evaluate the ecological
consequences of development proposals.
Environmental impact assessments have become an integral part of development projects in India ever since
1994, to formulate policies and guidelines for environmentally sound economic development. Proper
assessment of biological environment and compilation of its taxonomical data is essential for the impact
prediction, yet biodiversity is often inadequately addressed. There is a growing recognition of the need of
biodiversity considerations in environmental impact assessments. Important barriers to the incorporation of
biodiversity in impact assessment include low priority for biodiversity and limitations in one or more of the
following areas: capacity to carry out the assessments; awareness of biodiversity values; adequate data; and
post-project monitoring.
Consistent and regularly updated data on regional and local taxonomy and floristic and faunal diversity of
the areas are almost non-existent in country as diverse as India. Instant information on biodiversity profiles
of the area, where the proposed project is setting up, is an essential part of the baseline studies of EIA. In
such a situation, good primary baseline biodiversity survey is a pre-requisite for the collection of reliable
data. The professional ethic of the Biodiversity practitioners should be their will and skill to conduct
scientific field surveys. These contributions towards biodiversity surveys may sometimes recognized as the
actual value additions in terms of new records or a new data base but are more often recognized in the
validation and updating of the existing information base.
3.13.2 Period of Study

The baseline study area encompasses the geographic area of anticipated project activities and impacts - the
project area of influence. The baseline study for the evaluation of the floral and faunal biodiversity of the
terrestrial environment of the study area was carried out within 10 km radius from the proposed
modification project during study period Oct 2020 to Dec 2020.
3.13.3 Methodology
For purpose of Environment Impact assessment (EIA) studies, the term biodiversity survey defines
collection of spatial and or temporal data about spices/ community or a habitat. The information from the
survey provides a snap shot of presence or absence and spatial distribution of important species. In EIA
studies the survey data are used to evaluate the ecological resources on a site and its immediate
surroundings, which is then assessed or evaluated. Impacts are considered with respect to these resources
and assessed for significance.
The primary objective of the present survey was to describe the floristic and faunal communities within the
study area. Survey conducted for EIA studies aimed to provide information on the following. What species
and habitat occur in the project site and surroundings? Whether any threatened flora and fauna occur in the
study area? If so, where do they occur?
Extrapolation and prediction techniques were used to limit the number of sites to be assessed. The
knowledge of species habitats requirement, soil type, terrain, vegetation etc. were used to predict species
occurrence.
This Extrapolation assessment program conducts preliminary for the assessment of biological value of
poorly known area. The biological value of an area can be characterized by the species richness, degree of
spices endemism, uniqueness of the ecosystem and magnitude of threats of extinction. This Rapid
biodiversity assessment were undertaken by identifying potentially rich sites from satellite imaginary
(Google Earth) and conducting the field survey in the potential habitats. GPS was utilized for locating field
sample plots as well as gathering positional attributes of sighted flora and faunal species.
For Floral survey, sample plots have been randomly distributed across the suitable stratum within 10 km
radius of project site. Tree species were sampled using 10mx10m or 5mx5m plots depending upon the
stratum variability on the ground and tree species occurrence. For sampling shrub species, two plots of size
of 5-meter x 5 meter at two opposite corner of tree plots or the same 5meterX 5meter plot of tree plots were
taken. For herbaceous plant five plots of 1meter x 1 meter at four corners of tree plots and one at center.
The methodology adopted for faunal survey involve; faunal habitat assessment, random intensive survey,
opportunistic observations, diurnal bird observation, active search for reptiles, active search for scats and
foot prints and review of previous studies. The aim was to set baselines in order to monitor and identify
trends after the commencement of project activity. Emphasis has been placed on presence of rare, endemic,
migratory and threatened species, if any present in the study area. Desktop literature review was conducted
to identify the representative spectrum of threatened species, population and ecological communities as
listed by IUCN, ZSI, BSI and in Indian wild Life Protection act, 1972. The threat status of individual

species was assessed using the revised IUCN category system.
Presence –Absence:
Monitoring all species was not clearly feasible. Therefore, the most commonly used species-based attributes
of habitat composition are species presences or absences, abundance of typical species or vegetation
communities, and the distribution (range) of a species/ species.
The simplest target for a species is that its presence at the site or at defined location within the surrounding
of it is maintained. This normally straightforward to monitor, but there are occasions, when difficulties may
arise, especially when the species that are inconspicuous, difficult to identify or rare, or those that inhabit in
inaccessible areas. The distribution (range) of a species across a site can be monitored by assessing presence
–absence across a number of locations (grids)
Figure 3.17 Study Area Map
3.13.4 Biodiversity of Terrestrial Environment

3.13.4.1 Habitats Description of the Project Site and Its Immediate surroundings
The project site is the already established steel complex of M/s. ArcelorMittal Nippon Steel India Limited
(Formerly Essar Steel India Limited)., located at Hazira along the right bank of Tapti estuary. The M/s.
ArcelorMittal Nippon Steel India Limited (Formerly Essar Steel India Limited) complex, is itself occupied
a vast area in the peninsular like portion of landmass along the right bank of River Tapti. More over the
entire belt has witnessed enormous industrialization, in last few years with many large-scale industrial units
like; Reliance, Shell, Larsen & Toubro NTPC, ONGC, KRIBHCO, IOC, BPCL etc. These industrial units
and the colonies have occupied a major portion of the available land area of this belt.
As the surrounding area the project site are restricted for entry as it belongs to various industrial
establishments, not much data collection in this region especially within the close proximity of project site
was possible pertaining to the Ecological Biodiversity. The field survey was concentrated along the road,
barren lands, approachable area of seashore, and the scrub forest near Hazira village. Because of
industrialization, the tree cover in this area has been increased mainly due to the effort towards green belt
development by the individual industrial units.
The eco-sensitive area like large water bodies that attract migratory and other residential water fowls were
not observed within the close proximity of the project site. The main eco-sensitive receptors observed are
mangrove patches along the fringes of islands and mud banks in the mouth of Tapi estuary also a thick
patch of Prosopis juliflora dominated scrub land which is situated along the western side of the M/s.
ArcelorMittal Nippon Steel India Limited (Formerly Essar Steel India Limited) along the shoreline of
Hazira village.
The green belt in the industrial belt of Hazira was dominated by (Alstonia scholaris) (Kigelia Africana),
Asopalav (Polylathia longifolia), Sonmukhi, (Peltophorum pterocarpum), Sharu (Casuarina equisetifolia),
Pardesi Baval (Leucaena leucocephala) and Nilgari (Eucalyptus sp.)
3.13.4.2 Habitats Description of the Study Area (10 KM)

As already mentioned, the proposed site is located in the Notified Hazira industrial area along the right bank
of Tapti estuary, Gujarat. The major portion in the Northern side of the study area (10 km radius) is
occupied by the industrial establishments. Major Western portion of the study area was occupied by Gulf of
Khambhath while Southern portion was occupied by estuarine portion of river Tapti and intermittent mud
banks, and islands, most of them were colonized by Mangroves along its fringes. Due to the
industrialization and landscape features natural habitats in the area have been confined to very limited
patches.
Most of the barren land were occupied the largescale intrusion by Prosopis juliflora. Tree cover is
dominated by a palm, Borassus flabellifer (Tad). The agriculture lands are consigned to few pockets in the
Rajgari, Bhatlai and Vanta and Gaviar villages of the study area. Most of these villagers in these villages
are engaged in vegetable cultivation dominated by Papdi, Bengan and Garlic. Damka sea coast is dominated
by vast patches of fully grown mangroves of Avecinnia alba.
3.13.5 Floral Diversity of Study Area

The objective this floral inventory of the study area is to provide necessary information on floristic structure
in the study area for formulating effective management and conservation measures. The climatic, edaphic
and biotic variations with their complex interrelationship and composition of species, which are adapted to
these variations, have resulted in different vegetation cover, characteristic of each region. The following
account of floral inventory have been, based on the field survey conducted for a short duration in the study
period, is not very comprehensive data and is aimed only to give a general pattern of vegetation of this
region during the study period as a baseline data in absence of available secondary data. Listing of the
endangered, threatened and endemic species of flora in a locality and drawing the attention to the
occurrence of such species, would aid in creating awareness amongst the local people as a whole to protect
such species from extinction, and to take necessary measures for their conservation. These types of floristic
study is an inventory for such purpose and hence a necessity.
The tree species, herbs, shrubs, climbers and major crops, were documented during this base line study. The
list of floral species documented in the study area is enlisted in table 3.15
3.13.5.1 Trees
Tree cover in the study area is restricted to homestead/ or road side plantation and very few farmlands
plantation dominated by Borassus flabellifer (Tad). Otherwise, natural tree cover is very less in this part of
Surat District. Homestead plantation was dominated by Borassus flabellifer (Tad). Cocos nucifera (Narial).
Mangifera indica (Keri), Tamarindus indica (Amali), Moringa oleifera (Sargavo), Pithecellobium dulce
(Gorasmli), Ficus benghalensis (Vad), and Road side Plantations were dominated by Acacia auriculiformis,
Peltophorum pterocarpum (Sonmukhi), Delonix regia (Gaulmor), Azadirachta indica (Limbado), Acacia
leucophloea (Hermobaval), Acacia nilotica (Baval), Albizia lebbeck (Siris), Leucaena leucocephala
(Pardesi Baval), Prosopis cineraria (Khyigdo), Ficus benghalensis (Piplo), Ailanthus excelsa (Aurdso), and
Tectona grandis (Sag).The list of tree species observed in the study area is enlisted in the table 3.22. 43
species of trees belong to 24 families are enumerated from the study area.

Table 3.21 List of Tree species

Sr. No. Family & Scientific name Vernacular name
1 Family: Anacardiaceae
1/1 Mangifera indica L. Kari
2 Family: Annonaceae
2/1 Annona squamosaL
3/2 Polylathia longifolia (Conn.) Thw. Asopalav
3 Family: Apocynaceae
4/1 PLUMERIA RUBRA L. Champo
5/2 ALSTONIA SCHOLARIS L.
4 FAMILY: BOMACACEAE
6/1 ADANSONIA DIGITATA L Rukh, Rukhdo
5 Family: Arecaceae
7/1 Cocos nucifera L. Narial
8/2 Borassus flabellifer L. Tad
9/3 Phoenix sylvestris sp
10/4 Roystonea regia Bottlepalm
6 Family: Avicenniaceae
11/1 Avicennia alba Blume Patcheradi
7 Family: Bignoniaceae
12/1 Kigelia africana (Lam.) Benth. Sausage tree
8 Family: Caesalpiniaceae
13/1 Delonix regia (Boj.) Raf. Gaulmor
14/2 Cassia fistula L. Garmalo
15/3 Cassia siamea Lam. Kasid
16/4 Peltophorum pterocarpum (DC.) Backer ex Heyne Sonmukhi,
17/5 Tamarindus indica L. Amali
9 Family: Caricaceae
18/1 Carica papaya L. Papaya
10 Family: Casuarinaceae
19/1 Casuarina equisetifolia L. Sharu
11 Family: Combretaceae
20/1 Terminalia catappa L. Badam
12 Family: Malvaceae
21/1 Thespesia populnea (L.) Sol.ex Corr. Paras piplo
13 Family: Meliaceae
22/1 Azadirachta indica A.Juss Limbado
14 Family: Mimosaceae
23/1 Acacia auriculiformis Austrian baval,
24/2 Acacia leucophloea (Roxb) Willd. Hermobaval
25/3 Acacia nilotica (L.) Del.subsp.indica (Bth.) Brenan Baval
26/4 Albizia lebbeck (L.) Bth. Siris
27/5 Leucaena leucocephala (Lam.) De Pardesi Baval
28/6 Pithecellobium dulce (Roxb.) Bth. Gorasmli
29/7 Prosopis cineraria (L.) Druce Khyigdo
15 Family:Moraceae
30/1 Ficus benghalensis L. Vad
31/2 Ficus religiosa L. Piplo
32/3 Ficus hispida Dhedh Umardo,
16 Family:Moringaceae
33/1 Moringa oleifera Lam Sargavo
17 Family:Myrtaceae
34/1 Eucalyptus sp. Nilgari
35/2 Syzygium cumini (L.) Skeels. Jambu
18 PAPILIONACEAE
36/1 Pongamia pinnata (L.) Pierre Karanj
19 Family:Poaceae
37/1 Dendrocalamus strictus (Roxb) Bans
20 Family:Salvadoraceae
38/1 Salvadora persica L. Piludi
21 Family:Sapotaceae
39/1 Manilkara hexandra (Roxb.) Dub. Rayan


40/2 Manilkara zapota (L.) Chikoo
22 Family:Simaroubaceae
41/1 Ailanthus excelsa Roxb. Aurdso
23 Family:Rhamnaceae
42/1 Zizyphus glabrata Heyne ex Roth. Bor
24 Family:Verbenaceae
43/1 Tectona grandis L.f. Sag
3.13.5.2 Shrubs
Shrubs observed during the present survey are given in the table 3.23. 22 shrub species belong to 15
families are enumerated from the study area. The dominant shrub community in this area was represented
by Prosopis juliflora (Gando baval), Calotropis procera, C. gigantea (Akado), Ipomoea fistulosa
(Nasarmo), Lawsonia inermis (Mendhi), and Lantana camara (Ganthai).
Table 3.22 List of Shrubs

S. No. Family & Scientific name Vernacular name
1 Family :Apocynaceae
1/1 Nerium indicum Lalkaren
2/2 Thevetia peruviana Merr. Pili karan
2 Family: Asclepiadaceae
3/1 Calotropis gigantea (L.) R. Br Akado
6/2 Calotropis procera (Ait.) R.Br Akado
4/1 Cassia auriculata L Aval
4 Family: Convolvulaceae
5/1 Ipomoea carnea Jack. ssp. fistulosa Nasarmo
5 Family: Euphorbiaceae
6/1 Euphorbia neriifolia L. Thor
7/2 Jatropha curcas L. Ratanjot
6 Family: Lythraceae
8/1 Lawsonia inermis L. Mendhi
7 Family: Malvaceae
9/1 Abelomoschus manihot (L.) Medic. Jagali bhindi
10/2 Abelomoschus esculentus (L.) Bhindi
11/4 Hibiscus rosa –sinensis Jasund
8 Family: Musaceae
12/1 Musa paradisiaca L. Kela
9 Family: Mimosaceae
13/1 Prosopis juliflora DC Gando baval
10 Family:Nyctaginaceae
14/1 Bougainvillea spectabilis Willd. Bougainvel
11 Family: Papilionaceae
15/1 Sesbania sesban (L.) Merr. Shevari
12 Family: Poaceae
16/1 Saccharum officinarum L. Sherdi
13 Family: Rhamnaceae
17/1 Zizyphus nummularia (Burm.f.) W. &. Chanibor
14 Family: Solanaceae
18/1 Datura metel L Daturo
19/2 Solanum incanum L Ubhi ringan
20/3 Solanum indicum
15 Family : Verbenaceae
21/1 Clerodendrum inerme (L.) Gaertn. Madhi
22/2 Lantana camara L.var.aculcata (L.)Mold. Ganthai
3.13.5.3 Herbs
The herbs observed in the sampling plots, during the survey period within the study area have been enlisted
in table 3.24. 70 species of herbs belong to 29 families were documented from the sampling plots laid in
different habitats.

Table 3.23 List of Herbs

1 Family Acanthaceae
1/1 Hygrophila auriculata (Schum.) Kanatashelio,Akaro
2 Family Amaranthaceae
2/1 Aerva lanata L Gorakhganjo
3/2 Aerva Javanica L.(Burm.f.) Bur
4/3 Celosia argentea var argentea L. Lamdi
3 Family Aizoaceae
5/1 Sesuvium portulacastrum
4 Family Apiaceae
6/1 Coriandrum sativum L. Kothmir
5 Family Apocynaceae
7/1 Cathranthus roseus L.
6 Araceae
8/1 Colocasia esculenta L.
7 Family: Asteraceae
9/1 Ageratum conyzoidesL. Mankad Mari, Dholi saddi
10/2 Blumea mollis Bhutaco
11//3 Echinops echinatus Roxb Shulio
12/4 Tridax procumbens L Pardesi Bhangro
13/5 Parthenium hysterophorus L --
14/6 Xanthium strumarium L. Gokhru
8 Family: Boraginaceae
15/1 Heliotropium bacciferum Forsk
16/2 Heliotropium mariflolium Zinku okharad
17/3 Trichodesma indicum R. Br. Undha Fuli
9 Family: Chenopodiaceae
18/4 Suaeda fruticosa L Khari Luni
19/5 Suaeda nudiflora (Willd) Moras
10 Family: Commelinaceae
20/1 Commelina benghalensis L
21/1 Cressa cretica L. Palio, Rudanti
22/2 Convolvulus arvensis L.
23/3 Evolvulus alsinoides (L.)
12 Family: Cyperaceae
24/1 Cyperus sps. --
25/2 Fimbristylis dichotoma Vahl. --
26/3 Fimbristylis sps. --
13 Family: Euphorbiaceae
27/1 Euphorbia hirta L. --
14 Family: Gentianaceae
28/1 Nymphoides indicum (Roxb.) Kumudini
15 Family: Hydrocharitaceae
29/1 Hydrilla verticillata (L.f.) Royle
30/2 Ottelia alismodies L.
16 Family: Lamiaceae
31/1 Anisomeles indicaL. Chodharo
32/2 Ocimum basilicum L
33/3 Ociumum sanctum L tulsi
17 Family: Liliaceae
34/1 Aloe barbadensis Mill. Kunvarpato
18 Family: Malvaceae
35/1 Abutilon indicum L. Khapat,Dabaliar
36/2 Malachra capitataL. Pardesi bhindo
37/3 Sida sp. --
38/4 Pavonia sp.
19 Family: Nymphaeaceae
39/1 Nymphaea pubescens Wild Kamal
40/1 Alysicarpus longifolius (Rttl.ex Spreng) Motosamervo
41/2 Cajanus cajan (L) Tuvar

42/3 Cortalaria prostate
43/4 Cortalaria juncea Shun
44/5 Indigofera cardifoila Heyne ex Roth
45/6 Indigofera oblongifolia Forks. --
46/7 Indigofera sp.
47/8 Tehrosia purpurea L. Sarpankho
48/9 Tephrosia sps. --
50/10 Medicago sativa L Lachko
51/11 Cacia tora Kuvandio
21 Family: Poaceae
52/1 Aleuropus lagopoides (L) --
53/2 Cynodon barberi Rang. --
54/3 Cynodon dactylon (L.) --
55/4 Phragmites kara (Retz.) --
56/5 Oryza sativa L. Chokha
57/6 Sorghum bicolor (L.) Jowar
58/7 Urochondra setulosa (Trin.)
59/9 Zea mays Makai
22 Family: Poligonaceae
60/1 Poligonum sp.
23 Family: Pontederiaceae
61/1 Eichhornia crassipes (Mart.) Kanphutti
24 Family: Potamogetonaceae
62/1 Potomogetonsp.
25 Family: Solanaceae
63/1 Solanum nigrum L. Piludi
64/2 Solanum surattense Brum. Bhoringni
26 Family: Scrophulariaceae
65/1 Bacopa monnieri L.
27 Family: Tiliaceae
66/1 Corchorus depressus Stocks Bhuphali
67/2 Corchorus aestunans L. Chunch
28 Family: Typhaceae
68/1 Typha angustata Bory & Chaub Ramban,Ghabajariu
29 Family: Zygophyllaceae
69/1 Fagonia cretica L. --
70/2 Tribulus terrestris L. Mithu Gokhru
3.13.5.4 Climbers and Twiners

Climbers/ twiners in the study area dominated by, Ipomoea pes-tigridis (Wagpadi), Ipomea pes-caprae
(Dariani vel), Ipomea aquatica (Nali ni Bhaji), Coccinia grandis (Ghiloda), Luffa cylindrica (Galku), and
Abrus precatorius (Chanothai). The major climbers and twiners observed in the study area in the sampling
plots are given in table 3.25. 18 species of climbers/ twiners belongs to 8 families are recorded from the
area
Table 3.24 List of Climbers and Twiners

1 Family: Asclepiadaceae
1/1 Pentatropis spiralis (Forsk.) Decne Shingroti
2/1 Ipomea cairica (L.) --
3/2 Ipomea nili L.
4/3 Ipomoea obscura L. --
5/4 Ipomea pulchella Roth --
6/5 Ipomea aquatica Forsk. Nadinivel
7/6 Ipomoea pes-caprae var. pes-caprae Dariani vel/Maryad vel
8/7 Ipomoea pes-tigrides L
9/1 Caesalpinia crista L. Kachka

4 Family: Cucurbitaceae
10/1 Coccinia grandis Ghiloda
11/2 Corallocarpus epigeus (Arn.0 Cl.in HK.
12/3 Luffa cylindrica (L.) M.J.Roem Galku
13/4 L. acutangula (L) Jungli turia
5 Family: Cuscutaceae
14/1 Cuscuta reflexa Roxb. Amarvel
6 Euphorbiaceae
15/1 Dalechampia scanens L.
7 Family: Menispermaceae
16/1 Cocculus hirsutus (L.) Diels Vevdi
17/1 Abrus precatorius L. Chanothi
18/2 Clitoria ternatea L. Gokaran
3.13.6 Cultivated Plants in the study area

The major agriculture activity is restricted to few pockets of Rajgiri, Bhatlaj, Vanta and Gavier villages of
the study area. The major crops practiced are Guwar (Cyamopsis tetragonolob) Chana (Cicer erietinum),
Chaval /Choka (Oryza sativa), Val/Val papri (Lablab purpureus) Surati papdi papdi (Lablab purpureus
var.sweet) , Bajra (Pennisetum typhoides), and Jowar (Sorghum bicolar)
The crop occupying the highest percentage of the sown area of this region is taken as the major crop and all
other possible alternative crops which are sown in this region either as substitutes of the base crop in the
same season or as the crops which fit in the rotation in the subsequent season, are considered as minor crop.
3.13.6.1 Major Crops

Major crops in the study area are rice (Oryza sativa)
3.13.6.2 Minor Crops

The minor crops of this region are Bajra (Pennisetum typhoides), and Jowar (Sorghum bicolar) Chana
(Cicer erietinum),
3.13.6.3 Vegetables
The vegetables grown in the study area are, ladies Rigan (Solanum melongena), Guwar (Cyamopsis
tetragonolob), Val/Val papri (Lablab purpureus) and Surati papdi (Lablab purpureus var.sweet).
3.13.6.4 Horticulture Practices and Fruit Grown

Horticulture activity was found to be restricted in few villages like Suvali and Bhatlai villages observed
with orchards of Mango and Chikoo, Bore cultivation was observed at Damka village.
3.13.7 Rare and Endangered Flora in the Study Area

The IUCN Red List is the world's most comprehensive inventory of the global conservation status of plant
and animal species. It uses a set of criteria to evaluate the extinction risk of thousands of species and
subspecies. These criteria are relevant to all species and all regions of the world. With its strong scientific
base, the IUCN Red List is recognized as the most authoritative guide to the status of biological diversity.
Among the enumerated flora in the study area, none of them were assigned any threat category, by RED
data book of Indian Plants. (Nayar and Sastry,1990) and Red list of threatened Vascular plants (IUCN,2010,
BSI, 2003).
Rare Massive Tree Adansonia digitata observed in the study area

Adansonia digitata L. (Bombacaceae family) is a native deciduous tree from the African Savannas. The
English common name is probably derived from the Arabic buhibab, which means “fruit with several
seeds”. It is characterized by an unusual, swollen, relatively short, bottle shaped trunk in which spongy

fibres store water for the dry season. For this reason, it is also called “bottle tree”. The mature
circumference can exceed 20 m; the diameter at chest height is about 10 m. African baobab is a very long-
living tree. It normally lives for about 500 years, but it is believed that some trees are up to 5000 years old.
It is called as Kapavriksh in India, with great mythological significance. It is reported that Natural
regeneration of Baobab is poor due to the hard seed coat.
Description:
The massive, usually squat cylindrical trunk gives rise to thick tapering branches resembling a root-system,
which is why it has often been also referred to as the upside-down tree looking like it has been picked out of
the ground and stuffed back in upside-down. The stem is covered with a bark layer, which may be 50-100
mm thick. The bark is greyish brown and normally smooth but can often be variously folded and seamed
from years of growth. The baobab is leafless for nine months of the year. The leaves are hand-sized and
divided into 5-7 finger-like leaflets. Being deciduous, the leaves are dropped during the winter months and
appear again early summer. The large, pendulous flowers (up to 200 mm in diameter) are white and sweetly
scented. They emerge in the late afternoon from large round buds on long drooping stalks from October to
December. The flowers fall within 24 hours, turning brown and smelling quite unpleasant. The fruit is a
large, egg-shaped capsule, covered with yellowish brown hairs. The fruit consists of a hard, woody outer
shell with a dry, powdery substance inside thatcovers the hard, black, kidney-shaped seeds. Almost all parts
of A. digitata are used as medicines and also possess high nutritional value.
Geographic Distribution:
This enormous tree supposedly has its origin in the African continent and brought in by sailors who came to
establish trade links with India; they thereafter planted them across the Indian subcontinent.” A minority of
botanists have suggested that this tree is an Indian tree which has been mentioned in historical books,
etched on some of our ancient temple walls and even worshipped for ages as Kalpavriksha - the mythical
wish fulfilling tree.
Distribution in the study area:

Four trees of this non indigenous species were observed in the study area; two trees at Gavier village, one
tree at Hazira village and one tree in the township of Essar Steel India Ltd.
Status:
Regarded as the largest succulent plant in the world, the baobab tree is steeped in a wealth of mystique,
legend and superstition wherever it occurs in Africa. It is a tree that can provide food, water, shelter and
relief from sickness. IUCN have not evaluated this species. The tree at present is facing a crisis of survival;
natural regeneration potential of this tree is reported to be very poor. Very few trees observed in India.
Threat status:
Adansonia digitata is an important arboreal species with very limited distribution in India, which is being
faced threat into extinction. In order to preserve this genetic resource of great economic and medicinal
value, studies on germination has to be carried out.
Baobab trees flower for the first time at about 20 years. In mid-summer, dozens of luminous white
blossoms - the size of saucers - open at sunset and their strong musky odour attracts fruit bats and hosts of
insects. Large bats seek out the sweet nectar and collect and distribute pollen as they move from flower to
flower. The flower is short lived and it drops to the ground within hours of being pollinated. The resultant
seeds develop in a hairy pod which resembles a miniature rugby ball. The seeds are not generally eaten by
animals.
3.13.8 Endemic/Endangered plants of the Study Area

De Candolle (1855) first used the concept of “Endemic”, which is defined as an area of a taxonomic
unit, especially a species which has a restricted distribution or habitat, isolated from its surrounding
region through geographical, ecological or temporal barriers.

Among recorded plant species, during the survey period, none can be assigned the status of endemic
plant of this region.
3.13.9 Status of Forest and their Category in the Study Area

In the study area mangrove patches are present in the mouth of Tapti estuary along the fringes of islands
and mud banks. A thick patch of Prosopis juliflora dominated scrub land which is situated along the south
west side of the AMNS complex along the shoreline of Hazira village. As per the topomap it is shown as a
reserve forest. another reserve forest is observed Dumas reserve forest. The mangrove survey has been
conducted and it is found that no mangrove is present in the AMNS premises detailed mangrove survey
report is enclosed as annexure 16.
Sr. No. Forest Distance

2 Hazira Scrub Forest (Reserve forest) 2.0 km in SW
3 Dumas Reserve Forest 7.5 km in SE
Distance and aerial numbers of Mangroves from the project site.

Polygon ID Distance from Project Site (in Km)
1 4.4
2 4.3
3 5.9
4 6.1
5 5.4
6 3.1
7 3.5
8 2.25
9 2
10 2.3
11 3
12 4.7
13 4.4
14 6.2
15 7.8
GIS map showing Mangroves and its aerial numbers from the project site.

3.13.10 Faunal Biodiversity of the Study Area

For the documentation of the faunal biodiversity of the study area with respect to birds, reptiles,
amphibians, and butterfly species, a baseline survey had been conducted in study period.
3.13.10.1 Birds of the Study Area

The most commonly spotted bird species of this area were; Cattle Egret, and Little Egret, Systematic
account of the birds in the study area with the status of occurrence is given in table 3.26. The Gavier Talab
(21007 34.5, 720 44’ 02.4 “) located almost at the boundary of the study area attract many residential and
migratory birds during winter months.
Table 3.25 List of Birds

Old Common name New Common Name Scientific Name R-S
I ORDER: ANSERIFORMES
Shoveller Northern Shoveller Anas clypeata W
Spotbill Spot-billed Duck Anas poecilorhyncha R
II ORDER: APODIFORMES
Family: Apodidae (swifts)
Common Swift Common Swift Apus apus R
IIIORDER: FALCONIFORMES
Family: Accipitridae (vulture, Sparrow hawk, Eagle, Harrier, Kite and Vulture)
Shikra Shikra Accipiter badius R
Black-winged Kite Black-winged Kite Elanus caeruleus R
White backed or Bengal vulture White-rumped Vulture Gyps bengalensis R
IV. ORDER: : CICONIIFORMES
Family: Anhingidae
Darter or Snake Birds Oriental Darter Anhinga melanogaster R
Family: Ardeidae (heron, Egret, Bittern
Pond Heron Indian Pond-Heron Ardeola grayii R
Cattle Egret Cattle Egret Bubulcus ibis R
Mesophoyx intermedia
Median or Smaller Egret Intermediate Egret R
Egretta intermedia
Little Egret Little Egret Egretta garzetta R
Family: Charadriidae (Plover, Stilt, Oystercatcher, Lapwing, Avocet )
Black-winged Stilt Black-winged Stilt Himantopus himantopus R
Red-wattled Lapwing Red-wattled Lapwing Vanellus indicus R
Family: Jacanidae (Jacana
Bronze-winged Jacana Bronze-winged Jacana Metopidius indicus R
Family: Phalacrocoracidae ( Cormorant)
Indian Shag Indian Cormorant Phalacrocorax fuscicollis R
Little Cormorant Little Cormorant Phalacrocorax niger R
Family: Pteroclidae (Sandgrouse)
Indian Sandgrouse Chestnut-bellied sandgrouse Pterocles exustus R
Family: Threskiornithidae (Spoonbill and Ibis)
Black Ibis Red-naped Ibis Pseudibis papillosa R
White Ibis Black-headed Ibis Threskiornis melanocephalus R
V ORDER: COLUMBIFORMES
Family: Columbidae (Pigeon, Dove)
Blue Rock Pigeon Rock Pigeon Columba livia R
Ring Dove Eurasian Collared-Dove Streptopelia decaocto R
VI : ORDER: CORACIFORMES
Family: Dacelonidae (King fishers)
White breasted Kingfisher White-throated Kingfisher Halcyon smyrnensis R
Family: Meropidae (Bee Eater)
Small Green bee-eater Little Green Bee-eater Merops orientalis R
VII. ORDER: CUCULIFORMES
Family: Centropodidae (Cocucal)
Crow-Pheasant or Coucal Greater Coucal Centropus sinensis R
Family: Cuculidae (Cuckoo, Koel)
Koel Asian Koel Eudynamys scolopacea R
Indian Drongo Cuckoo Drongo Cuckoo Surniculus lugubris R
VIII. ORDER: GALLIFORMES

Old Common name New Common Name Scientific Name R-S

Family: Phasianidae (Peafowl , Partridge, Quail, francolin, spur fowl, jungle fowl, Monal)
Common Peafowl Indian Peafowl Pavo cristatus R
IX ORDER: GRUIFORMES
Family: Rallidae ( Waterhen, coot, crake water cock, Moorhen, Rail,)
White-breasted Water hen White-breasted Water hen Amaurornis phoenicurus R
Coot Common Coot Fulica atra R
Indian Moorhen Common Moorhen Gallinula chloropus R
Purple Moorhen Purple Swamphen Porphyrio porphyrio R
X. ORDER: PASSERIFORMES
Family: Paridae (Tit )
Grey Tit Great Tit Parus major R
Family: Corvidae
Coracina macei
Large Cuckoo-shrike Large Cuckoo-shrike R
Coracina novaehollandiae
Raven Common Raven Corvus corax R
House Crow House Crow Corvus splendens R
Tree Pie Rufous Treepie Dendrocitta vagabunda R
Family: Laniidae (shrike)
Rufous backed Shrike Long-tailed Shrike Lanius schach R
Grey Shrike Northern Shrike Lanius excubitor R
Family: Muscicapidae ( Short wing, Chat, Robin, Shama
Indian Robin Indian Robin Saxicoloides fulicata R
Pied Bushchat Pied Bush chat Saxicola caprata R
Family: Nectariniidae ( Sun Birds, Flower pecker, Spider hunter )
Purple Sunbird Purple Sunbird Nectarinia asiatica R
Small Sunbird Crimson-backed Sunbird Nectarinia minima R
Family: Passeridae ( Avadavat, Pipit, Wagtail, Munia, Snow finch, sparrow, weaver ,Accentor)
House Sparrow House Sparrow Passer domesticus R
Grey Tit Great Tit Parus major R
Family: Pycnonotidae (Bulbul, )
Red-vented Bulbul Red-vented Bulbul Pycnonotus cafer R
Family: Sturnidae (Myna, Starling)
Bank Myna Bank Myna Acridotheres ginginianus R
Indian Myna Common Myna Acridotheres tristis R
Rosy pastor Rosy Starling Sturnus roseus
Family: Sylviidae ( Warbler, Browning, Fulvetta ,Babbler, Laughing thrash, Tailor birds,
Common Babbler Common Babbler Turdoides caudatus R
Jungle Babbler Jungle Babbler Turdoides striatus R
Tailorbird Common Tailorbird Orthotomus sutorius R
XI. ORDER: PSITTACIFORMES
Family: Psittacidae (Parrot and Parakeet)
Rose-ringed Parakeet Rose-ringed Parakeet Psittacula krameri R
Order: Upupiformes
Family: Upupidae
Hoopoe Eurasian Hoopoe Upupa epops R
Note: R = Widespread Resident, W- winter visitor R/WM =Resident with winter influx as per the distribution given in WCMC&
BNHS
Source: Oriental Bird Club’s Check list of Indian Birds, Oxford university Press (2011), Birds of Indian Sub-continent
Kumar, A., J.P. Sati and P.C. Tak (2003): Checklist of Indian Waterbirds. BUCEROS 8 (1): 30 pp
3.13.10.2 Butterflies from the Study Area

Butterflies observed during the present study are documented in table 3.27.
Table 3.26 List of Butterflies

# Scientific name & family Common name
1 Family Papilionidae
1/1 Papilio polytes Linnaeus Common Mormon
2 Family: Pieridae
2/1 Eurema hecabe Linnaeus Common Grass yellow
3/2 Catopsilia pomona Fabricius Common Emigrant
# Scientific name & family Common name

4/3 Catopsilia pyranthe Linnaeus Mottled Emigrant
5/4 Ixias mariane Cramer White orange tip
6/5 Ixias pyrene Linnaeus Yellow orange tip
2 Family: Nymphalidae
7/1 Danaus genutia Cramer Stripped Tiger
8/2 Hypolimanas misippus Linnaeus Danaid egg fly
9/3 Mycalesis perseus Fabricius Common bush brown
3.13.10.3 Herpetofauna
One amphibian, skittering frog (Euphylyctis cyanophlyctis was sighted near the Gavier Talab in the study
area during the survey period. Reptiles document in the region is given in table 3.28.
Table 3.27 List of Herpetofauna

# Scientific name Common name
1 Calotes versicolor (Daudin) Common garden lizard
2 Eutropis carinata (Schneider) Common or Brahminy Skink
3 Ptyas mucosus (Linn.) Common rat snake
4 Varanus bengalensis ( Daudin) Common Indian monitor
5 Hemidactylus flaviviridis (Ruppell) House Gecko
6 Sitana ponticeriana ( Cuvier) Fan-Throated Lizard
7 Naja naja (Linn.) Indian Cobra 
8 Daboia russelii ( Shaw and Nodder) Russell’s Viper 
9 Bungarus caeruleus ( Schneider Common Indian Krait 
= Not sighted but included as per the information provided by villagers, during the interaction with them with pictorial
presentation
3.13.10.4 Mammals
The wild mammals observed other than domesticated ones from study area is documented in the table
3.29.
Table 3.28 List of Mammals

# Scientific name Common Name
1 Mus booduga (Gray) Indian field mouse
2 Herpestes edwardsi (Geoffroy) Common Mongoose
3 Lepus sp. Hare
4 Funambulus pennanii (Wroughton) Five striped Palm squirrel
5 Lutra lutra (Linnaeus),  Common Otter
6 Sufa scrofa (Linnaeus) Indian Wild boar
7 Pteropus giganteus( Brunnich) Indian flying fox
= Not sighted but included as per the information provided by villagers, during the interaction with them with pictorial
presentation.
3.13.11 Rare and Endangered Fauna of the Study Area

3.13.11.1 As per IUCN RED (2020) list
The IUCN Red List is the world's most comprehensive inventory of the global conservation status of plant
and animal species. It uses a set of criteria to evaluate the extinction risk of thousands of species and
subspecies. These criteria are relevant to all species and all regions of the world. With its strong scientific
base, the IUCN Red List is recognized as the most authoritative guide to the status of biological diversity.
Among the sighted fauna one bird, White-rumped Vulture (Gyps bengalensis ) is categorized by IUCN as
Critically Endangered while another bird, Black-headed Ibis (Threskiornis melanocephalus) and one
mammal Common Otter Lutra lutra (Linnaeus) fall under Near threatened category of IUCN Red data.
Table Threatened (Vulnerable) and Near Threatened and animals of the Study Area
Threat status
Species Habitat Location Coordinates Number
(IUCN, 2012)
White-rumped It occurs mostly in plains and Hazira 210 07’ 33.0” 1 Critically
Vulture less frequently in hilly regions. It region 720 37’ 12.2” Endangered
(Gyps feeds on carrion, both putrid and A2bce+4bce
bengalensis) fresh. While feeding ver 3.1
considerable aggregations can
form, and regular communal
roost sites are used. It is social
and usually found in conspecific
flocks. It breeds in colonies in
tall trees, often near human
habitation. Movements are
poorly known,
Black-headed It inhabits freshwater marshes, Hazira 21007’ 34.3” 4 Near threatened
Ibis lakes, rivers, flooded grasslands, 72038’40.2” ver.3.1
(Threskiornis paddy fields, tidal creeks,
melanocephalus) mudflats, saltmarshes and coastal
lagoons, usually in extreme
lowlands
Common Otter The Eurasian otter live in a wide Gavier lake 210 07’ 34.4” Secondary Near threatened
(Lutra lutra ) variety of aquatic habitats, 720 44’ 02.2” ver.3.1
including highland and lowland
lakes, rivers, streams, marshes,
swamp forests and coastal areas
independent of their size, origin
or latitude
Sources:
BirdLife International (2015) Country profile: India. Available from: http://www.birdlife.org/datazone/country/india. Checked: 2015-01-25 The
IUCN Red List of Threatened Species. Version 2014.3. <www.iucnredlist.org>.
3.13.11.2 As per Indian Wild Life (Protection) Act, 1972

Wild Life (Protection) Act, 1972, as amended on 17th January 2003, is an Act to provide for the protection
of wild animals, birds and plants and for matters connected therewith or ancillary or incidental thereto with
a view to ensuring the ecological and environmental security of the country. Among the birds in the, Pea
fowl (Pavo cristatus),) and White-rumped Vulture (Gyps bengalensis) are included in schedule I of Wild
life protection Act (1972), Most of other birds are included in schedule IV.
Some of the other sighted fauna were given protection by the Indian Wild Life (Protection) Act, 1972 by
including them in different schedules. Among the reptiles, Indian Cobra (Naja naja), and Common Rat
Snake (Ptyas mucosus) were provided protection as per Schedule-II of Wild life protection act, (1972).
Among mammals; Common Mongoose (Herpestes edwardsi), and Common Otter (Lutra lutra) are
schedule –II mammals. Wild Boars (Sus scrofa Linnaeus) are provided protection by incorporating them in
schedule–III,. Hares and five stripped squirrels are included in schedule IV, Indian Flying Fox (Pteropus
gigantus) is protected as schedule V of Wild Life Protection act 1972.
Schedule
Wild Life
Group Species Nearest village Coordinates Number
Protection
act 1972.
Hazira coastal 210 05’ 07.2” 3female
forest 720 38’ 11.2” 1 male
Birds Pea fowl (Pavo cristatus), Schedule I
Dumas coastal 21 05’ 06.2”
0
6 males
forest 720 43’ 01.4 5 females

Schedule
Wild Life
Group Species Nearest village Coordinates Number
Protection
act 1972.
White-rumped Vulture Hazira coastal 210 07’ 35.0”
1 Schedule I
(Gyps bengalensis) area 720 38’ 41.2”
Few other birds Throughout the area Schedule-IV
Indian Cobra (Naja naja), Secondary Schedule-II
Reptiles Common rat snake (Ptyas
Secondary Schedule-II
mucosus)
Common Mongoose 21 06’ 05. 8”
0
Hazira forest 1 adult Schedule-II
(Herpestes edwardsi), 720 37’ 58.2”
Common Otter Gavier lake 210 07’ 34.5”
1 Schedule-II
(Lutra lutra) 720 44’ 02.4”
Five striped Palm squirrel
Mammals Many places - >20 Schedule-IV
(Funambulus pennanii)
Wild Boars (Sus scrofa Hazira coastal
(Secondary)- Schedule-III
Linnaeus forest
Indian Flying Fox 210 10’ 55. 4”
Rajgiri village 4 Schedule-v
(Pteropus gigantus) 720 38’ 32.2”
The details of the conservation plan for the species Pea fowl (Pavo cristatus) and White-rumped Vulture
(Gyps bengalensis) is enclosed as annexure 17. The visibility of the white rumped vulture (Gyps
bengalensis) is found to be very rare and the local people have not reported the presence of the White-
rumped Vulture in the area.
3.13.12 Endemic Fauna of the Study Area

None of the sighted animal species can be assigned endemic species category of the study area.

Chapter – 4
Anticipated Environmental Impacts & Mitigation Measures
4.1 Identification and Evaluation of Impact
Various pollution sources concerning to wastewater generation includes the flue gas, and process gas
emissions, hazardous waste generation, noise generation related to ecology. The biodiversity impact along
with their qualitative and quantitative analysis as well as the effective control measures taken along with
mitigation measures are discussed herein with details. The Network method was adopted to identify the
potential impacts, which involves, understanding the cause-condition-effect relationship between an activity
and environmental parameters. This method involves the "Road Map" type of approach for the identification
of second and third-order effects. The basic idea is to account for the proposed modification project activity
and identify, the type of impact that could initially occur, followed by the identification of secondary and
tertiary impacts.
An impact can be defined as, any change in physical characteristics, chemical characteristics and biological
characteristics, cultural and social environment that can be attributed to activities related to alternatives under
study, for meeting the project needs.
An impact indicator is a parameter that provides a measure (At least some qualitative or quantitative sense)
of the significance and magnitude of the impacts. In India, the indicators developed by the Central Pollution
Control Board (CPCB)/ Ministry of Environment, Forest and Climate Change (MoEF&CC) in the form of
the standard parameters for water, noise, soil, air, hazardous waste, and ecology biodiversity, etc.
4.2 Predictions and Evaluation of Impacts

Evaluation is an absolute term used for the assessment and prediction by means of qualitative & quantitative
expression. Assessment is the process of identifying and interpreting the environmental consequences of the
significant actions while Prediction is a way of mapping these environmental consequences.
Significant action depicts direct adverse changes caused by the action and its effects on the health of biota
including flora, fauna and man, socio-economic conditions, landforms and resources, physical and cultural
heritage properties and the quality of bio-physics surrounds. Prediction requires scientific skills drawn from
many disciplines. The prediction of ecological components is often uncertain, because their response to
environmental stress cannot be predicted in absolute terms. The assessor (one who does the assessment) and
decision maker (one who takes the decision after adequate analysis of assessment report) is expected to be
aware of the degree of uncertainty. The assessor generally uses the specified methods and resources for impact
assessment
• Field surveys and monitoring

• Guideline and modeling
• Literature surveys and interviews
• Qualification and experience
The impact of the proposed modification project on the environment has been considered based on the
information provided by the proponent and baseline data collection of the study area during study period. The
environmental impacts have been categorized as long or short term and reversible or irreversible. Primary
impacts are those, which are attributed directly by the project while secondary impacts are those, which are
indirectly induced. These typically include the associated investment and changed pattern of social and
economic activities by the proposed modification. The operational phase of the proposed project comprises
several of which have been considered to assess the impact on one or another environmental parameter.
Scientific techniques and methodologies based on mathematical modeling are available for studying impacts
of various project activities on environmental parameters.

Minor and temporary impacts are expected due to the construction activities. All the impacts of construction
phase will be short term only and it is very limited as minor construction work is anticipated for requirement
of project.
Operation of the project carries the potential to affect the quality of life, air, noise, water, land, flora, fauna
along with the effect on human life on account of increase in air, noise and water pollution, increase in
hazardous waste generation, by pollution from spillage/surface run-off, by disturbance to flora and fauna, by
loss of trees resulting from increased assess, by increase in land values threatening agriculture, etc.
During the operation phase, the following activities are considered to have a significant impact:
• Air emission
• Noise generation
• Solid/Hazardous waste generation
• Water use and waste water discharge
• Employment Generation
4.3 Air Environment

4.3.1 Details of Environmental Impacts
A. During construction phase
Construction phase involves site cleaning, excavation, construction, grinding, cutting, erection or installation
of equipment & machinery, transportation and material handling. These activities result in the emission of
pollutants like dust, PM10, SO2 and NOx and fumes, into the atmosphere of the surrounding area.
To mitigate air pollution following measures will be adopted.

• Regular checking and maintenance of vehicles will be carried out.
B. During Operation phase:

Particulate Matter
Particulate matter (PM) is/shall be generated in each of the process steps, and may contain varying
concentrations of mineral oxides, metals (e.g. arsenic, cadmium, mercury, lead, nickel, chromium, zinc,
manganese), and metal oxides. Sources include all the stacks attached to the plants, handling of materials and
emissions include coal storage, conveying, charging, coking, pushing, and quenching.
Sulphur Dioxide
The main sources of SO2 from the steel plant operations are the coal used as a fuel and as a raw material. In
consideration to this, it is proposed to use low Sulphur blended coal.
Mitigation Measures to control SO2 emission:

- Selection of coal with low sulphur content
- Minimizing the sulphur content of the fuel
- Waste heat recovery systems
Nitrogen oxides:
NOx emissions will be due to high furnace temperature and the oxidation of nitrogen. NOx emissions are
associated with plant operations and fuel combustion, including the combustion of recycled coke oven gas;
hot stoves in the BF process, the use of process gases or high air combustion temperature in other plants.
Mitigation Measures to control NOx emission:

- Application of waste gas recirculation
- Use of oven batteries with multi-stage air supply systems

- Control of NOx with staggered heating in the oven & waste gas partial recirculation for reduction of
NOx will be done
The major sources of air pollution during operation phase are at source i.e. stack attached to existing steel
making facilities and with new proposed auxiliary facilities. Details of stacks along with emitted pollutants
is given in table 4.1.
Table 4.1 Details of Emission from Existing stack

Stack Stack Gas exit Gas Emission Rate (G/S)
Sr. No. Stack Attached to Height Diameter Velocity Temp.
(M) (M) (m/s) (K) PM SO2 NOx
1 Boiler of HRC Plant 30 1.25 8.49 470 0.04 0.03 0.06

2 CPP 31 -MW -HRSG 60 3.36 13.84 444 0.86 0.24 0.35
3 Reheating Furnace- I (PM) 88.5 4.017 8.59 605 0.22 0.17 0.49
4 Reheating Furnace II 88.5 4.017 8.79 370 0.3 0.16 0.68
5 Electric Arc Furnace I & II (PM) 45 4 15.1 343 0.54 - -
6 Electric Arc Furnace III (PM) 45 5.7 15.82 343 2.28 - -
7 Electric Arc Furnace IV (PM) 45 5.8 16.91 345 2 - -
8 CRM DSC Normalizing Furnace 30 1.6 5.59 370 0.04 0.03 -
9 Boiler No.1&2 of CRM 30 1.4 11.81 407 0.07 0.03 0.09
10 CRM - BAF 1 20 0.7 12.29 321 0.04 0.03 0.04
11 Heat Recovery Steam Generator (HRSG) - 25 MW 60 5 13.84 444 0.86 0.24 0.35
12 Reformer cum Recuperator- I (PM) * 30 3.7 18.83 628 4.93 - -
13 Reformer cum Recuperator - II (PM) * 30 3.7 19.18 614 5.14 - -
14 Reformer cum Recuperator- III [PM) * 30 3.7 18.95 633 4.92 - -
15 Reformer cum Recuperator - IV (PM) * 40 3.46 18.61 619 4.32 - -
16 Reformer cum Recuperator V 40 4.31 16.62 628 5.89 - -
17 Process dust collection system (PDCS) – I 20 0.9 19.94 325 0.5 - -
18 Process dust collection system (PDCS) - II 20 0.9 20.01 328 0.5 - -
19 Process dust collection system (PDCS)- III 20 0.9 20.92 329 0.52 - -
20 Process dust collection system (PDCS) – IV 20 0.7 20.2 335 0.49 - -
21 Process dust collection system (PDCS) - V 25 0.7 18.53 338 0.28 - -
22 Kiln - I 45 1.061 13.96 348 0.83 - -
23 Kiln - II 45 1.061 10.74 345 0.64 - -
24 Kiln - III 45 1.061 10.79 366 0.61 - -
25 Kiln – IV 45 1.061 10.74 342 0.63 - -
26 HCL Scrubber attached to Pickling operation - Line 1 25 1.2 7.29 290 - - -
27 HCL Scrubber attached to Pickling operation - Line 2 25 1.2 7.29 290 - - -
HCL Fume Scrubber attached to Acid Regeneration
28 25 0.6
Plant ARP 10.29 290 - - -
Fume Extraction System Attached to Cold Rolling Mill-
29 30 2
Line 1 8.29 285 - 0.52 0.06
Fume Extraction System Attached to Cold Rolling Mill -
30 30 2
Line 2 8.29 285 - 1.12 0.06
31 Gas Scrubber attached to Galvanizing operation-Line 1 30 0.6 10.29 525 - 0.09 0.04
32 Gas Scrubber attached to Galvanizing operation- Line 2 20 0.6 10.29 440 - 0.1 0.04


33 Pickling Line 3 30 0.8 0.29 3 - - -

34 Stove and Fume Extraction 75 6.3 4.99 376 6.07 0.15 1.17
35 Stock House 45 5 10.72 323 0.43 0.23 4.95
36 Turbo blower / Boiler 1 & 2 100 4 12.61 397 0.36 0.15 0.1
37 Slag Granulation Plant 70 4 - - - - -
38 Hot Metal Transfer / Fumes Exhaust 45 5.5 8.95 323 0.22 0.23 1.89
39 Sinter plant process stack (De Dusting) 45 5.5 15.56 348 15.62 0.25 0.52
40 Sinter plant process stack (Waste Gas) 60 3 17.01 371 1.9 0.12 0.22
41 Fume Extraction System (Conarc 1.1) 45 5.7 12.9 336 5.08 1.17 8.17
42 Fume Extraction System (Conarc 1.2) 45 6.13 18.4 334 2.01 2.1 14.29
43 Fume Extraction System (Conarc 2.1 & 2.2) 45 7.2 20.26 348 1.47 3.46 22.81
44 Tunnel Furnace – A Stack 1 60 2.1 14.89 996 0.07 0.04 0.45
47 Tunnel Furnace – B Stack 1 60 2.2 20.52 979 0.09 0.05 0.77
50 Tunnel Furnace – C Stack 1 60 1.93 21.65 984 0.06 0.12 0.8
53 Gas Flare (BF) 50 4 - - - 0.02 0.03
54 Pulverizad Coal Injection 50 1.3 11.82 327 - - -
55 De – dusting for mixer 50 4.1 11.82 327 0.31 - -
56 Reformer cum Recuperator VI 40 4.31 17.03 614 0.41 - -
57 Process dust collection system (PDCS) – VI 20 0.7 17.03 335 0.04 - -
58 Junction House – 2 3 30 0.7 19 331 0.03 - -
59 Junction House – 2 4 30 0.7 15.98 328 0.03 - -
60 FES of Cast House 1 30 4.2 11.62 320 0.17 - -
61 FES of Cast House 2 30 4.2 10.96 330 0.44 - -
62 Gas Flare 1 30 2.4 35.67 1676 - - -
63 Gas Flare 2 30 2.4 35.67 1676 - - -
64 FES Stock house oxide line 1 30 1.9 13.44 334 0.19 - -
65 FES Stock house oxide line 2 30 1.9 13.65 332 0.16 - -
66 FES Stock house Coal line 1 30 1.9 13.08 331 0.22 - -
67 FES Stock house Coal line 2 30 1.9 13.35 329 0.23 - -
68 De – dusting Coal Drying line no 123 30 2.3 13.1 334 0.32 - -
71 De – dusting Coal Transportation 1 30 1.388 10.03 332 0.06 - -
72 De – dusting Coal Transportation 2 18 1.388 10.64 334 0.14 - -
73 De – dusting Coal Blending 18 1.4 15.29 318 0.25 - -
74 Kiln – V 45 1.2 18.38 375 0.21 - -
75 Kiln – VI 45 1.2 18.65 390 0.22 - -
76 Kiln – VII 45 1.2 18.99 399 0.22 - -


77 RHF 1 & 2 106 3.64 25.48 623 0.15 0.91 3.85

78 Normalizing Furnace 1 30 1.7 14.53 394 0.15 0.15 1.36
79 Normalizing Furnace 2 30 1.7 13.66 387 0.12 0.13 1.12
80 Atstenising Furnace 1 30 1.6 13.59 365 0.11 0.08 0.79
81 Atstenising Furnace 2 30 1.6 13.77 387 0.11 0.12 0.92
82 Tempering Furnace 1 30 1.42 12.56 373 0.1 0.07 0.55
83 Cold leveler De – dusting system 30 1.4 10.29 326 0.17 - -
84 De-dusting Blower 1 30 0.64 10.43 325 0.05 - -
85 De-dusting Blower 2 30 1.4 12.24 326 0.25 - -
86 De-dusting Blower 3 30 0.64 10.43 325 0.05 0.02 0.03
87 De-dusting Blower 4 30 0.64 12.24 326 0.25 0.02 0.03
88 HRSG - 1 525 MW 68.6 5.9 13.84 444 0.86 0.24 0.35
89 HRSG - 2 525 MW 68.6 5.9 13.84 444 0.86 0.24 0.35
90 HRSG - 3 525 MW 68.6 5.9 13.84 444 0.86 0.24 0.35
91 GT-1 525 MW 30.5 5.6 11.81 407 - - -
92 GT-1 525 MW 32 5.6 11.81 407 - - -
93 GT-1 525 MW 32 5.6 11.81 407 - - -
Table 4.2 Details of Emission from Proposed stack

1 Boiler-VDVOD 30 1.25 8.2 467 0.02 0.01 0.03

2 Stack for Coal Feeding (Ferro Alloy Store) 20 0.5 19.91 332 0.47 - -
3 Caster 1: Steam Fan Exhaust 35 1.4 - - - - -
4 Caster 2: Steam Fan Exhaust 35 1.4 - - - - -
5 Caster 3: Steam Fan Exhaust-01 35 1.4 - - - - -
6 Caster 3: Steam Fan Exhaust-02 35 1.4 - - - - -
7 Gas Turbine – 31 MW 30 2.5 35.38 1673 0.05 0.01 0.06
8 Process Dust Collection System – DRI 20 0.7 10 437 0.05 - -
9 Module 2 Process Dust Collection Bubbler 60 1 16.72 368 0.21 - -
10 Module 2 Hot DRI Surge Bin Bubbler 30 0.5 10 522 0.05 - -
17 Turbo Expander Heater Stack 20 0.5 12 318 - - -
18 Chromic Dryer Blower - 01 for Galvanizing Line 1 30 0.5 8 282 - 0.5 0.03
19 Chromic Dryer Blower - 02 for Galvanizing Line 2 20 0.5 10 437 - 0.08 0.01
20 Alloy Furnace Fume Vent Common Facility for 30 0.2
10 522 - 0.07 0.01
Galvanizing Line 1&2


21 Hot Skin Pass Mill Vent 20 0.5 437 - - 0.01 437

22 PKL-3 (Boiler) 32 0.5 11.52 404 0.05 0.01 0.06
23 Kiln 1&2 Feeding and Storage 30 0.5 13.67 345 0.81 - -
30 DE System for Kiln 5 & 6 Feeding 25 0.7 11.53 324 0.29 - -
31 DE System for Kiln 7 & 8 Feeding 25 0.7 11.53 324 0.29 - -
32 DE System for Kiln 5 & 6 Product Junction House PJH-1 25 0.5 11.53 324 0.29 - -
33 DE System for Kiln 7 & 8 Product Junction House PJH-3 25 0.5 11.53 324 0.29 - -
34 Kiln – VIII 55 1.2 18.7 396 0.2 - -
35 Slag Granulation Plant (SGP-2) 70 - - - - - -
36 Product Bag Filter 36 1.45 8.2 467 0.02 0.01 0.03
37 Mixer Bag Filter 40 2 14.6 993 0.05 0.02 0.42
38 Cooler Stack 35 3.4 13.37 384 0.1 - -
39 Mixing Drum Steam Vent 20 2 12.29 321 0.4 - -
40 Boiler-RHTOB 32 1.55 11.52 404 0.05 0.01 0.06
41 CSP Caster 1: Steam Fan Exhaust 60 1.2 - - - - -
44 INI Caster: Steam Fan Exhaust 30 1.2 - - - - -
45 Corex 1 Tower Top De-dusting 30 0.5 11.53 324 0.29 - -
46 Corex 2 Tower Top De-dusting 30 0.5 11.53 324 0.29 - -
47 Corex 1 Slag Granulation Plant (SGP) 30 1 - - - - -
48 Corex 2 Slag Granulation Plant (SGP) 30 1 - - - - -
49 Smoke Unit - Extruder Fume Stack (Coating Plant) 15 0.95 15 315 0.23 - -
50 Epoxy Booth Stack (Coating Plant) 15 0.5 14 315 0.1 - -
51 De-dusting Blower 1 (New Coating Plant) 32 0.5 16.74 332 0.02 - -
52 De-dusting Blower 2 (New Coating Plant) 32 0.5 16.74 332 0.02 - -
53 De-dusting Blower (New Coating Plant) 32 0.7 16.74 332 0.02 - -
54 Epoxy Stack Vent (New Coating Plant) 20 0.5 19.65 322 0.48 - -
55 Smoke Unit - Suction Blower (H-Saw 1) 12 0.65 20.63 326 0.5 - -
56 CSH - Wet Coal Screen House 25 0.7 18.24 335 0.26 - -
57 OSS - Oxide Screen House 25 0.7 18.24 335 0.26 - -
58 NJH 22 - CC25 Head End 25 0.7 18.24 335 0.26 - -
59 JH23 - CC115 Tail End 25 0.7 18.24 335 0.26 - -
60 JH9A - CC 27, 28 Head End 25 0.7 18.24 335 0.26 - -
61 NJH-10: GJ3 Conveyor for Handling BF Coke 20 0.5 19.65 322 0.48 - -
62 NT-20-A: BF1 Conveyor for Handling BF Sinter Feeding. 20 0.5 19.65 322 0.48 - -
63 NT20-1-NC47 Conveyor for Handling Oxide to BF 20 0.5 19.65 322 0.48 - -


64 Junction House JH3A : Coal Feeding to Corex 20 0.5 19.65 322 0.48 - -
65 Junction House JH4A : Coal Feeding to Corex 20 0.5 19.65 322 0.48 - -
66 Junction House 2 20 0.5 19.65 322 0.48 - -
67 Dust Extraction System of Rotary drier 30 1.2 15.69 325 0.01 - -
68 HCL Fume Scrubber attached to Acid Regeneration Plant 35 1.2 - -
(ARP) - - -
69 Chimney 8 0.6 10 437 - 0.08 0.01
70 Rotary Kiln 30 1 10 323 0.15 - -
71 Kiln silo Dedusting system 10 1 10 323 0.15 - -
72 Limestone silo Dedusting system 10 1 10 323 0.15 - -
73 Thick plate Normalizing Chimney 30 1.2 11.95 323 0.23 - -
74 EAF Secondary Emission Control System 45 6.5 18.11 331 1.99 - -
75 Pickling Section 25 - - - - - -
76 Pickling Section 30 - - - - - -
77 Acid Regeneration Plant 25 - - - - - -
78 Tandem Mill Section in PLTCM 5 - - - - - -
79 Furnace of Galvanizing Lines (CGL#3 & CGL#4) 30 - - - - - -
and Annealing Lines
80 Dust Extraction System of Rotary drier 30 1.2 10.83 379 0.04 - -
81 Dust Extraction system for transfer points of belt conveyors 21 2.5 14.56 435 0.05 - -
82 Battery chimney – 1 125 5 8.3 439 5.09 9.86 9.57
83 Battery chimney – 2 125 5 8.3 439 5.09 9.86 9.57
84 Coke pushing ground de-dusting chimney 125 5.13 5.13 600 2.72 5.27 5.12
85 Environmental de-dusting system stack for CDQ 125 5.13 5.13 600 2.72 5.27 5.12
86 Battery chimney – 1 & 2 145 5 1.77 493 1.14 18.28 11.42
87 Coke pushing side de-dusting chimney 30 2.5 8 330 1.83 3.55 3.45
88 Coke pushing ground de-dusting chimney 30 2.5 8 330 1.83 3.55 3.45
89 Environmental de-dusting system stack for CDQ 50 1.8 10 330 1.19 5.27 5.12
Evaluation of Impacts using mathematical model

The dispersion of pollutants in the atmosphere is a function of several meteorological parameters viz.
temperature, wind speed and direction, mixing depths, inversion level, etc. A number of models have been
developed for the prediction of pollutant concentration at any point from an emitting source.
Atmospheric Dispersion Modeling System (AERMOD) is a steady-state plume model that incorporates air
dispersion based on planetary boundary layer turbulence structure and scaling concepts, including treatment
of both surface and elevated sources, and both simple and complex terrain.
The stable boundary layer (SBL), assumes that the concentration distribution is Gaussian in both the vertical
and horizontal direction. In the convective boundary layer (CBL), the horizontal distribution is also assumed
to be Gaussian, but the vertical distribution is described with a bi-Gaussian probability density function (pdf).
This behavior of the concentration distributions in the CBL was demonstrated by Willis and Deardorff (1981)
and Briggs (1993).
Additionally, the CBL and AERMOD treats “plume lofting,” whereby a portion of plume mass, released from
a buoyant source, rises to and remains near the top of the boundary layer before mixing into the CBL.
AERMOD also tracks any plume mass that penetrates into the elevated stable layer, and then allows it to re-

enter the boundary layer if and when appropriate. For sources in both the CBL and the SBL AERMOD treats
the enhancement of lateral dispersion resulting from plume meander.
There are two input data processors that are the regulatory components of the AERMOD modeling system:
AERMET, a meteorological data preprocessor that incorporates air dispersion based on planetary boundary
layer turbulence structure and scaling concepts, and AERMAP, a terrain data preprocessor that incorporates
complex terrain using USGS Digital Elevation Data.
The input data used for the modelling is as specified.
Micrometeorological Data:
Site specific micrometeorological data i.e. ambient temperature, Relative Humidity, wind speed, wind
direction, Cloud Cover, Rainfall, etc. were collected from the study area. Details of micrometeorological data
is presented and discussed in section 3.4.1 of Chapter-3
Mixing Height: Mixing Height (MH) is the vertical extent through which the contaminant plume can be
mixed. Forecasting of mixing height is done with the aid of the vertical temperature profile. The MH is a
function of stability. In unstable air the MH is higher and in stable air the MH is lower. With a lower MH,
there is a smaller volume of air in which the pollutant can be dispersed, resulting in higher concentrations in
the ambient environment. There is a seasonal variation of MH. During summer daylight hours, MH can be
few thousand feet whereas for winter it can be a few hundred feet. It varies also during the course of a day. It
is lowest at night and increases during the day. Secondary information has been used to determine the mixing
height over the study region for the study period (October 2020 to Dec, 2020) and it varies from 50-2600
meters (IMD).
Based on the atmospheric dispersion modelling result under observed meteorological condition, 24 hours
average maximum Ground Level Concentration (GLC) of PM, SO2 and NOx average over 24 hours are
estimated to be approximately 44.62, 45.82 and 25.69 g/m3 respectively and expected to occur in the
southwest at a distance of about 4.43 km from the center of project site. The modeling results are given in
table 4.2 and 4.3

Figure 4.1 Spatial distribution of 24-hour average pm conc. (g/m3)
Figure 4.2 Spatial distribution of 24-hour average SO2 conc. (g/m3)

Figure 4.3 Spatial distribution of 24-hour average NOx conc. (g/m3)
Table 4.3 Summary of AERMOD Model Output

Sr. LOCATIONS Maximum Incremental Concentration (µg/m3)
No. Due to Proposed Modification Due to Cumulative Impact
PM SO2 NOx PM SO2 NOx
1. Project site 2.24 2.79 1.36 2.58 11.52 2.13
2. Hazira 20.79 10.33 7.86 22.88 11.35 8.14
3. Nand Niketan 0.15 0.18 0.12 1.43 0.22 0.49
4. MRSS Building 0.88 1.41 0.95 1.15 1.58 0.97
5. Sunvali 0.15 0.18 0.12 0.15 0.18 0.12
6. Vanta 5.86 5.37 2.43 7.2 6.13 3.97
7. Mora 0.15 0.18 0.12 0.15 0.18 0.12
8. Dumas 10.44 8.99 4.32 11.91 9.38 6.38
Table 4.4 Maximum Ground Level Concentration

Sr. Parameters Maximum Ground Level Concentration
No. Due to Proposed Modification Due to Cumulative Impact
1. PM 44.62 g/m3 at 5.5 km in SSW direction 49.31 g/m3 at 6.8 km in SSW direction
2. SO2 45.82 g/m3 at 4.5 km in SSW direction 46.74 g/m3 at 4.5 km in SSW direction
3. NOx 25.69 g/m3 at 3.3 km in SSW direction 29.29 g/m3 at 3.6 km in SSW direction
4.3.2 Mitigation Measures Suggested Based on Air Dispersion Modelling:

• Adequate pollution control equipment like bag filter, ESP scrubber etc. along with online
• There shall be periodic checkup of all APC equipment to ensure proper functioning.

4.3.3 Secondary Fugitive Emission & Mitigation Measures

Following are the source of fugitive emission
• From the Loading and Unloading section of the plant
• From the activity in raw material storage, waste storage and product storage area
• From the transfer point of raw materials to the production area
• During the movement of vehicle in the plant area
• Raw material conveying between processing stages; and
Following control measures to prevent fugitive emission will be followed,

• Fume Extraction system has been modified and revived for efficient suction.
• Dust collection and extraction system is strengthened.
• Bag house capacity is increased & filter bags have been replaced.
• Manual water sprinkling is going on, in & around the plant as well as on roads
• 7 Road sweeping machines are provided for effective road cleaning.
• Manual cleaning of the roads and the surrounding areas is enhanced by increasing additional
manpower to 270 nos. per day.
• Regular cleaning of Factory shed is being done to remove dust deposition
• Conveyor belt cover will be installed at conveyor.
• For dust storage, Silo will be provided.
• All internal road area is/will be paved.
• It shall be ensured that the vehicle speed is limited.
• Proper housekeeping shall be made certain.
• Airborne dust shall be controlled through wetting of road
• Green belt will be developed in and around the plant area to arrest the fugitive emissions.
• All the workers shall be provided with disposable dust mask.
• Enclosures for all unloading operations
• Spraying of water prior and during loading
• Fully enclosed transfer point
• Dust extraction system at all transfer points
a) Suction is drastically improved by revival and modification of duct system.
b) Filter bags are replaced and bag house size increased with high suction capacity

Replacement of Bag-filters at - FES systems
Implementation of Wind Fence Cladding System (for arresting fine particles)
Control of fugitive emission due to vehicular movements

Deployment of water sprinklers
New battery operated scrubber machine used inside plants
Action Plan to reduce fugitive emission

Action Plan Cost
Sr. Target
Plant (Rs. In Status
No. Short Term Long Term Date
Cr)
1. SMP-2 Conarc-1 Leakage
Plant Handling & Control:
▪ Raw gas leakage
Dec-
from punching plate - 0.1143 Completed
2020
bag snap ring.
▪ Air leakage from
pulsing valve.
Conarc 2 RABH Bag - Jan-
2.4311 Completed
Replacement 2021
Conarc-1 Spare ID fan including Dec- Purchase Order (PO) -
- 0.905
casing 2021 4500287050 placed.
Bellow Replacement in C1, C2, C3 Purchase Order (PO) -
& C4 Compartment. 4400140266,
C1 Compartment - New water 4400141064,
cooled ducts fabricated, Expansion 4400142279,
bellows procured and already 4400143325,
planned for replacement. 4500277693,
1. D1, D3, D4 & ACD along with 4500265065,
bellow replacement. 4500277693,
2. Bellow replacement from FDC to 4500277761,
Bag house. 4500278988,
C2 Compartment Dec- 4500278989,
- 4.3362
1. D3 & D7 along with ACD 2021 4500278656,
replacement. 4500270694,
2. Tube bundle fabrication and 4500250018,
replacement. 4400140953 placed.
3. Bellow replacement from FDC to
Bag house.
C3 Compartment Service Purchase
1. D1, D2 & D4 replacement. Requisition (SPR) -
2. Bellow replacement from FDC to 2000100619,
Bag house. 2000099067,
C4 Compartment

Action Plan Cost

Sr. Target
Cr)
P2, P5, D1, D2, D3, D4 replacement 2000100630,
and duct rectification. 2000100640 Placed.
Bellow replacement from FDC to
Bag house.
LRF - Impeller and casing Purchase Order (PO) -
replacement. Dec- 4500270053,
2.8004
2021 4500270180,
4500280098 Placed.
Damper fixing in HMPS & Linear Purchase Order (PO) -
Actuator replacement in LF & 4500276171,
Canopy 4500280098,
Dec- 4500270180,
0.7415
2021 4500277598,
4500281867 &
Purchase Requisition
(PR) 33033202 Placed.
Lime Plant 2 (LP-2)
2 Lime Kiln 5 & 6 - Replacement of all 0.55 Dec- Purchase Requisition
Plant – filter bags and cages. 2021 (PR) - 33062754
2 ▪ Replacement of all filter bags Placed.
(LP-2) and cages. – Filter bags
replacement completed for
Kiln5 in Jan2021. Kiln6 part
replacement planned in
March2021.
▪ Installation of baffle plates at
-
bag house inlet. Baffle plates
designed in-house and fixed in
kiln 5 & 6 bag house.
▪ Engineering, manufacturing
and installation of Inlet and
outlet dampers with actuator
for operations.
▪ Manual dampers designed in-
house and fixed in kiln5.
Environment Improvement Photographs – SMP2
Ongoing work of Water-Cooled Duct Fabrication & Erection New impeller casing Installation
Corex Plant
3 Corex Skid Steer for cleaning
Jan-
in tower and stock - 0.25 Completed
2021
house surrounding area
Installation of retainer Feb-
- 0.55 Completed
wall in de-dusting silo 2021
Wind Screen Installation in between Sep- Purchase Requisition
- 0.2
CDP /ASU 2021 (PR) – 33056857 placed.
Concrete flooring for road and Oct-
- 0.40 Under Progress
Conveyor bottom area 2021
Provision of additional bin at JH-24 Nov-
- 0.5 Under Progress
and JH-25 2021
Concrete Flooring at Coal De-
Dec-
- dusting, Skip feeding and Stock 0.15 Under Progress
2021
house junction house area

Action Plan Cost

Sr. Target
Cr)
Bag replacement in Coal de-dusting
system in stage wise & Rectification
Purchase Order
of purging system and pneumatic
4500285248 &
conveying system.
4500280501 placed for
▪ Stage 1: 500 bags - Completed
bags.
in Aug’2020
▪ Stage 2: 1500 bags -will be Dec-
- 1.49 Purchase Order:
replaced in Corex 1 coal de- 2021
4400144976 &
dusting, CODT 1 and CDP
4400145874 placed for
line# 5.
bag installation.
▪ Stage 3:1500 bags - will be
Purchase Order:
replaced in CDP de-dusting.
4400147279 placed.
▪ Stage 4: 1500 bags – will be
replaced.
▪ De-dusting Coal Blending
- Dec-
station - Refurbishment of 0.7 Under Progress
2021
system.
Environment Improvement Photographs - Corex
Blast Furnace
Action Plan Cost
Sr. Target
Cr)
5 Blast Cast House 0.749 Feb- Completed
Furnace Bag Filters - 2021
Installation
PCI bag filter 0.0105 Feb- Completed
-
replacement. 2021
Concreting of Boiler and 0.86 Dec- Service Purchase Requisition (SPR)
-
Stock house road. 2021 No. 2000097635 placed
Stock House de-dusting bag 0.025 Dec- Service Purchase Requisition (SPR)
-
filter replacement. 2021 No. 2000099022 placed
Stock House Bag Filters 0.75 Dec- Purchase Requisition (PR) 33066464
-
Installation 2021 placed
Stock House Modification in 5.8 Dec- Service Purchase Requisition (SPR)
Oxide & Coke route De- 2021 27010902, 27011182 placed.
dusting and Additional de- Purchase Requisition (PR) –
dusting system Installation 28022733,28023176,
- for Tripper Level. 28024200,28024866 placed.
Purchase Order (PO) – 5200012368,
5200012259, 5200012228,
5200012249, 5200012432,
5200012839 placed
Concreting at stock house 0.75 Dec- Under Progress
-
area. 2021

Wind fence Installation 0.0673 Dec- Under Progress

-
around stock house 2021
Mechanized house-keeping 0.75 Dec- Under Progress
- for BF internal road and shop 2021
floor
Hot metal Transfer/Fumes 10 Dec- Under Progress
- Exhaust (Cast House) 2021
Installation
PCI Bag Filters Installation 0.2902 Dec- Under Progress
-
2021
De-dusting for mixer 0.9 Dec- Under Progress
additional suction point for 2021
-
ladle lancing and revamping
of existing system
Sinter Plant
Sr. Action Plan Cost Target
Plant Status
No. Short Term Long Term (Rs. In Cr) Date
6 Sinter Upgradation &
Jan-
Plant Revamping of De- - 9.2 Completed
2020
dust ESP
Installation of May-
- 4.5 Completed
Product Bag Filter 2020
Installation of Mixer Dec-
- 5.2 Completed
Bag Filter 2020
Concrete Flooring for proper & Purchase Order
Timely Cleaning. May- (PO) –
- 1
2021 5200012443
placed.
Pneumatic Dust handling system Purchase
Installation for eliminating very Requisition (PR) -
Micro-fines dust handling in Dec- 28022877 placed.
- 6.5
Conveying system. 2021 Offers are received
and under
Technical Review.
Purchase
Requisition (PR) -
Upgradation of Waste Gas ESP Dec- 28024920 placed.
- 28
system. 2021 Final Negotiation
with the vendor in
progress.
Complete Revamping for the De-
Dec-
- Dusting Network with 2.5 Under Progress
2021
upgradation of the Fan.
Environment Improvement Photographs – Sinter Plant
Upgradation & Revamping of De-dust ESP Product Bag Filter – New Installation
Sinter Plant Road Cleaning Photographs Water sprinkling activity in sinter plant

HRC Division – GPCB Login ID 20680
Sr. Plant Action Plan Cost Target Status

Short Term Long Term
1 Steel Step-1 EAF1 primary - 9.78 Jan-2020 Completed

Making Fume Extraction system
Plant – 1 up gradation.
(SMP-1) Step-2 EAF2 primary - 7.1 Jun-2020 Completed
Fume Extraction system
up gradation
Step-3 EAF3 primary - 5.68 Sep-2020 Completed
Fume Extraction system
up gradation
Step-4A LF1, LF2, Lf3 - 4.57 Jan-2021 Completed
Fume extraction
modification
- Step-4B LF-MH Bag- May-2021 Purchase Requisitions (PR) &
house Extension Purchase Orders (PO) placed for Rs.
(78% Completed) 11.97 Cr.
- Step-4C MFS Duct Dec-2021 Work in progress.
work and capacity
enhancement Purchase Requisition (PR) -
- Step-5 EAF4 Bag- 6.41 Sep-2021 28023748, 28024936, 33055513,
house Extension work 28024888, 28024525, 28024932,
27010730, 27011599, 27010721,
- Step-7 35m level 7.2 Dec-2021
27011099, 27011558, 27010584,
Ventilation
27010584 Placed.
Purchase Order (PO) / Work Order -

5200012589, 5200012396,
5200012372, 5200012372,
5200012815, 5200012806,
5200012451, 5300042865,
5300043699, 5300043101,
5300043885, 5300043026,
5300043360, 5300043697,
5300042947, 5300042884,
5300043931, 5300043350 placed.
- Step-6 EAF 38.62 Dec-2021 Design Engineering is in progress.

Secondary Emission
control System

4.4 Water Environment

With regard to water environment, three aspects are generally considered in EIA, the raw water availability,
consumption and wastewater generation. The first priority in water quality assessment is maintenance and
restoration of the desirable level of water quality in general.
4.4.1 Raw Water Availability

AMNS has two reservoirs with 360,000.00 m3 and 180,000.00 m3 capacities. This water is being sourced
from the Tapi river. The water intake permission from the Narmada Water Resources Water Supply and
Kalpsar Department Division Surat.
4.4.2 Construction Phase Impacts and Mitigation Measures

During Construction, drainage pattern and water supply system of overland water flow will be somewhat
changed due to the site preparation activities.
The local labor force will be deployed during construction phase and no colony has been proposed for
laborer’s as the workers will be employed from the nearby local village. During the construction phase of the
project, water requirement will be mainly for domestic purpose, construction activities, growing plants, etc.
As construction labor will be from local area, minor quantity of domestic water will be required. Proper
drinking water facility and sanitation facility will be provided to the construction worker. Generated domestic
waste water will be treated through the existing STP and treated water will be reused in the development of
green belt/ green cover. So, impact on the ground water and surface water will be negligible and it poses
minimum danger of contamination of ground or surface water in the nearby areas.
4.4.3 Operation Phase Impacts and Mitigation Measures

Existing Scenario
used for the industrial purposes. Detailed water balance is given in water balance diagram 2.6. of chapter 2.
Proposed scenario
purpose 1,41,264.00 m3/day and domestic purpose 12064 m3/day). Water will be sourced from the Tapi river.
reject will be generated. RO reject will be disposed to TSDF. The proposed water balance diagram is given
in figure 2.7 of chapter 2. There are three STPs dedicated to treat domestic waste water generated and treated
water will be used for plantation inside the premises.
4.4.4 Impact of Ground Water and its Mitigation Measures

For the proposed modification project, entire water will be sourced from surface water source and hence there
will be no impact on ground water due to water consumption requirement. However, rain water harvesting
practice will be followed to improve ground water condition.

During the industrial activities there may be a chance of contamination in ground water by leachate generation
from spillage of hazardous chemicals, storage of raw materials, finish products and solid waste., etc. following
mitigation measures for avoiding contamination of ground water will be implemented.

4.4.5 Execution Plan for Impervious flooring/RCC Flooring in Stock Yards

AMNS has presently 4 nos raw material storage stock yards. The storage capacity of stockyards is given in
table 4.5.
Table 4.5 Details of stockyards

Sr. No. Stockyards Storage Capacity
1. Coal Stockyard 0.030 MMT
2. Coke Stockyard 0.012 MMT
3. Flux Stockyard 0.020MMT
4. Oxide Stockyard 1.20MMT
4.4.6 Action plan to avoid leaching of materials to the ground water

- All the yards have RCC flooring after hard surface rolling and compacting so there is no chance of
water and slurry contamination in below ground level.
- Stock yards will have proper drainage system and retaining wall to evacuate ground water easily.
- Drain and retaining wall in Coal Yard, coke yard and flux yard is already available while in oxide yard
the same is under construction
Figure 4.4 RCC/Impervious flooring network

Figure 4.5 Drain and retaining wall drawing
Figure 4.6 Drain and retaining wall drawing Oxide yard.

4.5 Soil Environment

construction and operation activities. In addition to this accidental spillage of chemicals and effluent can also
degrade the soil environment.
4.5.1 Construction Phase Impact and Mitigation Measures

The proposed modification will be located on flat terrain no significant topographical change is expected due
to construction activities. Construction of proposed auxiliary facilities will help in fixation of soil, thereby
reducing the soil erosion.
Some construction operations shall disturb the soil profile, but the impact will be insignificant and well within
plant premises. The project did not involve displacement of any population.
4.5.2 Operation Phase Impact and Mitigation Measures

During operation phase of the project there will be generation of solid and as well as hazardous. Plane wise
details of hazardous waste generation and disposal method is given in the Chapter-2 section 2.12.
Chemical Composition of Solid waste

Chemical composition of solid waste is presented in given table 4.6.
Table 4.6 Chemical Characteristic of Solid Waste

Sr. No. Plant Solid Waste Chemical composition
1 MOD I-VI Iron Ore Fines This can be taken similar to Corex Plant Iron Ore Fines Fe (T)-
62.46; FeO-7.74, SiO2-3.71, Al2O3-2.37; CaO,2.04;
MgO,0.54; MnO,0.07; TiO2,0.12; P,0.04; Na2O,0.02;
K2O,0.02; ZNO,0.01; LOI,2.28
DRI Fines(Cyclone fines) sample received once and chemistry is : TFe ,83.51; MFe
,65.83; MetZ ,78.83; Carbon ,3.04; Sulphur ,0.0019;
Moisture,3.98;
Q.T Fines Tfe % - 85.98 ; Mfe % - 77.22 ; Metz - 89.82, FeO – 11.27% ;
Carbon – 2.96% ; Sulphur - 0.00061.
Sludge Pond Fines sample received once and chemistry is : TFe ,67.08; MFe
,8.93; Carbon ,1.56; Sulphur ,0.01; SiO2,3.78; Al2O3,1.56;
CaO,1.36; MgO,0.39; MnO,0.1; TiO2,0.09; P,0.03;
Na2O,0.06; K2O,0.007; ZnO,0.004; Moisture,14.5;
2 Corex Plant Iron Ore Fines Fe(T),62.46; FeO ,7.74; SiO2,3.71; Al2O3,2.37; CaO,2.04;
MgO,0.54; MnO,0.07; TiO2,0.12; P,0.04; Na2O,0.02;
K2O,0.02; ZNO,0.01; LOI,2.28;
Lime Stone fines Fe2O3 - 0.12%, SiO2 - 0.76%, Al2O3 -0.34%, CaO-54.05%,
MgO-1.10%, Na2O-0.030%, K2O-0.032%, LOI-43.05%.
Dolomite fines Fe2O3 - 0.2%, SiO2 - 1.07%, Al2O3 -0.32%, CaO-32.26%,
MgO-19.45%, Na2O-0.027%, K2O-0.030%, LOI-46.10%.
Granulated slag SiO2,32.51; FeO,0.41; Al2O3,17.87; CaO,37.91; MgO,9.13;
MnO,0.12; TiO2,0.47; S1,0.7; K2O,0.38; Na2O,0.19;
Dry pit slag SiO2- 31.22%, FeO- 0.38%, Al2O3- 18.17%, CaO- 38.19%,
MgO- 9.94%, MnO- 0.10%, TiO2- 0.34%, S1- 0.79%, K2O-
0.28%, Na2O- 0.10%
Dedusting dust FC-62-64%, Ash – 9-12 %, VM-24-26%.
Sludge MOISTURE,51.86; ASH,60.26; VM,9.53; CARBON,34.79;
SULFUR,0.65; TFe,32.6; SiO2,5.75; Al2O3,4.15; CaO,6.07;
MgO,1.51; MnO,0.11; TiO2,0.2; P,0.16; Na2O,0.07;
K2O,0.44; ZnO,0.11;
Coal Fines Ash, 9.37; VM, 27.68; FC, 59.59; S, 0.52;
Coke fines TM %,4.03; Ash,21.12; VM,1.99; FC,76.89;

Sr. No. Plant Solid Waste Chemical composition

CDP dust Ash,11.02; VM,24.63; FC,64.35;
3 Blast Furnace-1 BF Return Fines Fe(T),56.85; FeO ,5.1; SiO2,5.39; Al2O3,2.15; CaO,6.98;
MgO,1.66; MnO,0.12; TiO2,0.13; P,0.06; Na2O,0.04;
K2O,0.04; ZNO,0.01; LOI,2.36;
Granulated slag SiO2 35.04; FeO 0.55; Al2O3 18.51; CaO 35.47; MgO 7.4;
MnO 0.16; TiO2 0.71; S1 0.73; K2O 0.62; Na2O 0.51;
Dry pit slag As per BF TCG Pit slag will have same chemistry as
granulated Slag
Dedusting dust(Cast Cast House Dust : Fe (T),65.7; SiO2,1.5; Al2O3,0.52;
house&Stock house) CaO,0.86; MgO,0.44; MnO,0.15; TiO2,0.07; P,0.14; S,0.17;
Na2O,0.13; K2O,0.39; ZnO,0.09; LOI,1.58;
Stock House Dust : Fe (T),33.03; SiO2,6.77; Al2O3,3.87;
CaO,14.51; MgO,3.71; MnO,0.13; TiO2,0.12; P,0.07; S,0.31;
Na2O,0.05; K2O,0.48; ZnO,0.07; LOI,25.2;
Sludge Fe (T),39.76; SiO2,1.01; Al2O3,4.58; CaO,2.13; MgO,1.05;
TiO2,0.1; P2O5,0.11; SO3,0.43; Na2O,0.18; K2O,0.13;
ZnO,0.65; LOI,32.48;
Dust Catcher dust Fe (T),35.43; SiO2,1.13; Al2O3,4.54; CaO,2.32; MgO,1.12;
TiO2,0.11; P2O5,0.12; SO3,0.51; Na2O,0.18; K2O,0.27;
ZnO,0.33; LOI,38.45;
Coke fines Ash,17.14; V.M,3.02; Fix Carbon,79.84;
4 SMP-1 EAF Slag % CaO,31.84; % MgO,6.07; % SiO2,17.62; % Fe,20.79; %
Al2O3,7.61; % MnO,0.51; % P2O5,0.67; Basicity
CaO/SiO2,1.82;
LF slag % CaO,58.84; % MgO,4.43; % SiO2,4.62; % FeO,0.96; %
Al2O3,25.42; % MnO,0.92; % S,0.16; V Ratio,2.11;
FES dust Only one sample analysed : Fe,49.27; SiO2,2.47; Al2O3,0.52;
CaO,12.94; MgO,5.95; MnO,0.4; TiO2,0.04; P,0.11; S,0.19;
Na2O,0.36; K2O,0.65; Total alkali,1; ZnO,0.35;
5 SMP-2 Slag % CaO,38.71; % MgO,4.93; % SiO2,15.08; % Fe,21.42; %
Al2O3,4.35; % MnO,0.5; % P2O5,1.72; Basicity
CaO/SiO2,2.59;
LF slag % CaO,58.59; % MgO,4.31; % SiO2,2.01; % FeO,1; %
Al2O3,28.01; % MnO,0.91; % S,0.32; V Ratio,2.12;
HMPS SLAG TFe - 61.38, MFe-58.23%, SiO2-17.59%, Al2O3-11.03%,
CaO-3.89%, MgO-1.78%, Carbon - 3.21%, Sulfur-0.05%
FES dust Only one sample analysed : Fe,60.41; SiO2,1.43; Al2O3,0.19;
CaO,7.98; MgO,2.02; MnO,0.33; TiO2,0.02; P,0.09; S,0.19;
Na2O,0.27; K2O,0.59; Total alkali,0.86; ZnO,0.21;
6 Lime Plant Lime fines CaO-86.8%, MgO-2.68%, SiO2-1.52%, R2O3-2%, L.O.I.- 7%
Dolime fines CaO- 51.52%, MgO- 35.06%, SiO2- 1.39%, R2O3- 1.43%,
L.O.I.- 9.28%
9 Caster 1,2,3, INI, Mill Scale One Sample CSP mill : Fe(T),65.15; Fe2O3,99.23; MnO,0.23;
HSM, CSP, CSPM, SiO2,0.16; MgO,0.11; CaO,0.08; Al2O3,0.08; TiO2,0.01;
PM K2O,0.01; CuO,0.01; ZnO,0; MoO3,0; C,0.16; S,0.01;
10 CRM Iron Oxide TFe-69.16%, Fe2O3-98.89%, SiO2-0.25%, Al2O3-0.26%
11 Refractory Debris Grog+Muk Grog- Mgo-75-80 %, SiO2-2.34 %, Al2O3-9.65 %, CaO-
6.72 %, Fe2O3-2.53 %
MgC birck - MgO:97%, CaO:1.5%, Fe2O3:0.5%, SiO2:0.7%,
Al2O3:0.2%
HA Brick Al2O3:70%, Fe2O3:3%
DRM: MgO:75%, Fe2O3:3.6%, CaO:20%, SiO2:0.6%,
Al2O3:0.3%
Castable : Al2O3:85-90%, Fe2O3:1.5%, CaO:06%

Trace/heavy Metals
Parameters unit Blast Blast Corex Corex Corex SMP SMP SMP 2 SMP
Furnace Furnace Dry Granulated Sludge 1 LF 1 Conarc 2 LF
Dry Pit Granulated pit Slag Slag EAF Slag Slag
Slag Slag Slag Slag
Arsenic (mg/L) ND ND ND ND ND ND ND ND ND
Cadmium (mg/L) ND ND ND ND 0.1 0.045 ND ND ND
Lead (mg/L) 0.6 0.67 0.56 0.29 3.2 0.69 0.19 0.26 1.14
Mercury (mg/L) ND ND ND ND ND ND ND ND ND
Antimony (mg/L) ND ND ND ND ND ND ND ND ND
Copper (mg/L) 0.22 0.23 0.15 0.22 0.255 0.72 0.21 0.22 0.08
Nickel (mg/L) 0.73 0.68 0.5 0.86 0.837 0.47 0.72 0.61 0.033
Zinc (mg/L) 0.14 1.12 0.51 0.11 6.68 0.18 0.31 0.24 ND
Cyanide (mg/L) ND ND ND ND ND ND ND ND ND
Chromium (mg/L) ND ND ND ND ND ND ND ND ND
4.5.3 Slag Management Plan

Slag management plan is given table 4.7
Table 4.7 Slag Management Plan

Slag Management
Granulated Slag (IM) Sold to authorized vendor
Air Cooled Slag (IM) Used for internal roads and approach roads as a sub base material
Steel Slag Used for internal roads and approach roads as a sub base material
Used for internal railway network as ballast material
Under CSR activities used for making internal village roads to provide proper
approach to villagers
LF Slag Used for internal roads and approach roads as a sub base material
De Sulphurization
After recycling will be used in sinter plant
(HMDP) Slag
4.6 Noise Environment

4.6.1 Construction Phase Impact and Mitigation Measures
In the proposed modification, construction phase involves construction of auxiliary facilities. During
construction activity noise level will increase for short period due to cutting operation, earth moving machine,
operation of crane, construction equipment, etc.
Following are the mitigation measures proposed,

• Use of adequate noise control measures such as mufflers, silencers, anti-vibration pad for equipment
• Use of earmuff and earplugs to the operators, etc. would be provided.
• Housing / casing shall be provided for all noise generating machines.
• Regular maintenance of equipments.
• Limiting activity within day hours
• Regular monitoring of noise level
4.6.2 Operation Phase Impact and Mitigation Measures

level.
plant operation. Plant wise Noise generation details is given the following table 4.8.

Table 4.8 Plant Wise Noise Generation Points and Mitigation Measures
Unit Point of Generation Outlet Parameters Mitigation Measures
HBI Plant (DRI Mod. I to VI) Rotating equipment, 65.6 Use of as mufflers, silencers at
Plant machineries and the air inlet/outlet anti-
Blast Furnace 64.6
other plant facility vibration pad for equipment
Sinter Plant 71.5 with high vibration
Coke Oven (Recovery Type) 67.2 Use of earmuff and earplugs
Air Separation 71.4 Housing / casing to all noise
Steel Melt Shop-1 (EAF) (4Nos.) 70.5 generating machines
Steel Melt Shop-2 (4 EAF& 4LF) 72.0 Green belt all along the
boundary wall
Corex Plant (2 Nos.) 70.3
Lime Plant (Lime/ Dolime) 66.2
CPP 62.6
Plate Mill 69.4
CSP, Hot Rolling Mill & Long Product 70.4
-HRC
Caster Shop 71.0
CRM-1 66.2
Extension of Existing Jetty 71.2
Waste Heat Recovery Based Power 60.3
Plant
Pipe Mill 67.7
During operation phase over all noise level will be kept within norms prescribe by CPCB and hence there
will be insignificant impact is envisaged on noise environment of the surrounding area.
4.7 Ecology
The impact due to proposed modification and its activities on the ecological parameters like natural
vegetation, cropping pattern, fisheries and aquatic life, forests and species diversity.
Ecological Impact Assessment considered the following stages:

• Identification of the likely zone of influence arising from the whole lifespan of the project;
• assessment of the ecological impacts of the project and definition of the significance of these impacts;
• Identification and evaluation of ecological resources and features likely to be affected
• Identification of the biophysical changes likely to affect valued ecological resources and features;
• Assessment of whether these biophysical changes are likely to give rise to a significant ecological
impact, defined as an impact on the integrity of a defined site or ecosystem
• The conservation status of habitats or species within a given geographical area, including cumulative
impacts;
• Refinement of the project to incorporate ecological enhancement measures, mitigation measures to
avoid or reduce negative impacts, and compensation measures for any residual significant negative
impacts;
• Provision for monitoring and following up the implementation and success of mitigation measures
and ecological outcomes, including feedback in relation to predicted outcomes. (Already covered in
Post Project monitoring section)
When describing changes/activities and impacts on ecosystem structure and function, reference have been
made to the following parameters and presented in following table,
• Magnitude of Impact;
• Extent;
• Duration;
• Reversibility; and
• Timing and frequency.
Ecological Identified Impacts Ecological Significance of Impact Magni- Duration / Reversi Mitigation Cumulative
Criteria Tude Timing / bility Impact
Frequency
Construction Phase
Zone of Influence Project site habitat due to The proposed modification will take place No impact - - - No impact
site clearance premises of already established Industrial
Unit. As no ecological impact associated
with vegetation clearing or disturbances
to the existing vegetation is anticipated
from this project.
Zone of Influence Ecological Impact Dust/ Fugitive emission will be very less. Insignifican Only during the Reversibl As given in No impact
Surrounding habitat due t impact construction e EMP chapter
to fugitive emission activity
Accessibility Ecological Impact due to No new Road construction is required. No impact - - - No Impact
road construction The existing Internal Roads are well
developed and connected the project site
to the highway.
Operation Phase
Zone of Influence Impact on Surrounding The project site is located in the Premises Insignifican - - Green belt No impact
habitat due to emission of already established Industrial Unit. t impact development in the
from process and utility premises considering
emission Major Pollutants Nearest village is Hazira located in south the predominant
are SO2, NOx, and PM. direction at about 0.7 km, the other nearby wind direction will
habituated area is in Suvali village in NW, further reduce the
which is located more than 3.0 km. impact emission with
The nearest habitation in village is located respect to the
in zone of influence, there is significant magnitude and
impact in the village premises is distance.
anticipated during the operation phase.
The predicted pollution load after the Adequate APCM
incremental increase for all the will be installed with
parameters are within the stipulated stack which will
standard limit prescribed by CPCB except reduce the
PM10 and SO2. pollution load.
Zone of Impact on Surrounding No impact on the surrounding habitat are No impact - - ETP design and No impact
Influence Eco sensitive habitat due envisaged due the waste water generated Efficiency as given in
Ecological Identified Impacts Ecological Significance of Impact Magni- Duration / Reversi Mitigation Cumulative
Criteria Tude Timing / bility Impact
Frequency
to waste water generated from the project activity as it is utilized the EMP chapter
from the project activity. for gardening in the premises itself. No
waste water will be disposed outside the
The entire waste water premises.
will be treated in the ETP
and treated water will be
utilized for gardening
after confirming norms
prescribes by GPCB /
CPCB.
Zone of Ecological Impact on The Noise level during the operation No Impact - - As given in The EMP No impact
Influence Surrounding Eco phase is around 39-75 dB. The impact on section
sensitive habitat due to ambient noise level will be restricted only
Noise generated from the on the factory premises and may not have
project activity. any significance increase in the
surroundings due to the project activity.
Conservation Impact due to the One aquatic water body with ecological No Impact - - - -
status of Habitat emission from the project importance were observed in the study
and species activity area, this water bodies is an ideal habitat
encountered for many aquatic birds and including
many migratory birds.
As the location of bird species is far away
from the zone of influence of the project
activity, no impact on this species is
envisaged.
More over the stack height attached to
process and utilities many not disturb the
route taken by these birds.

4.8 Infrastructure and Services

Due to the development of industry will increase development of commercial & social activity in the
surrounding areas. The infrastructure services e.g. roads, state transport, post and telegraph, communication,
education and medical facilities, housing, etc. shall be improved in the surrounding areas.
4.8.1 Impact of the Transportation

Major impact on surrounding environment of this transportation will be mainly increase in noise and
vibration, dust, carbon monoxide, etc. There is no alternative option available for transportation of goods
other than road due to site location. Nearest railway station and airport is Surat railway station and Surat
Airport respectively which is around 27 km and 20 km away respectively from the site.
4.8.2 Impact on Existing Road Network:

In existing scenario around 30 no. of trucks per hour is required and due to proposed modification project,
it will be increased by 40 trucks per/hr (960 trucks/day) for the transportation (‘to and fro’ movement) of
raw material, finish products and other.
The estimated peak traffic in terms of PCUs, when compared to the stipulated standards by IRC road
carrying capacity i.e. 12500 PCU per day, it can be observed that the existing road network is adequate.
Company is in process for executing Railway sliding project along with Jetty expansion projects so major
cargo handling will be done through railway and sea which will reduce the traffic load on existing Roads.
Bypass Road also constructed for reduction of traffic on existing roads which is available dedicatedly for
Cargo handling of Port operations.
The Road need to be reconstructed ensuring enough strength to bare the additional impact due to increase
in nos. of the trucks and containers.
4.9 Environmental Hazard

Raw material and finish product will be transported by road and other transport network. Raw material and
product will be stored in the plant premises.
On site emergency plan has been prepared for storage and handling chemicals/raw material/product. The
Onsite emergency plan is enclosed herewith as annexure 18.
4.10 Impacts on Occupational Health & Safety

In the iron and steel making industry workers may expose to a wide range of hazards or workplace activities
or conditions that could cause ill health, diseases, incidents, injury or death.
Followings are the general mitigation measures will be implemented
• Safe working environmental

• Use of appropriate personal protective equipment
• Good house keeping
• Regular monitoring and maintenance of pollution control equipment
• Periodical medical check-up
• Safe drinking water facility
• Regular information, instruction and training
4.11 Impact on Socio-Economic Aspect

4.11.1 Positive Impact
The proposed modification project will generate direct and indirect positive and negative impacts on the
lives of the surrounding area.

Negative Impact
• Due to the proposed modification project, there will be an enhancement concerning in-migration,
hence increased population is envisaged.
• Some extent impact culture of the local society through multi-cultural impact.
• Migration also may bring health related problems to the area.
• Air pollution will increase, which might negatively impact people's health.
Positive Impact
• It will generate direct and indirect employment,
• Improvement in the socioeconomic status of the residents in the area,
• The rate of out migration will decrease.
• Due to CSR activity of the company surrounding villages will get developed.
• During the construction period employment will be generated especially for local people.
• Education facility will be improved under its CSR activities
• Infrastructures and communication facilities will improve.
4.12 Reserve Forest, National Parks / Sanctuaries

In the study area mangrove patches are present in the mouth of Tapti estuary along the fringes of islands and
mud banks. A thick patch of Prosopis juliflora dominated scrub land which is situated along the south west
side of the AMNS complex along the shoreline of Hazira village. As per the topomap a reserve forest is seen
near the project site. Another reserve forest observed is Dumas reserve forest at 5.5 km away from project
site. Mangrove survey has been conducted and it is found that no mangrove is present in the AMNS
premises.
Thick greenbelt is developed around the periphery and within the site. no significant impact on the same.
4.13 Matrix Representation

The parameters discussed are presented in the form of a matrix in table 4.9. The impact matrix relating to
the activities during construction and operation phase is presented.

Table 4.9 Impact Identification Matrix

Pre Construction Construction/Erection Operation and Maintenance
Burning of wastes, refuse
Civil works such as earth

Site Preparation/Change
Employment generation
Energy use and demand

Disposal of construction
moving and building of
metallurgical processes
and cleared vegetation
Erection of equipment
Detailed Topographic
Raw material use and

Influx of construction
Generation of sewage
temporary structures
Water extraction for

structures including
Land Acquirement
Heavy Equipment
Transportation of
Solid wastes from

in Topography
Emission from
Effluent from
Deforestation
Site Clearing
operations
Project Activity
handling
material
workers
Survey
wastes
Component
Parameter
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Physical Environment
Erosion Risks * * * *
Soil Contamination * * * *
Soil Quality * * * * *
Fuels/ Electricity * * * * * * *
Resources Raw materials * * * *

Land especially undeveloped or agricultural land
Interpretation or Alteration of River Beds
Alteration of Hydraulic Regime * *

Alteration of surface runoff and interflow * * * * *
Water
Alteration of aquifers
Water quality * * * * * *
Temperature * *
Air Air quality * * * * * * * *





Land Acquirement
Heavy Equipment
Transportation of
Solid wastes from

in Topography
Emission from
Effluent from
Deforestation
Site Clearing
operations
Project Activity
handling
material
workers
Survey
wastes
Component
Parameter
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Noise * * * * * * *
Climate * * * *
Biological Environment
Effect on grass & flowers * * * *
Effect on trees & shrubs * * *
Terrestrial
Flora Effect on farmland *
Endangered species *
Habitat removal
Aquatic Biota Contamination of habitats * *

Reduction of aquatic biota * *
Fragmentation of terrestrial habitats
Terrestrial Disturbance of habitats by noise or vibration * *
Fauna
Reduction of Biodiversity * * * * * * * *
Social Environment
Economy Creation of new economic activities * * * * *





Land Acquirement
Heavy Equipment
Transportation of
Solid wastes from

in Topography
Emission from
Effluent from
Deforestation
Site Clearing
operations
Project Activity
handling
material
workers
Survey
wastes
Component
Parameter
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Commercial value of properties * * *
Conflict due to negotiation and/ compensation
payments
Generation of temporary and permanent jobs * * * * *
Effect on crops * * * *
Reduction of farmland productivity * *
Income for the state and private sector * *
Electricity tariffs *
Training in new technologies *
Education
Training in new skills to workers * * *
Political Conflicts *
Public Order
Unrest, Demonstrations & Social conflicts * *
Infrastructure Conflicts with projects of urban, commercial or

*
and Services Industrial development
Increase in Crime *
Security and
Safety Accidents * * * *

1
Health
Cultural
Component
Land use
Recreation
Cultural status
Parameter
Aesthetics and human interest

Project Activity
M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat.

3
Survey
4
Land Acquirement
5
*
Site Clearing
Pre Construction

6

in Topography

8
Heavy Equipment
9
operations
10
wastes
*
11
4-32
Construction/Erection
12
workers
13
Deforestation
Transportation of
14
material
15
*
16
handling
Emission from
17
Effluent from
18
Solid wastes from
*
*
19
*
20
Operation and Maintenance
*
*
*
21
22

Chapter – 5
Environmental Monitoring Program
5.1 Introduction
This section covers the technical aspects of monitoring and the effectiveness of mitigation measures
suggested. This includes, measurement methodologies, frequency, location, data analysis, reporting
schedules, emergency procedures etc.
Environmental management is an essential tool for sustainable development and aids effective
implementation of mitigation measures. It is essential to keep updating the environmental management
system for effective conservation of the environment along with ongoing project activities/operation. The
environment monitoring plan enables environmental management system with early signs for the need of
additional action and modification for ongoing actions of environment management, improvement and
conservation. It provides a precise idea for mitigation measures that are to be to be implemented, as it is
linked with actual distraction of environmental quality due to the project activities. Hence, monitoring of
critical parameters of environmental quality is very essential in the routine activity schedule of project
operation. An Environmental Monitoring Program shall be scheduled for the following major objectives:
• Assessment of the changes in environmental conditions, if any, during the project operation/activities.
• Monitoring and tracking the effectiveness of Environment Management Plan and the implementation
of mitigation measures planned.
• Identification of any significant adverse transformation in environmental condition to plan additional
mitigation measures
5.2 Environmental Management Cell

For the effective implementation of EMP, it is mandatory to assign a group in organizational setup for taking
up the additional charge of monitoring and ensuring environmental protection. M/s. ArcelorMittal Nippon
Steel India Limited proposes to assign officers from concerned department to co–ordinate the activities
concerned with the management and implementation of the environmental control measures.
• The proposed cell shall, undertake to monitor the environmental pollution levels by measuring
emissions from stacks, ambient air quality, water and effluent quality, ambient noise level etc. either
departmentally or by appointing external agencies wherever necessary.
• In case the monitored results of environmental pollution are found exceeding the allowable values,
the environmental management cell will suggest remedial action and get these suggestions
implemented through the concerned plant authorities. The actual operation and maintenance of
pollution control equipment of each unit will be under the respective plant managers.
• The Environmental Management Cell (EMC) will handle of all the related activities such as
collection of statistics of health of workers and population of the region, afforestation and green belt
development.
5.3 Monitoring Schedule and Monitoring Locations and Monitoring Frequency

The environmental monitoring points shall be decided considering the environmental impacts likely to occur
due to the operation of proposed modification project as, the main scope of monitoring program is to track,
timely and regularly, the change in environmental conditions and to take timely action for the protection of
environment. The monitoring points/location and significant parameters analyzed is given in table 5.1.

Table 5.1 Schedule of Environmental Monitoring

2. SVC – MRSS, Benzo(a) Pyrine, Lead, Nickel, 5,6 – Once in a Month
3. Near Suprabhat, Arsenic.
4. CRM Office,
5. AMNS
Township,
2. West Station
3. South Station
4. North Station
Environment
(Fugitive)
5. Industrial effluent All Effluent generated Flow, pH, Temperature, SS, Oil & Once in a Month
plant Grease, BOD, COD, Iron, Total
Cr., Hexa. Cr., Copper, Sulphides,
Fluoride, Zinc, Cyanide, Lead,
Nickel, Ammonical Nitrogen,
Phenolic Compounds, Colour,
Arsenic, Sulphate, Chloride,
Cyanide, Bio-Assay Test.,
Phosphate.
Effluent
Colour, Taste, pH, Turbidity, Total
Dissolved Solids, Total Hardness as
CaCO3, Alkalinity, Residual
Chlorine, Chloride as Cl, Heavy
Metals & Other Parameters : Calcium
as Ca, Magnesium as Mg, Oil &
Grease (Mineral Oil), Phenolic
Compound as C6H5OH, Hexavalent
Chromium as Cr+6, Cadmium as Cd,
Copper as Cu, Zinc as Zn, Iron as Fe,
Lead as Pb, Mercury as Hg, Selenium
as Se, Aluminium as Al, Manganese
as Mn, Arsenic as As, Sulphate as
SO4, Cyanide as CN, Boron as B,
Fluoride as F, Nitrate Nitrogen as
NO3 , Anionic Detergents as MBAS,
Bacteriological : Coliform, E. Coli.
Copper, Iron, Nickel, Zinc, Cadmium, Once in a 6 Month.
Lead, Chromium, Manganese,
Sodium, Molybdenum, Selenium,
Arsenic, Mercury, Barium,
Aluminium, Silver, Stannous, Cobalt,
Boron.
Building Conductivity, C: N Ratio, Organic

Carbon, N, P, K, Na, Ca, Mg, CEC,

Cl, Fe, Mn, Cu, Zn, B, Mo.
Phenolic compounds.
and outside plant
Monitoring
Urin, RBS, etc.
check-up both are
same.
5.4 Monitoring Methodologies

Monitoring of environmental samples shall be done as per the guidelines provided by MoEF&CC/CPCB/
SPCB. The method followed shall be recommended/standard method approved/ recommended by CPCB.
5.5 Reporting and Documentation

The records of the monitoring carried out shall be maintained for all aspects of the monitoring. Separate
records for water, wastewater, solid wastes, air emission, and soil shall be analyzed and preserved.
Immediately upon the completion of monitoring as per the planned schedule, report shall be prepared and
forwarded to the concerned in-charge including top management.
Methodology of monitoring (sampling and analysis) shall be prepared as separate documents as SOP
(Standard Operating Procedure) wherever required.
The records showing results/outcome of the monitoring programs shall be prepared as per the requirement of
the schedule mentioned above. Systematically, these documents and records shall be reviewed on a regular
basis for necessary improvement of the monitoring plan/mitigation measures/environmental technologies as
well as for necessary actions of Environmental Management Cell.
All the above Environmental Monitoring activities have been carried out through NABL & MoEF&CC
Approved Third Party laboratory.
5.6 In-house Laboratory Facility

Company will be setting up a facility for regular monitoring to ensure that the pollution is below standard
permissible limits and takes effective amendment measures. The list of equipment available in laboratory is
furnished in table 5.2.
Table 5.2 List of Equipment Available for Monitoring

Sr. Name of Equipment Purpose / Work Quantity
No.
1. Fine Particulate Sampler Ambient Air Monitoring 5
2. Respirable Dust Sampler Work zone Air Monitoring 5
3. Sound Level Meter Noise Level Monitoring 2
4. Stack Monitoring Kit 610 Stack Air Monitoring 5
5. Velocity Monitoring Kit Stack/Duct Velocity Monitoring 3
6. pH Meter pH Analysis of Effluents 2

7. Spectrophotometer, shimadzu, UV/VIS Colorimetry Analysis of Parameters 2
8. Digital Balance Weighing / Gravimetry Analysis 2
9. BOD Incubator Incubation of BOD Samples. 2
10. Oven Demoisturising of SS filter Papers 2
11. Weather Monitoring Station Meteorological Parameters 2
12. Fume Chamber Hood Digestion / Heating / Boiling of samples 2
13. Hot Plate Digestion / Heating / Boiling of samples 3
14. COD Apparatus COD Sample Analysis for Reflux 3
15. SS Filtration Assembly Filtration of SS samples 3
16. Noise Dosimeter Noise Monitoring 2
17. Refrigerator For Sample / Solution Preservation 2
18. HACH DR 5000 Spectrophotometer Water / Air Heavy Metals Analysis. 2
19. Balance 4 Kg. Capacity Weighment of Chemicals 3
20. Desiccator Moisture Removal 2
21. Gaseous Pollutant Sampler Ambient Air Monitoring 2
22. Online Ambient Air Monitoring Station Ambient Air Monitoring 3
23. Handy Sampler Ambient Air Monitoring 3
24. Thermoelectrically Cool Gas Assembly Ambient Air Monitoring 3
25. Total Chromium Analysis Apparatus Total Chromium Analysis 2
26. Arsenic Analysis Apparatus Arsenic Analysis 2
27. Wind Anemometer Wind Speed Monitoring 2
28. Wind Director Wind Direction Monitoring 2
29. Barometer Atmospheric Pressure Monitoring 2
30. Min-Max Thermometer Min-Max Temperature Monitoring 2
31. Dry-Wet Bulb Thermometer Relative Humidity Monitoring 2
32. Rain Monitor Rainfall Monitoring 2
33. Humidity & Temperature Meter Humidity & Temperature Monitoring 2

Chapter – 6
Additional Studies
6.1 Public Consultation/Hearing
incorporating the compliance of Terms of References issued by Ministry of Environment, Forest and Climate
Change vide letter No. F. No. J11011/44/2004-IA. II(I) dated 8.02.2021.
6.2 Philosophy and Methodology of Risk Assessment

Industries have a wide variety of process involving consumption, production and storage of chemicals. The
condition that contributes to the danger, by these chemicals, are when these chemicals are not kept/stable at
normal pressure and temperature. Very often these chemicals are kept at/or high pressure and temperatures;
these gases in liquefied state by refrigeration, to facilitate storage in bulk quantities. Under these
circumstances, it is essential to achieve and maintain high standards of plant integrity through good design,
management and operational controls.
However, accidents do occur and these can cause serious injuries to employees or the public, and damage to
property. The public concern at such events invariably leads to call for additional control at national and
international levels. It is against this background that the various Section and Rules under the Environment
Protection Act, 1986, the Factories Act, 1948 and other Acts specify the requirements for a safe and reliable
working of an industry. They require carrying out various studies and analysis to assess and mitigate hazards
prevalent in the factory in line with the above goal of safe and reliable working. These are more commonly
known as “Risk Assessment Studies”. This chapter explains the basis of Risk Assessment and its objectives.
Major hazard installations have to be operated to a very high degree of safety; this is the core responsibility
of the management. In addition, management holds a key role in the organization in the implementation of a
major hazard control systems. In particular, the management has the responsibility to
• Provide the information required to identify major hazard installations.
• Carry out hazard/risk assessment.
• Report to the authorities on the results of the hazard / risk assessment.
• Conceive Disaster Management plans and carryout “MOCK DRILLS” on the scenarios envisaged.
• Adequately inform the Vulnerability status of the company to district management.
• Undertake measures to in-plant safety assurance systems.
• In order to fulfill the above responsibility, the Management must be aware of the nature of the hazard,
of the events that cause accidents and of the potential consequences of such accidents.
• In order to control a major hazard successfully, the Management must have answers to the following
questions:
• Do toxic, explosive or flammable substances in our facility constitute a major hazard?
• Which failures or errors can cause abnormal conditions leading to a major accident?
• If a major accident occurs, what are the consequences of a fire, an explosion or a toxic release for the
employees, people living outside the factory, the plant or the Environment?
• What can Management do to prevent these accidents from happening?
• What can be done to mitigate the consequences of an accident?
The most appropriate way of answering these questions is to carry out a hazard or risk assessment study, the
purpose of which is to understand, why accidents occur and how they can be avoided or at least mitigated. A
properly conducted RISK assessment will therefore to
• Analyze the existing safety concept or develop a new one;
• Develop optimum measures for technical and organization protection in event of an abnormal plant
operation.

6.3 Objective of the Risk Assessment Study

The main objectives of the Risk Assessment Studies are as given below:
• To inform the employees, the general public and the authority about the hazards / risk assessed,
safeguards provided, residual risk if any and the role to be played by them in the event of emergency.
• To inform Police, Fire Brigade, District Authority and Statutory Bodies to come for help.
• To rescue and give treatment to the casualties and to count the number of injured.
• Evacuation of persons to safe areas and to identify and list any death.
• To identify the persons affected, notify the relatives and extending necessary assistance.
• To provide welfare assistance to the casualties / victims.
• To secure the safe rehabilitation of affected areas and to restore normalcy.
• To provide authoritative information to the media.
• Monitoring and review of current control measures to ensure efficiency and effectiveness e.g. (This
might mean that where, in spite of the implemented control measures, there is significant residual risk
the hierarchy of control will have to be reapplied).
• Reassessment when there are changes to the work process or the working environment.
• Reassessment if and when an incident occurs to address the causes of the incidents
• Update current risk assessment to reflect the above
• Periodical review to keep up with new trends and knowledge in the sector.
• Outcomes of surveys or inspections involving the health and safety of persons in the organization.
• To preserve records, equipment, etc., and to organize investigation into the cause of emergency and
preventive measures to stop its recurrences.
• To ensure safety of the workers before person re - enter and resume work.
• To work out a plan with all provisions to handle emergencies and to provide for emergency
preparedness and the periodical rehearsal of the plan.
• To collect information regarding the incident and latest status of the situation and actions taken.
• To define and assess emergencies, including risk and environmental impact assessment.
• To control and contain incidents.
• To safeguard employees and people residing in vicinity of the company and to minimize damage to
property and environment through appropriate installed mitigating procedures.
• To be ready for mutual aid if need arise to help neighboring units. Normal jurisdiction of an OEP (ON-
SITE EMERGENCY PLAN) is to control events in own premises only. When it comes to the mutual
aid it requires catering to Mutual Aid Partners also.
6.4 Elements of the RH Study

6.4.1 Storage and Handling of Hazardous Chemicals
Identification, analysis and assessment of hazard and risk are very useful in providing information to risk
management. It provides basis for what should be the type and capacity of its, on-site and off-site emergency
plans and disaster management plan. Risk analysis is carried out considering storage and handling of various
hazardous raw materials, manufacturing process and storage of hazardous finished goods. Toxic Effects of
Chemical Substances limits are given in table 6.1
Table 6.1 Toxic Effects of Chemical Substances.
Sr. No Toxicity Oral Toxicity Dermal Toxicity Inhalation Toxicity

D50(mg/kg) LD50(Mg/Kg) LC50(mg/l)
1. Extremely toxic >5 <40 < 0.5
2. Highly toxic >5-50 >40-200 < 0.5 - 2.0
3. Toxic >50-200 > 200-1000 >2-10

6.4.2 Toxic Hazards of Substances

Toxic substances affect in three ways by ingestion, absorption & inhalation. Adequate provision of safety
along with personal protective equipment will be made; emergency kit shall be provided at various locations
of the installation.
6.4.3 Assessment of Flammability & Explosive Properties

Flammable Chemicals: what law interprets and gives limits.
1. Flammable gases: Gases which at 20°C and at standard pressure of 101.3 Kpa are: -
a) Ignitable when in a mixture of 13 percent or less by volume with air, or;
b) Have a flammable range with air of at least 12 percentage points regardless of the lower flammable
limits.
Note: The flammability shall be determined by tests or by calculation in accordance with methods adopted
by International Standards Organization ISO Number 10156 of 1990 or by Bureau of Indian Standard ISI
Number 1446 of 1985.
2. Extremely flammable liquids: Chemicals which have flash point lower than or equal to 23°C and
boiling point less than 35°C.
a) Very highly flammable liquids: Chemicals which have a flash point lower than or equal to 23°C and
initial boiling point higher than 35°C.
b) Highly flammable liquids: Chemicals which have a flash point lower than or equal to 60°Cbut higher
than 23°C.
c) Flammable liquids: Chemicals which have a flash point higher than 60°C but lower than 90°C.
3. Explosives: Explosives mean a solid or liquid or pyrotechnic substance (or a mixture of substances) or
an article.
a) Which is in itself capable by chemical reaction of producing gas at such a temperature and pressure
and at such a speed as to cause damage to the surroundings
b) Which is designed to produce an effect by heat, light, sound, gas or smoke or a combination of these
as the result of non-detonative self-sustaining exothermic chemical reaction.
Toxic hazards of substances

Intoxication – Analytical Analysis.
The consequences from inhalation of a toxic vapour/gas are determined by the toxic dose.
This dose D is basically determined by:

- Concentration of the vapour in air;
- Exposure duration.
Furthermore, of course, the breathing rates of the victim, as well as the specific toxic mechanism unto the
metabolism play an important role.
n
The dose is defined as D = C .t, with:
C = concentration of the toxic vapour, in [ppm] or [mg/m3];

t = exposure duration, in [sec] or [min];
n = exponent, mostly > 1.0; this exponent takes into account the fact that a high concentration
over a short period results in more serious injury than a low concentration over a relatively
longer period of exposure. The value of n should be greater than zero but less than 5.
The given definition for D only holds if the concentration is more or less constant over the exposure time;
this may be the case for a (semi) continuous source. In case of an instantaneous source, the concentration
varies with time; the dose D must be calculated with an integral equation:
D = Cn.dt

For a number of toxic materials, so-called Vulnerability Models (V.M.) have been developed. The general
equation for a V.M. (probit function) is:
Pr = a + b.ln (Cn.t), with

Pr = probit number, being a representation of the percentage of people suffering a certain kind of
damage, for instance lethality
Pr = 2.67 means 1% of the population;

Pr = 5.00 means 50% of the population;
a and b material dependent numbers;
Cn.t = dose D, as explained above.
The values for a and b are mostly derived from experiments with animals; occasionally, however, also human
toxicity factors have been derived from accidents in past. In case only animal experiments are available, the
inhalation experiments with rats seem to be best applicable for predicting the damage to people from acute
intoxication. Although much research in this field have been done over the past decades, only for a limited
number of toxic materials consequence models have been developed. Often only quite scarce information is
available to predict the damage from an acute toxic exposition. Data transformation from oral intoxication
data to inhalation toxicity criteria is sometimes necessary. Generally, in safety evaluations pessimistic
assumptions are applied in these transformation calculations. The calculated damage (distance) may be
regarded as a maximum. For the purposes of a response to a major incident, the IDLH value level has been
chosen for the ‘wounded ‘criteria. This type of injury will require medical attention.
6.4.3.1 Flammability Hazards of Substances

Since the Stone Age term 'fire' is associated with fear. Fire destroys everything when not controlled. It is very
dangerous if occurs in uncontrolled manner. It should be clearly understood that when a liquid is used having
flash point (Beginning of transformation phase from liquid to vapor) below the normal ambient temperature,
it could, in suitable circumstances, liberate a sufficient quantity of vapor to give rise to flammable mixtures
with air. Any source of ignition will transform the vapor to fire.
Heat Radiation – Analytical Analysis Parameters.

The consequence caused by exposure to heat radiation is a function of:
2
• The radiation energy onto the human body [kW/m ];
• The exposure duration [sec];
• The protection of the skin tissue (clothed or naked body).
• The limits for 1% of the exposed people to be killed due to heat radiation, and for second-degree burns
are given in the table herein:
Table 6.2 Damages to Human Life Due to Heat Radiation
Exposure Radiation for Radiation for 2nd degree Radiation for first
Duration 1% lethality (kW/m2) burns(kW/m2) degree burns, (kW/m2)
10 Sec 21.2 16 12.5
30 Sec 9.3 7.0 4.0
Since in practical situations, only the own employees will be exposed to heat radiation in case of a fire, it is
reasonable to assume the protection by clothing. Damages to Human Life Due to Heat Radiation is given in
table 7.2. It can be assumed that people would be able to find a cover or a shield against thermal radiation in
10 sec. time. Furthermore, 100% lethality may be assumed for all people suffering from direct contact with
flames, such as the pool fire, a flash fire or a jet flame. The effects due to relatively lesser incident radiation
intensity are given below in table 6.3.

Table 6.3 Effects Due to Incident Radiation Intensity

Incident Radiation Type of Damage
– kW/m2
0.7 Equivalent to Solar Radiation
1.6 No discomfort for long exposure
4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are
likely)
9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.
12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing
etc.
6.4.3.2 Explosion Hazards

Release of energy in a rapid and uncontrolled manner gives rise to explosion. Explosion is very dangerous
because it has the potential to spread the flammable material and fire on low flammable substances also. This
effect of spreading fire instantaneously at different installations due to explosion is called “DOMINO
EFFECT”.
Explosion –Analytical Analysis Parameters

In case of vapour cloud explosion, two physical effects may occur:
* A flash fire over the whole length of the explosive gas cloud;
* A blast wave, with typical peak overpressures circular around ignition source.
As explained above, 100% lethality is assumed for all people who are present within the cloud proper.
For the blast wave, the lethality criterion is based on:
* A peak overpressure of 0.1 bar will cause serious damage to 10% of the housing/structures.
* Falling fragments will kill one of each eight persons in the destroyed buildings.
The following damage criteria given in table 6.4 may be distinguished with respect to the peak overpressures
resulting from a blast wave:
Table 6.4 Damage Due to Overpressures

Peak Overpressure Damage Type
0.83 bar Total Destruction
0.30 bar Heavy Damage
0.10 bar, 0.03 bar Moderate Damage, Significant Damage
0.01 bar Minor Damage
From this it may be concluded that p = 0.17 E+5 pa corresponds approximately with 1% lethality.
Furthermore, it is assumed that everyone inside an area in which the peak overpressure is greater than 0.17
E+ 5 pas will be wounded by mechanical damage. For the gas cloud explosion this will be inside a circle with
the ignition source as its centre.
6.4.3.3 Corrosion Hazards

Corrosion is a chemical reaction-taking place at the surface of metal. It is also the effects of tissue damage
caused to human beings when contacted accidentally. All substances pH 0-5 & 8.0-12.0 are corrosive. Most
corrosive substances will produce chemical burns, while certain chemical substances produce deep ulceration.
The effect will be for internal organs also when the fumes are inhaled/ ingested. Other damages are, has a
detailing effect on skin and may cause dermatitis.
On contact with metals, corrosive substances will oxidize the load bearing columns, beams and truss structure
and bring down the stability factor of the buildings.
M/s. AM/NS India Limited, Surat will take due care to overcome the hazard. The complete structure of the
manufacturing area is painted with special type of anticorrosive paint. Good quality materials shall be used

for transferring corrosives. Regular thickness testing of equipment, pipelines etc. will be carried out to have
the exact picture of effect of corrosion.
6.4.3.4 Reactivity Hazards

Reactivity is a property of causing a violent chemical reaction when TWO OR MORE compatible materials
coming in contact. The resulting impetus shall release energy in the form of heat, detonation, vapors/gases.
The criteria of avoiding reactivity type hazards are to follow the REACTIVITY MATRIX for storing
materials given in table 6.5. (Enlarge to view and read).
6.5 Details of Manufacturing Process

Detailed Manufacturing process of steel making is given Chapter No.2
6.5.1 Description of Hazardous Chemicals

Both hazardous and non-hazardous materials generated within the manufacturing units and in the proposed
modification project facility shall be accommodated in designated storage units within the project facility
built/made in line with the safety, health and environmental standards (Gujarat Factories Rules 1963 (2004)
and MSIHC rules 1989 (2000).

Table 6.5 Incompatible Storage Recommendations.

Chemical Segregation Class 1 2 3 4 5 6
by chemical Group
1.0 Segregat Segregat Segrega Segrega Segrega Segregate Segregate

Explosives 1 Segregate from
Explosive e From e From te From te From te From from From
Flammable Segregate Keep
2 Keep Apart Keep Apart
Liquids FROM Apart
Readily Segregate Keep
Keep Apart
Combustible From Apart
flammable Spontaneously Segregate Segregat KEEP
3 Keep Apart Keep Apart
Solids Combustible From e From APART
Dangerous Segregate Segregat
When Wet From e From
OXIDIZING Segregate Segregat
Keep Apart keep Apart
Oxidizing SUBSTANCE From e From
4
Substances ORGANIC Segregate Segregat Keep
Keep Apart Keep Apart
PEROXIDE From e From Apart
Segregate Keep Keep Keep Keep
Keep Apart
Toxic From Apart Apart Apart Apart
5
Substances Segregate Keep Keep Keep Keep
Keep Apart
From Apart Apart Apart Apart
Corrosive segregate Keep Keep Keep Keep
6 Keep Apart
Substances from Apart Apart Apart Apart

6.6 Raw Materials Storage

Raw materials are stored in the manufacturing units in many ways. There is different system of storage
practices for storing
a. Liquid Raw Materials

a.1 In Storage Tanks - Stored in multiple units of tanks same chemical when the quantity is very large in a
tank-farm.
a.2 In Storage Tanks - Stored in a single tank, with other material tanks in a tank –farm. (Mixed materials
tank-farm.
a.3 In Storage Tanks - Specific material stored in A TANK / TANKS in a tank-farm demarcated and isolated
storage, Licensed and separated with minimum safe distances.
a.4 In Storage Sheds - Separate storage sheds made for storing specifically raw materials in drums and
carboys.
b. Solid Raw Materials

b.1 In Silos - Large quantities of powder / Granules are stored in silos. The handling of materials are done
pneumatically. The quantity dispatch in terms of weight are measured with the provision of load cells.
b.2 In Bags & Boxes - Solid raw materials are received in bags and boxes are stored in closed sheds as per
the compatibility norms.
C. Gaseous Raw Materials

C.1 In Tonners & Gas Cylinders- Flammable and toxic raw materials are stored in demarcated and isolated
storage in Licensed premises.
C.2 In Pipelines - Received in pipelines up to the unit and parameters processed in the skid for end use.
The raw materials are planned for storage in drums and carboys in Raw Materials Stores as shown in table
6.6.
Hazardous Chemicals Used in M/s. AM/NS

Hazard Parameters Chart - Raw Materials in Tank Farms, Cylinder, Pipelines, Gas Holder & Drums.

AM/NS India Limited
Table 6.6 Facilities and Inventory OF Hazardous Materials at Various Locations of the plant
Sr. No. Chemical Type of Number Capacity Total Types of Location of Parameter
storage of vessel/ of each Capacity Hazard Storage Pressure Temp.
Protection System
tank/ Vessel of Tank /
cylinder Vessel
A. Highly Toxic Chemicals
Blast Furnace
1 BF Gas (CO- Buffer 1 1,35,000 1,35,000 CO Blast furnace Warning limit and danger limit are set for 800 mm 35°c
22%, CO2- Tank m3 m3 poisoning, movement of piston, Safety bleeding pipe, Main of water
21%, N2 - fire explosion bleeding tube, CO alarm device, Fire water line & column or
56%, H2- (in case of hydrants, Elevator (500 Kg capacity) is provided 0.08 bar
1.2%, CH4- any leakage) for maintenance and safety purpose, approached
0.04%, H2O- up to 74.9 m level platform. Emergency cage (250
2%) Kg capacity) and manual winch (100 Kg) in case
of power failure.
Corex Plant
2 Corex Gas- Gas 1 60,000 M3 60,000 M3 CO Corex Plant Limit Switches are fixed to restrict unsafe 700mm of 35 °c to
(CO-44%, Holder Poisoning, movement of piston. CO detector are fixed on water 40 °c
CO2-29%, H2- Suffocation, piston and roof. Fire water hydrant is extended till column or
21% H2O-2% death from roof of the Gas holder. External elevator is 0.07 bar
CH4- 1% asphyxiation, provided for emergency rescue. Internal winch is
N2- 3 %) Fire & provided for safe approach of piston. U- Seal is
Explosion. provided at inlet/outlet of gas holder. Lighting
arrester and earthlings are in place. LHS cable is
installed in case of oil temperature inside GH is
rising.
3 Corex gas Pipelin Network - - CO Corex, SMP- Schedule is made and followed for thickness check HP- 1.0 bar 35 °c to
(CO-44%, e Poisoning, 2, DRI of pipe line. Regular draining of moisture from seal & LP- 0.07 40 °c
CO2-29%, Suffocation, MOD- V-V, pots are being done once in a shift. bar.
H2-21% H2O- death from HSM, 270M Network is being checked once in a shift for any
2% CH4- 1% asphyxiation, W PP. CO leakage.
N2- 3 %) Fire &
Explosion

AM/NS India Limited
Protection System
cylinder Vessel
HBI Plant
4 Tail Gas (C0- Buffer 2Nos. CO Warning limit and danger limit are set for 550 mm of 50°C
19%, CO2- Tank poisoning, VPSA movement of piston, Safety bleeding pipe, Main water
47%, N2 -6%, /Gas fire & Mod – 5 bleeding tube, CO monitoring. CO alarm device, column
H2-23%, holder 1000 explosion (in Mod – 6 Level monitoring Fire water line, high pressure (0.055 bar
CH4-5%, M3 2000 M3 case of any protection G)
H2/CO- 1.29% leakage)
NCV-1500)
CRM
5 Ammonia Tank 2 10 MT 20 MT Irritating to CRM 1.Water curtain to dilute ammonia 8 to 10 Ambient
gas (NH3) (19.02 (38.04 exposed (galvanizing) 2.excess flow valve kg/cm2
kl) kl) tissues. 3.Safety relief Valve
Inhalation of 4.NRV
vapors may
result in
pulmonary
edema and
chemical
Pneumonitis.
Pipe Mill
6 H2S Cylind 5 Nos 5 Kg 25 Kg Inhalation Near Isolated Storage, Online breathing air masks, 180 Ambien
ers may result NACE Water Sprinklers, H2S Detectors kg/cm2 t
in Lab
bronchitis
and death
due to
respiratory
paralysis
B. Highly Hazardous Chemicals
Blast Furnace

AM/NS India Limited
Protection System
cylinder Vessel
1 HCl Storage 3 5.5 ton 5.5 ton Burn Blast Caution boards are provided. Ambient Ambient
tank Injuries, furnace Access control provided. 24 hours monitoring by
Fumes can shift engineers.
cause Hazard specific PPEs are used for unloading.
Injuries to
respiratory
system
2 Sulphuric Drums 50 50 kg 42 kg Burn Blast Caution boards are provided. Ambient Ambient
Acid Injuries,Fum furnace Access control provided. 24 hours monitoring by
es can cause shift engineers.
Injuries to Hazard specific PPEs are used for unloading.
respiratory
system
Corex Plant
3 Ethanol Buffer 4 1200 Ltr 4800 Ltr Fire and Corex MSDS Displayed at storage tank Fire - 35°c
Tank Explosion Extinguisher provided
HBI Plant
4 Natural Gas Pipelin A) 1 A) A) a) HRC Lighting arrestor, Earthing, bonding of flanges,
e working 36,000 36,000 Suffocatio NGPRS Flame proof light fittings, NG sensors, Fire
/1 Nm3/hr. Nm3/hr n, Death hydrants, fire extinguishers, Fire monitors, Inlet- 10-
standby B) from b) Plate mill Signage’s, Thickness measurement as per 40 bar 10 to
B) 1 2602 B) 26020 asphyxiatio NGPRS schedule, Quick shutoff valves, Safety valves. Outlet 6- 40°c
working 0 Nm3/hr. n, Flash 8 bar
/1 Nm3/hr. fire,
standby explosion,
CO
poisoning
5 Purge gas N2 9 Nos. Mod-1 to 1860 M3 asphyxia Mod- 1&2: Safety valve 9 to 10 35°C
tank (N2 Gas) tank 4– Mod-3 &4: Bar G
300 M3 Mod-5 & 6:
Mod-5&
6-330

AM/NS India Limited
Protection System
cylinder Vessel
M3
6 Purge gas tank N2 7 Nos. 3.1 M3 21.7 M3 asphyxia One each at Safety valves 8 to 9 35°C
at PG roof Tank PG roof of Bar G
(N2 gas) Module 1, 2,
3, 4 & 6
and 2 Nos. at
Mod 5 PG
roof
7 HCl HCL 1 tank 10 M3 10 M3 Acid Burn, Mod-6 near Surrounding wall provided. Ambient Ambient
Release of DM plant
Acidic
Fumes
Oxygen Plant
8 Oxygen gas Buffer 14 200 M3 x 5 60,750 High Oxygen In the purview of SMPV(U), two nos. safety 30 bar Ambient
Tank Nos. 100 NM3 (87 Pressure, Plant-A valves on each vessel, online monitoring of
M3 x 5 MT) Oxygen pressure at Control Room
enrichment
Nos. 125
M3 x 4
Nos.
Buffer 2 2500 M3 80,000 INOXA 16 bar Ambient
Tank x 2Nos. NM3 (114 P Plant (Plant-
MT) B ASU)
9 Liquid Cryoge 2 400 M3 6,38,960N Oxygen Oxygen Breather at top, Pressure controller, monitoring of 0.1 bar -183 °c
Oxygen nic M3 (912 enrichment Plant-A pressure and temperature from Control Room
Storage in case of
MT)
vessel leakage
1 1150 9,30,000 INOXA 0.34 bar -183 °c
M3 NM3 P Plant- A
(1330 MT)
11,98,000 INOXA
AM/NS India Limited
Protection System
cylinder Vessel
1 1500 NM3 P Plant (Plant- 0.15 bar -183 °c
M3 (1712 MT) B ASU)
1 105 M3 83,000 18 bar -183 °c
NM3 (120
MT)
10 Nitrogen gas Buffer 2 2500 M3 80,000 High INOXA In the purview of SMPV(U), two nos. safety valves 16 bar Ambien
Tank x 2 Nos. NM3 Pressure, P Plant on each vessel, online monitoring of pressure at t
(100 MT) Asphyxiatio (Plant- B Control Room
n in case of ASU)
leaked in
large qty.
Nitrogen Cryoge 1 50 M3 32,800 Asphyxiatio Oxygen In the purview of SMPV(U), two nos. safety 5 bar -195 °c
11 Liquid nic NM3 (41 n in case of Plant-A valves, online monitoring of pressure at Control
Storage MT) leaked in Room
vessel 1 794 M3 5,13,600 large qty. INOXA Breather at top, Pressure controller, monitoring of .0.34 bar -195 °c
NM3 (642 P Plant- A pressure and temperature from Control Room
MT)
1 1500 M3 Breather at top, Pressure controller, monitoring of 0.15 bar -195 °c
9,69,600 INOXA pressure and temperature from Control Room
NM3 P Plant (Plant-
(1212 MT) B ASU)
105 M3 68,000 In the purview of SMPV(U), two nos. safety 16 bar -195 °c
NM3 (85 valves, online monitoring of pressure at Control
1 MT) Room
12 Hydrogen Gas Buffer 1 13.5 M3 175 NM3 Explosion Oxygen In the purview of SMPV(U), Water spray nozzles, 13 Ambient
Vessel (0.016 hazard Plant-A monitoring from Control Room kg/cm2
MT)
CRM
2 safety relief valves in each tank, sprinkler
fire & system, platform is provided to reach top of
Hydrogen gas Buffer explosion the tank for maintenance and safety purpose,

AM/NS India Limited
Protection System
cylinder Vessel
13 tank 4 9.9 KL 39.6 KL (in case of CRM emergency alarm system installed, fire water 10 bar Ambient
any leakage) line and hydrant, wind socks, N₂ purging
system in case of any emergency.
HCL acid Proper Tank farm storage area with Dyke wall
spillage, CRM- to accommodate acid spillage/Tanks failure
14 HCl FRV 3 150 / 310KL fumes ARP disaster, safety showers fixed for flushing, Ambient Ambient
tank 80KL inhalation Tank Tank level monitoring by Physical to 45°c
and Burn farm and plc.
injury
HCL acid Proper Tank farm storage area with Dyke wall
spillage, CRM- to accommodate acid spillage/Tanks failure
fumes ARP disaster, safety showers fixed for flushing,
15 Spent HCl FRV 7 150 KL 1050 inhalation Tank Tank level monitoring by Physical and plc. Ambient Ambient
tank and Burn farm
injury
Suffocatio
A)1worki A) A) n, Death A) HRC Lighting arrestor, Earthing, bonding of flanges,
ng / 1 36,00 36,00 from NGPRS Flame proof light fittings, NG sensors, Fire Inlet- 10- 10 to
Natural Gas Pipelin standby 0 0 asphyxiatio B) PLATE hydrants, fire extinguishers, Fire monitors, 40 40°c
16 e B)1worki Nm3/hr. Nm3/hr. n, Flash MILL Signage’s, Thickness measurement as per bar
ng / 1 B) B) fire, NGPRS schedule, Quick shutoff valves, Safety valves. Outlet 6-
standby 2602 2602 explosion, 8 bar
0 0 CO
Nm3/hr. Nm3/hr. poisoning
Utility
17 3 Ton-1
Nos. Skin injury
6 Ton- 7 if contact in
Nos. 9.45 human body Safety shower.
Sulphuric acid Buffer 15 Ton- 5 HRC, PVC apron must use while handling, SOP for
Storage nos. Nos. 106 TON SMP2, acid handling, Neutralization pit available in Ambient Ambient
Tank 14 Ton- Plate mill case of leakage
AM/NS India Limited
Protection System
cylinder Vessel
1 no.
C.Other Chemicals
Blast Furnace
Can cause
Caution boards are provided.
respiratory
Access control provided. 24 hours
Storag diseases. Blast
monitoring by shift engineers.
1 Caustic e tank 2 5 MT 5 MT Can cause furnace Ambient Ambient
Hazard specific PPEs are used for unloading.
damage to
eye if came
in contact
Caution boards are provided.
Magnesi-um Storag Fire, Burn
MSDS displayed at site.
2 e tank 1 4 MT 3MT Injuries Blast 3.5 BAR Ambient
furnace Safety Valve, Bleeding valve and Relief valves
provided.
Area declared as no Hot Work Zone.
Storag Caution boards are provided.
Magnesi-um e tank Fire, Burn MSDS displayed at site.
3 1 500KG 300KG Injuries Blast Safety Valve, Bleeding valve and Relief valves 4.5 BAR Ambient
furnace provided.
Area declared as no Hot Work Zone.
Storag
4 Fluidized e tank 1 55 MT 45 MT Skin and Blast Pressure Recovery line provided, Bleeding Ambient Ambient
Lime Eye Injury furnace valve provided.
Fluidized Storag Skin and Blast Pressure Recovery line provided, Bleeding
5 Lime e tank 1 3 MT 3MT Eye Injury furnace valve and Safety Valve. 4.7 BAR Ambient
HBI Plant
Mod-6 near
6 Caustic Causti 1 tank 10 M3 10 M3 Caustic DM Surrounding wall provided. Ambient Ambient
c Burn plant
Oxygen Plant
AM/NS India Limited
Protection System
cylinder Vessel
Cryoge 31,000 In the purview of SMPV(U), two nos. safety
nic 2 20 M3 NM3 (56 Asphyxiatio valves, online monitoring of pressure at Control 24 bar -186 °c
Storage MT) n in case of Oxygen Room
7 Argon vessel leaked in Plant-A
Liquid 25,200 large qty. Breather at top, Pressure controller, monitoring of
2 16 M3 NM3 (45 pressure and temperature from Control Room 0.5 bar -186 °c
MT)
1,54,500 INOXA Breather at top, Pressure controller, monitoring
1 200 M3 NM3 P Plant- A of pressure and -186 °c
(278 MT) temperature from Control Room
1,94,880N Breather at top, Pressure controller, monitoring

1 250 M3 M3 (348 INOXA of pressure and 0.6 bar -186 °c
MT) P Plant temperature from Control Room
(Plant- B
15,680 ASU) In the purview of SMPV(U), two nos. safety
1 20 M3 NM3 (28 valves, online monitoring of pressure at Control 16 bar -186 °c
MT) Room
CRM
CRM,
Alkali Cylind Heavy Skin ST bay col Overflow arrangement provided
3 3
8 (UNIKLEE N rical, 1 20 M 20 M Irritation, , level switches provided Ambient Ambient
no 21-22
95L) horizo Burn injury
ntal
tank
SMP-2
SILO
9 @ 10 1 150.3 150.3 Highly Plant PPE's , eye washer and shower Ambient Ambient
m MT. MT Toxic & Area
Calcium Above corrosive
Carbide earthle
vel

AM/NS India Limited
Protection System
cylinder Vessel
SILO
10 Magnesium @ 10 1 167.3 167.3 Highly Plant PPE's , eye washer and shower Ambient Ambient
m MT MT Toxic & Area
above corrosive
earth
level
Table 6.7 Hazardous Chemicals Used. - Raw Materials Bulk in Tank Farms & RM Stores. - Hazard Parameter
Sr. RAW NFPA F- STORA MOL. WA LEL VP TWA STEL IDL EXP
SPO. IGN
AUTO
WATER
BP°c
NO. MATERIAL CAS H-R- GE WT TER UEL mm VD SG ppm ppm H LOSI
REACT
FPc
0SIVE
CORR
DIZIN
34.99bar Cr. Pr
(-) 142 Cr.Te
O m3/MT SOL Hg VE
OXY
S/L
(-) 191.1
(-)191
605
NO
1. BF -CO G 630-08- 3-4-0- X 135,00 28.09 NO 10.9 NA 0.97 0.79 75 NA 1200 NO NO NO NO
0 0 nm3 74.2
COREX- CO
34.99bar
(-) 191.1
(-) 142
(-)191
605
NO
2 GAS HOL G 630-08- 3-4-0- X 60,000 28 NO 11 NA 0.97 0.79 75 NA 1200 NO NO NO NO
0 nm3 76
COREX- CO 3,00,000
34.99bar
(-) 191.1
(-) 142
(-)191
605
2A NETWOR G 630-08- 3-4-0- X nmn3 28 NO 11 NA 0.97 0.79 75 NA 1200 NO NO NO NO
NO
K 0 76
34.99bar
(-) 191.1
(-) 142
(-)191
605
NO
3 TAIL GAS G 630-08- 3-4-0- X 2000 28 NO 11 NA 0.97 0.79 75 NA 1200 NO NO NO NO
0 nm3 76
AMMONI A 7664- 1-3-0- X 17.03 16 76 0.68 CORR

651
NO
(-)
4 L 41-7 20 mt YES NA 25 00 0.6 30 220 300 NO NA NO NO TOXIC

(-) 60.3
HYDROG 7783- 4-4-0- X 5-cylinder 34.08 4.3 15 1.19 0.910 0.7

260
NO
5 EN SUPFIDE G 06-4 s 5 m3 NO NA 45 20 0.33 5 100 NO NA NO NO TOXIC
0

AM/NS India Limited
Sr. RAW NFPA F- STORA MOL. WA LEL VP TWA STEL IDL EXP
SPO. IGN
AUTO
WATER
BP°c
REACT
FPc
0SIVE
CORR
DIZIN
Cr. Pr
Cr.Te
O m3/MT SOL Hg VE
OXY
S/L
7647- 0-3-1- X 5+10+31 36.4 41
50.5
NA
NA
6 HCL L 01-0 0 kl 6 YES NA NA 4 NA NA 1.8 1.8 50 NO NA NA NA TOXIC
7664- 0-3-2- 98.0 1.84 0.2 0.2 15 CORR
YES
290
NA
7 H2SO4 L 93-9 W 106 mt 8 YES NA NA 0 3.4 mg/ mg/ mg/ NO NA NO NO TOXIC
m3 m3 m3
NATURA 4-3-0- X 62020 5.3 ASPH
161(-)
537.2
NO
8 L GAS G 74-82-8 m3/hr 16 NO NA 14 NA NA 0.45 NA NA NA NO NA NO NO YXIA NT
(LNG)
9 OXYGEN G 7782- 0-3-0- 201 32 NO NA NA NA NA 1.14 NA NA NA NO NA YES NO NA
183(-
NO
NA
44-7 OX
10 LIQUID L 7782- 0-3-0- 4074 32 NO NA NA NA NA 1.14 NA NA NA NO NA YES NO NA
183(-
NO
NA
OXYGEN 44-7 OX
196(-) 196(-
11 NITROGEN G 7727- NA 1881.7 28 NO NA NA NA NA 0.807 NA NA NA NO NA NO NO NA
NO
NA
37-9 m3
LIQUID 7727- 0-3-0- X 0.807
NO
NA
12 NITROGEN L 37-9 50 m3 28 NO NA NA NA NA NA NA NA NO NA NO NO NA
NA FLAM E
196 (-)
13 HYDROGEN G 1333- 4-0-0- X 4.0 0.071 INVIS

74-0 39.6 kl 2 NO NA 75 NA NA NA NA NA NO NA NO NO NO IBLE
14 CAUSTIC L NA NA 10 m3 NA NA NA N NA NA NA NA NA NA NA NA NA NA NA NA NA YES
A
15 MAGNESIU S 7439- 0-1-1- 167.3 24.3 NO NA NA 473 NA NA NA 1.74 NA NA NA NO NO YES NO
1100
YES
M 95-4 X
FLUIDIZE D 1305- 0-3-1- X 45+3 56.0 6mg/ 25 IRRIT
VERY
YES
NA
16 LIME L 78-8 mt 8 NO NA NA 0 NA NA m3 NA mg/ NO NA NO NO ANT

m3

AM/NS India Limited
/
Sr. RAW NFPA F- STORA MOL. WA LEL VP TWA STEL IDL EXP m
SPO. IGN
AUTO
WATER
BP°c
REACT
FPc
0SIVE
CORR
DIZIN
Cr. Pr
Cr.Te
O m3/MT SOL Hg VE
OXY
S/L
LIQUID NA Repla ces

17 ARGON L 7440- NA 727.0 NA NA NA N NA NA NA NA NA NA NA NA NA NA NA NA oxyge
(Asphyxiant) 37-1 m3 A n
18 UNIKLEE N L NA NA 20 m3 NA NA NA N NA NA NA NA NA NA NA NA NA NA NA NA NA NA
ALKALI A
CALCIUM 3-3-0- 150.3 N 120 WET
YES
19 CARBIDE S 75-20-7 W MT 64.1 NA NA N NA A NA NA 2.2 mg/ NA NA NA NA NA NA C₂H₂
A m3
ETHANO L 3-2-0- X 46.0 12. 3.3 1.59 0.79 330 FLAM
78.5
365
NO
20 L 64-17-5 4.8 KL 7 YES 7 19 50 1800 NA 0 NO NA NO NO MABL E
S/L: SOLID/LIQUID, NFPA: HAZARD PARAMETERS LABEL , CAS: CASE ABSTCT REGISTRY NO , TPQ - THRESHOLD PLANNED QUANTITY, MOL WT: MOLECULAR WEIGHT, SOL: SOLUBLE IN
WATER, FP – FLASH POINT, BP – BOILNG POINT, , AUTO: AUTO IGNITION TEMPERATURE, VP VAPOR PRESSURE,VD – VAPOR DENSITY , SG- SPECIFIC GRAVITY, LEL/UEL – EXPLOSIVE
LIMITS, TWA – TIME WEIGHTED AVERAGE , STEL : SHORT TIME EPOSURE LIMIT, IDLH – IMME. DANGER TO LIFE & HEALTH, EXPL: EXPLOSIVE, ACE/AKL: ACID/ALKALI, OXY: OXIDIZING,
WATER: WATERREACTIVE, SPON: SPONTENEOUSIGNITION, CORR: CORROSIVE. FLAMMABLETOXIC

AM/NS India Limited
6.7 Risk Scenarios: Quantitative Analysis

The hazardous chemicals are assessed with the scenarios, for deriving and identifying the vulnerable zones
are given table 6.8.
Table 6.8 vulnerable zones

Sr. Source Scenarios Failure Mechanism RISK Probabilit Severity 2 Risk
No. Consequences y¹ Rating3
BF GAS HOLDER – CO Leakage TOXIC GAS Cloth TOXIC CLOUD
due to fabric sealing arrangement sealing arrangement LEAKAGE
1 failure. (40 cm long, 7cm wide) entangling with PREAD 3 5 15
WORST CASE SCENARIO structure and gets from a height of 85
torn. m.
“COREX GAS” GAS HOLDER – TOXIC GAS Cloth TOXIC CLOUD
CO Leakage due to fabric sealing sealing arrangement LEAKAGE
2 arrangement failure. (30 cm long, entangling with SPREAD from a 3 5 15
7cm wide) structure and gets height of 85 m.
WORST CASE SCENARIO torn.
STORAGE IN VERTICAL TOXIC GAS outlet AMMONIA GAS at
BULLETS: LEAKAGE OF gas fittings leakage a pressure leaks out
3 AMMONIA GAS from the main near the bullet. and toxic cloud 2 5 10
connection outlet point spreads.
WORST CASE SCENARIO
PIPELINE LEAKAGEOF HIGH PRESSURE HIGH PRESSURE
HYDROGEN GAS IN HYDROGEN HYDROGEN GAS
4 HYDROGEN PUMPING AREA FLAMMABLE GAS gushes out and due 2 5 10
TO STORAGE TANKS. pipeline filling the to light WIEGHT
WORST CASE SCENARIO vertical storage gas moves up fast.
tanks fail.
H₂S GAS LEAKS when cylinder HIGH PRESSURE HIGHLY
outlet valve damage during handling H₂S flammable, Toxic
5 of cylinder. gas gushes out of the H₂S GAS gushes 2 5 10
WORST CASE SCENARIO gas cylinder due to outside the
damaged valve PIPESHOP
premises.
LEGEND
1 2 3
probability: severity: risk Rating:
1 – Highly Unlikely 1 – Extremely Mild Probability x Severity
2 – UNLIKE 2 – MILD
3 – SOMEWHAT LIKELY 3 – MODERATE
4 – LIKELY 4 – SEVERE
5 – VERY LIKELY 5 – MOST SEVERE
• There are more numbers of TOXIC SEVERITY SCENARIO RISKS from the following chemicals,
(OLEUM, ACETIC ACID, ACETIC ANHYDRIDE, HCL, H2SO4, CHLORINRE,
FORMALDEHYDE, PHENOL), on the Bulk storage and transfer of chemicals.
• Fire protection/ control / mitigation measures are to be planned and fully incorporated.

AM/NS India Limited
6.7.1 Software Used for Calculations

ALOHA (Areal Locations of Hazardous Atmospheres):
Aloha is a computer program designed especially for use by people responding to chemical accidents, as
well as for emergency planning and training. ALOHA can predict the rates at which chemical vapours may
escape into the atmosphere from broken gas pipes, leaking tanks, and evaporating puddles. It can then
predict how a hazardous gas cloud might disperse in the atmosphere after an accidental chemical release.
ALOHA is an air dispersion model, which you can use as a tool for predicting the movement and dispersion
of gases. It predicts pollutant concentrations downwind from the source of a spill, taking into consideration
the physical characteristics of the spilled material. ALOHA also accounts for some of the physical
characteristics of the release site, weather conditions, and the circumstances of the release. Like many
computer programs, it can solve problems rapidly and provide results in a graphic, easy-to-use format. This
can be helpful during an emergency response or planning for such a response.
ALOHA provides output as amount of chemical discharged from the source as well as its concentration in
air it takes in to account different levels of concentrations for a specified chemical. Different concentration
levels are given below:
ERPG 1: is the maximum airborne concentration below which it is believed that nearly all individuals could
be exposed for up to 1 hour without experiencing other than mild transient adverse health effects or
perceiving a clearly defined, objectionable odor.
be exposed for up to 1 hour without experiencing or developing irreversible or other serious health effects
or symptoms which could impair an individual's ability to take protective action.
be exposed for up to 1 hour without experiencing or developing life-threatening health effects.
IDLH: The Immediately Dangerous to Life or Health (IDLH) level. A chemical's IDLH is an estimate of
the maximum concentration in the air to which a healthy worker could be exposed without suffering
permanent or escape-impairing health effects.
6.7.1.1 Vulnerability Analysis

A vulnerability analysis is carried out on the MAXIMUM CREDIBLE ACCIDENT SCENARIO and the
WORST-CASE SCENARIO. The analysis is carried out using the help of sophisticated computer software
which provides the zone of influence as well as the geographical risk contours.
The calculations are complex in nature, and various parameters are defined to assist the software in
simulating the risk contours. The parameters include details such as the size of the leakages / holes, quantity
of materials released, duration of the release, weather and geographical conditions.
The simulations are generated under standard operating conditions. Data given in the reports and manuals
are taken as correct information.
6.7.1.2 Maximum Credible Accident Scenario

The MAXIMUM CREDIBLE ACCIDENT SCENARIO was analyzed based on flammable vapor and
toxic vapor risks. The ALOHA simulation software was used to obtain the risk contours and the zone of
influence, as well as levels of risk associated with each zone.
The calculations performed are based on Unified Dispersion Modeling and provide the foot prints of
hazardous chemical dispersion and the distances of critical concentrations for flammability and toxicity. The
model considers a three-stage method as given in the following illustration.

AM/NS India Limited
POOL SPREADING AND VAPORIZATION

The release containing liquid droplets forms a pool. Any
evaporation from this pool will contribute to the dispersing
pool.
Evaporation
↓
DISPERSION
The vapor cloud disperses in the atmosphere until it has
reached harmless concentration.
Calculation of the concentration profile of the cloud

↓
FLAMMABILITY AND TOXICITY
The results of the ALOHA simulation as well as the parameters used for carrying out the simulations is given
below in table-6.9. Downwind concentrations of chemicals are shown.
List of Scenarios for Sketching Dispersion Pattern of Hazardous Materials
Table 6.9 list of Risk Dispersion Scenarios:

Sr. Scenario Description for BF-CO GAS Equipment Pressure Effect
No. Involved Temp
A BF CO GAS – RISK SCENARIOS
BF GAS HOLDER – CO Leakage due to fabric sealing 1.08bar 35°C
1 arrangement failure. (40 cm long, 7cm wide) GAS HOLDER 1,35,000 nm³ TOXIC
WORST CASE SCENARIO CLOUD
BF GAS HOLDER – CO Leakage due to fabric sealing 1.08bar 35°C FIRE
2 arrangement failure. (40 cm long, 7cm wide) MCAS GAS HOLDER 1,35,000 nm³ CLOUD
BF GAS HOLDER – CO Leakage due to fabric sealing 1.08 bar 35°C BLAST
3 arrangement failure. (40 cm long, 7cm wide) MCAS GAS HOLDER 1,35,000 nm³ FORCE
4 PACKAGING WATER AREA BF CO LEAKAGE: Packaging 1.08 bar 50°C TOXIC
near platform 3,50,000 nm3/hr - Ø2100 MCAS water CLOUD
STEAM GENERATORS 3 NUMBERS: Supply line Steam 1.08 bar 50°C TOXIC
5 Ø600 mm Pipe rupture and leakage of gas. MCAS Generator 75,000nm³ /hr CLOUD
STEAM GENERATORS 3 NUMBERS: Supply Steam 1.8 bar 50°C FIRE
6 lineØ600 mm Pipe rupture and leakage of gas. MCAS Generator 75,000 nm³ /hr CLOUD
TRT TURBINE 10 MW: Supply line Ø2100 mm 1.08 bar 38°C TOXIC
7 Pipe rupture and leakage of gas. MCAS TRT Turbine 3,50,000 nm³ /hr CLOUD
KALUJIN STOVES: Supply line Ø1800 mm Pipe KALUJIN 1.08 bar 50°C FIRE
8 rupture and leakage of gas (heating arrangement for STOVES 1,00,000 nm³ CLOUD
HOT BLAST) Ø1800mm, flow rate 1,00,000nm3/hr, /hr
two stoves MCAS
KALUJIN STOVES: Supply line Ø1800 mm Pipe KALUJIN 1.08 bar TOXIC
9
rupture and leakage of gas (heating arrangement for STOVES 50°C CLOUD
HOT BLAST) Ø1800mm, flow rate 1,00,000nm3/hr, 1,00,000 nm³/hr
two stoves MCAS
PCI COAL DRYING OVENS: Supply line Ø600 mm PCI Drying 1.08 bar 50°C FIRE
10 Pipe rupture and leakage of gas. MCAS Ovens 12,000 nm³/hr CLOUD
AM/NS India Limited

No. Involved Temp
BF FURNACE 10M WORKING PLATFORM BF FURNACE 3.5 bar 50°C TOXIC
11 AREA: Exposure to different Leakages of CO gas 10m platform CLOUD
MCAS
SINTER PLANT: Supply line Ø800 mm Pipe rupture 1.08 bar 50°C TOXIC
12 and leakage of gas. MCAS SINTER Plant 6000 nm³/hr CLOUD
B SCENARIO DESCRIPTION FOR COREX - CO GAS.
“COREX GAS” GAS HOLDER – CO Leakage due to 1.07 bar 50°C TOXIC
1 fabric sealing arrangement failure. (30 cm long, 7cm GAS HOLDER 60,000 nm³ CLOUD
wide)
WORST CASE SCENARIO
“COREX GAS” GAS HOLDER – CO Leakage due to 1.07 bar 50°C FIRE
2 fabric sealing arrangement failure. (30 cm long, 7cm GAS HOLDER 60,000 nm³ CLOUD
wide) MCAS
“COREX GAS” GAS HOLDER – CO Leakage due to 1.07 bar 50°C BLAST
3 fabric sealing arrangement failure. (30 cm long, 7cm GAS HOLDER 60,000 nm³ FORCE
wide) MCAS
HOT STRIP MILL – Network 2.0 bar 50°C TOXIC
4 CO Supply line Ø800 mm Pipe rupture and leakage of pipeline 40,000 m³/hr CLOUD
gas. MCAS route
270 MW POWER HOUSE – 2.0 bar 50°C TOTOXIC
5 Supply line Ø1400 mm Pipe rupture and leakage of gas. -Do- 1,80,000 CLOUD
MCAS nm³/hr
270 MW POWER HOUSE – 2.0 bar 50°C FIRE
6 Supply line Ø1400 mm Pipe rupture and leakage of gas. -Do- 1,80,000 nm³/hr CLOUD D
MCAS
DRI – 6: Supply line Ø1800 mm Pipe rupture and 2.0 bar 50°C TOXIC
7 leakage of gas. M CAS -Do- 90,000 nm³/ hr CLOUD
DRI – 6: 2.0 bar 50°C FIRE
8 Supply line Ø1800 mm Pipe rupture and leakage of gas. -Do- 90,000 nm³/ hr CLOUD
M CAS
LIME PLANT: NETWORK 2.0 bar 50°C
9 Supply line Ø700 mm Pipe rupture and leakage of gas Pipeline 34,500 nm³/ TOXIC
MCAS route hr CLOUD
CDI 1-9 FURNACES: 2.0 bar 50°C
10 Supply line Ø500 mm Pipe rupture and leakage of gas -Do- 6,500 nm³/ hr FIRE
MCAS CLOUD
PLATE MILL: 1.07 bar 50°C
11 Supply line Ø1800 mm Pipe rupture and leakage of gas. LP LINE route 48,000 nm³ /hr TOXIC
MCAS CLOUD
PLATE MILL: 1.07 bar 50°C
12 Supply line Ø1800 mm Pipe rupture and leakage of gas. LP LINE route 48,000 nm³ /hr FIRE
MCAS CLOUD
TUNNEL MILL: 1.11 bar 50°C
13 Supply line Ø1500 mm Pipe rupture and leakage of gas -Do- 51,000 nm³ /hr TOXIC
MCAS CLOUD
TUNNEL MILL: 1.11 bar 50°C
14 Supply line Ø1500 mm Pipe rupture and leakage of gas -Do- 51,000 nm³ /hr FIRE
MCAS CLOUD
BOILER: 1.07 bar 50°C
M CAS CLOUD
SMP 2: 1.07 bar 50°C
AM/NS India Limited

No. Involved Temp
M CAS CLOUD
C SCENARIO DESCRIPTION FOR AMMONIA GAS.
STORAGE IN VERTICAL BULLETS: LEAKAGE MAIN 8.0 BAR 30 °C
1 OF AMMONIA FROM THE MAIN CONNECTION CONNECTION TOXIC
OUTLET POINT WORST CASE SCENARIO OUTLET CLOUD
2 PIPELINE CARRYING AMMONIA TO CRACKER ¾” PIPELINE. 2.0 BAR 30 °C TOXIC
PLANTLEAKAGE DUE TO FAILURE. MCAS CLOUD
3 LEAKAGE OF AMMONIA FROM TANKER 3” 8.0 BAR 30 °C TOXIC
DECANTING HOSE MCAS FLEXIBLE CLOUD
HOSE PIPE.
D SCENARIO DESCRIPTION FOR HYDROGEN GAS.
HYDROGEN STORAGE TANKS – RELEASE SAFETY 10.125 BAR AT FIRE
1. THROUGH PUFFING OFF FROM SAFETY RELIEF RELIEF VALVE 50°C CLOUD
VALVE- DUE TO HIGH SUMMER
DAY TEMPERATURE. MCAS
PIPELINE LEAKAGEOF HYDROGEN GAS IN 14 BAR AT 30°C FIRE
2 HYDROGEN PUMPING AREA TO STORAGE 1” PIPE CLOUD
TANKS.
WORST CASE SCENARIO
3 PIPELINE LEAKAGEOF HYDROGEN GAS IN 1” PIPE 14 BAR AT 30°C EXPLO
HYDROGEN PUMPING AREA TO STORAGE SION
TANKS. MCAS
E SCENARIO DESCRIPTION FOR HYDROGEN SULPHIDE GAS.
GAS CYLINDER OUTLET VALVE DAMAGE Filled Cylinder 15 bar TOXIC
1 DURING HANDLING OF CYLINDER. WORST Dropped During 30 °C CLOUD
CASE SCENARIO Handling G
2 GAS CYLINDER OUTLET VALVE DAMAGE Filled Cylinder 15 bar FIRE
DURING HANDLING OF CYLINDER. M CAS Dropped 30 °C CLOUD
During LOUD
Handling

AM/NS India Limited
6.7.1.3 Dispersion Scenarios of Hazchem - Emergency Releases. Blast Furnace “CO” Scenarios:
Site Data: Location: AM / NS INDIA, HAZIRA, GUJARAT. Building Air exchanges per Hour: 10 (user
specified)
1.A BF CO GAS HOLDER – CO Leakage due to fabric 1.B BF CO GAS HOLDER – CO Leakage due to fabric sealing
sealing arrangement failure. (40 cm long, 7cm wide). Toxic arrangement failure. (40 cm long, 7cm wide). Toxic cloud
cloud Atmospheric stability: ‘F’ (worst case scenario)
Atmospheric stability: ‘D’ (worst case scenario)
THREAT ZONE: Model Run: Gaussian THREAT ZONE: Model Run: Gaussian
Red : 243 meters --- (330 ppm = AEGL-3 [60 min]) Red : 1.4 kilometers --- (330 ppm = AEGL-3 [60 min])
Orange: 520 meters --- (83 ppm = AEGL-2 [60 min]) Orange: 3.4 kilometers --- (83 ppm = AEGL-2 [60 min])
Yellow: no recommended LOC value -(N/A = AEGL-1 [60 Yellow: no recommended LOC value ---(N/A = AEGL-1 [60
min])
THREAT AT POINT: Concentration Estimates at the point: THREAT AT POINT: Concentration Estimates at
Downwind: 50 meters Off Centerline: 25 the point: Downwind: 50 meters Off Centerline:
meters Note: Concentration not drawn because there is no 25 meters
significant concentration at the point selected. Note: Concentration not drawn because there is no significant
concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
MONOXIDE CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL- min):
3 (60
330 ppm IDLH: 1200 ppm LEL: 125000 ppm EL: 742000
min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm EL: 742000 Ambient Boiling Point: -191.5°C Vapor Pressure at
ppm Ambient Boiling Point: -191.5°C Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient
Ambient Temperature: greater than 1 atm Ambient Saturation Saturation Concentration: 1,000,000 ppm or 100.0%
Concentration: 1,000,000 ppm or
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
Wind: 3 meters/second from 45° true at 3 meters
Ground Roughness: open country Cloud Cover:
Ground Roughness: open country Cloud Cover: 5 tenths
5 tenths Air Temperature: 25° C Stability Class: F (user
Air Temperature: 32° C Stability Class: D
override)
No Inversion Height Relative Humidity: 50%
SOURCE STRENGTH: Leak from hole in vertical cylindrical
tank Flammable chemical escaping from tank (not burning)
Tank Diameter: 45 meters ank Length: 85 metersTank Volume:
135,187 cubic meters Tank contains gas only Internal
Tank Diameter: 45 meters Tank Length: 85 meters. Tank
Temperature: 32° C Chemical Mass in Tank: 187 tons Internal
Volume: 135,187 cubic meters Tank contains gas only Internal
Press: 1.12 atmospheres Opening Length: 40cm Opening
Temperature: 25° C Chemical Mass in Tank: 191 tons
Width: 7 cm Release Duration: ALOHA limited the duration to
Internal Press:
1-hour Max Average Sustained Release Rate: 166
1.12 atmospheres Opening Length: 40 cm Opening Width: 7 cm
kilograms/min (averaged over a minute or more)
Release Duration: ALOHA limited the duration to 1-hour Max
Total Amount Released: 8,539 kilograms
Average Sustained Release Rate: 168 kilograms/min (averaged
over a minute or more)

AM/NS India Limited
2A BF CO GAS HOLDER – CO Leakage due to fabric 2B BF CO GAS HOLDER – CO Leakage due to fabric sealing
sealing arrangement failure. (40 cm long, 7cm wide). FIRE arrangement failure. (40 cm long, 7cm wide). FIRE cloud
cloud Atmospheric stability: ‘D’ Atmospheric stability: ‘F’
(MAXIMUM CREDIBLEACCIDENT SCENARIO) (MAXIMUM CREDIBLEACCIDENT SCENARIO)
THREAT ZONE: Model Run: Gaussian THREAT ZONE: Threat Modeled: Flammable Area of Vapor
Threat Modeled: Flammable Area of Vapor Cloud Cloud Model Run: Gaussian
Red 21 meters (75000 ppm = 60% LEL = Flame Pockets) Red : 105 meters -(75000 ppm = 60% LEL = Flame Pockets
Note: Threat zone was not drawn because effects of near-field Yellow: 265 meters --- (12500 ppm = 10% LEL)
patchiness make dispersion predictions less reliable for short
distances.
Yellow: 52 meters --- (12500 ppm = 10% LEL)
THREAT AT POINT: Concentration Estimates at the THREAT AT POINT: Concentration Estimates at

point: Downwind: 50 metersOff Centerline: 25 meters the point Downwind: 50 meters Off Centerline: 25
Note: Concentration not drawn because there is no significant meters
concentration at the point selected. Note: Concentration not drawn because there is no significant
CHEMICAL DATA: Chemical Name: CARBON
CHEMICAL DATA:
MONOXIDE CAS Number: 630-8-0 Molecular Weight: 28.01
Chemical Name: CARBON MONOXIDE CAS Number: 630-8-0
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm Molecular Weight: 28.01 g/mol AEGL-1 (60 min): N/A AEGL-2
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 (60 min): 83 ppm AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm
ppm UEL: 742000 ppm, Ambient Boiling Point: 191.5°C, LEL: 125000 ppm
Vapor Pressure at Ambient Temperature: greater than 1 atm, UEL: 742000 ppm Ambient Boiling Point: -
Ambient Saturation Concentration: 1,000,000 ppm 191.5° C Vapor Pressure at Ambient Temperature: greater than 1
atm Ambie Saturation Concentration: 1,000,000 ppm or 100.0%
No Inversion Height Relative Humidity: 75% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
SOURCE STRENGTH: Leak from hole in vertical cylindrical Wind: 3 meters/second from 45° true at 3 meters
tank Flammable chemical escaping from tank (not burning) Ground Roughness: open country Cloud Cover: 5
Tank Diameter: 45 meters Tank Length: 85 meters Tank tenths Air Temperature: 25° C Stability Class: F (user
Volume: 135,187 cubic meters Tank contains gas only Internal override)
Temperature: 32° C Chemical Mass in Tank: 187 tons Internal No Inversion Height Relative Humidity: 50%
Press: 1.12 atmospheres Opening Length: 40 cm
SOURCE STRENGTH: Leak from hole in vertical
Opening Width: 7 cm Release Duration: ALOHA limited the cylindrical tank Flammable chemical escaping from tank
duration to (not burning)
1-hour Max Average Sustained Release Rate: 166 Tank Diameter: 45 meters Tank Length: 85
kilograms/min (averaged over a minute or more) meters Tank Volume: 135,187 cubic meters Tank contains
Total Amount Released: 8,539 kilograms gas only Internal Temperature: 25° C Chemical Mass in
Tank: 191 tons
Internal Press: 1.12 atmospheres Opening Length: 40 centimeters
Opening Width: 7 centimeters Release Duration: ALOHA limited
the duration to 1-hour Max Average Sustained Release Rate: 168
AM/NS India Limited
3A. BF CO GAS HOLDER – CO Leakage due to fabric 3B. BF CO GAS HOLDER – CO Leakage due to fabric sealing
sealing arrangement failure. (40 cm long, 7cm wide). Blast arrangement failure. (40 cm long, 7cm wide). Blast force
force Atmospheric stability: ‘D’ Atmospheric stability: ‘F’
THREAT ZONE: Threat Modeled: Overpressure (blast THREAT ZONE: Threat Modeled: Overpressure (blast force)
force) from vapor cloud explosion Model Run: Gaussian from vapor cloud explosion Model Run: Gaussian
Type of Ignition: ignited by spark or flame Type of Ignition: ignited by spark or flame
Level of Congestion: uncongested Level of Congestion: uncongested
Red : LOC was never exceeded -(8.0 psi = destruction of Red : LOC was never exceeded --- (8.0 psi = destruction of bldg
bldg. b Orange: LOC was never exceeded -(3.5 psi = Orange: LOC was never exceeded - (3.5 psi =serious injury
serious injury likely) likely)
Yellow: LOC was never exceeded --- (1.0 psi = shatters Yellow: LOC was never exceeded --- (1.0 psi = shatters glass
glass)
THREAT AT POINT: Overpressure Estimate at the
point: Downwind: 50 meters Off Centerline: 25
THREAT AT POINT: Overpressure Estimate at the meters Overpressure: 0.176 psi
point: Downwind: 50 meters Off Centerline: 25 meters.
There is no significant overpressure at the point selected.
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
CHEMICAL DATA: Chemical Name: CARBON CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
MONOXIDE AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
CAS Number: 630-8-0 Molecular Weight: 28.01
min)
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm
IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000 ppm
AEGL-3 (60
Ambient Boiling Point: -191.5° C Vapor Pressure at Ambient
min): 330 ppm IDLH: 1200 ppm LEL:
Temperature: greater than 1 atm
125000 ppm UEL: 742000 ppm Ambient
Boiling Point: -191.5° C Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Vapor Pressure at Ambient Temperature: greater than 1 atm
Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 3 meters/second from 45° true at 3 meters
Wind: 10 meters/second from 225° true at 3 meters Ground Roughness: open country Cloud Cover: 5
Ground Roughness: open country Cloud Cover: 7 tenths tenths Air Temperature: 25° C Stability Class: F (user
Air Temperature: 32° C Stability Class: D override)
No Inversion Height Relative Humidity: 75% No Inversion Height Relative Humidity: 50%
SOURCE STRENGTH:
SOURCE STRENGTH: Leak from hole in vertical cylindrical tank
Leak from hole in vertical cylindrical tank Flammable chemical escaping from tank (not
Flammable chemical escaping from tank (not burning) burning) Tank Diameter: 45 meters Tank Length: 85
Tank Diameter: 45 meters Tank Length: 85 meters Tank Volume: 135,187 cubic meters
meters Tank contains gas only Internal Temperature: 25° C
Tank Volume: 135,187 cubic meters Tank contains gas only Chemical Mass in Tank: 191 tons Internal Press: 1.12 atmospheres
Internal Temperature: 32° C Chemical Mass in Tank: Opening Length: 40 centimeters Opening Width: 7-centimeter
187 tons Internal Press: 1.12 atmospheres Opening Release Duration: ALOHA limited the duration to 1 hour
Length: 40 centimeters Opening Width: 7 Max Average Sustained Release Rate: 168
centimeters kilograms/min (averaged over a minute or more)
Release Duration: ALOHA limited the duration to 1-hour Max Total Amount Released: 8,659 kilograms.
Average Sustained Release Rate: 166 kilograms/min
(averaged over a minute or more) Total
Amount Released: 8,539 kilograms

AM/NS India Limited
4A. PACKAGING WATER AREA BF CO LEAKAGE: near 4B. PACKAGING WATER AREA BF CO LEAKAGE:
platform near platform
TOXIC cloud Atmospheric stability: ‘D’ TOXIC cloud Atmospheric stability: ‘F’
THREAT ZONE: Model Run: Gaussian\ THREAT ZONE: Model Run: Gaussian
Red : 51 meters --- (330 ppm = AEGL-3 [60 min]) Red : 258 meters --- (330 ppm = AEGL-3 [60 min])
Orange: 103 meters --- (83 ppm = AEGL-2 [60 min]) Orange: 537 meters --- (83 ppm = AEGL-2 [60 min])
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
min]) min])
THREAT AT POINT: Concentration Estimates at the THREAT AT POINT: Concentration Estimates at

point: Downwind: 10 metersOff Centerline: 5 meters the point: Downwind: 10 meters Off Centerline:
Note: Concentration not drawn because there is no significant 5 meters
CAS Number: 630-8-0 Molecular Weight: 28.01 CHEMICAL DATA: Chemical Name: CARBON
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm MONOXIDE
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm CAS Number: 630-8-0 Molecular Weight: 28.01
LEL: 125000 ppm UEL: 742000 ppm g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm
Ambient Boiling Point: -191.5° C AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm
Vapor Pressure at Ambient Temperature: greater than 1 atm LEL: 125000 ppm
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% UEL:
742000 ppm Ambient Boiling Point: -191.5° C
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Vapor Pressure at Ambient Temperature: greater than 1 atm
Wind: 10 meters/second from 225° true at 3 meters Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Ground Roughness: open country Cloud Cover: 5
tenths Air Temperature: 32° C Stability Class: D ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
No Inversion Height Relative Humidity: 50% Wind: 3 meters/second from 45° true at 3 meters
SOURCE STRENGTH: 5 tenths Air Temperature: 25° C Stability Class: F (user
Source: 500 kilograms/ hr Pipe Ø2100 mm Pr. 2.0 atm, override)
Release from a pipe crack opening,
Source Height: 0 Release Duration: 60 minutes
Release Rate: 8.33 kilograms/min
SOURCE STRENGTH:
Total Amount Released: 500 kilograms (Assumed).
Direct Source: 500 kilograms/ hr Pipe Ø2100 mm Pr. 2.0 atm,
Release from a pipe crack opening,
Source Height: 0 Release Duration: 60 minutes
Release Rate: 8.33 kilograms/min
Total Amount Released: 500 kilograms (Assumed).

AM/NS India Limited
5A. BF STEAM GENERATORS 3 NUMBERS: Supply line 5B. BF STEAM GENERATORS 3 NUMBERS: Supply line
Ø600 mm Pipe rupture and leakage of gas TOXIC cloud Ø600 mm Pipe rupture and leakage of gas TOXIC cloud
Atmospheric stability: ‘D’ Atmospheric stability: ‘F’
Note: Threat zone was not drawn because effects of near-field Orange : 408 meters --- (83 ppm = AEGL-2 [60 min])
patchiness make dispersion predictions less reliable for short Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
distances. min])])
Orange: 80 meters --- (83 ppm = AEGL-2 [60 min])
Yellow: no recommended LOC value (N/A = AEGL-1 [60 min])
THREAT AT POINT: Concentration Estimates at

the point: Downwind: 10 meters Off Centerline: THREAT AT POINT: Concentration Estimates at
5 meters the point: Downwind: 10 meters Off Centerline:
Note: Concentration not drawn because there is no significant 5 meters
CAS Number: 630-8-0 Molecular Weight: 28.01 CHEMICAL DATA: Chemical Name: CARBON
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm MONOXIDE
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: CAS Number: 630-8-0 Molecular Weight: 28.01
125000 ppm UEL: 742000 ppm Ambient Boiling Point: - g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm
191.5° C AEGL-3 (60 min): 330 ppm IDLH: 1200
Vapor Pressure at Ambient Temperature: greater than 1 atm ppm LEL: 125000
Ambient Saturation Concentration: 1,000,000 ppm or ppm UEL: 742000 ppm Ambient
100.0% Boiling Point: -191.5° C
ATMOSPHERIC DATA: (MANUAL INPUT OF Vapor Pressure at Ambient Temperature: greater than 1 atm
DATA) Wind: 10 meters/second from 225° true at 3 meters Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Ground Roughness: open country Cloud Cover: 5 tenths Air
Temperature: 32° C Stability Class: D
SOURCE STRENGTH: Ground Roughness: open country Cloud Cover:
Direct Source: 300 kilograms/hr Source 5 tenths Air Temperature: 25° C Stability Class: F (user
Height: 0 Pipe Ø600 Pr. 2.0 atm flow 75,000 override)
nm³/hr, No Inversion Height Relative Humidity: 50%
Release Duration: 60 minutes Release Rate: 5 kilograms/min
SOURCE STRENGTH:
Total Amount Released: 300 kilograms
Direct Source: 300 kilograms/hr Source
Height: 0 Pipe Ø600 Pr. 2.0 atm flow 75,000
nm³/hr,

AM/NS India Limited
6A. BF STEAM GENERATORS 3 NUMBERS: Supply line 6B. BF STEAM GENERATORS 3 NUMBERS: Supply line
Ø600 mm Pipe rupture and leakage of gas FIRE Ø600 mm Pipe rupture and leakage of gas FIRE cloud
cloud Atmospheric stability: ‘D’ Atmospheric stability: ‘F’
(MAXIMUM CREDIBLEACCIDENT SCENARIO) MAXIMUM CREDIBLEACCIDENT SCENARIO)
THREAT ZONE: THREAT ZONE:
THREAT AT POINT: Concentration Estimates at THREAT AT POINT: Concentration Estimates at the

the point: Downwind: 10 meters Off point: Downwind: 10metersOff Centerline: 5 meters
Centerline: 5 meters Note: Concentration not drawn because there is no significant
Note: Concentration not drawn because there is no significant concentration at the point selected.
concentration at the point selected.
CHEMICAL DATA: Chemical Name: CARBON CAS Number: 630-8-0 Molecular Weight: 28.01
MONOXIDE g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm
CAS Number: 630-8-0 Molecular Weight: 28.01 AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000
g/mol ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 Vapor Pressure at Ambient Temperature: greater than 1 atm
(60 min): Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
742000
ppm Ambient Boiling Point: -191.5° C
Wind: 10 meters/second from 225° true at 3 ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
meters Ground Roughness: open country Cloud Wind: 3 meters/second from 45° true at 3 meters
Cover: 7 tenths Air Temperature: 32° C Stability Ground Roughness: open country Cloud Cover: 5
Class: D tenths Air Temperature: 25° C Stability Class: F (user
No Inversion Height Relative Humidity: 75% override)
SOURCE STRENGTH
Direct Source: 300 kilograms/hr SOURCE STRENGTH:
Source Height: 0 Pipe Ø600 Pr. 2.0 atm flow Direct Source: 300 kilograms/hr
75,000 nm³/hr, Source Height: 0 Pipe Ø600 Pr. 2.0 atm
Release Duration: 60 minutes Release Rate: 5 flow 75,000 nm³/hr,
kilograms/min Total Amount Released: 300 kilograms Release Duration: 60 minutes Release Rate: 5 kilograms/min

AM/NS India Limited
7A. BF TRT TURBINE 10 MW: Supply line Ø2100 mm 7A. BF TRT TURBINE 10 MW: Supply line Ø2100 mm
Pipe rupture and leakage of gas.TOXIC cloud Atmospheric
Pipe rupture and leakage of gas. TOXIC cloud Atmospheric
stability: ‘D’ MAXIMUM CREDIBLEACCIDENT
stability: ‘F’ (MAXIMUM CREDIBLEACCIDENT
SCENARIO)
SCENARIO)
Red : 284 meters --- (330 ppm = AEGL-3 [60
Red : 56 meters --- (330 ppm = AEGL-3 [60 min] min]) Orange: 594 meters --- (83 ppm =
Orange: 114 meters --- (83 ppm = AEGL-2 [60 min]) AEGL-2 [60 min])

the point: Downwind: 10 meters Off point: Downwind: 10 metersOff Centerline: 5 meters
Note: Concentration not drawn because there is no significant concentration at the point selected.
CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
MONOXIDE
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-
3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83
UEL: 742000 ppm Ambient Boiling Point: -191.5° C
ppm AEGL-3 (60 min): 330 ppm IDLH: 1200
ppm LEL: 125000
ppm UEL: 742000 ppm Ambient Saturation Concentration: 1,000,000 ppm or
100.0%
Ambient Boiling Point: -191.5° C
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
tenths Air Temperature: 25° C Stability Class: F (user
override)
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) No Inversion Height Relative Humidity: 50%
Ground Roughness: open country Cloud Cover: 7 SOURCE STRENGTH:
tenths Air Temperature: 32° C Stability Class: D Direct Source: 600 kilograms/hr
No Inversion Height Relative Humidity: 75% Source Height: 0 Pipe Ø600 Pr. 1.12.0 atm flow
3,50,000 nm³/hr,
SOURCE STRENGTH Release Duration: 60 minutes Release Rate: 10 kilograms/min
Direct Source: 300 kilograms/hr Total Amount Released: 600 kilograms.
Source Height: 0 Pipe Ø600 Pr. 2.0 atm flow
75,000 nm³/hr,

AM/NS India Limited
8A. BF KALUJIN STOVES: Supply line Ø1800 mm Pipe 8B. BF KALUJIN STOVES: Supply line Ø1800 mm Pipe
rupture and leakage of gas (heating arrangement for HOT rupture and leakage of gas (heating arrangement for HOT
BLAST) BLAST)
TOXIC CLOUD Atmospheric stability: ‘D’ TOXIC CLOUD Atmospheric stability: ‘F’
(MAXIMUM CREDIBLEACCIDENT SCENARIO) MAXIMUM CREDIBLEACCIDENT SCENARIO)
THREAT ZONE: Model Run: Gaussian

Red : 284 meters --- (330 ppm = AEGL-3 [60
THREAT ZONE: Model Run: Gaussian min]) Orange: 594 meters --- (83 ppm = AEGL-
Red : 56 meters --- (330 ppm = AEGL-3 [60 min]) 2 [60 min])
Orange: 114 meters --- (83 ppm = AEGL-2 [60 min]) Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 min])
min])

the point: Downwind: 10 meters Off point: Downwind: 10 metersOff Centerline: 5 meters
Note: Concentration not drawn because there is no concentration at the point selected
significant concentration at the point selected.
CHEMICAL DATA: Chemical Name: CARBON CAS Number: 630-8-0 Molecular Weight: 28.01
MONOXIDE g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm
CAS Number: 630-8-0 Molecular Weight: AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000
28.01 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C
83 ppm AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm Vapor Pressure at Ambient Temperature: greater than 1 atm
LEL: 125000 ppm UEL: 742000 ppm Ambient Boiling Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Point: -191.5° C
Vapor Pressure at Ambient Temperature: greater than 1
atm Ambient Saturation Concentration: 1,000,000 ppm or ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
100.0% Wind: 3 meters/second from 45° true at 3 meters
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) tenths Air Temperature: 25° C Stability Class: F (user
Wind: 10 meters/second from 225° true at 3 meters override)
Ground Roughness: open country Cloud Cover: 5 No Inversion Height Relative Humidity: 50%
tenths Air Temperature: 32° C Stability Class: D
SOURCE STRENGTH:
Direct Source: 600 kilograms/hr Source Height: 0 Pipe
SOURCE STRENGTH: Ø 1800 Pr. 1.08 atm Temp: 25°C Flow rate: 1,00,000
Direct Source: 600 kilograms/hr Source Height: 0 nm3/hr Release Duration: 60 minutes
Pipe Ø 1800 Pr. 1.08 atm Temp: 32°C Flow rate: Release Rate: 10 kilograms/min
1,00,000 nm3/hr Release Duration: 60 minutes Total Amount Released: 600 kilograms
Release Rate: 10 kilograms/min

AM/NS India Limited
9A. BF KALUJIN STOVES: Supply line Ø1800 mm Pipe 9B. BF KALUJIN STOVES: Supply line Ø1800 mm Pipe
rupture and leakage of gas (heating arrangement for HOT rupture and leakage of gas (heating arrangement for HOT
BLAST) FIRE CLOUD Atmospheric stability: ‘D’ BLAST)
(MAXIMUM CREDIBLEACCIDENT SCENARIO) FIRE CLOUD Atmospheric stability: ‘F’
MAXIMUM CREDIBLEACCIDENT SCENARIO)
THREAT ZONE: Model Run: Gaussian THREAT ZONE: Threat Modeled: Flammable Area of
Vapor Cloud Model Run: Gaussian
THREAT AT POINT: Concentration Estimates at the point:
Downwind: 10meters Off Centerline: 5 meters Red : 25 meters --- (75000 ppm = 60% LEL = Flame
Note: Concentration not drawn because there is no significant Pockets) Note: Threat zone was not drawn because
concentration at the point selected. effects of near-field patchiness make dispersion
predictions less reliable for short distances.
Yellow: 63meters --- (12500 ppm = 10% LEL) Model
Run: Gaussian THREAT AT POINT: Concentration
Estimates at the point: Downwind: 10meters Off
Centerline: 5 meters
Note: Concentration not drawn because there is no
significant concentration at the point sele

MONOXIDE
CAS Number: 630-8-0 Molecular Weight:
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60 28.01 g/mol AEGL-1 (60 min): N/A AEGL-2 (60
min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm min): 83 ppm AEGL-3 (60 min): 330 ppm IDLH:
UEL: 1200 ppm LEL: 125000 ppm UEL: 742000 ppm
742000 ppm Ambient Boiling Point: -191.5° C Ambient Boiling Point: -191.5° C
Vapor Pressure at Ambient Temperature: greater than 1 atm Vapor Pressure at Ambient Temperature: greater than
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% 1 atm Ambient Saturation Concentration: 1,000,000
ppm or 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF

DATA)
Ground Roughness: open country Cloud
Cover: 5 tenths Air Temperature: 25° C Stability
Class: F (user override) No Inversion Height
Relative Humidity: 50%
SOURCE STRENGTH:
Direct Source: 600 kilograms/hr Source Height:
0 Pipe Ø 1800 Pr. 1.08 atm Temp: 25°C Flow
rate : 1,00,000 nm3/hr Release Duration: 60 minutes
SOURCE STRENGTH: Release Rate: 10 kilograms/min
Direct Source: 600 kilograms/hr Source Height: 0 Pipe Total Amount Released: 600 kilograms
Ø 1800 mm Pr. 1.08 atm Temp: 32°C
Flow rate: 1,00,000 nm3/hr

AM/NS India Limited
10 A. BF PCI COAL DRYING OVENS: Supply line Ø 600 mm 10 B.BF PCI COAL DRYING OVENS: Supply line Ø
Pipe rupture and leakage of gas. FIRE CLOUD 600 mm
Atmospheric stability: ‘D’ Pipe rupture and leakage of gas.
(MAXIMUM CREDIBLEACCIDENT SCENARIO) FIRE CLOUD Atmospheric stability:
‘F’
MAXIMUM CREDIBLEACCIDENT SCENARIO)
Note: Threat zone was not drawn because effects of near-field Orange: 476 meters --- (83 ppm = AEGL-2 [60 min]
patchiness make dispersion predictions less reliable for short Yellow: no recommended LOC value --- (N/A = AEGL-
distances. 1 [60 min])
THREAT AT POINT: Concentration
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 min])
Estimates at the point: Downwind: 10 meters
Off Centerline: 5
Downwind: 10 meters Off Centerline: 5 meters
meters
Note: Concentration not drawn because there is no significant
Note: Concentration not drawn because there is no
significant concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE CHEMICAL DATA: Chemical Name: CARBON
CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol MONOXIDE
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60 CAS Number: 630-8-0 Molecular
min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000 Weight: 28.01 g/mol AEGL-1 (60 min): N/A
ppm Ambient Boiling Point: -191.5° C AEGL-2 (60 min): 83 ppm AEGL-3 (60 min): 330
Vapor Pressure at Ambient Temperature: greater than 1 atm ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% 742000 ppm Ambient Boiling Point: -191.5° C
Vapor Pressure at Ambient Temperature: greater
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) than 1 atm Ambient Saturation Concentration:
Wind: 10 meters/second from 225° true at 3 meters Ground 1,000,000 ppm or 100.0%
Roughness: open country Cloud Cover: 7 tenths Air
Temperature: 32° C Stability Class: D ATMOSPHERIC DATA: (MANUAL INPUT OF
No Inversion Height Relative Humidity: 75% DATA)
SOURCE STRENGTH: Ground Roughness: open country Cloud
Direct Source: 400 kilograms/hr Source Height: 0 Pipe Cover: 5 tenths Air Temperature: 25° C Stability
Ø600 Mm Pressure: 1.08 atm Flow RATE: 12,000 nm3/hr Class: F (user override)
Release Duration: 60 minutes Release Rate: 6.67 No Inversion Height Relative Humidity:
kilograms/min. Total Amount Released: 400 kilograms 50%
SOURCE STRENGTH:
Direct Source: 400 kilograms/hr Source
Height: 0 Pipe Ø600 Mm Pressure: 1.08 atm Flow
RATE: 12,000 nm3/hr
Release Duration: 60 minutes Release Rate: 6.67
kilograms/min. Total Amount Released: 400 kilograms

AM/NS India Limited
11A. BF FURNACE 10M WORKING PLATFORM AREA: 11B. BF FURNACE 10M WORKING PLATFORM
Exposure AREA: Exposure
to different Leakages of CO gas TOXIC CLOUD Atmospheric to different Leakages of CO gas TOXIC CLOUD
stability: ‘D’ Atmospheric stability: ‘F’
(MAXIM
UM MAXIMUM
CREDIBLEACCIDENT SCENARIO) CREDIBLEACCIDENT SCENARIO)
Red: 230 meters --- (330 ppm = AEGL-3 [60
Red: 45 meters --- (330 ppm = AEGL-3 [60 min])
min]) Orange: 476 meters --- (83 ppm =
Note: Threat zone was not drawn because effects of near-field
AEGL-2 [60 min])
patchiness make dispersion predictions less reliable for short distances.
Yellow: no recommended LOC value --- (N/A =
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 min]) AEGL-1 [60 min])
Downwind: 10 meters Off Centerline: 5 meters THREAT AT POINT: Concentration
Note: Concentration not drawn because there is no significant Estimates at the point: Downwind: 10 meters
concentration at the point selected. Off Centerline: 5
meters
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE Note: Concentration not drawn because there is no
CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol significant concentration at the point selected
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60 CHEMICAL DATA: Chemical Name: CARBON
min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000 MONOXIDE
ppm Ambient Boiling Point: -191.5° C CAS Number: 630-8-0 Molecular
Vapor Pressure at Ambient Temperature: greater than 1 atm Weight: 28.01 g/mol AEGL-1 (60 min): N/A
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% AEGL-2 (60 min): 83 ppm AEGL-3 (60 min): 330
ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) 742000 ppm Ambient Boiling Point: -191.5° C
Wind: 10 meters/second from 225° true at 3 meters Ground Vapor Pressure at Ambient Temperature: greater
Roughness: open country Cloud Cover: 5 tenths Air than 1 atm Ambient Saturation Concentration:
Temperature: 32° C Stability Class: D 1,000,000 ppm or 100.0%
SOURCE STRENGTH: Direct Source: 1000 kilograms/hr ATMOSPHERIC DATA: (MANUAL INPUT OF
Source Height: 0 Pressure: 1.0 atm Temp: 50°C DATA)
Release Duration: 60 minutes Release Rate: 6.67 kilograms/min. Wind: 3 meters/second from 45° true at 3 meters
Total Amount Released: 1000 kilograms Ground Roughness: open country Cloud
Cover: 5 tenths Air Temperature: 25° C Stability
Class: F (user override)
No Inversion Height Relative
Humidity: 50%
SOURCE STRENGTH: Direct Source: 1000

kilograms/hr Source Height: 0 Pressure: 1.0
atm Temp: 50°C
Release Duration: 60 minutes Release Rate: 6.67
kilograms/min. Total Amount Released: 1000
kilograms

AM/NS India Limited
12 A SINTER PLANT: Supply line Ø800 mm Pipe rupture 12 B SINTER PLANT: Supply line Ø800 mm Pipe rupture and
and leakage of gas.TOXIC CLOUD Atmospheric stability: leakage of gas. TOXIC CLOUD
‘D’ MAXIMUM CREDIBLEACCIDENT SCENARIO) Atmospheric stability: ‘F’ MAXIMUM
CREDIBLEACCIDENT
SCENARIO)
min]) min])

the point: Downwind: 10 meters Off Centerline: point: Downwind: 10 metersOff Centerline: 5 meters
5 meters Note: Concentration not drawn because there is no significant
Note: Concentration not drawn because there is no significant concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
MONOXIDE AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
CAS Number: 630-8-0 Molecular Weight: min):
28.01 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
ppm AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 742000
125000 ppm UEL: 742000 ppm Ambient Boiling Point: - ppm Ambient Boiling Point: -191.5° C
191.5° C Vapor Pressure at Ambient Temperature: greater than 1 atm
Vapor Pressure at Ambient Temperature: greater than 1 Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
atm Ambient Saturation Concentration: 1,000,000 ppm or
100.0% ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Ground Roughness: open country Cloud Cover: 5
Wind: 10 meters/second from 225° true at 3 meters tenths Air Temperature: 25° C Stability Class: F (user
Ground Roughness: open country Cloud Cover: 5 override)
tenths Air Temperature: 32° C Stability Class: D
SOURCE STRENGTH: Direct Source: 600
SOURCE STRENGTH: Direct Source: 600 kilograms/hr
kilograms/hr Source Height: 0 Pressure: 1.08 atm Pipe Source Height: 0 Pressure: 1.08 atm Pipe Ø 800 mm
Ø 800 mm Temp: 50°C Release Duration: 60 minutes Release Rate: 6.67
Temp: 50°C Release Duration: 60 minutes Release Rate: 6.67 kilograms/min. Total Amount Released: 600 kilograms
kilograms/min. Total Amount Released: 600 kilograms

AM/NS India Limited
VULNERABILITY ANALYSIS: BF CO GAS HOLDER CATASTROPHIC FAILURE EFFECT ON THE “SOCIETAL RISK”.
BF CO GAS HOLDER TOXIC CLOUD RELEASE. ATMOSPHERIC STABILITY FACTOR: ‘F’. DOWNWARD WIND DIRECTION N 45 NE
DISTANCE TRAVELLED 1400 m MARKED: WORST CASE SCENARIO: BF CO GAS HOLDER CATASTROPHIC FAILURE.

AM/NS India Limited
SCENA INPUT SOFTWARE DATA OF HAZARD. HAZARD SCENARIO ILLUSTRATION & MANAGEMENT
RIO OF RISKS (WORST CASE SCENARIO)
• ILLUSTRATION:
THREAT ZONE: It is the area encompassed by the TOXIC CLOUD first shown as highest risk,
accompanied by lower risks. They are colour coded. RED COLOR ZONE displays the highest
concentration zone followed by ORANGE COLOR ZONE and then the least by
YELLOW COLOR ZONE. Only 60 minutes duration of the scenario is mapped. Otherwise it
is assumed that the Mitigation operations will be COMPLETED within that specified time.
• RED ZONE : 1400 m long, Leakage of CO GAS from the GAS HOLDER in the night wee
hour time , when atmospheric conditions are very still & stable. Dispersion of TOXIC
CLOUD will be very slow but exposure time is very high, results higher inhalation to all the
habitants of the AREA. The spread to an area of 1400 m length at 330 ppm stays almost for
a duration of MINIMUM ONE HOUR. The entire eastern part of HAZIRA village is
subjected to VERY HIGH TOXIC CO Exposure risk.
• ORANGE ZONE: 3400 m long. This area also has a GAS CONCENNTRATION of 83
ppm which is near to the permissible exposure limit of 75ppm.
1 • THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is
selected where the effect of CO GAS will be zero and have the shortest distance w.r.t the
CONFIDENCE LINES drawn surrounding the dispersion pattern of TOXIC CLOUD. This
point will provide the strategic safe location for the emergency key personnel to perform
Mitigation operations on both sides of the dispersion cloud propagation.
• RISK MANAGEMENT
• Around 3000 estimated population in the HAZIRA VILLAGE has to be evacuated to
UPWIND SIDE in less than ONE HOUR time. The most probable location suggested shall be
the NAND NIKETAN AREA (Residential area of AM/NS INDIA employees). First all the
habitants of the affected area has to be provided with nose mask, goggles and then they have to
get transported to the area. All the transport facilities (Four wheelers, Two- wheelers, Bicycles,
Hand Lorries can be used.)
• As the wind direction will change theoretically every 2 hours the employees OF AM/NS
INDIA in the BF CO SPREAD AREA has to be treated similarly as OUTSIDERS.
• Entrance to the HAZIRA village from all sides have to be blocked for at least 8 HOURS
DURATION from the time of accident. (Entry for only Disaster Management Personnel)

AM/NS India Limited
• At regular intervals of ONE HOUR the gas concentration (in at least) 12 IMPORTANT
locations chosen shall be checked for CO gas concentration. The concentration has to be
reduced to MINIMUM HALF the permissible value of 75 ppm for undertaking any
rehabilitation operations.
• Involvement of DISTRICT DISASTER MANAGEMENT PERSONNEL is essential for
undertaking smooth hurdle free operations. Timely information and their timely arrival are
important parameters for successful operations.
• All the provisions of ON-SITE MERGENCY PLAN has to be fully operational for early
mitigation of the EMERGENCY CREATED.
• MOCKDRILL performed documents shall be suitably used for reference for mitigating the
emergency situation.
• The MAPS given and the use of Nose mask cum goggles have to be displayed (as
visuals) at all the affected places. Also UPWIND direction shall be displayed.
• Sizable numbers authorized plant employees shall be used as GUIDES to help the
affected inhabitants
• The dynamic shift in the wind direction shall be studied using portable anemometers.
• EMERGENCY SIREN has to be operational ONCE in an hour. This will give the
announcement that EMERGENCY CONDITIONS are in existence.
• All clear shall be made operational after the declaration of COMPLETION OF
EMERGENCY.
• HEALTH MANAGEMENT
• CHECK OXYGEN LEVEL for the people complaining disorderliness & dizziness.
• Send them to NEAREST hospitals planned by the LIAISON TEAM.
• ESTABLISH temporary habitation facilities for the people evacuated.
• REPORT all the details to DISTRICT DISASTER MANAGEMENT COMMITTEE.
• NOSE MASKS &GOGGLES shall be stored in houses of the authorized employees. They
can be distributed immediately after the DISASTER is announced.
RISK POTENTIAL: HIGH HAZARD POTENTIAL

AM/NS India Limited
BF CO GAS HOLDER TOXIC CLOUD RELEASE. ATMOSPHERIC STABILITY FACTOR: ‘F’. DOWNWARD WIND DIRECTION MARKED:
MAXIMUM CREDIBLE ACCIDENT SCENARIOS: BF CO UTILITIES OPERATIONS – HAZARDOUS SCENARIOS.

AM/NS India Limited
SCENA INPUT SOFTWARE DATA OF HAZARD. HAZARD SCENARIO ILLUSTRATION & MANAGEMENT
RIO (MAXIMUM CREDIBILITY ACCIDENT SCENARIO)
• RED ZONE : 198 m long, Leakage of CO GAS from the supply line Ø600 mm in the
night wee hour time , when atmospheric conditions are very still & stable. Dispersion
of TOXIC CLOUD will be very slow but exposure time is very high, results higher
inhalation to all the habitants of the AREA. The spread to an area of 198 m distance at
330 ppm stays almost for a duration of MINIMUM ONE HOUR. The entire area
spread is within the factory premises. ON-SITE EMERGENCT PLAN PROVISIONS
& MOCK DRILL RECORDS shall be referred for mitigation operations.
• ORANGE ZONE: 408 m long. This area also has a GAS CONCENNTRATION
of 83 ppm which is near to the permissible exposure limit of 75ppm. MOCK
DRILL provisions shall be applied to mitigate the risk scenario.
2A
• THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario
is selected where the effect of CO GAS will be zero and have the shortest distance
w.r.t the CONFIDENCE LINES drawn surrounding the dispersion pattern of TOXIC
CLOUD. This point will provide the strategic safe location for the emergency key
personnel to perform Mitigation operations on both sides of the dispersion cloud
propagation.

AM/NS India Limited
SCENA INPUT SOFTWARE DATA OF HAZARD. HAZARD SCENARIO ILLUSTRATION &

RIO MANAGEMENT
(MAXIMUM CREDIBILITY ACCIDENT
SCENARIO)
RED ZONE : 284 m long, Leakage of CO GAS from the GAS PIPE Ø 1800 mm in the night wee
hour time , when atmospheric conditions are very still & stable. Dispersion of TOXIC CLOUD
will be very slow but exposure time is very high, results higher inhalation to all the habitants of
the AREA. The spread to an area of 284 m length at 330 ppm stays almost for a duration of
MINIMUM ONE HOUR. The entire area spread is within the factory premises. ON-SITE
EMERGENCT PLAN PROVISIONS & MOCK DRILL RECORDS shall be
referred for mitigation operations.
ORANGE ZONE: 594 m long. This area also has a GAS CONCENNTRATION of 83 ppm
which is near to the permissible exposure limit of 75ppm. MOCK DRILL provisions shall be
applied to Mitigate the risk scenario.
2B THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is

AM/NS India Limited
SCENARIO INPUT SOFTWARE DATA OF HAZARD SCENARIO ILLUSTRATION & MANAGEMENT

HAZARD. (MAXIMUM CREDIBILITY ACCIDENT SCENARIO)
RED ZONE : 230 m long, Leakage of CO GAS all around the BF WORK PLATFORM 10
m, in the night wee hour time , when atmospheric conditions are very still & stable.
Dispersion of TOXIC CLOUD will be very slow but exposure time is very high, results higher
inhalation to all the habitants of the AREA. The spread to an area of 284 m length at 330 ppm
2C stays almost for a duration of MINIMUM ONE HOUR. The entire area spread is within the
factory premises. ON-SITE EMERGENCT PLAN PROVISIONS & MOCK DRILL
RECORDS shall be referred for mitigation operations.
THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is

AM/NS India Limited
SCENARIO INPUT SOFTWARE DATA OF HAZARD SCENARIO ILLUSTRATION & MANAGEMENT

HAZARD. (MAXIMUM CREDIBILITY ACCIDENT SCENARIO)
RED ZONE : 284 m long, Leakage of CO GAS from the GAS PIPE Ø 1800 mm in the night
wee hour time , when atmospheric conditions are very still & stable. Dispersion of TOXIC
habitants of the AREA. The spread to an area of 284 m length at 330 ppm stays almost for a
duration of MINIMUM ONE HOUR. The entire area spread is within the factory premises.
ON-SITE EMERGENCT PLAN PROVISIONS & MOCK DRILL RECORDS shall be
referred for mitigation operations.
2D
THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is selected
where the effect of CO GAS will be zero and have the shortest distance w.r.t the CONFIDENCE
LINES drawn surrounding the dispersion pattern of TOXIC CLOUD. This point will provide the
strategic safe location for the emergency key personnel to perform Mitigation operations on
both sides of the dispersion cloud propagation.

AM/NS India Limited
6.7.1.4 Dispersion Scenarios of Hazchem- Emergency Releases. Corex “CO” Scenarios

Site Data: Location: AM / NS INDIA, HAZIRA, GUJARAT. Building Air exchanges per Hour: 10
(user specified)
1 A “COREX GAS” GAS HOLDER – CO Leakage due to 1 B “COREX GAS” GAS HOLDER – CO Leakage due to
fabric sealing arrangement failure. (30 cm long, 7cm wide). fabric sealing arrangement failure. (30 cm long, 7cm wide)
TOXIC CLOUD Atmospheric stability: ‘D’ TOXIC CLOUD Atmospheric stability: ‘F’
WORST CASE SCENARIO) WORST CASE SCENARIO)
Red : 207 meters --- (330 ppm = AEGL-3 [60 min]) Red : 1.1 kilometers --- (330 ppm = AEGL-3 [60 min])
Orange: 439 meters --- (83 ppm = AEGL-2 [60 min]) Orange: 2.7 kilometers --- (83 ppm = AEGL-2 [60 min])
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 Yellow: no recommended LOC value --- (N/A = AEGL-1
min]) [60 min])
THREAT AT POINT: Concentration Estimates at the point: THREAT AT POINT: Concentration Estimates at the
Downwind: 30 meters Off Centerline: 20 meters point: Downwind: 30 metersOff Centerline: 20 meters
Note: Concentration not drawn because there is no significant Note: Concentration not drawn because there is no significant
concentration at the point selected. concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
CAS Number: 630-8-0 Molecular Weight: 28.01 CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000
min):
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C
742000
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
Tank Diameter: 38 meters Tank Length: 52.9
meters Tank Volume: 60000 cubic meters Tank contains
gas only Tank Diameter: 38 meters Tank Length: 52.9 meters
Internal Temperature: 32° C Chemical Mass in Tank: 82.9 tons Tank Volume: 60000 cubic meters Tank contains gas only
Internal Press: 1.12 atmospheres Opening Length: 30 centimeters Internal Temperature: 25° C Chemical Mass in Tank: 84.9
Opening Width: 7 centimeters tons Internal Press: 1.12 atmospheres Opening Length: 30
Please Duration: ALOHA limited the duration to 1-hour centimeters Opening Width: 7 centimeters Release
Max Average Sustained Release Rate: 123 Duration: ALOHA limited the duration to 1-hour Max
kilograms/min Average Sustained Release Rate: 125 kilograms/min
(averaged over a minute or more) Total
(averaged over a minute or more)
Amount Released: 5,579 kilograms

AM/NS India Limited
2 A “COREX GAS” GAS HOLDER – CO Leakage due to 2 A “COREX GAS” GAS HOLDER – CO Leakage due to
fabric sealing arrangement failure. (30 cm long, 7cm wide). fabric sealing arrangement failure. (30 cm long, 7cm wide).
FIRE CLOUD Atmospheric stability: ‘D’ FIRE CLOUD Atmospheric stability: ‘F’
MAXIMUM CREDIBLEACCIDENT SCENARIO MAXIMUM CREDIBLEACCIDENT SCENARIO)
THREAT ZONE: Threat Modelled: Flammable Area of

Vapor Cloud Model Run: Gaussian
Red : 18 meters --- (75000 ppm = 60% LEL = Flame Pockets)
distances.
distances.
THREAT AT POINT: Concentration Estimates at the

point: Downwind: 30 metersOff Centerline: 20 meters
concentration at the point selected. THREAT ZONE: Threat Modeled: Flammable Area of Vapor
Cloud Model Run: Gaussian
Red : 91 meters --- (75000 ppm = 60% LEL = Flame Pockets)
THREAT AT POINT: Concentration Estimates at
the point: Downwind: 30 meters Off
Centerline: 20 meters
CHEMICAL DATA: Chemical Name: CARBON concentration at the point selected
MONOXIDE
CAS Number: 630-8-0 Molecular Weight: 28.01 CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C min):
Vapor Pressure at Ambient Temperature: greater than 1 atm 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% ppm Ambient Boiling Point: -191.5° C
atm Ambient Saturation Concentration: 1,000,000 ppm or
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) 100.0% ATMOSPHERIC DATA: (MANUAL INPUT
Wind: 10 meters/second from 225° true at 3 meters OF DATA)
Ground Roughness: open country Cloud Cover: 7 tenths Wind: 3 meters/second from 45° true at 3 meters
Air Temperature: 32° C Stability Class: D Ground Roughness: open country Cloud
No Inversion Height Relative Humidity: 75% Cover: 5 tenths Air Temperature: 25° C Stability Class:
F (user override)
SOURCE STRENGTH: Leak from hole in vertical cylindrical No Inversion Height Relative Humidity: 50%
Tank Diameter: 38 meters Tank Length: 52.9 SOURCE STRENGTH: Leak from hole in vertical cylindrical
meters Tank Volume: 60000 cubic meters Tank contains tank Flammable chemical escaping from tank (not burning)
gas only Tank Diameter: 38 meters Tank Length: 52.9 meters
Internal Temperature: 32° C Chemical Mass in Tank: 82.9 tons
Tank Volume: 60000 cubic meters Tank contains gas only
Internal Press: 1.12 atmospheres Opening Length: 30
Internal Temperature: 25° C Chemical Mass in Tank: 84.9
centimeters Opening Width: 7 centimeters
tons Internal Press: 1.12 atmospheres Opening Length: 30
Please Duration: ALOHA limited the duration to 1-hour
centimeters Opening Width: 7 centimeters Release
Max Average Sustained Release Rate: 123
Duration: ALOHA limited the duration to 1-hour Max
(averaged over a
minute or more)

AM/NS India Limited
3 A “COREX GAS” GAS HOLDER – CO Leakage due to 3 B “COREX GAS” GAS HOLDER – CO Leakage due to
fabric sealing arrangement failure. (30 cm long, 7cm wide). fabric sealing arrangement failure. (30 cm long, 7cm wide).
BLAST FORCE Atmospheric stability: ‘D’ BLAST FORCE Atmospheric stability: ‘F’
THREAT ZONE: Threat Modeled: Overpressure (blast force) THREAT ZONE:Threat Modeled: Overpressure (blast force)
from vapor cloud explosion Type of Ignition: ignited by spark from vapor cloud explosion Type of Ignition: ignited by spark or
or flame Level of Congestion: congested Model Run: Gaussian flame Level of Congestion: congested Model Run: Gaussian
Red : LOC was never exceeded --(8.0 psi = destruction of Red : LOC was never exceeded --- (8.0 psi = destruction of
bldg) Orange: LOC was never exceeded -3.5 psi = serious buildings)
injury likely) Yellow: 12 meters --- (1.0 psi = shatters glass) Orange: LOC was never exceeded --- (3.5 psi = serious injury
likely) Yellow: 50 meters --- (1.0 psi = shatters glass)
THREAT AT POINT: Overpressure Estimate at the point: THREAT AT POINT: Overpressure Estimate at the point:
Downwind: 30 m Off Centerline: 20 m Overpressure: 0.154 psi Downwind: 30 m Off Centerline: 20 m Overpressure: 0.569
CHEMICAL DATA: Chemical Name: CARBON psi
MONOXIDE CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 min):
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
742000
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) atm Ambient Saturation Concentration: 1,000,000 ppm or
Wind: 10 meters/second from 225° true at 3 meters 100.0% ATMOSPHERIC DATA: (MANUAL INPUT
Ground Roughness: open country Cloud Cover: 7 tenths OF DATA)
Air Temperature: 32° C Stability Class: D Wind: 3 meters/second from 45° true at 3 meters
No Inversion Height Relative Humidity: 75% Ground Roughness: open country Cloud
SOURCE STRENGTH: Leak from hole in vertical cylindrical Cover: 5 tenths Air Temperature: 25° C Stability Class:
tank Flammable chemical escaping from tank (not burning) F (user override)
Tank Diameter: 38 meters Tank Length: 52.9 No Inversion Height Relative Humidity: 50%
meters Tank Volume: 60000 cubic meters Tank contains SOURCE STRENGTH: Leak from hole in vertical
gas only cylindrical tank Flammable chemical escaping from tank
Internal Temperature: 32° C Chemical Mass in Tank: 82.9 tons (not burning)
Internal Press: 1.12 atmospheres Opening Length: 30 Tank Diameter: 38 meters Tank Length: 52.9 meters
centimeters Opening Width: 7 centimeters Tank Volume: 60000 cubic meters Tank contains gas only
Please Duration: ALOHA limited the duration to 1-hour Internal Temperature: 25° C Chemical Mass in Tank: 84.9
Max Average Sustained Release Rate: 123 tons Internal Press: 1.12 atmospheres Opening Length: 30
kilograms/min (averaged over a minute or more) centimeters Opening Width: 7 centimeters Release
Total Amount Released: 5,491 kilograms Duration: ALOHA limited the duration to 1-hour Max
Average
Sustained Release Rate: 125 kilograms/min (averaged over
a minute or more)

AM/NS India Limited
4A “HOT STRIP MILL – CO Supply line Ø800 mm Pipe 4 B “HOT STRIP MILL – CO Supply line Ø800 mm Pipe
rupture and leakage of gas. rupture and leakage of gas. TOXIC CLOUD Atmospheric
TOXIC CLOUD Atmospheric stability: ‘D’ AXIMUM stability: ‘F’ MAXIMUM CREDIBLEACCIDENT
CREDIBLEARIO SCENARIO)
THREAT ZONE:: Model Run: Gaussian THREAT ZONE: Model Run: Gaussian
Note: Threat zone was not drawn because effects of near-field Orange: 408 meters --- (83 ppm = AEGL-2 [60
patchiness make dispersion predictions less reliable for short min])
distances. Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
Orange: 80 meters --- (83 ppm = AEGL-2 [60 min]) min])
Yellow: no recommended LOC value (N/A = AEGL-1 [60 min])

point: Downwind: 10 meters Off Centerline: 5 meters THREAT AT POINT: Concentration Estimates at
the point: Downwind: 10 meters Off Centerline: 5
concentration at the point selected. meters
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE concentration at the point selected.
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm CHEMICAL DATA: Chemical Name: CARBON
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 MONOXIDE
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
Vapor Pressure at Ambient Temperature: greater than 1 atm AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% (60 min): 330 ppm IDLH: 1200 ppm
LEL: 125000 ppm UEL: 742000 ppm
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Ambient Boiling Point: -191.5° C
Wind: 10 meters/second from 225° true at 3 meters Vapor Pressure at Ambient Temperature: greater than 1 atm
Ground Roughness: open country Cloud Cover: 7 tenths Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Cover: 5 tenths Air Temperature: 25° C Stability Class:
F (user override)
SOURCE STRENGTH: Leak from hole in Pipeline Ø 800 No Inversion Height Relative Humidity: 50%
mm Flammable chemical escaping Pipeline pressure: 2.0
atm Flow rate : 40000 nm3/hr Temp: 32°C SOURCE STRENGTH: Leak from hole in Pipeline Ø
Direct Source: 300 kilograms/hr Source Height: 0 800 mm Flammable chemical escaping Pipeline
Release Duration: 60 minutes Release Rate: 5 kilograms/min pressure: 2.0 atm Flow rate : 40000 nm3/hr Temp: 25°C
Total Amount Released: 300 kilograms Direct Source: 300 kilograms/hr Source Height: 0
Release Duration: 60 minutes Release Rate: 5
kilograms/min

AM/NS India Limited
5 A “270 MW POWER HOUSE” - Supply line Ø1400 mm 5 B “270 MW POWER HOUSE” - Supply line Ø1400 mm
Pipe rupture and leakage of gas. TOXIC CLOUD Atmospheric Pipe rupture and leakage of gas. TOXIC CLOUD
Note: Threat zone was not drawn because effects of near-field Orange: 476 meters --- (83 ppm = AEGL-2 [60 min])
distances. min]
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
min])
point: Downwind: 10 meters Off Centerline: 5
Downwind: 10 meters Off Centerline: 5
meters Note: Concentration not drawn because there is no
MONOXIDE CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
CAS Number: 630-8-0 Molecular Weight: 28.01 AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm min):
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C 742000
Vapor Pressure at Ambient Temperature: greater than 1 atm ppm Ambient Boiling Point: -191.5° C
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Vapor Pressure at Ambient Temperature: greater than 1 atm
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Ground Roughness: open country Cloud Cover: 7 tenths ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
No Inversion Height Relative Humidity: 75% Ground Roughness: open country Cloud Cover:
SOURCE STRENGTH: Leak from a crack hole in pipeline 5 tenths Air Temperature: 25° C Stability Class: F (user
carrying “CO” gas. Flammable chemical escaping from tank override)
(not burning. Direct Source: 400 kilograms/hr Source Height: No Inversion Height Relative Humidity: 50%
0 Release from a Pipe Ø 1400 mm Pr. In the pipe : 2.0 atm
Temp: 32 °C Flow rate 1,80,000 nm3/hr SOURCE STRENGTH: Leak from a crack hole in pipeline
Release Duration: 60 minutes Release Rate: 6.67 Kgs/min carrying “CO” gas. Flammable chemical escaping from tank (not
Total Amount Released: 400 kilograms. burning. Direct Source: 400 kilograms/hr Source Height: 0
Release from a Pipe Ø 1400 mm Pr. In the pipe : 2.0 atm Temp:
25 °C Flow rate 1,80,000 nm3/hr
Release Duration: 60 minutes Release Rate: 6.67 Kgs/min
Total Amount Released: 400 kilograms.

AM/NS India Limited
6 A “270 MW POWER HOUSE” - Supply line Ø1400 mm 6 B “270 MW POWER HOUSE” - Supply line Ø1400 mm
Pipe rupture and leakage of gas. FIRE CLOUD Atmospheric
Pipe rupture and leakage of gas. FIRE CLOUD Atmospheric
stability: ‘F’
stability: ‘D’ MAXIMUM CREDIBLEACCIDENT SCENARIO)
MAXIMUM CREDIBLEACCIDENT SCENARIO
THREAT ZONE:

ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C THREAT ZONE: Threat Modeled: Flammable Area of Vapor
Vapor Pressure at Ambient Temperature: greater than 1 atm Cloud Model Run: Gaussian
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Red : 20 meters --- (75000 ppm = 60% LEL = Flame
Pockets) Note: Threat zone was not drawn because effects of
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) near-field patchiness make dispersion predictions less
Wind: 10 meters/second from 225° true at 3 meters reliable for short distances.
Ground Roughness: open country Cloud Cover: 7 tenths Yellow: 51 meters --- (12500 ppm = 10% LEL)
Air Temperature: 32° C Stability Class: D THREAT AT POINT: Concentration Estimates at the
No Inversion Height Relative Humidity: 75% point: Downwind: 10 meters Off Centerline: 5
SOURCE STRENGTH: Leak from a crack hole in pipeline significant concentration at the point selected
carrying “CO” gas. Flammable chemical escaping from tank CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
(not burning. Direct Source: 400 kilograms/hr Source Height: 0 CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
Release from a Pipe Ø 1400 mm Pr. In the pipe: 2.0 atm Temp: AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
32 °C Flow rate 1,80,000 nm3/hr min):
Release Duration: 60 minutes Release Rate: 6.67 Kgs/min 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000
Total Amount Released: 400 kilograms.
Ambient Saturation Concentration: 1,000,000 ppm or
100.0% ATMOSPHERIC DATA: (MANUAL INPUT
OF DATA)
override)
SOURCE STRENGTH: Leak from a crack hole in pipeline
carrying “CO” gas. Flammable chemical escaping from tank (not
burning. Direct Source: 400 kilograms/hr Source Height: 0
Release from a Pipe Ø 1400 mm Pr. In the pipe: 2.0 atm Temp:
25 °C Flow rate 1,80,000 nm3/hr
Release Duration: 60 minutes Release Rate: 6.67 Kgs/min Total
Amount Released: 400 kilograms.

AM/NS India Limited
7 A DRI–6: Supply line Ø1800 mm Pipe rupture and 7 B DRI–6: Supply line Ø1800 mm Pipe rupture and leakage of
leakage of gas. TOXIC CLOUD Atmospheric stability: ‘D’ gas. TOXIC CLOUD Atmospheric stability: ‘F’
MAXIMUM CREDIBLEACCIDENT SCENARIO MAXIMUM CREDIBLEACCIDENT SCENARIO
Red: 32 meters --- (330 ppm = AEGL-3 [60 min]) Red: 160 meters --- (330 ppm = AEGL-3 [60 min])
patchiness make dispersion predictions less reliable for short Yellow: no recommended LOC value --- (N/A = AEGL-1
distances. [60 min]) THREAT AT POINT: Concentration Estimates at
Orange: 64 meters --- (83 ppm = AEGL-2 [60 min]) the point: Downwind: 10 meters Off Centerline: 5
Yellow: no recommended LOC value (N/A = AEGL-1 [60 meters Note: Concentration not drawn because there is no
min]) THREAT AT POINT: Concentration Estimates at the significant concentration at the point selected
point: Downwind: 10 meters Off Centerline: 5 meters
Note: Concentration not drawn because there is no significant CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
concentration at the point selected CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE min):
CAS Number: 630-8-0 Molecular Weight: 28.01 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm 742000
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm Ambient Boiling Point: -191.5° C
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C Vapor Pressure at Ambient Temperature: greater than 1 atm
Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) 5 tenths Air Temperature: 25° C Stability Class: F (user
Wind: 10 meters/second from 225° true at 3 meters Ground override)
Roughness: open country Cloud Cover: 7 tenths Air No Inversion Height Relative Humidity: 50%
No Inversion Height Relative Humidity: 75% SOURCE STRENGTH Leak from a crack hole in pipeline
carrying “CO” gas. Flammable chemical escaping from tank
SOURCE STRENGTH: Leak from a crack hole in pipeline (not burning. Direct Source: 200 kilograms/hr Source Height: 0
carrying “CO” gas. Flammable chemical escaping from tank Release from a Pipe Ø 1800 mm Pr. In the pipe : 2.0 atm Temp:
(not burning. Direct Source: 200 kilograms/hr Source Height: 0 25 °C Flow rate 90,000 nm3/hr
Release from a Pipe Ø 1800 mm Pr. In the pipe: 2.0 atm Temp: Release Duration: 60 minutes Release Rate: 3.33 Kgs/min
32 °C Flow rate 90,000 nm3/hr Total Amount Released: 200 kilograms

AM/NS India Limited
8 A DRI–6: Supply line Ø1800 mm Pipe rupture 8 B DRI–6: Supply line Ø1800 mm Pipe rupture and
and leakage of gas. FIRE CLOUD Atmospheric leakage of gas. FIRE CLOUD Atmospheric stability:
stability: ‘D’ ‘F’
MAXIMUM CREDIBLEACCIDENT MAXIMUM CREDIBLEACCIDENT SCENARIO
SCENARIO
THREAT AT POINT: Concentration Estimates at the THREAT AT POINT: : Concentration Estimates at the
point: Downwind: 10 meters Off Centerline: 5 meters point: Downwind: 10 meters Off Centerline: 5
Note: Concentration not drawn because there is no meters Note: Concentration not drawn because there is
significant concentration at the point selected no significant concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON CHEMICAL DATA: Chemical Name: CARBON
MONOXIDE MONOXIDE
CAS Number: 630-8-0 Molecular Weight: CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
28.01 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3
min): 83 ppm AEGL-3 (60 min): 330 ppm IDLH: 1200 (60 min):
ppm LEL: 125000 ppm UEL: 742000 ppm Ambient 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
Boiling Point: -191.5° C 742000
Vapor Pressure at Ambient Temperature: greater than ppm Ambient Boiling Point: -191.5° C
1 atm Ambient Saturation Concentration: 1,000,000 Vapor Pressure at Ambient Temperature: greater than 1 atm
ppm or 100.0% Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

DATA) Wind: 3 meters/second from 45° true at 3 meters
Wind: 10 meters/second from 225° true at 3 Ground Roughness: open country Cloud Cover: 5
meters Ground Roughness: open country Cloud tenths Air Temperature: 25° C Stability Class: F (user
Cover: 7 tenths Air Temperature: 32° C Stability override)
Class: D No Inversion Height Relative Humidity: 50%
SOURCE STRENGTH: : Leak from a crack hole in pipeline
SOURCE STRENGTH: Leak from a crack hole in carrying “CO” gas. Flammable chemical escaping from tank
pipeline carrying “CO” gas. Flammable chemical (not burning.
escaping from tank (not burning. Direct Source: 200 Direct Source: 200 kilograms/hr Source Height: 0 Release
kilograms/hr Source Height: 0 Release from a Pipe Ø from a Pipe Ø 1800 mm Pr. In the pipe : 2.0 atm Temp: 25 °C
1800 mm Pr. In the pipe : 2.0 atm Temp: 32 °C Flow Flow rate 90,000 nm3/hr
rate 90,000 nm3/hr Release Duration: 60 minutes Release Rate: 3.33 Kgs/min
Release Duration: 60 minutes Release Rate: 3.33 Total Amount Released: 200 kilograms
Kgs/min Total Amount Released: 200 kilograms

AM/NS India Limited
9 A LIME PLANT: Supply line Ø700 mm Pipe rupture and 9 B LIME PLANT: Supply line Ø700 mm Pipe rupture and
leakage of gas. TOXIC CLOUD Atmospheric stability: ‘D’ leakage of gas. TOXIC CLOUD Atmospheric stability: ‘F’
THREAT ZONE:


ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C THREAT ZONE: Model Run: Gaussian
Vapor Pressure at Ambient Temperature: greater than 1 atm Red: 113 meters --- (330 ppm = AEGL-3 [60 min])
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Orange: 229 meters --- (83 ppm = AEGL-2 [60 min])
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) min])
Wind: 10 meters/second from 225° true at 3 meters THREAT AT POINT: Concentration Estimates at the point:
Ground Roughness: open country Cloud Cover: 7 tenths Downwind: 10 meters Off Centerline: 5 meters
Air Temperature: 32° C Stability Class: D Note: Concentration not drawn because there is no significant
No Inversion Height Relative Humidity: 75% concentration at the point selected
SOURCE STRENGTH: Leak from a crack hole in pipeline CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
carrying “CO” gas. Flammable chemical escaping from pipe CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
(not burning. Direct Source: 100 kilograms/hr Source Height: 0 AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
Release from a Pipe Ø 700 mm Pr. In the pipe: 2.0 atm Temp: min):
32 °C Flow rate 34,500 nm3/hr 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000
Release Duration: 60 minutes Release Rate: 1.67 Kgs/min ppm Ambient Boiling Point: -191.5° C
Total Amount Released: 100 kilograms Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

override)
SOURCE STRENGTH Leak from a crack hole in pipeline

carrying “CO” gas. Flammable chemical escaping from
pipeline (not
burning. Direct Source: 100 kilograms/hr Source Height: 0 Release
from a Pipe Ø 700 mm Pr. In the pipe: 2.0 atm Temp: 25 °C Flow
rate 34,500 nm3/hr
Release Duration: 60 minutes Release Rate: 1.67 Kgs/min Total
Amount Released: 100 kilograms

AM/NS India Limited
10 A CDI 1-9 FURNACES: Supply line Ø500 mm Pipe 10 B CDI 1-9 FURNACES: Supply line Ø500 mm Pipe
rupture and leakage of gas. TOXIC CLOUD Atmospheric rupture and leakage of gas. TOXIC CLOUD


MONOXIDE
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 THREAT ZONE: Model Run: Gaussian
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C Red: 113 meters --- (330 ppm = AEGL-3 [60 min])
Vapor Pressure at Ambient Temperature: greater than 1 atm Orange: 229 meters --- (83 ppm = AEGL-2 [60 min])
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
min])
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) THREAT AT POINT: Concentration Estimates at the point:
Wind: 10 meters/second from 225° true at 3 meters Downwind: 10 meters Off Centerline: 5 meters
Ground Roughness: open country Cloud Cover: 7 tenths Note: Concentration not drawn because there is no significant
Air Temperature: 32° C Stability Class: D concentration at the point selected
SOURCE STRENGTH: Leak from a crack hole in pipeline CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
carrying “CO” gas. Flammable chemical escaping from pipe AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60 min):
(not burning. Direct Source: 100 kilograms/hr Source Height: 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000
0 Release from a Pipe Ø 500 mm Pr. In the pipe: 2.0 atm ppm Ambient Boiling Point: -191.5° C
Temp: 32 °C Flow rate 6,500 nm3/hr Vapor Pressure at Ambient Temperature: greater than 1 atm
Release Duration: 60 minutes Release Rate: 1.67Kgs/min Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Total Amount Released: 100 kilograms Wind: 3 meters/second from 45° true at 3 meters
override)

carrying “CO” gas. Flammable chemical escaping from pipeline
(not burning. Direct Source: 100 kilograms/hr Source Height: 0
Release from a Pipe Ø 500 mm Pr. In the pipe : 2.0 atm Temp: 25
°C Flow rate 6,500 nm3/hr

AM/NS India Limited
11 A PLATE MILL: Supply line Ø1800 mm Pipe rupture and 11 B PLATE MILL: Supply line Ø1800 mm Pipe rupture and
leakage of gas. TOXIC CLOUD Atmospheric stability: ‘D’ leakage of gas. TOXIC CLOUD Atmospheric stability: ‘F’
patchiness make dispersion predictions less reliable for short Yellow: no recommended LOC value (N/A = AEGL-1 [60 min])
distances.
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 THREAT AT POINT: Concentration Estimates at the point:
min]) Downwind: 10 meters Off Centerline: 5 meters
THREAT AT POINT: Concentration Estimates at the point: Note: Concentration not drawn because there is no significant
Downwind: 10 meters Off Centerline: 5 meters concentration at the point selected
concentration at the point selected CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
CAS Number: 630-8-0 Molecular Weight: 28.01 min):
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 742000
ppm UEL: 742000 ppm Ambient Boiling Point: -191.5° C ppm Ambient Boiling Point: -191.5° C
Vapor Pressure at Ambient Temperature: greater than 1 atm Vapor Pressure at Ambient Temperature: greater than 1 atm
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
Wind: 10 meters/second from 225° true at 3 meters Wind: 3 meters/second from 45° true at 3 meters
Ground Roughness: open country Cloud Cover: 7 tenths Ground Roughness: open country Cloud Cover: 5
Air Temperature: 32° C Stability Class: D tenths Air Temperature: 25° C Stability Class: F (user
SOURCE STRENGTH: Leak from a crack hole in pipeline SOURCE STRENGTH Leak from a crack hole in pipeline
carrying “CO” gas. Flammable chemical escaping from pipe (not carrying “CO” gas. Flammable chemical escaping from pipeline
burning). Direct Source: 300 kilograms/hr Source Height: 0 (not burning. Direct Source: 300 kilograms/hr Source Height: 0
Release from a Pipe Ø 1800 mm Pr. In the pipe:1.07 atm Release from a Pipe Ø 1800 mm Pr. In the pipe : 1.07 atm Temp:
Temp: 32 °C Flow rate 48,000 nm3/hr. 25 °C Flow rate 48,000 nm3/hr
Release Duration: 60 minutes Release Rate: 5.0 Kgs/min Release Duration: 60 minutes Release Rate: 5.0 Kgs/min
Total Amount Released: 300 kilograms Total Amount Released: 300 kilograms

AM/NS India Limited
12 A PLATE MILL: Supply line Ø1800 mm Pipe rupture and 12 B PLATE MILL: Supply line Ø1800 mm Pipe rupture and
leakage of gas. FIRE CLOUD Atmospheric stability: ‘D’ leakage of gas. FIRE CLOUD Atmospheric stability: ‘F’
THREAT AT POINT: Concentration Estimates at the point: THREAT AT POINT: Concentration Estimates at the point:
Downwind: 10 meters Off Centerline: 5 meters Downwind: 10 meters Off Centerline: 5 meters
concentration at the point selected concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 min):
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% 742000
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Vapor Pressure at Ambient Temperature: greater than 1 atm
Wind: 10 meters/second from 225° true at 3 meters Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Air Temperature: 32° C Stability Class: D ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
SOURCE STRENGTH: Leak from a crack hole in pipeline tenths Air Temperature: 25° C Stability Class: F (user
carrying “CO” gas. Flammable chemical escaping from pipe (not override)
burning). Direct Source: 300 kilograms/hr Source Height: 0 No Inversion Height Relative Humidity: 50%
Release from a Pipe Ø 1800 mm Pr. In the pipe:1.07 atm
Temp: 32 °C Flow rate 48,000 nm3/hr. SOURCE STRENGTH Leak from a crack hole in pipeline
Release Duration: 60 minutes Release Rate: 5.0 Kgs/min carrying “CO” gas. Flammable chemical escaping from pipeline
Total Amount Released: 300 kilograms Release from a Pipe Ø 1800 mm Pr. In the pipe: 1.07 atm Temp:
25 °C Flow rate 48,000 nm3/hr

AM/NS India Limited
13 A: TUNNEL MILL: Supply line Ø1500 mm Pipe rupture and 13 B TUNNEL MILL: Supply line Ø1500 mm Pipe rupture and
leakage of gas. TOXIC CLOUD Atmospheric stability: ‘D’ leakage of gas.
MAXIMUM CREDIBLEACCIDENT SCENARIO TOXIC CLOUD Atmospheric stability: ‘F’
distances. min])
Yellow: no recommended LOC value --- (N/A = AEGL-1 [60 THREAT AT POINT: Concentration Estimates at the point:
min]) Downwind: 10 meters Off Centerline: 5 meters
THREAT AT POINT: Concentration Estimates at the point: Note: Concentration not drawn because there is no significant
Downwind: 10 meters Off Centerline: 5 meters concentration at the point selected
concentration at the point selected CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
CAS Number: 630-8-0 Molecular Weight: 28.01 min):
g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 742000
Wind: 10 meters/second from 225° true at 3 meters Ground ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
Roughness: open country Cloud Cover: 7 tenths Air Wind: 3 meters/second from 45° true at 3 meters
Temperature: 32° C Stability Class: D Ground Roughness: open country Cloud Cover: 5
No Inversion Height Relative Humidity: 75% tenths Air Temperature: 25° C Stability Class: F (user
override)
SOURCE STRENGTH: Leak from a crack hole in pipeline No Inversion Height Relative Humidity: 50%
carrying “CO” gas. Flammable chemical escaping from pipe (not
burning). Direct Source: 250 kilograms/hr Source Height: 0 SOURCE STRENGTH Leak from a crack hole in pipeline
Release from a Pipe Ø 1500 mm Pr. In the pipe:1.10 atm carrying “CO” gas. Flammable chemical escaping from pipeline
Temp: 32 °C Flow rate 51,000 nm3/hr. (not burning. Direct Source: 250 kilograms/hr Source Height: 0
Total Amount Released: 250 kilograms Release Duration: 60 minutes Release Rate: 4.17 Kgs/min

AM/NS India Limited
14 A: TUNNEL MILL: Supply line Ø1500 mm Pipe rupture and 14 B TUNNEL MILL: Supply line Ø1500 mm Pipe rupture and
leakage of gas. FIRE CLOUD Atmospheric stability: ‘D’ leakage of gas FIRE CLOUDAtmospheric stability: ‘F’

Downwind: 10 meters Off Centerline: 5 meters THREAT AT POINT: Concentration Estimates at the
Note: Concentration not drawn because there is no significant point: Downwind: 10 meters Off Centerline: 5
concentration at the point selected meters Note: Concentration not drawn because there is no
significant concentration at the point selected
CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60 CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
742000 ppm Ambient Boiling Point: -191.5° C min): 330 ppm IDLH: 1200 ppm
Vapor Pressure at Ambient Temperature: greater than 1 atm LEL: 125000 ppmUEL: 742000
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
Wind: 10 meters/second from 225° true at 3 meters Ground
Roughness: open country Cloud Cover: 7 tenths Air ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
SOURCE STRENGTH: Leak from a crack hole in pipeline 5 tenths Air Temperature: 25° C Stability Class: F (user
carrying “CO” gas. Flammable chemical escaping from pipe (not override)
burning). Direct Source: 250 kilograms/hr Source Height: 0 No Inversion Height Relative Humidity: 50%
Release from a Pipe Ø 1500 mm Pr. In the pipe:1.10 atm
Temp: 32 °C Flow rate 51,000 nm3/hr. SOURCE STRENGTH Leak from a crack hole in pipeline
Release Duration: 60 minutes Release Rate: 4.17 Kgs/min carrying “CO” gas. Flammable chemical escaping from pipeline
Total Amount Released: 250 kilograms Release from a Pipe Ø 1500 mm Pr. In the pipe : 1.10 atm Temp:
25 °C Flow rate 51,000 nm3/hr Release Duration: 60 minutes
Release Rate: 4.17 Kgs/min

AM/NS India Limited
15 A: SMP 2: Supply line Ø600 mm Pipe rupture and leakage of 15 B SMP 2: Supply line Ø600 mm Pipe rupture and leakage of
gas TOXIC CLOUD Atmospheric stability: ‘D’ gas TOXIC CLOUD Atmospheric stability: ‘F’


AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm
UEL: 742000 ppm Ambient Boiling Point: -191.5° C
Vapor Pressure at Ambient Temperature: greater than 1 atm THREAT ZONE: Model Run: Gaussian
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Red: 113 meters --- (330 ppm = AEGL-3 [60 min])
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Yellow: no recommended LOC value --- (N/A = AEGL-1 [60
Wind: 10 meters/second from 225° true at 3 meters Ground min]) THREAT AT POINT: Concentration Estimates at the
Roughness: open country Cloud Cover: 7 tenths Air point: Downwind: 10 meters Off Centerline: 5 meters
Temperature: 32° C Stability Class: D Note: Concentration not drawn because there is no significant
No Inversion Height Relative Humidity: 75% concentration at the point selected
SOURCE STRENGTH: Leak from a crack hole in pipeline CHEMICAL DATA: Chemical Name: CARBON MONOXIDE
carrying “CO” gas. Flammable chemical escaping from pipe (not CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
burning). Direct Source: 100 kilograms/hr Source Height: 0 AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
Release from a Pipe Ø 600 mm Pr. In the pipe:1.07 atm Temp: 32 min): 330 ppm IDLH: 1200 ppm
°C Flow rate 10,000 nm3/hr. LEL: 125000 ppm UEL: 742000
Release Duration: 60 minutes Release Rate: 1.67 Kgs/min ppm Ambient Boiling Point: -191.5° C
Total Amount Released: 100 kilograms Ambient Saturation Concentration: 1,000,000 ppm or 100.0%

override)

carrying “CO” gas. Flammable chemical escaping from pipeline

AM/NS India Limited
AMNS “COREX” CO GAS HOLDER: LEAKAGE OF “CO” GAS DUE TO CLOTH SEAL FAILURE (30 cm x7cm) INSIDE THE GAS HOLDER.
“CO” GAS SPREAD 0F 1100 m DISTANCE OF 330 ppm CONCENTRATION IN THE “45°N NE” DIRECTION.

AM/NS India Limited
SCENAR INPUT SOFTWARE DATA OF HAZARD. HAZARD SCENARIO ILLUSTRATION & MANAGEMENT
IO (WORST CASE SCENARIO)
• ILLUSTRATION:
YELLOW COLOR ZONE. Only 60 minutes duration of the scenario is mapped. Otherwise it is
assumed that the Mitigation operations will be COMPLETED within that specified time.
• RED ZONE : 1100 m long, Leakage of CO GAS from the GAS HOLDER in the night wee
hour time , when atmospheric conditions are very still & stable. Dispersion of TOXIC CLOUD
the AREA. The spread to an area of 1100 m length at 330 ppm stays almost for a duration of
MINIMUM ONE HOUR. The entire eastern part of HAZIRA village is subjected to VERY
HIGH TOXIC CO Exposure risk.
• ORANGE ZONE: 2700 m long. This area also has a GAS CONCENNTRATION of 83 ppm
which is close to the permissible exposure limit of 75ppm.
1 • THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is
• RISK MANAGEMENT
• Around 3000 estimated population in the HAZIRA VILLAGE has to be evacuated to UPWIND
SIDE in less than ONE HOUR time. The most probable location suggested shall be the NAND
NIKETAN AREA (Residential area of AM/NS INDIA employees). First all the habitants of the
affected area has to be provided with nose mask, goggles and then they have to get transported to
the area. All the transport facilities (Four wheelers, Two- wheelers, Bicycles, Hand Lorries can
be used.)
• As the wind direction will change theoretically every 2 hours the employees OF AM/NS INDIA
in the BF CO SPREAD AREA has to be treated similarly as OUTSIDERS.
• Entrance to the HAZIRA village from all sides have to be blocked for at least 8 HOURS

AM/NS India Limited
locations chosen shall be checked for CO gas concentration. The concentration has to be
• Sizable numbers authorized plant employees shall be used as GUIDES to help the
affected inhabitants
EMERGENCY.
• NOSE MASKS &GOGGLES shall be stored in houses of the authorized employees. They can
be distributed immediately after the DISASTER is announced.
• RISK POTENTIAL: HIGH HAZARD POENTIAL

AM/NS India Limited
SCENARIO INPUT SOFTWARE DATA OF HAZARD. HAZARD SCENARIO ILLUSTRATION & MANAGEMENT
(MAXIMUM CREDIBLE ACCIDENT SCENARIO)
• RED ZONE : 91 m long, Leakage of CO GAS due to fabric sealing arrangement failure in the
night wee hour time , when atmospheric conditions are very still & stable. Dispersion of FIRE
CLOUD will be very slow but DILUTION time is very high, results in higher fire risk to all the
habitants of the AREA. The spread to an area of 91 m distance at 75,000 ppm stays almost for
a duration of MINIMUM ONE HOUR. The entire area spread is within the factory premises.
ON-SITE EMERGENCY PLAN PROVISIONS & MOCK DRILL RECORDS shall be referred
for mitigation operations.
• YELLOW ZONE: 227 m long. This area also has a GAS explosion limit of 12500 ppm to
2A fire breakdown. The entire area spread is within the factory premises. ON-SITE
EMERGENCY PLAN PROVISIONS & MOCK DRILL RECORDS shall be referred for
mitigation operations.
• THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario, is
CONFIDENCE LINES drawn surrounding the dispersion pattern of FLAMMABLE
CLOUD. This point 30 m on DOWNWIND and 20m on CROSS WIND will provide the
strategic safe location for the emergency key personnel – FIRE TEAM to perform
RISK POTENTIAL: MEDIUM HAZARD POENTIAL

AM/NS India Limited
• RED ZONE::LOC never exceeded 8.0 psi level.
• ORANGE ZONE: LOC never exceeded 8.0 psi level.
• YELLOW ZONE: 50 M DISTANCE greater than 1.0 psi has the capacity to shatter the
glass window and door GLASS panels.
• THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is
2B point will provide the strategic safe location for the emergency key personnel to perform
RISK POTENTIAL: LOW HAZARD POENTIAL

AM/NS India Limited
• RED ZONE: 198 m long, Leakage of CO GAS from the supply line Ø800 mm in the night wee
hour time, when atmospheric conditions are very still & stable. Dispersion of TOXIC CLOUD
the AREA. The spread to an area of 198 m distance at 330 ppm stays almost for a duration of
EMERGENCT PLAN PROVISIONS & MOCK DRILL RECORDS shall be referred for
which is near to the permissible exposure limit of 75ppm. MOCK DRILL provisions shall
2C be applied to mitigate the risk scenario.

AM/NS India Limited
AMNS 270 MW POWER STATION. COREX “CO” GAS SPREAD DUE TO LEAK FROM THE GAS PIPELINE SUPPLYING GAS TO THE
POWER STATION. SPREAD DIRECTION 45°N NE TO A DISTANCE OF 476 m

AM/NS India Limited
• RED ZONE: 230 m long, Leakage of CO GAS from the supply line Ø1400 mm in the night
wee hour time, when atmospheric conditions are very still & stable. Dispersion of TOXIC
habitants of the AREA. The spread to an area of 230 m distance at 330 ppm stays almost for a
ON-SITE EMERGENCT PLAN PROVISIONS & MOCK DRILL RECORDS shall be referred
2D be applied to mitigate the risk scenario.

AM/NS India Limited
AMNS COLD DRI – 6 “CO” GAS SPREAD DUE TO LEAK FROM THE GAS PIPELINE SUPPLYING GAS TO THE “DRI” UNIT 6. SPREAD
DIRECTION: 45°N NE TO A DISTANCE OF 329 m.

AM/NS India Limited
SCENAR INPUT SOFTWARE DATA OF HAZARD. HAZARD SCENARIO ILLUSTRATION & MANAGEMENT
IO (MAXIMUM CREDIBLE ACCIDENT SCENARIO)
• RED ZONE : 160m long, Leakage of CO GAS from the supply line Ø1800 mm in the night
2E be applied to mitigate the risk scenario.

AM/NS India Limited
AMNS LIME PLANT: COREX “CO” GAS SPREAD DUE TO LEAK FROM THE GAS PIPELINE SUPPLYING GAS TO THE LIME STATION.
SPREAD DIRECTION 45°N NE TO A DISTANCE OF 229 m.

AM/NS India Limited
• RED ZONE : 113 m long, Leakage of CO GAS from the supply line Ø600 mm in the night
2F be applied to mitigate the risk scenario.

AM/NS India Limited
AMNS PLATE MILL: COREX “CO” GAS SPREAD DUE TO LEAK FROM THE GAS PIPELINE SUPPLYING GAS TO THE PLATE MILL
SPREAD DIRECTION 45°N NE TO A DISTANCE OF 408 m.

AM/NS India Limited
• RED ZONE : 198 m long, Leakage of CO GAS from the supply line Ø600 mm in the night
2G be applied to mitigate the risk scenario.

AM/NS India Limited
AMNS TUNNEL MILL: COREX “CO” GAS SPREAD DUE TO LEAK FROM THE GAS PIPELINE SUPPLYING GAS TO THE TUNNEL
MILL. SPREAD DIRECTION 45°N NE TO A DISTANCE OF 370 m.

AM/NS India Limited
• RED ZONE: 180 m long, Leakage of CO GAS from the supply line Ø600 mm in the night wee
hour time, when atmospheric conditions are very still & stable. Dispersion of TOXIC CLOUD
the AREA. The spread to an area of 180 m distance at 330 ppm stays almost for a duration of
EMERGENCT PLAN PROVISIONS & MOCK DRILL RECORDS shall be referred for
2H be applied to mitigate the risk scenario.

AM/NS India Limited
6.7.1.5 Dispersion Scenarios of hazchem - EMERGENCY RELEASES. “CRM” AMMONIA

SCENARIOS SITE DATA: Location: AM / NS INDIA, HAZIRA, GUJARAT. Building Air
exchanges per Hour: 10 (user specified)
1 A AMMONIA STORAGE IN VERTICAL BULLETS: LEAKAGE 1 B AMMONIA STORAGE IN VERTICAL BULLETS:
OF AMMONIA FROM THE MAIN CONNECTION OUTLET LEAKAGE OF AMMONIA FROM THE MAIN
POINT. TOXIC CLOUD Atmospheric stability: ‘D’ CONNECTION OUTLET POINT. TOXIC CLOUD
MAXIMUM CREDIBLEACCIDENT SCENARIO Atmospheric stability: ‘F’
Red : 54 meters --- (1100 ppm = AEGL-3 [60 min]) Red : 276 --- (1100 ppm = AEGL-3 [60 min])
Yellow: 362 meters --- (30 ppm = AEGL-1 [60 min]) Yellow: 2.2 kilometers --- (30 ppm = AEGL-1 [60
THREAT AT POINT: Concentration Estimates at the point: min]) THREAT AT POINT: Concentration
Downwind: 10meters Off Centerline: 5 meters Estimates at the point: Downwind: 10meters
Note: Concentration not drawn because there is no significant Off
concentration at the point selected Centerline: 5 meters
CHEMICAL DATA: Chemical Name: AMMONIA concentration at the point selected
CAS Number: 7664-41-7 Molecular Weight: 17.03 g/mol CHEMICAL DATA: Chemical Name: AMMONIA
AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm AEGL-3 CAS Number: 7664-41-7 Molecular Weight: 17.03
(60 min): 1100 ppm IDLH: 300 ppm LEL: 150000 g/mol AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160
ppm UEL: 280000 ppm Ambient Boiling Point: -33.4° C ppm AEGL-3 (60 min):
Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient 1100 ppm IDLH: 300 ppm LEL: 150000 ppm UEL:
Saturation Concentration: 1,000,000 ppm or 100.0% 280000 ppm
Ambient Boiling Point: -33.4° C
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Vapor Pressure at Ambient Temperature: greater than 1
Wind: 10 meters/second from 225° true at 3 meters Ground atm Ambient Saturation Concentration: 1,000,000 ppm
Roughness: open country Cloud Cover: 7 tenths Air or 100.0%
No Inversion Height Relative Humidity: 75% ATMOSPHERIC DATA: (MANUAL INPUT OF
DATA)
SOURCE STRENGTH: Flammable gas escaping from pipe (not Wind: 3 meters/second from 45° true at 3 meters
burning) Pipe Diameter: 1 inches Pipe Length: 20 feet Unbroken Ground Roughness: open country Cloud
end of the pipe is connected to an infinite source Pipe Roughness: Cover: 5 tenths Air Temperature: 25° C Stability
smooth Hole Area: 0.79 sq in Pipe Class: F (user override)
Press: 8 atmospheres Pipe Temperature: 32° C No Inversion Height Relative Humidity:
Release Duration: ALOHA limited the duration to 1 hour Max 50%
Average Sustained Release Rate: 19.1 kilograms/min (averaged SOURCE STRENGTH: Flammable gas escaping from
over a minute or more) pipe (not burning Pipe Diameter: 1 inchesPipe Length:
20 feet Unbroken end of the pipe is connected to an
Total Amount Released: 1,144 kilograms infinite source Pipe Roughness: smooth Hole Area: 0.79
sq in

AM/NS India Limited
Pipe Press: 8 atmospheres Pipe Temperature: 25° C

Release Duration: ALOHA limited the duration to
1 hour Max Average Sustained Release Rate: 19.3
kilograms/min averaged over a minute or more)
2 A LEAKAGE OF AMMONIA FROM TANKER DECANTING 2 B LEAKAGE OF AMMONIA FROM TANKER

HOSE DUE TO LOOSE CONNECTION TOXIC CLOUD
DECANTING HOSE DUE TO LOOSE CONNECTION
Atmospheric stability: ‘D’ MAXIMUM
CREDIBLEACCIDENT SCENARIO TOXIC CLOUD TAtmospheric stability: ‘F’ MAXIMUM
CREDIBLEACCIDENT SCENARIO
Red : 82 meters --- (1100 ppm = AEGL-3 [60 min])
Red : 242 meters --- (1100 ppm = AEGL-3 [60 min])
Yellow: 573 meters --- (30 ppm = AEGL-1 [60 min]) Yellow: 1.8 kilometers --- (30 ppm = AEGL-1 [60 min
THREAT AT POINT: Concentration Estimates at the point: THREAT AT POINT: Concentration Estimates at the
Downwind: 20 meters Off Centerline: 10 meters point: Downwind: 20 meters Off Centerline: 10
Note: Concentration not drawn because there is no significant meters Note: Concentration not drawn because there is no
concentration at the point selected significant concentration at the point selected
CHEMICAL DATA: Chemical Name: AMMONIA CHEMICAL DATA: Chemical Name: AMMONIA
CAS Number: 7664-41-7 Molecular Weight: 17.03 g/mol CAS Number: 7664-41-7 Molecular Weight: 17.03
AEGL-1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm AEGL-3 g/mol AEGL- 1 (60 min): 30 ppm AEGL-2 (60 min): 160 ppm
(60 min): 1100 ppm IDLH: 300 ppm LEL: 150000 AEGL-3 (60 min):
ppm UEL: 280000 ppm Ambient Boiling Point: -33.4° C 1100 ppm IDLH: 300 ppm LEL: 150000 ppm UEL:
Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient
280000
Saturation Concentration: 1,000,000 ppm or 100.0%
Ambie Saturation Concentration: 1,000,000 ppm or 100.0%
Temperature: 32° C Stability Class: D Wind: 3 meters/second from 45° true at 3 meters
Cover: 5 tenths Air Temperature: 25° C Stability Class:
F (user override)
SOURCE STRENGTH: Evaporating Puddle (Note: chemical is
flammable) Puddle Area: 5 m² Puddle Volume: 200 m³ Ground No Inversion Height Relative Humidity: 50%
Type: Default soil Ground Temperature: 32° C Initial Puddle
Temperature: -33.4° C SOURCE STRENGTH: Evaporating Puddle (Note:
Release Duration: ALOHA limited the duration to 1-hour Max chemical is flammable) Puddle Diameter: 5 meters Average
Average Sustained Release Rate: 43.2 kilograms/min (averaged Puddle Depth: 5 centimeters Ground Type: Default soil
over a minute or more) Ground Temperature: 25° C Initial Puddle Temperature: -
33.4° C

AM/NS India Limited
Total Amount Released: 1,710 kilograms Release Duration: ALOHA limited the duration to 1-
hour Max Average Sustained Release Rate: 36.7
3 A: PIPELINE CARRYING AMMONIA TO CRACKER PLANT 3 B PIPELINE CARRYING AMMONIA TO CRACKER PLANT
LEAKAGE DUE TO FAILURE. TOXIC CLOUD Atmospheric LEAKAGE DUE TO FAILURE. TOXIC CLOUD Atmospheric
stability: ‘D’ stability: ‘F’
Red: 27 meters ---(1100 ppm = AEGL-3 [60 min]) Note: Threat zone Red: 136 meters --- (1100 ppm = AEGL-3 [60 min])
was not drawn because effects of near-field patchiness make Orange: 371 meters --- (160 ppm = AEGL-2 [60 min])
dispersion predictions less reliable for short distances. Yellow: 930 meters --- (30 ppm = AEGL-1 [60 min])
Yellow: 172 meters --- (30 ppm = AEGL-1 [60 min]) THREAT AT POINT: Concentration Estimates at the
THREAT AT POINT: Concentration Estimates at the point: point: Downwind: 10 meters Off Centerline: 5 meters
Downwind: 10 meters Off Centerline: 5 meters Note: Concentration not drawn because there is no significant
Note: Concentration not drawn because there is no significant concentration at the point selected
CHEMICAL DATA: Chemical Name: CARBON MONOXIDE CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol
CAS Number: 630-8-0 Molecular Weight: 28.01 g/mol AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60
AEGL-1 (60 min): N/A AEGL-2 (60 min): 83 ppm AEGL-3 (60 min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL:
min): 330 ppm IDLH: 1200 ppm LEL: 125000 ppm UEL: 742000 742000 ppm Ambient Boiling Point: -191.5° C
ppm Ambient Boiling Point: -191.5° C Vapor Pressure at Ambient Temperature: greater than 1 atm
Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient Saturation Concentration: 1,000,000 ppm or
Ambient Saturation Concentration: 1,000,000 ppm or 100.0% 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 3 meters/second from 45° true at 3 meters
Wind: 10 meters/second from 225° true at 3 meters Ground Ground Roughness: open country Cloud Cover: 5
Roughness: open country Cloud Cover: 7 tenths Air tenths Air Temperature: 25° C Stability Class: F (user
Temperature: 32° C Stability Class: D override)
No Inversion Height Relative Humidity: 75% No Inversion Height Relative Humidity: 50%
SOURCE STRENGTH Flammable gas escaping from pipe
SOURCE STRENGTH: Flammable gas escaping from pipe (not (not burning) Pipe Diameter: 1 inches Pipe Length: 20 feet
burning) Pipe Diameter: 1 inches Pipe Length: 20 feet Unbroken end of the pipe is connected to an infinite source
Unbroken end of the pipe is connected to an infinite source Pipe Pipe Roughness: smooth Hole Area: 0.79 sq in
Roughness: smooth Hole Area: 0.79 sq in Pipe Press: Pipe Press: 2 atmospheres Pipe Temperature: 25°
2 atmospheres Pipe Temperature: 32° C C Release Duration: ALOHA limited the duration to 1-
Release Duration: ALOHA limited the duration to 1-hour Max hour Max Average Sustained Release Rate: 4.89
Average Sustained Release Rate: 4.84 kilograms/min kilograms/min
(averaged over a minute or more) (averaged over a minute or more)
Total Amount Released: 290 kilograms Total Amount Released: 294 kgs

AM/NS India Limited
CRM AMMONIA STORAGE LOCATION. AMMONIA STORAGE YARD. AMMONIA GAS SPREAD DUE TO LEAK FROM THE STORAGE
BULLET SUPPLYING AMMONIA GAS TO THE CRM GALVENIZING PLANT. SPREAD DIRECTION 45°N NE, TO A DISTANCE OF 783 m.

AM/NS India Limited
(WORST CASE SCENARIO)
• ILLUSTRATION:
DOWNWIND direction is N 45 NE.
• THREAT AT A POINT: This point fixed from the ORIGIN of the dispersion scenario is selected
where the effect of AMMONIA GAS will be zero and have the shortest distance
w.r.t the CONFIDENCE LINES drawn surrounding the dispersion pattern of TOXIC CLOUD.
This point will provide the strategic safe location for the emergency key personnel to perform
Mitigation operations on both sides of the dispersion cloud propagat
• RED ZONE : 276 m long, Leakage of AMMONIA GAS from the AMMONIA BULLET in the
night wee hour time , when atmospheric conditions are very still & stable. Dispersion of TOXIC
habitants of the AREA. The spread to an area of 276 m length at 1100 ppm stays almost for a
1
duration of MINIMUM ONE HOUR. The entire PLANT AREAS OF CRM COMPLEX IS IN
THE DANGER ZONE. These areas are subjected to VERY HIGH TOXIC ammonia vapor
Exposure risk.
and can spread up-to AMNS OXYGEN PLANT AREA.
• YELLOW ZONE: 2200 m long. This area also has a GAS CONCENNTRATION of 30 ppm
which is close to the permissible exposure limit of 30 ppm.
• RISK MANAGEMENT
• Around 500 estimated population in the AMNSI Plant locations is to be evacuated to UPWIND
SIDE in less than ONE HOUR time. The most probable location suggested shall be the NAND
NIKETAN AREA (Residential area of AM/NS INDIA employees). First all the employees,
contract people, visitors of the affected area has to be provided with nose mask, goggles and then
they have to get transported to the area. All the transport facilities (Four wheelers, Two-
wheelers, Bicycles can be used.)
in the CRM AMMONIA SPREAD AREA has to be treated similarly as OUTSIDERS.

AM/NS India Limited
• Entrance to the CRM PLANT AREA rom all sides have to be blocked for at least 8 HOURS
locations chosen shall be checked for AMMONIA gas concentration. The concentration has to be
• MOCKDRILL peemployeesrformed documents shall be suitably used for reference for
mitigating the emergency situation.
• Sizable numbers authorized plant employees shall be used as KEY PERSONNEL to help the
affected AMNS Employees.
EMERGENCY.
• RISK POTENTIAL: MEDIUM HAZARD POENTIAL

AM/NS India Limited
CRM AMMONIA PIPELINE TO CRACKER PLANT. AMMONIA GAS SPREAD DUE TO CRACK LEAK FROM THE PIPELINE
SUPPLYING AMMONIA GAS TO THE CRM GALVENIZING PLANT. SPREAD DIRECTION 45°N NE, TO A DISTANCE OF 371 m.

AM/NS India Limited
• RED ZONE:: 136 m long, Leakage of AMMONIA GAS from the supply line Ø2” HEADING
TOWARDS CRACKER PALNT in the night wee hour time , when atmospheric conditions are
very still & stable. Dispersion of TOXIC CLOUD will be very slow but exposure time is very
high, results higher inhalation to all the habitants of the AREA. The spread to an area of 136 m
distance at 1100 ppm stays almost for a duration of MINIMUM ONE HOUR. The entire
area spread is within the factory premises. ON-SITE EMERGENCY PLAN PROVISIONS &
MOCK DRILL RECORDS shall be referred for mitigation operations.
• ORANGE ZONE: 371 m long. This area also has a GAS CONCENNTRATION of 160 ppm.
MOCK DRILL PROVISIONS SHALL BE REAPPLIED to mitigate the risk scenario.
3B
• YELLOW ZONE: 930 m long. The gas concentration is very near to TLV.

AM/NS India Limited
CRM AMMONIA TANK FARM. AMMONIA GAS/ LIQUID SPREAD DUE TO LOOSENING OF DECANTING HOSE.
AMMONIA GAS/LIQUID SPREAD ON THE FLOOR AND FORMS A POOL. EVAPORATING LIQUID/ GAS SPREAD IN THE DIRECTION
225° S SW, TO A DISTANCE OF 681 m.

AM/NS India Limited
• RED ZONE:: 242 m long, Leakage of AMMONIA GAS from the supply line Ø2” HEADING
TOWARDS CRACKER PALNT in the night wee hour time , when atmospheric conditions are
very still & stable. Dispersion of TOXIC CLOUD will be very slow but exposure time is very
high, results higher inhalation to all the habitants of the AREA. The spread to an area of 136 m
distance at 1100 ppm stays almost for a duration of MINIMUM ONE HOUR. The entire
area spread is within the factory premises. ON-SITE EMERGENCY PLAN PROVISIONS &
MOCK DRILL RECORDS shall be referred for mitigation operations.
• ORANGE ZONE: 681 m long. This area also has a GAS CONCENNTRATION of 160 ppm.
MOCK DRILL PROVISIONS SHALL BE REAPPLIED to mitigate the risk scenario.
2B
• YELLOW ZONE: 1800 m long. The gas concentration is very near to TLV.

AM/NS India Limited
6.7.1.6 Dispersion Scenarios of Hazchem - Emergency Releases. “CRM” Hydrogen Scenarios SITE
DATA: Location: AM / NS INDIA, HAZIRA, GUJARAT. Building Air exchanges per Hour: 10 (user
specified)
1 A HYDROGEN STORAGE TANKS–RELEASE FROM 1 B HYDROGEN STORAGE TANKS – RELEASE FROM
PUFFING OFF FROM SAFETY RELIEF VALVE DUE TO PUFFING OFF FROM SAFETY RELIEF VALVE DUE TO
HIGH TEMPERATURE. FIRE CLOUD Atmospheric stability: HIGH SUMMER DAY TEMPERATURE. FIRE CLOUD
‘D’ Atmospheric stability: ‘F’
THREAT AT POINT: Concentration Estimates at the point: THREAT AT POINT: Concentration Estimates at the point:
Downwind: 10 meters Off Centerline: 5 meters Downwind: 10 meters Off Centerline: 5 meters
concentration at the point selected concentration at the point selected
CHEMICAL DATA: Chemical Name: HYDROGEN CHEMICAL DATA: Chemical Name: HYDROGEN
CAS Number: 1333-74-0 Molecular Weight: 2.02 g/mol CAS Number: 1333-74-0 Molecular Weight: 2.02
PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000 ppm g/mol PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3:
LEL: 40000 ppm UEL: 750000 ppm Ambient Boiling Point: - 400000 ppm
252.8° C Vapor Pressure at Ambient Temperature: greater than 1 LEL: 40000 ppm UEL: 750000 ppm Ambient Boiling
atm. Ambient Saturation Concentration: 1,000,000 ppm or 100.0% Point: - 252.8° C Vapor Pressure at Ambient Temperature:
greater than 1 atm. Ambient Saturation Concentration:
1,000,000 ppm or 100.0%
Ground Roughness: open country Cloud Cover: 7 tenths ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)
No Inversion Height Relative Humidity: 75% Ground Roughness: open country Cloud Cover: 5 tenths
tank Flammable chemical escaping from tank (not burning) No Inversion Height Relative Humidity: 50%
Tank Diameter: 2.1 meters Tank Length: 3.0 meters - 4 SOURCE STRENGTH: Leak from hole in vertical cylindrical
NOS Tank Volume: 10.4 cubic meters Tank contains gas only tank Flammable chemical escaping from tank (not burning)
Internal Temperature: 32° C Chemical Mass in Tank: 8.37Kgs Tank Diameter: 2.1 meters Tank Length: 3.0
Internal Press: 10 atmospheres Circular Opening Diameter: meters Tank Volume: 10.4 cubic meters Tank
0.04 inches Release Duration: ALOHA limited the duration to 1- contains gas only Internal Temperature: 25° C
hour Max Average Sustained Release Rate: 18.2 grams/min Chemical Mass in Tank: 8.56 Kgs Internal Press:
(averaged over a minute or more) 10 atmospheres Circular Opening Diameter: 0.04
Total Amount Released: 1.03 kilograms inches Release Duration: ALOHA limited the
duration to 1-hour Max Average Sustained Release
Rate: 18.4 grams/min (averaged over a minute or
more)
Total Amount Released: 1.04
kilograms

AM/NS India Limited
2 A CRM HYDROGEN PUMPING AREA: PIPELINE 2 B CRM HYDROGEN PUMPING AREA:

LEAKAGE OF HYDROGEN GAS TO STORAGE PIPELINE LEAKAGE OF HYDROGEN GAS TO
TANKS. FIRE CLOUD STORAGE TANKS. FIRE CLOUD
THREAT ZONE: Threat Modeled: Flammable Area of THREAT ZONE: Threat Modeled: Flammable Area of
Vapor Vapor Cloud Model Run: Gaussian
Cloud. Model Run: Gaussian Red: 155 meters --- (24000 ppm = 60% LEL = Flame
Red: 46 meters --- (24000 ppm = 60% LEL = Flame Pockets) Yellow: 395 meters --- (4000 ppm = 10%
Pockets) LEL)
Note: Threat zone was not drawn because effects of near- THREAT AT POINT: Concentration Estimates at
field the point: Downwind: 10 meters Off Centerline:
patchiness makes dispersion predictions less reliable for 5 meters Note: Concentration not drawn because
short there is no significant concentration at the point
distances. selected
Yellow: 116 meters --- (4000 ppm = 10% LEL) CHEMICAL DATA: Chemical Name: HYDROGEN
CAS Number: 1333-74-0 Molecular
THREAT AT POINT: Concentration Estimates at the Weight: 2.02 g/mol PAC-1: 65000 ppm PAC-2:
point: 230000 ppm PAC-3: 400000 ppm
Downwind: 10 meters Off Centerline: 5 LEL: 40000 ppm UEL: 750000 ppm Ambient
meters Boiling Point: - 252.8° C Vapor Pressure at Ambient
Note: Concentration not drawn because there is no Temperature: greater than 1 atm. Ambient Saturation
significant Concentration: 1,000,000 ppm or 100.0%
concentration at the point selected ATMOSPHERIC DATA: (MANUAL INPUT OF
DATA)
Wind: 3 meters/second from 45° true at 3
meters Ground Roughness: open country
Cloud Cover: 5 tenths Air Temperature: 25°
C Stability Class: F

AM/NS India Limited
2 A CRM HYDROGEN PUMPING AREA: PIPELINE 2 B CRM HYDROGEN PUMPING AREA: PIPELINE
LEAKAGE OF HYDROGEN GAS TO STORAGE TANKS. LEAKAGE OF HYDROGEN GAS TO STORAGE TANKS.
FIRE CLOUD FIRE CLOUD
THREAT ZONE: Threat Modeled: Flammable Area of Vapor

THREAT ZONE: Threat Modeled: Flammable Area of Vapor Cloud Model Run: Gaussian
Cloud. Model Run: Gaussian Red: 155 meters --- (24000 ppm = 60% LEL = Flame Pockets)
Red: 46 meters --- (24000 ppm = 60% LEL = Flame Pockets) Yellow: 395 meters --- (4000 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near-field THREAT AT POINT: Concentration Estimates at the point:
patchiness makes dispersion predictions less reliable for short Downwind: 10 meters Off Centerline: 5 meters
distances. Note: Concentration not drawn because there is no significant
Yellow: 116 meters --- (4000 ppm = 10% LEL) concentration at the point selected
CHEMICAL DATA: Chemical Name: HYDROGEN
THREAT AT POINT: Concentration Estimates at the point: CAS Number: 1333-74-0 Molecular Weight: 2.02
Downwind: 10 meters Off Centerline: 5 meters g/mol PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3:
Note: Concentration not drawn because there is no significant 400000 ppm
concentration at the point selected LEL: 40000 ppm UEL: 750000 ppm Ambient Boiling
Point: - 252.8° C Vapor Pressure at Ambient Temperature:
greater than 1 atm. Ambient Saturation Concentration:
1,000,000 ppm or 100.0%
CHEMICAL DATA: Chemical Name: HYDROGEN tenths Air Temperature: 25° C Stability Class: F
g/mol No Inversion Height Relative Humidity: 50%
PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000 ppm SOURCE STRENGTH Flammable gas escaping from pipe
LEL: 40000 ppm UEL: 750000 ppm Ambient Boiling Point: - (not burning) Pipe Diameter: 1 inches
252.8° C Vapor Pressure at Ambient Temperature: greater Pipe Length: 50 feet Unbroken end of the pipe is connected to
than 1 atm. Ambient Saturation Concentration: 1,000,000 ppm an infinite source Pipe Roughness: smooth Hole Area:
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) 0.79 sq in
Wind: 10 meters/second from 225° true at 3 meters Pipe Press: 14 atmospheres Pipe Temperature: 25°
Ground Roughness: open country Cloud Cover: 7 tenths C Release Duration: ALOHA limited the duration to 1-hour
Air Temperature: 32° C Stability Class: D Max Average Sustained Release Rate: 8.28 kilograms/min.
No Inversion Height Relative Humidity: 75% (averaged over a minute or more)
SOURCE STRENGTH: Flammable gas escaping from pipe (not
burning) Pipe Diameter: 1 inches Pipe Length: 50 feet Total Amount Released: 497 kilograms
Unbroken end of the pipe is connected to an infinite source Pipe
Roughness: smooth Hole Area: 0.79 sq in. Pipe Press: 14
atmospheres Pipe Temperature: 32° C. Release Duration:
ALOHA limited the duration to 1-hour Max Average Sustained
Release Rate: 8.18 kilograms/min (averaged over a minute or
more)

AM/NS India Limited
CRM HYDROGEN TANK FARM. HYDROGEN GAS SPREAD DUE TO PIPELINE CONNECTING PRODUCTION PLANTS TO STORAGE TANKS FAILS.
LEAKAGE OF HYDROGEN GAS SPREAD IN THE TANK FARM, HAS FIRE POTENTIAL. IN THE DIRECTION 45° N NE TO A DISTANCE OF 155 m

AM/NS India Limited
• ILLUSTRATION:
where the effect of Hydrogen sulfide GAS will be zero and have the shortest distance w.r.t the
CONFIDENCE LINES drawn surrounding the dispersion pattern of TOXIC CLOUD. This point
will provide the strategic safe location for the emergency key personnel to perform Mitigation
operations on both sides of the dispersion cloud propagation.
• RED ZONE : 155 m long, Leakage of Hydrogen gas from the Hydrogen gas pipeline carrying
gas to the storage tanks in the night wee hour time , when atmospheric conditions are very still &
stable. Dispersion of FIRE CLOUD will be very slow but exposure time is very high, results
higher FIRE RISK to all the habitants of the AREA. The spread to an area of 155 m length at
1
2400 ppm ( 60% OF LEL) stays almost for a duration of MINIMUM ONE HOUR. The entire
PLANT AREAS OF CRM PLANT is in the DANGER ZONE. These areas are subjected to
VERY HIGH FIRE POTENTIAL OF hydrogen vapor Exposure risk.
• YELLOW ZONE: 395 m long. This area also has a GAS CONCENNTRATION of 4000 ppm
( 10% 0F LEL).
• RISK MANAGEMENT
• Around 200 estimated population in the AMNSI Plant locations (CRM SHOP) are to be
evacuated to UPWIND SIDE in less than ONE HOUR time. The most probable location
suggested shall be the NAND NIKETAN AREA (Residential area of AM/NS INDIA
employees). First all the employees, contract people, visitors of the affected area has to be
provided with nose mask, goggles and then they have to get transported to the area. All the
transport facilities (Four wheelers, Two- wheelers, Bicycles can be used.)
in the CRM PLANT AREA has to be treated similarly as OUTSIDERS.
• Entrance to the CRM PLANT AREA from all sides have to be blocked for at least 8
HOURS DURATION from the time of accident. (Entry for only Disaster Management
Personnel)

AM/NS India Limited
locations chosen shall be checked for H₂ gas concentration. The concentration has to be reduced
to MINIMUM HALF the permissible value of 40000 ppm for undertaking any rehabilitation
operations.
EMERGENCY.
• RISK POTENTIAL: LOW HAZARD POTENTIAL

AM/NS India Limited
6.7.1.7 Dispersion Scenarios of Hazchem - Emergency Releases in “Pipe Shop” Hydrogen Sulfide gas
Release Scenarios
SITE DATA: Location: AM / NS INDIA, HAZIRA, GUJARAT. Building Air exchanges per Hour: 10 (user
specified)
1 A HYDROGEN SULPHIDE gas cylinder outlet valve 1 B HYDROGEN SULPHIDE gas cylinder outlet valve
damage during handling of cylinder. TOXIC CLOUD damage during handling of cylinder. TOXIC CLOUD
Atmospheric stability: ‘D’. (WORST CASE SCENARIO) Atmospheric stability: ‘F’.

Red : 16 meters --- (50 ppm = AEGL-3 [60 min]) THREAT ZONE: Model Run: Gaussian
Orange: 22 meters --- (27 ppm = AEGL-2 [60 min]) Red : 64 meters --- (50 ppm = AEGL-3 [60 min])
patchiness make dispersion predictions less reliable for short Yellow: 718 meters --- (0.51 ppm = AEGL-1 [60 min])
distances. (Both RED & ORANGE ZONES)
Yellow: 172 meters --- (0.51 ppm = AEGL-1 [60 min]) THREAT AT POINT: Concentration Estimates at the
THREAT AT POINT Thermal Radiation Estimates at the point: Downwind: 10 meters Off Centerline: 5
point: Downwind: 10 meters Off Centerline: 5 meters meters Note: Concentration not drawn because there is
Max Thermal Radiation: 0.194 kW/(sq. m) no significant concentration at the point selected.
CHEMICAL DATA: Name HYDROGEN SULFIDE CAS CHEMICAL DATA: Name HYDROGEN SULFIDE CAS
Number: 7783-6-4 Molecular Weight: 34.08 g/mol AEGL-1 (60 Number: 7783- 6-4 Molecular Weight: 34.08 g/mol AEGL-1
min): 0.51 ppm AEGL-2 (60 min): 27 ppm AEGL-3 (60 min): 50 (60 min): 0.51 ppm AEGL-2 (60 min): 27 ppm AEGL-3 (60
ppm IDLH: 100 ppm LEL: 40000 ppm UEL: 440000 ppm min): 50 ppm IDLH: 100 ppm
Ambient Boiling Point: -60.3° C Vapor Pressure at Ambient LEL: 40000 ppm UEL: 440000 ppm Ambient Boiling
temperature: greater than 1 atm Ambient Saturation Concentration: Point: -60.3° C Vapor Pressure at Ambient temperature:
1,000,000 ppm or 100.0% greater than 1 atm Ambient Saturation Concentration:
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) 1,000,000 ppm or 100.0%
Temperature: 32° C Stability Class: D No Inversion Height
Relative Humidity: 75%
tenths Air Temperature: 25° C Stability Class: F
No Inversion Height Relative Humidity:
SOURCE STRENGTH: Leak from hole in vertical cylindrical tan
50%
Flammable chemical escaping from tank (not burning)
SOURCE STRENGTH: Leak from hole in vertical
Tank Diameter: 0.25 meters Tank Length: 1.75 meters Tank
cylindrical tan Flammable chemical escaping from
Volume: 0.086 cubic meters Tank contains liquid Internal
tank (not burning)
Temperature: 32° C Chemical Mass in Tank: 8.33 kilograms
Tank Diameter: 0.25 meters Tank Length: 1.75 meters
Tank is 8% full. Circular Opening Diameter: 0.04 inches
Tank Volume: 0.086 cubic meters Tank contains liquid
Opening is 1.75 meters from tank bottom. Release Duration:
Internal Temperature: 25° C Chemical Mass in Tank:
ALOHA limited the duration to 1-hour Max Average Sustained
8.33 kilograms Tank is 9 % full. Circular Opening
Release Rate: 165 grams/min (averaged over a minute or more)
Diameter: 0.04 inches Opening is 1.75 meters from tank
Total Amount Released: 2.67 kilograms (Escaped as GAS)
bottom. Release Duration: ALOHA limited the duration
to 1-hour Max Average Sustained
Release Rate: 139 grams/min (averaged over a minute or
more)
Total Amount Released: 2.45 kilograms (Escaped as GAS)

AM/NS India Limited
2 A HYDROGEN SULPHIDE gas cylinder outlet valve damage 2 B HYDROGEN SULPHIDE gas cylinder outlet valve damage
during handling of cylinder. FIRE CLOUD Atmospheric during handling of cylinder. FIRE CLOUD Atmospheric stability:
stability: ‘D’. ‘F’.
(Maximum Credible Accident Scenario (Maximum Credible Accident Scenario)
THREAT AT POINT Thermal Radiation Estimates at the THREAT AT POINT: Concentration Estimates at the point:
point: Downwind: 10 meters Off Centerline: 5 meters Downwind: 10 meters Off Centerline: 5 meters
concentration at the point selected. concentration at the point selected.
CHEMICAL DATA: Chemical: HYDROGEN SULFIDE CHEMICAL DATA: Chemical: HYDROGEN SULFIDE
g/mol AEGL-1 (60 min): 0.51 ppm AEGL-2 (60 min): 27 ppm AEGL- 1 (60 min): 0.51 ppm AEGL-2 (60 min): 27 ppm AEGL-3
AEGL-3 (60 min): 50 ppm IDLH: 100 ppm LEL: 40000 ppm UEL:
(60 min): 50 ppm IDLH: 100 ppm LEL: 40000 440000 ppm
Ambient Boiling Point: -60.3° C Vapor Pressure at Ambient Temperature: greater than 1 atm
Vapor Pressure at Ambient Temperature: greater than 1 atm Ambient Saturation Concentration: 1,000,000 ppm or 100.0%
ATMOSPHERIC DATA: (MANUAL INPUT OF DATA) Wind: 3 meters/second from 45° true at 3 meters Ground
Wind: 10 meters/second from 225° true at 3 meters Roughness: open country Cloud Cover: 5 tenths Air
Ground Roughness: open country Cloud Cover: 7 tenths Temperature: 25° C Stability Class: F
Air Temperature: 32° C Stability Class: D No Inversion Height Relative Humidity: 50%
SOURCE STRENGTH: Leak from hole in vertical Tank Diameter: 0.25 meters Tank Length: 1.75 meters
cylindrical tank Flammable chemical escaping from tank (not Tank Volume: 0.086 cubic meters Tank contains liquid Internal
burning) Temperature: 25° C Chemical Mass in Tank: 8.33 Kgs Tank is
Tank Diameter: 0.25 meters Tank Length: 1.75 9% full Circular Opening Diameter: 0.04 inches Opening is
meters Tank Volume: 0.086 cubic meters Tank contains 1.75 meters from tank bottom Release Duration:
liquid ALOHA limited the duration to 1 hour. Max Average Sustained
Internal Temperature: 32° C Chemical Mass in Tank: 8.33 Kgs Release Rate: 139 grams/min (averaged over a minute or more)
Tank is 8% full Circular Opening Diameter: 0.04 inches Total Amount Released: 2.45 kilograms
Opening is 1.75 meters from tank bottom Release Duration: Note: The chemical escaped from the tank as a gas.
ALOHA limited the duration to 1 hour
Max Average Sustained Release Rate: 165 grams/min
Total Amount Released: 2.67 kilograms
Note: The chemical escaped from the tank as a gas.

AM/NS India Limited
PIPE SHOP HYDROGEN SULFIDE GAS CYLINDER AREA. HYDROGEN SULFIDE GAS SPREAD DUE TO DAMAGE OF CYLINDER VALVE DAMAGE.
EVAPORATING LIQUID/ GAS TOXIC CLOUD SPREAD IN THE DIRECTION 45° N NE, TO A DISTANCE OF 88 m.

AM/NS India Limited
• ILLUSTRATION:
where the effect of Hydrogen sulfide GAS will be zero and have the shortest distance w.r.t the
CONFIDENCE LINES drawn surrounding the dispersion pattern of TOXIC CLOUD. This point
will provide the strategic safe location for the emergency key personnel to perform Mitigation
operations on both sides of the dispersion cloud propagation.
• RED ZONE : 64 m long, Leakage of Hydrogen sulfide GAS from the Hydrogen sulfide gas
cylinder in the night wee hour time , when atmospheric conditions are very still & stable.
Dispersion of TOXIC CLOUD will be very slow but exposure time is very high, results higher
inhalation to all the habitants of the AREA. The spread to an area of 64 m length at 50 ppm
1 stays almost for a duration of MINIMUM ONE HOUR. The entire PLANT AREAS OF LAW
pipe shop is in the DANGER ZONE. These areas are subjected to VERY HIGH TOXIC
hydrogen sulfide vapor Exposure risk.
• ORANGE ZONE: 88 m long. This area also has a GAS CONCENNTRATION of 27 ppm and
can spread up-to small area around the LAW Pipe shop.
• YELLOW ZONE: 718 m long. This area also has a GAS CONCENNTRATION of 0.51 ppm
which is close to the permissible exposure limit.
• RISK MANAGEMENT
• Around 500 estimated population in the AMNSI Plant locations (LSW PIPE SHOP& SPIRAL
PIPE SHOP) are to be evacuated to UPWIND SIDE in less than ONE HOUR time. The most
probable location suggested shall be the NAND NIKETAN AREA (Residential area of AM/NS
INDIA employees). First all the employees, contract people, visitors of the affected area has to be
provided with nose mask, goggles and then they have to get transported to the area. All the
transport facilities (Four wheelers, Two- wheelers, Bicycles can be used.)
in the PIPE SHOPS AREA has to be treated similarly as OUTSIDERS.

AM/NS India Limited
• Entrance to the PIPE SHOPS AREA from all sides have to be blocked for at least 8 HOURS
locations chosen shall be checked for H₂S gas concentration. The concentration has to be
reduced to MINIMUM HALF the permissible value of 0.51 ppm for undertaking any
EMERGENCY.
• RISK POTENTIAL: MEDIUM HAZARD

AM/NS India Limited
• RED ZONE : 11 m long, Leakage of HYDROGEN SULFIDE GAS from a gas cylinder due to
cylinder valve damage, occurs In the night wee hour time , when atmospheric conditions are very
still & stable. Dispersion of FIRE CLOUD will be very slow but FIRE EXPLOSION time is very
high, results higher risk to fire to all the habitants of the AREA. The spread to an area of 11 m
distance at 24000 ppm (60% of LEL) stays almost for a duration of MINIMUM ONE HOUR.
The entire area spread is within the factory premises. ON-SITE EMERGENCY PLAN
PROVISIONS & MOCK DRILL RECORDS shall be referred for mitigation operations.
2B • YELLOW ZONE: < 11 m long. This area also has a GAS CONCENNTRATION of 4000 ppm
(10% OF LEL) . MOCK DRILL PROVISIONS SHALL BE REAPPLIED to mitigate the fire
risk scenario.
RISK POTENTIAL: LOW HAZARD

AM/NS India Limited
6.7.1.8 Dispersion Scenarios of Hazchem - Emergency Releases in “COKE OVEN PLANT” Methane
gas Release Scenarios
SITE DATA: Location: AM / NS INDIA, HAZIRA, GUJARAT. Building Air exchanges per Hour: 10
(user specified)
1 A Coke Oven Gas from the coke oven plant release 1 B Coke Oven Gas from the coke oven plant release
from the from the
GAS HOLDER-Seal leak. Opening30cm x 6 cmr. FIRE GAS HOLDER-Seal leak. Opening30cm x 6 cmr. FIRE
CLOUD CLOUD Atmospheric stability: ‘F’.
Atmospheric stability: ‘D’. (Maximum Credible Accident Scenario
(Maximum Credible Accident Scenario
THREAT ZONE: Threat Modeled: Flammable Area of THREAT ZONE: Threat Modeled: Flammable Area of
Vapor Vapor
Cloud. Model Run: Gaussian Cloud Model Run: Gaussian
Red : 37 meters (30000 ppm = 60% LEL = Flame Red : 186 meters (30000 ppm = 60% LEL = Flame Pock
Pockets) Yellow: 477 meters --- (5000 ppm = 10% LEL)
Note: Threat zone was not drawn because effects of near- THREAT AT POINT Thermal Radiation Estimates at the
field point: Downwind: 10 meters Off Centerline: 5 meters
patchiness make dispersion predictions less reliable for Note: Concentration not drawn because there is no
short di significant
Yellow: 93 meters --- (5000 ppm = 10% LEL) concentration at the point selected.
THREAT AT POINT Thermal Radiation Estimates at the CHEMICAL DATA: CHEMICAL NAME: METHANE
point: CAS Number: 74-82-8 Molecular Weight: 16.04 g/mol
Downwind: 10 meters Off Centerline: 5 meters PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000
Note: Concentration not drawn because there is no ppm
significant LEL: 50000 ppm UEL: 150000 ppmAmbient Boiling
concentration at the point selected. Point: -
CHEMICAL DATA: CHEMICAL NAME: METHANE 161.5° CVapor Pressure at Ambient Temperature: greater
CAS Number: 74-82-8 Molecular Weight: 16.04 g/mol than 1
PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000 atm Ambient Saturation Concentration: 1,000,000 ppm
ppm or 100.0%
LEL: 50000 ppm UEL: 150000 ppmAmbient Boiling Ambient Saturation Concentration: 1,000,000 ppm or
Point: -161.5° 100.0%
CVapor Pressure at Ambient Temperature: greater than 1 ATMOSPHERIC DATA: (MANUAL INPUT OF
atm Ambient DATA)
Saturation Concentration: 1,000,000 ppm or 100.0% Wind: 3 meters/second from 45° true at 3 meters Ground
ATMOSPHERIC DATA: (MANUAL INPUT OF Roughness: open country Cloud Cover: 7 tenths Air
DATA) Wind: 10 Temperature: 25° C Stability Class: F
meters/second from 45° true at 3 metersGround No Inversion Height Relative Humidity: 75%
Roughness: open SOURCE STRENGTH: Leak from hole in vertical
country Cloud Cover: 7 tenthsAir Temperature: 32° C cylindrical tank Flammable chemical escaping from tank
Stability Class: D No Inversion Height Relative (not
Humidity: 75% burning) Tank Diameter: 35.0 meters Tank Length: 52
SOURCE STRENGTH:Leak from hole in vertical meters
cylindrical tank Tank Volume: 50000 cubic meters Tank contains gas
Flammable chemical escaping from tank (not burning) only
Tank Diameter: 35.0 meters Tank Length: 52 meters Internal Temperature: 25° C Chemical Mass in Tank:
39,433
AM/NS India Limited
Tank Volume: 50000 cubic meters Tank contains gas kilograms Internal Press: 1.2 atmospheres
only Internal Opening Length: 30 centimeters Opening Width: 7 cm
Temperature: 32° C Chemical Mass in Tank: 38,522kgs Release Duration: ALOHA limited the duration to 1 hour
Internal Press: 1.2 atmospheres Opening Length: 30 CM Max Average Sustained Release Rate: 117
Opening kilograms/min
Width: 7 centimeters Release Duration: ALOHA limited (averaged over a minute or more)
the duration Total Amount Released: 5,006 kilograms
to 1 hourMax Average Sustained Release Rate: 118
kilograms/min
2 A Coke Oven Gas from the coke oven plant release 2 B Coke Oven Gas from the coke oven plant release
from the from
GAS HOLDER-Seal leak. Opening30cm x 6 cmr. the GAS HOLDER-Seal leak. Opening30cm x 6 cmr.
BLAST FORCE BLAST FORCE Atmospheric stability: ‘F’.
Atmospheric stability: ‘D’. (Maximum Credible Accident Scenario
(Maximum Credible Accident Scenario
THREAT ZONE: Threat Modeled: Flammable Area of THREAT ZONE: Threat Modelled: Overpressure (blast
Vapor Cloud. force)
Model Run: Gaussian from vapor cloud explosion Model Run: Gaussian
Red : 37 meters (30000 ppm = 60% LEL = Flame Red : LOC was never exceeded --- (8.0 psi = destruction
Pockets) of buildings) Orange: LOC was never exceeded --- (3.5
Note: Threat zone was not drawn because effects of near- psi = serious injury likely)
field patchiness make dispersion predictions less reliable Yellow: 110 meters --- (1.0 psi = shatters glass)
for short di THREAT AT POINT Thermal Radiation Estimates at the
Yellow: 93 meters --- (5000 ppm = 10% LEL) point: Downwind: 10 meters Off Centerline: 5 meters
THREAT AT POINT Thermal Radiation Estimates at the Overpressure: 0.778 psi
point: CHEMICAL DATA: CHEMICAL NAME: METHANE
Downwind: 10 meters Off Centerline: 5 meters CAS Number: 74-82-8 Molecular Weight: 16.04 g/mol
Note: Concentration not drawn because there is no PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000
significant ppm
concentration at the point selected. LEL: 50000 ppm UEL: 150000 ppmAmbient Boiling
CHEMICAL DATA: CHEMICAL NAME: METHANE Point: - 161.5° CVapor Pressure at Ambient
CAS Number: 74-82-8 Molecular Weight: 16.04 g/mol Temperature: greater than 1 atm Ambient Saturation
PAC-1: 65000 ppm PAC-2: 230000 ppm PAC-3: 400000 Concentration: 1,000,000 ppm or 100.0%
ppm ATMOSPHERIC DATA: (MANUAL INPUT OF
LEL: 50000 ppm UEL: 150000 ppmAmbient Boiling DATA)
Point: -161.5° Wind: 3 meters/second from 45° true at 3 meters Ground
CVapor Pressure at Ambient Temperature: greater than 1 Roughness: open country Cloud Cover: 7 tenths Air
atm Ambient Saturation Concentration: 1,000,000 ppm Temperature: 25° C Stability Class: F
or 100.0% No Inversion Height Relative Humidity: 75%
ATMOSPHERIC DATA: (MANUAL INPUT OF SOURCE STRENGTH: Leak from hole in vertical
DATA) Wind: 10 meters/second from 45° true at 3 cylindrical tank Flammable chemical escaping from tank
meters Ground Roughness: open country Cloud Cover: 7 (not burning) Tank Diameter: 35.0 meters Tank Length:
tenthsAir Temperature: 32° C 52
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Stability Class: DNo Inversion Height Relative meters Tank Volume: 50000 cubic meters Tank contains
Humidity: 75% gas only Internal Temperature: 25° C Chemical Mass in
SOURCE STRENGTH: Leak from hole in vertical Tank:
cylindrical tank 39,433 kilograms Internal Press: 1.22 Opening Width: 7
Flammable chemical escaping from tank (not burning) cm Release Duration: ALOHA limited the duration to 1
Tank Diameter: hour Max Average Sustained Release Rate: 117
35.0 meters Tank Length: 52 meters Tank Volume: kilograms/min (averaged over a minute or more)
50000 cubic meters Tank contains gas only Internal Total Amount Released: 5,006 kilograms
Temperature: 32° C
Chemical Mass in Tank: 38,522kgs Internal Press: 1.2
atmospheres
Opening Length: 30 CM Opening Width: 7 centimeters
Release
Duration: ALOHA limited the duration to 1 hourMax
(averaged over a minute or more) Total Amount
Released: 4,918 kilograms
6.8 Management of Risk and Health Scenarios

6.8.1 Risk Assessment & Management-
• A written OHS policy which is a statement of the management commitment to health and safety in the
organization
• Defines and allocates various responsibilities accountabilities and authorities in the organization
• Ensures effective arrangements for the full participation of workers and their representatives in the
fulfillment of the OHS policy
• Defines the necessary competencies and training needs
• Ensures the availability of information to workers in a language they can understand
• Establishes and maintains proper documentation and communication arrangements
• Identifies the hazards and carry out assessments of the specific risks to health and safety of workers in
the workplace.
• Establishes hazard prevention and control measures including emergency prevention, preparedness and
response arrangements
• Establishes procedures for compliance with OHS requirements in purchasing and leasing specifications
for contractors on site.
• Develops, establishes and review procedures to monitor measure and record OHS performance
• Identifies and implements preventive and corrective actions for continual improvement.
6.8.2 Health Management (Large Hazard Unit)

• Occupational health management encompasses the physical, mental and social well-being of the people
working in the company
• Occupational health management promotes the safety of employees, contractors and visitors by
preventing personal injuries in the workplace
• Deal with accidents, dangerous occurrences and incidents that may involve hazards or
• risks to safety and health from the production
• Competency of persons working shall be fully established. Work related trainings shall be imparted
periodically. Records are to be maintained.
• Roles and responsibilities shall be assigned clearly and reviewed periodically. Performance indicators
shall be devised and assessed for performance of the personnel.
• PPEs shall be kept at designated places and indicated on the layout plan. Daily shift-wise tool box talk
shall emphasis these points.
• Periodic Mock Drills of GROUND LEVEL shall be conducted. Records shall be maintained. These
records shall be available at the PLANT concerned.
• Firefighting using first aid fire extinguishers and hydrant system shall be practiced at monthly intervals.
Every workman, management staff have to undergo the training. Records have to be maintained.
• Personal Hygiene practices shall be strictly implemented to avoid, inhalation and ingestion of gases.
• Regular practice sessions for wearing the equipment shall be undertaken.
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• Periodic health checkup programs have to be organized and records maintained. Critical Health
parameters of the employees have to be monitored.
• Establishment of a system to record, report and monitor occupational accidents and diseases, and
dangerous occurrences.
6.9 Description of Information or Organizational Systems Used to Carry on Industrial Activity Safety,
Namely
6.9.1 Maintenance & Inspection Schedule

Schedule for maintenance & Inspection of equipment involved in continuous and safe operation in
manufacturing, handling and storage, are categorized as per following;
6.9.1.1 Planned Maintenance

Preventative Maintenance
The regular planned activity set by the engineering Department consists of:
• Checking Electrical equipment in classified areas.
• The checking of flameproof electrical fitting in flammable zone.
• Checking of safety devices like safety valve, pressure gauge.
• Computer Operating System
• Pipelines, Joints, Valves etc.
• Regular Inspection
• Tightening Connections and checking
• General Cleaning removal of oil, dust etc.
• Scrubber at chlorine handling area and water shower with eye washer at chlorine location.
• Electric wires, switches, lights, siren
• Machine guarding, fencing etc.
Periodical Maintenance
The equipment, instruments, vessels, pipelines etc. are required to get examined & certified by competent
person to comply statutory provisions. Such list is given as below:
• Lifting Tackles, Chain pulley blocks etc.
• Lift, Hoist
• Pressure vessels, Air receivers, Boilers etc.
• Furnace, Ladle furnace etc.
• Noise, Vibration, Illumination etc.
• Monitoring Working environment & stack.
• Fire extinguishers, Fire alarm system & Fire prevention.
• Communication system
6.9.1.2 Unplanned Maintenance

Sudden Breakdown OF equipment/Process/Operation
As far as possible, the plan maintenance schedule eliminates the breakdown maintenance. But, wherever the
breakdown take place, the equipments or area are promptly attended with the help of experienced technicians
& expert person. It is ensure that adequate stock of the spares shall be available for such purposes. Further,
breakdown is carried out on more sound basis rather than as a more patch up activity.
Inspection of Equipment
The safety aspect of the plant & equipment as a whole always are dealt more timely in our complex. All the
equipment, process plant, involved in safety in the areas of hazardous substances are frequently inspected and
kept in total working condition.

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6.9.2 Schedule Maintenance

• Monthly monitoring- Toxic & Flammable gas detection system etc.
• Daily- All alarms & Interlock/trips system etc. functioning of sensors.
• Annually - All critical instruments, control valves etc.
• Continuously - Ambient air quality
6.10 Guidelines for the Training of Personnel

Safety training for all levels of employees/workers/ Contractor’s workers is given great emphasis. Various
safety training programmes, Safety seminars, competition etc. are organized for motivation and to increase
effectiveness of all personnel.
The major programs are explained as:
1. New Recruits (Including Contractor’s workers: All the new entrants have to undergo basic safety
training programme at training centre.
2. First Aid Training: The first aid training is conducted and certificate are awarded by St. John
Ambulance.
3. Transportation Safety: Special Training programme for transport drivers on defensive driving and
transportation safety was conducted.
4. Comprehensive Safety Orientation Programme: The subjects such as process safety, Manual
Handling, Electrical safety, working in confine space, Safety permits etc. are included.
5. Special Training Programme: Special safety training programme, OSAS-18001, BSC, 5-S, safety
provisions under applicable statutes, Hazop study, Risk assessment etc. training programme are regularly
conducted.
6. Constructional Safety: The workers engaged in construction work are trained on constructional safety at
the training centre.
7. Emergency Mock- drills/exercise: To create preparedness, awareness amongst the workers, a mock drill
on emergency is conducted periodically by involving them.
8. Industrial Visit: Similar type of process industries are visited to enhance knowledge.
9. Faculties: The training is imparted with the help of internal faculties, external faculties or through
professional institution like Gujarat Safety Council, Rams Safety consultant, Synergic Safety Engineers,
DNV, BSE-UK etc.
6.11 Allocation and Delegation of Responsibility for plant Safety

Each HOD is responsible for the safety of his plant. Fire and Safety department looks after the fire and safety
work. The guide lines for involvement of safety by individuals explained below
6.11.1 Responsibility of Employee’s

• Every employee, contractor’s workers are expected to get trained in the subject of safety and pertaining
Safety Rules which are designed basically to protect employee/workers in the plants against potential
hazards. The employees/workers have responsibility to protect themselves, their follow employees and
plants by way of proper compliance of safety Rules and Regulations.
• They should go through various Safety Rules, Instructions & Procedures and follow them time-to-time.
• They must wear the personal protective equipments issued to them while they are in process area.
• They are also expected to see instruction notices, safety slogans, safety signs, safety operational
instruction as displayed at different locations in the plants.
• It is the responsibility of employees/workers to report promptly to their immediate manager of any

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dangerous or unsafe condition which noticed by them.
6.11.2 Responsibility of Manager

• The manager must ensure that the person engaged in any job/operation as fully aware of the hazards
associated with the job and they have to follow the safe methods of working.
• It must be observed that responsible person must be present, where job involving high hazards is carried
out. It must not be left to the workers only to decide whether the job is safe or not.
• Manager must go through all the safety rules and regulations along with procedures. He will ensure
that all rules are followed in the interest of the safety.
• It is responsibility of Manager to follow various safety permit systems during various maintenance and
repair jobs in the plants or areas.
• Manager shall arrange to maintain all the safety equipments, PPEs, Fire Extinguishers, First aid boxes
in good condition and in easily accessible position. In case of any defect or unavailability, they should
try to get them replacement from concern department.
• It will be responsibility of the Manager to ensure that workers, under him come in proper clothing, PPE
and other instruments as required.
• The Manager must check by taking frequent rounds of the plant or work area that all jobs are being
done with observing safety precautions.
• The manager should also get themselves familiar with statutory requirements on safety and follow them
in their work area.
• The manager must always set the right example by strictly following all safety rules & regulations and
taking right type of precautions in any job and also by wearing PPE or other safety equipments as
provided.
6.11.3 Responsibility of Safety Personnel

• The functions of safety department and safety personnel are to develop safety consciousness among all
level of workers, contractor workers, visitors etc. in order to reduce the accidents & losses.
• The safety personnel will make frequent safety inspection of the plants, processes and various
departments in order to check up observance of safety rules & practices and as an advisory capacity.
• Wherever any major or hazardous nature of job or work is to be carried out in the plant, they advise
plant, maintenance and engineering departments.
• Safety departments is organizing various safety training programme to impart training on safety rules,
regulations, safe method of working, safety motivation etc. for employees as well as contractor’s
workers also.
6.11.4 Implementations of Safety Procedure

• Procedures for test, examination, and certification of lifting tackles, chain pulley blocks,
slings, cranes, overhead cranes.
• Procedures for test, examination, and certification of pressure vessels, air receivers,
vaporizers, boilers etc.
• All type of safe work permits procedure.
• Procedure for checking & Inspection of instrumentations, trips, safety devices, alarms,
siren etc.
• Procedure for checking & Inspection of safety valves, breathers, gas detectors, smock
detectors.
• Procedure for checking & Inspection of Ladles, furnace etc.
• Procedure for checking & Inspection of earthing, jumpers etc.
• Procedure for checking of fire extinguishers, fire hydrant, fire pipeline network, fire
detection system etc.
• Accident/injury reporting and investigation
• Procedure for procurement of PPE
• Procedure for organizing safety training program.
• Procedure for modification, addition, alternation in the plant
• Procedure for testing work environment, noise level, vibration, illumination & Periodicity.

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• Procedure for preparedness and awareness amongst the workers and officers for
• Organizing safety committee meeting and maintaining the minutes.
• Display of safety posters, safety slogans, notices, instructions etc.
• Preparing safety budgets.
• Preparation of safety documents like safety manual, safety reports, safety audit, Risk
Assessment etc.
6.12 Risk Prevention and Risk Mitigation

Accident prevention is the primary safety goal of any organization. There are risks that can be eliminated
through preventive measures and those which can be reduced through mitigation measures.
6.12.1 Preventive Measures

The 4 E’s for elimination of hazards and prevent accidents are as follows:
1. Engineering and technological innovation to improve reliability
2. Experience in the study of hazards and operations- Risk analysis
3. Enforcement of decisions on study results – Preventive mechanisms
4. Education, awareness, and practice in prevention of accidents (Training & drills)
Various measures will be adopted at each stage of the project for ensuring safety of people, environment, and
property. These measures include the following:
1. Site selection
2. Choice of technology
5. Incorporation of interlocks and protection systems in plant design
6. Safety awareness for key management persons
7. Safety training of all operational, maintenance staff
8. Regular safety monitoring - Audits and inspections
3. Equipment design incorporating domestic and international safety codes
4. Plant layout with utmost consideration given to operational safety aspects
A. Site Selection
The plant is located in at Hazira, about 18 km away from the Surat City.
The site soil conditions are rigid and safe, complying with the requirements of the load bearing capacity of
various installations.
The size of the plot is large enough to ensure proper layout of plant buildings with adequate interconnecting
roads and distance from administrative areas.
B. Choice of Technology
The process is carefully chosen for reducing wastes, reducing the risk to human beings and the
environment. It is the proven one and acknowledged internationally.
C. Equipment Design
Equipment will be designed environment friendly and with all necessary safety features.
General / Other Areas

• The plant is laid out in such a way that hazards are either eliminated or isolated so as to manage it
effectively.
• The location of the disaster-prone areas of the plant is such that, they cause less impact to the
nearby factories or inhabitations.
• Buildings housing heat generating equipment or containing chemicals are well-ventilated with
adequate air circulation.
• Administrative office is located away from process plants and storage tanks.
• Security office is located close to gate and away from process plants and storage tanks.
• Workers’ rest area, shower, and dispensary is located close to administrative office, away from

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process plants.
• Canteen is located close to administrative office and away from process plants.
• A large area has been provided on site in the upwind direction for emergency evacuation Assembly
Points
• Interconnecting roads within the plot are made circular so that more than one get-away is available
at any point.
• A second trackable gate is provided for use in case of emergency.
• Proper drainage and enclosures are provided to drain away storm water from unforeseen flooding.
• Flame proof areas have been isolated from the non-flameproof areas.
• DG room and electrical transformer located away from administrative office, process plant and
storage tanks.
• The storage tanks of Hazchem are located in an isolated area, protected by dykes with adequate
facilities for handling spills and leakages.
• Fire hydrant system covers the entire operating area of the plant.
• Separate installation for fire water storing and pump house, with alternate and independent power
source.
• Separate power distribution and isolation boards in each building.
• Hazardous waste bins are located away from processing and administrative areas in an area clearly
demarcated for the same.
• Warning boards will be put up in areas where entry is restricted
• No Smoking boards will be put up at the entrance and at other locations throughout the plant
• Boards showing the numbers and contact details of government / district officials as well as fire
department, police department, district commissioner, etc. will be installed at security gate as well
as in the operational area.
• Hazardous chemicals shall be stored as per compatibility and based on corrosive and reactive
capabilities as per the guidelines in the MSDS.
• MSDS of all hazardous chemicals will be kept in the areas where such materials are used and
stored.
• Waste containers will be located at appropriate locations throughout the plant and will be coded
according to the type of waste.
E. Safety Awareness for Key Management

1. Key management personnel will be made aware from the beginning of the project of the key issues
regarding the safety in design and operation of the plant.
2. Project management personnel have visited several industrial plants where Hazchem is used in bulk
as a raw material for the production of finished products. Discussions with operational staff of the
plants during these visits has given them valuable insight into the safety aspects of handling of
Hazchem.
3. Discussions on safe handling of hazchems have been carried out with various safety experts, technical
collaborators, and with overseas suppliers through conference calls.
F. Safety Training for All Operational Staff

1. All operational staff will be given safety training as a compulsory part of their induction program.
2. Safety training will include, among other things, the following important aspects:
• Awareness of hazards of individual chemicals through study of MSDS
• Correct usage of Personal Protective Equipment (PPE)
• Explanation of the hazards and risks present in the premises, as well as their analysis
• Impact on safety, health, and environment due to improper handling of hazardous chemicals
• Guidelines for safety in operations
• Do’s and Don'ts

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G. Safety Audits and Inspections

• Regular safety audit will be conducted once a year to ascertain the safety levels followed in the
plant and suggestions for improvement
• Special safety audits will be conducted whenever there is process-related equipment / operational
changes made in the plant
• Safety audits will be carried out jointly by HSE personnel and external agencies, and corrective
actions will be recorded and presented to management for review.
• Daily safety inspections are carried out throughout the plant by HSE personnel.
• Testing and inspection of high pressure equipment with periodical hydrotesting and thickness
testing will be carried out once in a year during maintenance shutdown
• Testing of pressure safety valves and setting will be carried out once in a year during maintenance
shutdown
• Calibration of control valves, instruments as and when required, but at least once in a year during
maintenance shutdown
• Testing of thickness of all equipments with thickness meter will be carried out at least once in three
years during maintenance shutdown
• Testing of electrical measurements, such as earthing resistance, will be carried out every month
• Testing of all fire hydrant installations, fire extinguishers, fire pumps, fire water level monitors will be
carried out on a daily basis by HSE personnel.
6.13 Disaster Management Plan

Introduction
The term ‘Disaster’ owes its origin to the French word disaster, which is a combination of two words ‘des’
meaning bad and ‘aster’ meaning star. Thus, the term ‘disaster’ refers to ‘Bad or Evil Star’. In earlier days
disasters were considered to be an outcome or outburst of some unfavorable star.
Ideally, a disaster may be defined as “an event concentrated in time and space which threatens a society or a
relative self-sufficient subdivision of a society with major unwanted consequences as a result of the collapse
of precautions which had hitherto been culturally accepted as adequate”.
Disaster according to the Disaster Management Act 2005 means “a catastrophe, mishap, calamity or grave
occurrence in any area, arising from natural or manmade causes, or by accident or negligence which results
in substantial loss of life or human suffering or damage to, and destruction of property, or damage to, or
degradation of, environment, and is of such a nature or magnitude as to be beyond the coping capacity of the
community of the affected area”.
Disasters are extreme events which cause great loss to life and property. They pose a serious threat to the
normal life as well as the process of development and strike with sudden violence, tearing bodies, destroying
lives and structures and throwing apart families. Natural disasters, which are both sudden and powerful,
damage national economy and cause hardships to a large section of the population. They are the single largest
concern for most of the nations as they take a heavy toll of human life, destroy belongings and infrastructure
and have far reaching economic and social consequences for communities. Thus, the impact of disasters on
human life is multi – dimensional, affecting it in all aspects- domestic, social, economic etc.
Disaster Management Act:

The Disaster Management Act, 2005 provides for the requisite institutional mechanism for drawing up and
monitoring the implementation of the DM Plans ensuring measures by various wings of government for
prevention and mitigation effects of disasters and for undertaking a holistic coordinated and prompt response
to any disaster situation. The Act seeks to institutionalize the mechanisms at the national, state and district
levels to plan, prepare and ensure a swift response to both natural calamities and man-made
disasters/accidents IN THREE LEVELS.
1. National Level
2. State Level
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3. District Level (In a state) - Local level in a district.
6.13.1 Types of Disasters:

Generally, disasters are of two types – Natural and Manmade. Based on the devastation, these are further
classified into major/minor natural disaster and major/minor man-made disasters. Some of the disasters are
listed below:
Major natural disasters Minor natural Major man-made disaster: Minor man-made
Flood disasters Setting of Fires disaster:
Cyclone Cold wave Epidemic Road / train accidents, riots
Drought, Thunderstorms Deforestation Food poisoning
Earth quake Heat waves Wars Environmental pollution
Major Forest Fires Mud slides Pollution due to prawn
Major Epidemic Breakup Storm cultivation
Industrial disaster/Crisis
Chemical disaster/pollution
Industrial hazards are threats to people, and life-support systems that arise from the mass production of goods
and services. When these threats exceed human coping capabilities, or the absorptive capacities of
environmental systems, they give rise to industrial disasters.
Industrial hazards can occur at any stage in the production process, including extraction, processing,
manufacture, transportation, storage, use, and disposal. Losses generally involve the release of damaging
substances (e.g. chemicals, radioactivity, and genetic materials) or damaging levels of energy from industrial
facilities or equipment into surrounding environments.
The growth of chemical industries has led to an increase in the risk of occurrence of incidents associated with
hazardous chemicals (HAZCHEM). A chemical industry that incorporates the best principles of safety can
largely prevent such incidents. Common causes for chemical accidents are deficiencies in safety management
systems and human errors, or they may occur as a consequence of natural calamities or sabotage activities.
Chemical accidents result in fire, explosion and/or toxic release.
The nature of chemical agents and their concentration during exposure ultimately decides the toxicity and
damaging effects on living organisms in the form of symptoms and signs like irreversible pain, suffering, and
death. Meteorological conditions such as wind speed, wind direction, height of inversion layer, stability class,
etc., also play an important role by affecting the dispersion pattern of toxic gas clouds.
The Bhopal Gas tragedy of 1984—the worst chemical disaster in history, where over 2000 people died due
to the accidental release of the toxic gas Methyl Iso-cyanate, is still fresh in our memories. Such accidents
are significant in terms of injuries, pain, suffering, loss of lives, damage to property and environment. A small
accident occurring at the local level may be a prior warning signal for an impending disaster. Chemical
disasters, though low in frequency, have the potential to cause significant immediate or long-term damage.
Objectives of Emergency Procedures

Measures, which are required, to be taken during emergencies include co-ordination of activities with several
concerned departments/services and outside resources.
The objectives of the procedures include defining the role of key personnel of different services during major
emergencies who can be effectively utilized to:
• Warn the relevant person/company who might get affected.

• Assembling the inside resources
• Guide them to use emergency escape route
• Get information about incident and bring it under control
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• Inform the rescue team and ambulance

• Identification of affected persons, inform to relatives and give them proper medical assistance.
• Providing relevant information to higher authority.
• Plan the precaution list for future
• Turn off the plant and Alert everyone with help of emergency siren.
• Guide them to use emergency escape route
• Collect all information about loss.
• Welfare assistance for those who lose their lives
Disaster Management is with the guidelines of

1. ON –SITE EMEGENCY PLAN - prepared by the plant
2. OFF-SITE EMERGENCY PLAN- Prepared by DDMA
6.13.2 On-Site Emergency

Disaster within the premises of the PLANT / FACTORY describes the action scenarios, complying with a
documented Plan, to manage and eliminate the Disaster by the Plant personnel.
An emergency plan generally constitutes system of organization used to fight the emergency, the alarm and
communication routes, guidelines for fighting the emergency and examples of possible accident sequences.
Being an alert management, On-Site Emergency plan is prepared & updated from time to time, the plan helps
provide clear action lines to the designated person.
The objectives of On-Site Emergency plan are as follows:

• To provide information to higher authorities, police and the news media.
• To control and comprehend incidents.
• To safeguard employees and people in the neighborhood.
• To minimize damage to property or/and the environment.
• Inform everyone about the emergency siren and with the help of wireless and inform the fire brigade
or ambulance to come for help, guide everyone about emergency escape route or assembly point.
• To be ready for mutual aids if need arises to help neighboring unit. Normal jurisdiction of an on-site
emergency is the own premises only but looking to the time factor in arriving the external help or
off-site plant agency, the jurisdiction is extended outside to the extent possible in case of
emergency occurring outside.
• To affect rescue and treatment of casualties to count injured.
• To identify and list any who lose their lives. And help their relatives.
• To rescue the safe rehabilitation of affected areas and restore normalcy.
• Turn off the plant and describe and assess the emergencies, including risk and environmental impact.
• To carefully preserve records, equipment etc. and to organize investigation into the cause of the
emergency and preventive measures to stop this recurrence.
• Take care of safety precautions before the start of the work.
• Inform everyone about the emergency siren and with the help of wireless and inform the fire brigade
or ambulance to come for help, guide everyone about emergency escape route or assembly point.
• To be ready for mutual aids if need arises to help neighboring unit. Normal jurisdiction of an on-site
emergency is within own premises only, but looking into the time factor in arriving for the external
help or off-site plant agency, the jurisdiction is extended outside to the extent possible in case of
emergency occurring outside.
6.13.3 Off-Site Emergency

Disaster spilled outside the factory premises, describes the action scenarios, complying with a documented
plan to manage and eliminate the disaster, by both the plant personnel and District Disaster Management
Authorities. This plan will be prepared by DDMA seeking the details from plant authorities.
Co-ordination with the District Collector or district Emergency Authority and its Off-site Emergency Plan
are as follows:
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The unit has intimated the district emergency authorities and local authorities by the submission of various
information. Moreover, the unit is a member of the Local Crisis Group for Hazira-Olpad Taluka & Surat
District Crisis Group, being a MAH unit. One representative from the unit attends the meeting of Local Crisis
Group as well as District Crisis Group from time to time. Being a member of the offsite emergency plan, the
factory has all emergency phone nos. of District authorities, who can be contacted during major
emergency/offsite emergency. Further, a tracking system has been adopted to connect directly with the
authority by a wireless. List of Emergency Telephone Nos., which includes Telephone Nos. of District
Authority like Collector, Director Industrial safety & Health, Police Department, Central Control Room,
Hospitals, Fire Stations, etc. are displayed at conspicuous places including main security office and the
emergency control center.
Glossary
Terms and Interpretations:
Disaster: “means a catastrophe, mishap, calamity or grave occurrence in any area, arising from natural or
man-made causes, or by accident or negligence which results in substantial loss of life & sufferings or damage
& destruction of property, or damage & degradation of environmental systems, and is of such a magnitude as
to be, beyond the coping capacity of the community of the affected area”
Management: “means a group of employees unifying to mitigate the undesirable effects of a disaster,
controlling and eliminating its effects fully to bring back to erstwhile normal operating conditions”
Emergency: “an undesirable state of events of loss, beyond the coping capacity of the designated operating
personnel of the plant”
Plan: “means set of activities laid in series, arrangements made in advance with internal trained personnel &
external agencies, to perform them in a systematic way to mitigate, control and eliminate an emergency”
On-Site Emergency: “means an EMERGENCY SITUATION – Radiation, Toxicity, impact on environment,

confined to the plant premises” to cause loss.
Off-Site Emergency: “means an adverse emergency situation- radiation, toxicity, impact on environment,
spilling outside the plant premises to cause loss”
Loss: “means - ill health to people, destruction to property, stoppage of plant operations, forced layoff to
employees, increased debt burden of loans on purchase of plant & machinery, good will loss, loss of
employee’s confidence level, impact on environmental systems which supports life in the area. (Loss of
greenery, loss of cattle, and loss of aquatic life, land and water pollution)
Emergency Control Room: “means designated room for the “incident controller” to perform his role on
mitigating, controlling, eliminating the emergency and bring the plant back to normal working environment.”
Incident Controller (IC): “means a designated person, vested with overall responsibility & authority to
mitigate, control and eliminate emergency and put the plant in normal working condition.” “it includes
controlling the entire operations as a team leader and reporting to top management / owners of the plant.
normally this position is given to the plant coordinator or no.1 position holder of the plant.”
Accident Site Controller (ASC): “means a designated person, vested with overall responsibility to mitigate,
control and eliminate emergency from the designated site / sites inside the plant premises. He mitigates,
controls, and eliminates the actual accident which has later become an emergency. (Engineering team, Rescue
& Relief team, Firefighting team, and other miscellaneous services will report to him.)”. Normally this
position is held by concerned plant head.
Rescue & Relief Head (RRH): “means a designated person, who will perform rescue operations, take relief
measures to the injured, co-ordinates with liaison officer. rescue operations in the entire plant being a big

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operation he will have a fairly big team to perform this operation.” this position is given to the head - civil
department.
Engineering Head (EH): “means a designated person, who will advise operations to save damages to plant
& machinery, operations to mitigate and control processes, performs safe shutdown operations, safely
operating the utility services (electricity, instrument air, various water systems, waste water systems,). this
position is given to the head - maintenance (mechanical, utility, electrical & instrumentation).
Liaison Head (LH): “means a person authorized by incident controller for coordinating the external
resources & services. he interacts with incident controller and communicates to mainly district disaster
management authorities. he receives the requirements, analyses and coveys the same to his spokesperson,
who in turn, contacts the concerned external agency, and gets the required external resources sought.”
Spokes Person: “means a person authorized by liaison head to contact and arrange for external resources /
help (like district administration-collector, commissioner of police, commissioner of labor, factory
inspectorate, health inspector, fire brigade head, local panchayat head, district transport officer……etc.”).
Key Emergency Personnel: “means employees, who take responsibilities and take positions to mitigate,
control and eliminate emergency. they report to their respective team heads. during the entire course of
emergency these personnel will be inside the plant to perform above operations. they will note down the real
performance of operations carried out, analyze the gaps in the performance and discuss the same in the post
emergency feedback meeting.”
Non-Emergency Personnel: “means employees, visitors, contractors and other outsiders required to be
evacuated from the factory premises on “declaration of emergency”.
Safety Materials: “means additional materials, tools, PPEs and appliances required for use during
EMERGENCY operations by the persons inside the factory.” Also, the additional safety materials required
to be provided to district administration in the event of an OFF-SITE EMERGENCY”.
Emergency Plan: “means an authorized document (preconceived, discussed and agreed methodology of
operations and responsibilities) having clear cut action scenarios without aberrations, to be performed by key
emergency personnel, during MOCK DRILLS or REAL EMERGENCY situations.”
Site Plan: “means a print copy of the layout of the plant / factory displaying the locations of different
buildings, facilities, storage locations, roads, referred for easy communication and action during emergency.
Area Plan: “means plan showing the area e.g., jolwa industrial area to scale. useful for assessing the affected
area in the event of an off-site emergency and preparations for evacuation of people till the emergency is
over.
Toxicity: “means - Toxicity is, the degree to which a substance can damage an organism.
Three types of toxicity are
1. CHEMICAL
2. BIOLOGICAL
3. PHYSICAL
The entry routes for damage of the organism are

1. INHALATION
2. INGESTION
3. SKIN ABSORPTION
Isolation from the source of origination is the effective way of safe guard. The degree of toxicity is given by
the Threshold Limit Value (TLV), Immediate Danger to Life & Health (IDLH).

AM/NS India Limited
Flammability: “means- Flammability is, as how easily matter will burn or ignite, causing FIRE or
COMBUSTION.” The degree of flammability is determined by the explosion limits of the hazardous
chemical, and its quantity & calorific value determines the “thermal radiation flux” liberated on combustion.
Spot Fire: “means fire liberated from a point or line opening of a container due to leakage of a flammable
gas.”
Flash Point/ Fire Point: - “the flash point of a volatile liquid is the lowest temperature at which it can
vaporize to form an ignitable mixture in air”. The fire point, a higher temperature, is defined as the
temperature at which the vapor continues to burn after being ignited.
Threshold Limit Value: “means -The threshold limit value (TLV) of a chemical substance, is a level to
which it is believed, a worker can be exposed day after day, for a working lifetime without adverse health
effects.” It is expressed in ppm or mg/kg of body weight.
Threshold Quantity: “means the highest quantity of a Hazchem (in m³ or mt) of liquid or solid stored in a
manufacturing unit storage area (in one or more vessels) at any point of time throughout the year, above
which certain regulatory compliances are required.
Scenario: “means the mathematically arrived “virtual physical effects” of an accident, for the input
conditions given.” It is presented in the form of a x-y graph.
Dispersion: “means the spread of any flammable combustible vapor or toxic cloud of vapor, in the
atmosphere for a given set of wind speed and atmospheric stability conditions.”
Dispersion Foot Prints: “means graphical mapping of the dispersion clouds in the x-y-z coordinates with
respect to distance traveled and over a said period of time.
Thermal Radiation Flux: “means the amount of thermal energy released by a flammable cloud of vapor in
the atmosphere on a unit area, and its radiation effects, at a particular distance in the hazardous zone.
Safe Zone: “means a safe limit of toxic vapor cloud existing in an area where there is no damage to human
beings or environment when they live in a free exposed condition for an hour or more. “means a safe limit of
thermal radiation flux existing in an area, where there is no damage to human beings or environment when
they live in a free exposed condition.”
Emergency Siren: “means a siren with a blowing range of 1 km radius, all around the source, and capable
of giving long and short variances sound for a period of minimum 3 minutes.”
All Clear Siren: “means a siren with a blowing range of 1km radius, all around the source, and capable of
giving a continuous non-variant sound for 5 minutes.”
6.13.4 Organization set Up Plan

• Approved ON-SITE, OFF-SITE EMERGENCY plans shall be available with OH&S Head.
• All plant personnel have to be trained on the Emergency Plans.
• Rescue members have to be additionally trained as per the TEAM responsibility.
• Mock drills have to be performed once in every 6 Months. The drills shall be witnessed by DISH
officials OR Senior management members of same group of Industries. The EXTERNAL
OBSERVERS concept in MOCKDRILLS will improve the quality of drills.
• All the improvements suggested in the Mock Drills have to be implemented through a MOM.
• The reports of MOCKDRILLS have to be sent to DISH officials as a record.
• A list of Risk Scenarios has to be identified and listed for performing the Mock Drills at periodic
intervals.

AM/NS India Limited
ORGANIZATION SET UP FOR EMERGENCY
Incident Controller
Liaison Officer Accident Site Controller
Fire/ Toxicity Engineering Rescue & Security Medical

Team Rehalibation Team HR Team
Team Team
TEAM Team
Safety Team Plant Engineering + Safety Team Security

& Rescue Maintenance & Rescue Officer + OHC + Personal
Team Department Team Rescue Rescue Rescue

AM/NS India Limited
Teams Fitment Plan

Sr. No. Team Team Leaders
1 Incident Controller Senior Management Person
in Charge of Accident plant
2 Accident Site Controller
Sr. Supervisor /Chemist (II shift & III shift)
3 Liaison HEAD HOD -HR
Senior Management Personnel from projects, design,
4 Engineering Team
maintenance
5 Rescue & Relief Team Senior Management Personnel from personnel, accounts
6 Fire Team Safety Personnel
7 Medical Team OHC Personnel
Security Officers
8 Security Team
Security Guards
6.13.4.1 Responsibilities of Key Emergency Personnel - Teams

Incident Controller – Responsibilities
• The head of the PLANT will be normally the Incident Controller (IC). Ensures the emergency is
properly dealt with, eliminated and normal operating conditions are restored as soon as possible.
• Ensures all the managers and officers of the plant are included as “key emergency personnel.”
• Ensures the On-site Emergency Plan is prepared, and general training is given to all the employees
of the plant. On-site Emergency Plan is submitted to Department of Industrial safety & Health for
review.
• Ensures Mock drills (Virtual Emergency) are conducted quarterly in different shifts as per the
provisions of On-Site Emergency plan.
• Ensures one or two District disaster management Authority (DDMA) personnel are invited to
participate in the mock-drills.
• Ensures On-Site Emergency Plan is revised, based on the Mock-drill feed backs, till he is satisfied,
that the plan is acceptable to all key emergency personnel.
• To officiate a person responsible to co-ordinate with District Disaster Management Authorities to
prepare OFF-SITE EMERGENCY PLAN for the plant. The LIASION HEAD may be the appropriate
person for the same.
• Ensure the firefighting system, safety materials required for use during real emergency, and first-aid
medical facilities, are in order by review of documents, inspections and trials.
• Ensures to name the alternate key emergency personnel IC, ASC, LH, EH, RRH in case the
emergency is reported after general shift hours. The key emergency personnel will take positions as
soon as possible and replace the alternate team. (Mock drills conducted in II & III shifts will give
necessary guidance to select the personnel)
On Declaration of Real Emergency

• Soon after hearing the emergency from the Main gate security or SMS –Emergency, incident
controller rushes to ECC.
• He takes control on all operations to deal with the emergency from ECC.
• He ensures all the team leaders are in their respective positions of operation, soon after ordering to
blow the emergency siren.
• On the advices of ASC, LH, EH, RRH analyzes the actual situation at periodic intervals and declares
off-site emergency if required.
• He ensures through liaison head, external emergency services are informed and called for help in
time.
• Take periodic rounds to provide guidance and help to team leaders for effectively discharging their
duties. notes down the short comings in the operations.

AM/NS India Limited
• Once the risk is eliminated completely as declared by accident site controller, he orders to blow “all
clear siren”.
• He calls a feedback meeting at ECC. all the key emergency personnel are to attend the meeting and
participate in the deliberations.
• He co-ordinaries with department heads to normalize the plant for regular production activities and
support services.
Accident Site Controller - Responsibilities

• Coordinates with ENGG TEAM, FIRE TEAM, RESCUE &RELIEF TEAM to mitigate emergency
conditions’
• Ensures to finally eliminate the Emergency condition completely inside the plant.
• Ensures after eliminating emergency the area/s worked, are kept clean for normal operations.
• Ensures the required number of teams and personnel are kept ready for eliminating the emergency.
• Ensures all required materials, equipment and resources are available for eliminating the emergency.
Is requested and brought in time.
• Ensures right information is given to IC at periodic intervals.

• Soon after hearing the emergency siren or SMS Emergency, ACCIDENT SITE CONTROLLER
rushes and takes control of the site inside the plant, which created an emergency situation.
• He assesses the risk, computes the requirements of teams, the requirement of key emergency
personnel for each team, requirement of reserve teams in case the risk spreads, and orders them to
take their positions.
• He assesses the complete scenario and decides whether to declare off-site emergency and informs to
IC accordingly.
• Ensures all the requirements for fighting the Emergency is available to eliminate the emergency at
the shortest possible time.
• Ensures all requirements of external resources are informed in time to liaison team.
• He takes regular rounds and gives necessary guidance and help to teams to deal with emergency.
• He applies strategies and tries all possible permutations & combinations to limit the emergency as
on-site emergency.
• Ensures all the key emergency personnel, are operating strictly complying safety parameters.
• Gives constant feedback on the Emergency situation and post his requirements to IC.
• He ensures emergency conditions are completely eliminated, areas are cleared, and informs to IC for
blowing all clear siren.
• Notes down the short comings in the operations performed for eliminating the emergency, during his
rounds.
LIAISON HEAD - RESPONSIBILITIES

• Head – HR department is nominated as Liaison Head.
• Ensures district disaster administration authorities are informed about the declaration of emergency
and constantly keeps in touch with them. Informs the actions initiated by district administration
officials to IC.
• Ensures local in habitations are well informed and measures taken for their safety.
• Ensures the external resource help is given in time to ASC.
• Ensures the medical assistance for the injured, in nearby Hospitals, and transport for non-emergency
personnel movement.
• Ensures constant dialogue with nearby industries and arranges all possible help through district
administration.
• Ensures proper gate security is maintained for preventing outside persons unauthorized entry inside
the industry.

AM/NS India Limited

• Soon after hearing the emergency siren or SMS Emergency, Liaison Head rushes to main gate.
• Briefly informs the district administration of the Emergency situation and the help required.
• Informs the Fire Brigade for fire tenders and transport department for buses to evacuate the non-
emergency employees.
• Informs the nearby industries about the impact and precautions to be taken by them. On request
distribute chemical masks for the employees inside factory.
• Takes periodic rounds of the affected areas and studies the situation. Notes down the points of
concern of the Egg. Team, Fire mitigation Team, Rescue & Relief teams.
• Asks his spokesperson to meet the nearby village head and brief the actions taken for the safety of
the people of that village.
• Keeps the district administration informed about the latest situation and the help required.
Engineering Team- Responsibilities

• Engineering team head is nominated from Maintenance Department.
• Mechanical, Electrical & Instrumentation & Utility Maintenance Head will be the team leaders.
• Ensures the Plant & Machinery inside the plant are protected from damages.
• Isolates EB power and takes essential operations on standby power.
• Ensures the plant with minimum required illumination to carryout emergency operations.
• Ensures the systematic stoppage of plant and machinery to cause minimum LOSS, and pave way for
easy restart conditions.
• Ensures isolation of systems which can otherwise raise the risk level of emergency.
• Ensures the semi-finished products on the process line are protected from unwanted reactions and
prevent it from becoming a waste.
• Ensures all the machines are in shutoff condition.
• Ensures the unaffected storage locations are well protected, using the built-in safety protection
systems.

• Soon after hearing the emergency siren or SMS - emergency, Engineering Heads rushes and takes
control of his key personnel to deal with the conditions of emergency.
• Associates with the site controller wherever he demands help in controlling the emergency.
• Isolates EB power and takes the unit on standby power.
• Provides minimum illumination required for the control of emergency operations throughout the
plant.
• Puts off all running equipment and shuts off the continuous process plant following emergency shut-
down procedures.
• Ensures unwanted chemicals are drained off the reactor vessels, heat exchangers and other systems
as the plant demands.
• Keeps the waste water treatment plant running to clear off the excess load on the system
• In the Tank storage farms take appropriate actions like – draining the Hazchem in the dyke,
transferring from one vessel to another standby vessel, additional cooling arrangements of the
equipment wherever required.
Rescue and Relief Team – Responsibilities

• On receiving information from SMS emergency rushes to accident site and coordinates activities with
ASC.
• Group the team members and inform all non-emergency personnel to assemble at assembly points
(Assembly points are located near main security gate).
• Subdivide the group and perform intensive search operation at all location to find out the injured.
• Make arrangements to transport to injured on stretcher to the medical team stationed at medical
center.

AM/NS India Limited
• Search for the missing person given in the list by LH. Give periodic feedback to ASC.

• Soon after hearing the emergency siren or SMS - emergency, Rescue and Relief Team Head rushes
to accident site.
• Associates with the accident site controller wherever he demands help in controlling the emergency.
• Makes arrangements to search employees, contract persons and visitors missing in the HEAD
COUNT.
• Search teams go all around the plant to search for the missing persons in the head count.
Fire Team – Responsibilities

• Fire Team head is nominated from Safety Department.
• Fire Team consists of Key emergency personnel from safety Department, First aid center, process
department and security departments.
• He ensures all electrical systems are isolated except emergency lighting systems.
• He ensures all the fuel /heating systems are isolated from both the ends of flow.
• He ensures required numbers of fire mitigation equipment are fully operational.
• He ensures all firefighting persons are performing the operations safe.
• He ensures all external help required is informed to ASC in time.
• He ensures the water resources are fully operational.
• He ensures smooth co-ordination with external Fire Mitigation Agencies.
On Declaration of real Emergency

• Soon after hearing the emergency siren or SMS Emergency FIRE Team Head rushes to Accident site
and takes Instructions from ASC.
• He plans with ASC and EH to isolate systems prior to start of fire extinguishing operations.
• He takes note of wind direction and proper ventilation systems prior to start of fire-fighting.
• He ensures the required number of fire-fighting teams is kept for fire-fighting and preventing fire
spreading.
• He ensures appropriate extinguishing systems are optimally used for controlling the situation.
• He ensures wherever inert gases are used for controlling the fire, safe systems of operations are
adopted.
• He ensures personal safety is given utmost importance.
• After ensuring complete extinguishment reports to ASC.
• He ensures complete cleanup operations are performed prior to allowing persons for inspection.
Security Team – Responsibilities

Security Team head is nominated from Security Department.
 Security Team reports to Liaison Head. It is divided into three divisions
a) Gate security Team
b) Team to associate fire team
c) Team to perform inside factory security and cordoning operations.
• He ensures overall assistance is given to all teams.
• He ensures non-emergency persons are guided to Assembly points.
• He ensures traffic regulation inside the plant is done to the requirement.
• He ensures gate security team protects all inside plant persons. Records the in time of key emergency
personnel.
• Stops all persons/ vehicular movements as soon as Emergency Call is received.
• Allows DDMA vehicles, emergency service vehicles and guides them properly.
• He ensures all instructions given by Liaison Head are strictly followed.

AM/NS India Limited

• Soon after hearing the emergency call OR SMS-emergency, Security Team Head rushes and takes
Instructions from LH.
• He plans his persons for various operations and assigns a security supervisor for the same.
• He takes note of wind direction and guides the persons to Assembly point/s.
• He controls the gate operations and records the movement of vehicles and persons after the
declaration of emergency.
• He interacts with LH and performs his instructions.
Medical Team – Responsibilities

• Medical Team head is nominated from OHS Department.
• He ensures the ambulance and one male nurse is kept in the accident site.
• Ensures CPR is given to unconscious persons in the accident site.
• Depending on the requirement requests LH for additional ambulances.
• He ensures proper prearrangements are done at nearby hospitals for treatment of injured.
• Keeps records of injured persons and monitor the progress of injured regularly.

• Soon after hearing the emergency call OR SMS - emergency, Medical Team Head rushes and takes
Instructions from LH.
• He will be stationed in OHS center and monitor the medical needs of the injured.
• He will ensure the required medicine, fire blankets, first aid boxes, and other essentials are kept ready
for the injured persons.
• One additional ambulance will always be kept at OHC depending on the emergency conditions.
• He will have constant interactions with LH on the medical treatment to injured persons.
6.13.4.2 Communication System

Communication will be exchanged mainly from team to team or person to person using
• Mobile cell phones, Group SMS for Key emergency personnel.
• Land line phones wherever available.
• Designated intercom cell phones.
• Public Address system installed in offices & Plants.
First - Incident Information:

The first incident information about, informing an incident/accident will be given by an employee, who has
seen the incident. He will give the information to the main Security Main Gate/ Fire Room, giving his identity
in full.
The security officer on duty/ Safety Person on duty, who receives the information informs to their Heads.
Both the fire team lead by safety supervisor/ security persons will rush to incident site immediately for
mitigating the emergency. The Head of Safety/Security passes information by flashing SMS message
(Template) to all the KEY EMERGENCY PERSONNEL by group SMS using Mobile Cell phone. For easy
sending, each group is recommended to have 10 persons. The person informed is requested to REPLY
positively.
By this system all the Key members of the emergency will be officially informed about the emergency. Their
replies will confirm their receipt. The replies shall be as concise as ‘YES’.
Emergency Siren
Emergency ‘on’ Siren:
Fire mode / Toxic Mode 0-0-0-0-0-0-0-0 Wailing Siren
(10 sec) (5 sec) (10 sec) (5 sec) …UP-Down-UP-Down - for Three Minutes All Clear Siren: Continuous Siren
for 5 Minutes

AM/NS India Limited
Emergency Control Centre (ECC)

ECC will be occupied by Incident Controller. It will have provisions for seating five persons, a conference
room to house 15 persons, and a store to accommodate safety materials storage required during Emergency.
The following documents, (latest revisions) will be kept in the emergency Control Center, for immediate
reference and use, in the event of an Emergency. A key will be kept with IC.
Reference Documents
• On-site Emergency Plan – 5 copies
• Off-site Emergency Plan – 5 copies
• Plant - site plan - 5 copies
• MSDS of all HAZCHEMS – Each chemical.
• Short note books -25 no’s
• Ball pens, Pencils, erasers, sharpeners -25+10 + 10+ 2 no’s
• Digital Cameras – 2 no’s
• Laptops – 2 no’s networks connected.
List of Safety Materials

• Self-Contained Breathing Apparatus- 10kg - 10 no’s
• Full Face masks - 25 no’s
• Trolley mounted oxygen cylinders - 05 no’s
• Full body chemical protection suits - 10 no’s
• Chemical splash proof goggles - 50 no’s
• Aluminized firefighting suits - 10 no’s
• 25mm hose clips with screw clips - 10 no’s
• Gum boots full length - 25 pairs
• Leather hand gloves - 50 pairs
• Electrical hand gloves - 05 pairs
• Non-permeable hand gloves - 25pairs
• Safety helmets - 50 no’s
• Safety shoes sizes - 60 pairs
• Pick axles - 02 no’s
• Shovels - 05 no’s
• Rain coats full size - 10 no’s
• Stretchers - 02 no’s
First- aid Medical Services

A First –Aid service center is available in the Main gate of plant. There is a doctor and qualified medical
nurses. They will be assisted by trained first aiders whenever there is an urgent need.
Medical examinations are out sourced, and reports are maintained by the HR department. EHS manager has
a formal agreement, with “Full-fledged hospitals” in the nearby area of the plant, for immediate admission
and treatment to the injured.
Assembly Point/s
Assembly point is the place, where the non-emergency employees are assembled for head count. Later they
are assembled at the same place OR shifted to a safer place on the advice of IC. Two assembly points are
planned.
Assembly point is located inside the site of the plant. Normally assembly points are away from the bulk
storage locations, near to the plant main security gate, and located in upward side of the predominant wind
direction. The wind sock is installed, for instantly knowing the current wind direction, is located on the top
of the plant building, and is clearly seen from the assembly points.
FIRST ASSEMBLY POINT: Near ADMIN building

AM/NS India Limited
SECOND ASSEMBLY POINT: Near the MAIN GATE.
Fire Fighting built in Facilities

• Fire hydrant system – Fire water storage, Fire Pump, Jockey pump, PP Power / DG Power, Fire
Room, systems to control water supply and power.
• Hydrant Pipes, Risers, Spray Nozzles, control gate valves, Hydrant boxes, Hydrant control valves.
• DCP, CO₂, FOAM portable fire extinguishers of different capacity.
• Water and Foam Fire Tender stationed at CP.
The firefighting activity in M/s. AMNS India Ltd. is coordinated with safety, this is identified as a good
system. A well-structured FIRE DEPARTMENT is headed by HOD (Fire & Safety) and assisted by- 1 DGM
assisted by 1 senior manager and other managers. The fire station is manned round the clock in 3 shifts. Each
shift is managed by a “shift in change” with fire crew. The fire control room is equipped with the modern
communication facilities like Micro Pressure based computerized addressable Fire Alarm System, the
wireless (VHF) and mobile phones. The fire department can identify, probable emergency situation like gas
leakage, Hydraulic Oil leakage, Toxic release, fire explosion (such as failure of furnace) etc. and can control
such situation effectively.
Fire Hydrant Network

The entire M/s.AM/NS INDIA LIMITED complex is protected by a well-designed Fire Hydrant Network,
which consists of the following:
• Fire Pump Houses - 04 Nos.

• Jockey pump - 08 Nos. (40 m3/hr at 9.5 Bar)
• Centrifugal pump -07 Nos. (Electrical Motor -410 m3/hr at 8.8 Bar)
• Centrifugal pump -07 Nos. (Diesel engine - 410 m3/hr at 8.8 Bar)
• Double Headed Hydrant (DSC + Jetty) -20 Nos.
• Single Headed Hydrant - 316 Nos.
• Fire Escape Hydrant - 16 Nos.
• Hydrant on risers - 52 Nos.
• Fixed Type Water monitors - 12 Nos.
• Water/Foam monitors - 08 Nos.
• Hose Boxes - 404 Nos. (Hose-2, Branch -1)
Fire Water Reservoir

1.Independent Pumping Station
2.HBI, HRC and 1 Fire Water Reservoirs (which can last more than 4hours)
Fire Fighting Appliance

• Foam Tender - INO
• Combined DCP CUM foam Tender - 01 No.
• Portable pumps - 03 Nos.
• Fire Jeep - 01 No.
• Foam Trolley - 03 Nos.
• S.B.A. sets - 32 Nos. (+43 spare cylinders)
• Exhaust cum blowers -10 Nos.
Portable Fire Extinguishers

1.DCP, CO2, ABC, Clean Agent, Foam – As per the standard requirement
Fire Detection & Protection Systems

• Smock Detectors - 1065 Nos. (ISD & PSD)
• Heat Detectors - 105 Nos.
• Manual Call Points - 54 Nos.

AM/NS India Limited
• Fire Alarm system - covering all plant

• Harm Flooding System - 1301
• CO2 Total Flooding System - At Electrical Arc Furnace, Ladle Furnace, Caster Turrets,
Transformers, Generators, Turbines.
• Automatic Foam/Water spray system - LPG Plant & NGL Tank
• Medium Velocity Water spray - Cable Tunnel
• Foam Compound - 10,000 Liters AFFF
• Fire Entry Suit - 1 No.
Alarm/ Siren
• Microprocessor based computerized addressable Fire alarm system is installed in entire complex.
• Wireless (V.H.F.)
• Mobile Phones
• Fire services & local authorities - Wireless Network
• Electric Siren
• Security staff Messenger
• Trunk System
Pollution Control
• The water used for firefighting will be diverted to ETP
• The wastes collected at the site of accident will be sent to waste yard in designated packages. EHS
environment department will do the necessary formalities for its disposal.
Wind Socks
• Wind socks are installed on buildings to instantly catch up the wind direction. The sock flying
indicates the DOWNWIND direction. Luminous chemical coated windsocks will glow in the nights
also.
• TWO wind socks shall be installed. One at the NE corner, and the second at SW corner.
Rescue Teams.
• The positions of RESCUE TEAM MEMBERS are created in all plants, departments and service
centers. They are given a RED HELMET for easy identification. They are being trained in different
aspects of activities involving emergencies. They are from workers, operators, supervisors and
chemists. They are well distributed in the shifts so that their availability is felt, round the clock.
• On hearing the emergency siren, the RESCUE team members (Respective shift) are requested to rush
to the emergency site location and assemble at the Ground floor. Information will be given about
their arrival to accident site controller.
• They will form the team members for performing necessary activities as per the directions of their
respective team leaders.
• Both during accidents and big events like emergencies they will be fully utilized.
6.14 Occupational Health and Safety Program- mitigating measures.

Health hazards associated with the occupation are called occupational hazards. In chemical industry due to
handling of toxic and hazardous chemicals there are possibilities of developing occupational diseases. The
manufacturing process does not involve hazardous chemicals of high health effects.
These diseases are caused due to
1. Acute exposure of chemical vapors
2. Chronic effects of exposure of chemical vapors
M/s. AM/NS, has planned for the following checks to curb the problem:
 Pre - employment medical checkup at the time of employment.
 Annual medical check must be done for all employees.
* <30 years - Once in five years
* 31-40 years - Once in four years

AM/NS India Limited
* 41-50 years - Once in two years

* >50 years once every year.
i. Occupational Health center for rendering immediate first aid prior to sending to nearby hospitals.
First aid training must be given to “a section” of employees.
ii. Monitoring of occupational hazards like noise, ventilation, chemical exposure shall be carried out at
frequent intervals, the records of which shall be documented.
iii. Suitable PPEs have to be provided and application enforced. All the PPEs procured are of BIS
approved products. Work place enforcement of wearing is done regularly. The same will be followed
in the extension unit also.
iv. All the hazardous chemicals are to be identified by the Hazchem visuals. All the workmen have to
be properly trained.
v. Evaluation of health of workers viz. chest x ray, Audiometry, Spirometry Vision testing (Far and
Near vision, color vision and any other ocular defect) ECG, during pre-employment and periodical
examinations must be carried out.
vi. The injuries record and the gas effect record shall be maintained for assessing the controls at the
workplace monitoring.
6.14.1 Occupational Health center. (OHC)

• The OHC shall be maintained and controlled by qualified medical team consisting of doctors, nurses
and other Para medical staff.
• Medical center at Nand Niketan is working as Medical Treatment Dispensary employing qualified
doctors & para–Medical Staff and beds with facilities. Further, a local medical Centre is also working,
which is called as medical Centre at plant or Occupational Health Centre.
• The Occupational Health Centre with adequate arrangement is maintained by the management.
M.S.D.S. of hazardous chemicals are available with safety department and user department.
• The OHC shall be maintained for 24x7 – 365 days operation.
• All the available antidotes as available, shall be maintained by the OHC personnel.
• A fully loaded ambulance shall be maintained for carrying persons to nearby Hospitals.
• The safety officer shall maintain the legal requirement records in the prescribed formats as called in
different laws.
• Symptomatic treatment is given to the persons affected by chemicals by the authorized Medical
Practitioner.
• HSE monthly reports have to be maintained.
OHC provides round the clock coverage at Plant Medical Centre and Nand Niketan. Details of officials
available at Medical Center (OHC) are as follows:
• Head Medical Services (M.D. Internal Medicine (AFIH))

• Sr. Medical Officer (MBBS.AFIH)
• Sr. Consultant (MD(Anae), AFIH)
• Medical Officer (MBBS.AFIH)
• Medical Officer (MBBS)
Equipment
Following equipment are available at OHC:
• Automatic external defibrillator – Useful for cardiac arrest pt.
• Artificial respiration set (Ambu Bag)
• X-Ray Machine
• Oxygen Cylinder
• Nebulizer
• Blood Glucose Monitor
• Suction Machine
• Stitching material
• Autoclave Machine

AM/NS India Limited
• Emergency beds– 4+ tables

• All emergency & routine medicine, I/V Fluids, Injections etc.
• Ambulance – Fully equipped ambulance available for
• Transportation of emergency patient.
• Well Equipped Laboratory.
6.14.2 HSE Organization.

The systems to be maintained by HSE department shall be taken from BIS 14489 1998. There shall be
appropriate staff qualified as per the requirement of law, has to be maintained in the HSE department.
Periodic reports shall be sent to director of industrial safety &health (dish) authorities as specified in the law
books.
The Inspection book remarks made by the Factory Inspector shall be fully complied and records maintained.
6.14.3 DOS &DON’TS to be Followed.

• All the machines are to undergo Preventive Maintenance latest by once in a year. Productive
maintenance rounds (Daily visual rounds) have to be undertaken periodically to assess the healthiness
of the machines. Records to be maintained.
• For critical machines: All fasteners, gaskets, oil rings, lubricating oils, plastic parts, hose pipes etc.,
have to be changed at the time of maintenance.
• All load bearing members of the machine parts have to be thoroughly cleaned and visually inspected
for any cracks and other defects.
• All the PPEs procured shall conform to BIS or other equivalent standards.
• Use of PPEs in the form of visuals has to be displayed at appropriate places.
• All Hygiene practices are to be followed, restrictions for entry to specified places have to be displayed.
• Emergency escape routes and exit points have to be vividly displayed.
• Near- miss inspections have to be carried out, discussed with area owners and hazards to be mitigated.
• Ammonia used in the chilling plants have to be suitably disposed, when there is leakage.
• REUSE, RECYCLE, RECOVERY of chemicals and liquids shall be devised and practiced.
• All hazardous wastes in the form of solids and liquids shall be disposed off as per the stipulated
regulations.
• EMERGENCY mitigation equipment locations and routing has to be displayed at prominent locations.
• Pressure and temperature parameters have to be monitored and records maintained wherever called
for.
• All cooling arrangements for controlling temperatures shall have standby arrangements.
• All continuous processing facilities shall have power backup facility.
• Emergency lighting system shall be available during emergencies.

Chapter – 7
Project Benefits
7.1 Introduction
This section covers the project benefits from the proposed activities with regard to the following sectors:
• Health
• Education
• Livelihood/Women Empowerment
• Portable Water/Infrastructure
7.2 Corporate Social Responsibility (CSR)

Corporate Social Responsibility (CSR) has been in practice in India by large corporates for a
considerable period of time. The goal of CSR is to be responsible for social activities and to encourage a
positive impact through these activities on the environment, consumers, employees, communities,
stakeholders and all other related spheres.
Corporate Social Responsibility (CSR) is an integral part of ArcelorMittal Nippon Steel India Limited
business operations aiming make a positive impact on communities where it operates. ArcelorMittal Nippon
Steel CSR team is actively engaged with the local community in implementing the CSR activities in the
nearby villages of Hazira facility and the society at large. CSR policy of the company drives the social efforts.
A dedicated CSR team is in place to plan and implement the projects.
7.3 Existing CSR Activity

Arcelor Mittal Nippon Steel India recognizes the social impacts that the proposed expansion unit will bring
about and has accordingly planned, need based CSR activities in systematic manner. The Company under
CSR, has already undertaken for their existing plant a wide range of initiatives in the sphere of (i) education
(ii) community health (iii) livelihood (iv) sports and culture and (v) infrastructure and Environment. These
are as follows:
Health Initiatives:
• General Health Checkup services conducted in neighboring village of Hazira belt and reached out to
6500 patients especially for pregnant women, lactating mothers, children below five years and
adolescent girls
• More than 3 lakh lives touched through COVID- 19 response measures.
• Menstrual Hygiene Awareness camp was conducted benefitting 4250 women.
• 3000 patients benefited from Hemophilia Care Center at New Civil Hospital Surat.
• Supported Taluka Panchayat Education Officer (TPO) for organizing medical Checkup for the
students.
Education Initiatives:
• Computer, spoken English and science subject teachers have been appointed in Nav Jagruti Vidhya
Vihar School in Hazira.
• Summer vacation activities such as dance and drawing classes were conducted engaging about 220
children.
• 30- students were imparted basic computer classes at Lok Vikas Kendra, Hazira.
• An exposure visit was organized at Apparel Park, Surat for school children.
• Local festivals are celebrated with school children and also that of the surrounding villages.
Livelihood Promotion & Women Empowerment:

• Empowering 1500 Women of Hazira, Junagam, Mora and Damka village by imparting tailoring
training through Lok Vikas Kendra.

• Partnered with the Gujarat Rural Industries Making Corporation (GRIMCO), Gandhinagar to conduct
a one-month training Program from 1st October to 30th October 2019 at Lok Vikas Kendra, Junagam
to train rural women in Natural Fiber Articles making.
• Celebration of International women’s Day by bringing women from 8 villages on a common platform
and felicitating women for inspiring changes in their respective villages.
Youth Development & Sports:

• Freedom Cup 2018, cricket tournament was organized with the Viklang Kalyan Society Trust Surat
on 3rd and 4th December 2018 for differently abled person. Four teams participated in this
tournament.
Infrastructure Development:
• Strengthening community infrastructure and ensuring 24/7 drinking water supply to Hazira village
to cater population of 16750 persons daily.
• Land filling to address water logging and road connectivity
Other Initiatives:
• Cleanliness drive conducted under “Swatch Bharat Abhiyan” in Hazira Village.
• Tree Plantation drive on World Environment Day at NJVV School, Hazira.
COVID Response Measures:

• To ensure protection against Covid-19, awareness was raised through posters and announcements.
Sanitization drive was organized in the surrounding villages namely Hazira, Junagam, Rajgari,
Suwali, Mora, Bhatlai, Damka and Vansva.
• Supply of food grains and ration (350 quintals Rice, 80 quintals Dal, 3500 liters’ edible oil) for
migrant labor through Surat Municipal Cooperation.
• A total of 500 food packets were distributed on a day-to-day basis to daily wage labourers.
• 1200 Hygiene kits were given to daily wage workers.
• 3000 packed energy drink was provided to police personnel for 3 days.
• Distribution of 500 ration kits in Hazira village for migrant labors.
Glimpses of Initiatives:
Digital classroom in School Dental Health Check-up camp Eye Check-up camp
Menstrual hygiene camp Tailoring Center at Lok Vikas Kendra

CSR activities done by AMNS in the period

Activity Description Photographs
Health • An Eye Checkup Camp at Nav Jagruti Vidhya Vihar Secondary
School, Hazira with the team of Prizma Eye Hospital Surat (Dr,
Tejal Paneria, Opthmologist, Dr. Ronak Bhatt and Hari Pal,
Technician) on the 12th March’-2021.Total 75 Students
participated in the camp.
• We at AM/NS India, look forward to increase awareness about

health of females in and around the villages. To strengthen the
health awareness, this time, on 29th January and 5th February
2021 a female health checkup was organized by Orkid
Magukiya Hospital, Surat in the esteemed presence of Dr. Kajal
Magukiya (MD DGO Mumbai),primarily focussing on
gynecological health issues, consulting was offered free of cost
at their hospital which also included sonography, around -300
females received the benefit through this awareness program, at
Hazira Village.
Education • Computer Literacy skill training at Lok Vikas Kendra, and Nav
Jagruti Vidhy Vihar School Hazira, attended by 20 and 54
students benefited every day. MS word, excel, and power point
is being taught to the students along with the training on how to
bring proficiency in typing.
• Working towards imparting quality education, we support Nav

Jagruti Vidhyavihar Hazira by providing two teachers, (Science
and Computer Subject) around 60 students benefited every day.
Livelihood/Wo International Women’s Day Celebration

men • AM/NS India, Celebrated Women’s Day in light with CSR
Empowerment activity to encourage the choice to challenge by inviting women
from nearby villages, this event was witnessed by more than 80
women including young girls from Hazira, Mora, Junagam,
Suwali, Rajgari, Bhatlai,and Damka villages. It was our pleasure
to honour 18- women from these surrounding villages.
• Awards were given in five categories namely.1. Commitment

and dedication to community health.2. Contribution as an
elected panchayat member i.e. lady Sarpanch, Taluka panchayat
members, District Panchayat Members,3. Successful case of
self-employment 4. Entrepreneurship 5. Individual achievement
that became an inspiration to other community Members. The
celebration was energized by Song, Drama, and Traditional
dance of their community, On the occasion the key Speaker,
Mrs. Hema Mishra (M.B.A) explained on the about the
differences between India and China, & how to save time.
• Dr. Ami Yagnik (M.S) a renowned gynecologist spoke on the

maternal and child health issues,
• Mrs. Falguni Desai (Taluka Livelihood Manager) Spoke on the
“Gruh Udhyog” & Scheme to promote entrepreneurship,
• HR Head Anil Matoo Sir, Bharatbhai Trivedi Sir, Hitesh Sheth
Sir and Baiju Marsrani sir motivated through their words for

Activity Description Photographs

women to move forward in their respective field,
• The women present is the function had troughed AM/NS & CSR
team by wonderful encouragement through this program.
• Skill training at Essar Lok Vikas Kendra
• Every day 130 village women taking tailoring training at our
four Essar Lok Vikas Kendra, Hazira, Mora, Junagam and
Damka village. Women had undergone 06 month tailoring
training, during the period, training on design making on paper,
cutting, sewing machine operation etc., was being imparted to
the trainees Salwar Suit, Frock, on paper cutting and sewing
machine.
• Making of cotton masks at Low Vikas Kendra

• The women of our Lok Vikas Kendra, Hazira village in received
an order from gam panchayat member to make a washable 350
masks.
• CSR provides support in skill development of tailoring in

various villages. In addition, to enhance morale, we have
organized competition of “Frock Making” at Damka Village on
21st January ‘-2021. The event was organized very well and
prizes were distributed to provide them inspiration to do more.
Total 35 Students are participated
Potable Water Supply

Drinking • A continuous, 365 days water supply of 9.5 lac liters to 18,500
Water and persons is ensured at Hazira village. Water received from the
Land Filling Gujarat water supply department is being treated in our facility
and then supplied to the village, water is being stored in an
underground sump located in the Gram panchayat premises
and lifted to overhead tank for supply in different parts of the
village, the operation and maintenance of the sump along with
its supply is being managed by Panchayat.
Provided Dozer Machine for Land Filling

• The Sarpanch of Hazira Village had approached us that they
are making a Recycling plant in Hazira village for solid waste
management as part of environment conservation measures,
Sarpanch Dharmendra Bhai Patel has required Dozer machine
for Levelling of land which will be engaged for one month
(18th feb'-2021 to 17th March'-2021).
7.4 Proposed CSR Activities and Estimated Cost:

CSR activities shall be undertaken in and around the nearby villages of proposed expansion project. A total
amount of Rs. 16 crores would be utilized for CSR activities for five years and the company will identify
stakeholders for the planning and implementation of CSR activities. Activities with its estimated cost is given
in table-7.1 for benefitting the society at large and the local rural community in particular for a period of 5
years.
The area has sound infrastructural resources with reference to housing facility, education, medical facility,
drinking water supply, Post and Telegraph, transportation, approach roads, and bank facilities to cater the
additional population. The company through its existing plant operation under CSR has developed
infrastructures like drinking water facility, upgradation of schools, roads, water storage tank etc. in
neighboring areas.

Keeping the current need in view it has been felt that the Company will be able to undertake wide range of
fresh initiatives including playground development, transformational project in high school, upgradation of
anganwadi center, vocational skill training to local unemployed youths, piped drinking water facility and a
range of other activities. With time it will progressively be able to find new ways to address social, economic,
and environmental effects of their business while balancing conflicting demands.
An annual plan or calendar will be prepared on the basis of the initial assessment. Indicators for assessing the
progress of initiatives and a systemic database on the CSR activities will; be developed. The Company shall
submit a report of its activities on completion half yearly of the year. A strategic review should follow in
order to streamline the CSR programs. Budget for each activity will be outlined in the annual calendar/plan.
7.4.1 CSR Budget

The total cost estimation has been split into different thematic area of work. However, this should be treated
as indicative and may be modified as per the contextual needs arising out of changing social and political
dimensions. The total costs of all proposed program implementation during 1- 5 years will be around Rs.
16,00,00,000 (Rupees Sixteen Crores only). The estimated budget for the planned CSR activities is given
below. In future the responsibilities for all these facilities will be handed over to the Government. A CSR
cost estimation for period of 5 years is given in the following table 8.1:
Table 7.1 Proposed CSR budgetary Plan

CSR Budget - Yearly (1-5 yrs.)
Sr. Major activities 1st 2nd 3rd 4th 5th Total Amount
No. Year Year Year Year Year in lacs
A Education
1 High School Transformational Project (smart class, 20 20 20 20 18 98
science lab, tinkering lab etc under digital education)
in partnership with Govt.
2 Improvement in basic amenities & teaching learning 15 15 15 15 15 75
materials in Anganwadi center
3 Improvement in basic amenities & teaching learning 20 20 20 20 20 100
materials in Primary and Middle School
Sub Total 55 55 55 55 53 273
B Health & Sanitation
1 Health Camps - Free Doctor consultation and 12 12 12 12 12 60
medicine
2 Health Awareness program on AIDS, Malaria, TB, 6 6 6 6 6 30
Anaemia etc.
3 Haemophilia Care Center at New Civil Hospital Surat 15 17 19 21 24 96
Sub Total 33 35 37 39 42 186
C Infrastructure Development
1 Drinking Water supply through pipe line 97 97 97 97 97 485
2 Construction of Community Centre in 4 villages 15 15 15 15 60
Sub Total 112 112 112 112 97 545
D Sustainable Livelihood
1 Vocational Skill Training for youths- Setting up 20 20 20 20 20 100
Digital/Computer skill centre in partnership with
NSDC.
2 Setting up Paper Recycling Unit 24 24 24 24 24 120
3 Promotion of Income Generation Activities- Poultry, 25 25 25 25 25 125
Dairy, Pickle, Tailoring & embroidery, vegetable
Cultivation etc.
Sub Total 69 69 69 69 69 345
E Sports and Youth Development

CSR Budget - Yearly (1-5 yrs.)

Sr. Major activities 1st 2nd 3rd 4th 5th Total Amount
No. Year Year Year Year Year in lacs
1 Supporting village youths for sports tournaments and 10 10 10 10 10 50
materials
2 Annual Freedom Cup Cricket Tournament for 6 5 5 5 5 26
differently abled person
Sub Total 16 15 15 15 15 76
F Environment
1 Plantation and Greening Drive in villages and School 15 15 15 15 15 75
premise
Sub Total 15 15 15 15 15 75
Contingency (government requests and relief 20 20 20 20 20 100
measures etc.)
Grand Total 320 321 323 325 311 1600
7.5 Employment Potential

The project will positively deliver socio-economic benefits as follows:
• The positives impacts include enhanced direct employment for technical/administrative works and
indirect employment opportunities for transporters of raw materials and finished goods.
• Due to the proposed modification project indirect employments will be generated. The project will
generate indirect employment in service sector like transport, housekeeping, security, construction
labour, daily wage labour, workshop and repair shops. These kinds of requirements will increase the
prevailing scenario, which will generate the indirect employment.
• Local villagers of the area will be able reap larger benefits if preference is given to them in relation
to direct employment associated with the various project activities. Construction and operation phase
of the proposed modification project will involve a certain number of laborers, contractors and
construction workers. For this purpose, local people shall be given higher preference. The operation
phase will involve a number of skilled and unskilled workers. Total employment generation for the
proposed modification project is evaluated to be 1770 personnel.
7.6 Benefits of the Industry

There shall be a maximum utilization of skilled and unskilled workers from the local area. The increasing
industrial activity will boost up the commercial and economical status of the locality, to some extent.
Summarily, the proposed activities will not cause any adverse impact on sanitation, communication and
community health, as sufficient measures have been proposed to be taken under the Environmental
Management Plan. Due to proposed modification project, the surrounding environment will not face any
problems relating to the pollution because all kind of wastes will be handled properly and no alteration in
transport routes will be required.
7.7 Direct Earning Benefits to the Nation and State

Excise duty, State sales tax or VAT, Income by way of registration of trucks, Payment of road tax and
payment of tax for interstate movements, Income tax from individuals as well as corporate taxes from
company and ancillary units. Indirectly, the proposed modification project will help the Government by
paying different taxes (sales tax, excise duty, etc.) from time to time, which is a part of revenue and thus, will
help in developing the local area.
7.8 Other Tangible Benefits

Villages in the study area lie in the notified areas also. This has impacted the lifestyle of the villagers to some
extent. Local villagers giving houses on rents have added on to their incomes. There can be seen blending of
certain common attributes like food, common practices, lifestyle patterns, educational preferences etc. of the
rural community by coming in contact with in-migrated population in their area. Due to the coming of
industries now there can be seen hotel/restaurant facilities available in the study area.

Chapter 8
Impact Assessment and Environmental Management Plan
8.1 Introduction
With the aim to reduce the potential environmental impacts to the acceptable levels, institutional measures
like mitigation, monitoring, management, have to be considered under the Environmental Management
Plan. the present environmental management plan addresses the components of the environment affected
during to the proposed modification of the plant and the different activities forming a part of the
manufacturing processes. Industrial development is associated with both positive and negative impacts on
the environment. The negative impacts should not hinder the industrial development but they should be
properly mitigated.
Environmental Management Plan (EMP) facilitates monitoring of environmental parameters and

preparation of the proposed modification project to minimize the negative impacts.
EMP is constituted on the basis of the prevailing environmental conditions and potential impacts of
proposed modification on various environmental parameters.
Environmental Management Plan includes the scheme for proper and scientific treatment and disposal
mechanism for air, liquid and solid hazardous pollutants. EMP is required for the formulation,
implementation and monitoring of environmental protection measures and it is encompasses green belt
development, safety aspect of the workers, noise control, fire protection etc. The various components of the
EMP are outlined in subsequent sections.
8.2 Purpose of Environmental Management Plan

Various purposes for the preparation of environmental management plan are as follows:
➢ Identification of key points of environmental value and any relevant matters of national
environmental significance
➢ Ensure that O&M activities include measures to effectively manage potential and actual impacts to
the environment and community
➢ Provide certainty of delivery of the prescribed environmental outcomes for relevant O&M activities
➢ To treat and dispose of all the pollutants viz. air, liquid, gaseous and solid waste so as to meet
statutory requirements (Relevant Pollution Control Acts) with appropriate technology.
➢ To obtain environmental standards and to improve the methods of environmental management.
➢ Implementation of proper management plan will maintain good health of the employees and
surrounding environment and promotes green-belt development
➢ To ensure good working conditions of employees and it may results increase in the working
potential of employee
➢ To minimize the risk associated and reduce fire and accident hazards
➢ Budgeting and allocation of funds for environment management system and to adopt cleaner
production technology and waste minimization program
8.3 Corporate Environmental Policy

➢ Overall conservation of environment.
➢ Reducing incidents that result in liability
➢ Conserving raw materials and energy
➢ Improving the monitoring of environmental impacts
➢ Improving the efficiency of your processes
➢ Judicious use of natural resources and water.
➢ Safety, welfare and good health of the work force and populace.
➢ Vigilance against probable disasters and accidents.
➢ Monitoring of cumulative and longtime impacts.
➢ Ensure effective operation of all control measures.
➢ Helping you to stay within the law

➢ Improving information for employees about their environmental roles and responsibilities
➢ Improving cost control
➢ Minimization of waste generation and pollution.
➢ Ensure effective operation of all control measures
For the proposed modification project, Annual review of the entire system and various environment
management as well as process control and monitoring systems shall be done. Environmental monitoring
shall be done to collect the data on air, water, soil, noise etc. and duly recorded. The Environmental
Management Plan to eb implemented shall be divided under the following heads.
➢ Pollution Control Systems
➢ Waste Minimization and Resource Conservation
➢ Occupational Health and Safety
➢ Socio-Economic Development
➢ Greenbelt Development Plan
8.4 Details of Environment Management Plan

8.4.1 During Construction Phase
Detailed study of the project covering an area of 10 km of the surrounding environment and also the likely
(and predicted) implications after the plant commissioning, suggests that the following preventive/control
measures are considered necessary to reduce the adverse impacts to the utmost practical limit. Construction
phase will be for a short period and hence the impacts are also anticipated to be temporary.
8.4.1.1 Air Environment

During construction activities, mainly emission of dust and gases from modification activities along with its
supported facilities and movement of vehicles.
As construction activities are found to be the greatest contributors of pollution. Within the project site
AMNS shall take the responsibility to limit the pollution by taking the following steps.
➢ Adopting well developed hybrid technology and internal roads in the existing unit area for easy
movements of vehicles.
➢ Site will be covered to confine the emissions and employees shall wear appropriate PPE for the
protection.
➢ Use renewable or sustainable materials in the sites for construction and ensuring proper provisions
of necessary infrastructure/services.
➢ Use of water sprays or sprinklers to lose top soil to prevent re-suspension of dust into ambient air
due to the movement of vehicles etc.
➢ A separate civil construction material storage yard will be constructed within the site and it will be
covered.
➢ The possibility of raising green belt along with construction activity will also be explored.
➢ Covering of all dusty vehicle loads transported to, from and between site locations.
➢ Vehicles and equipment will be periodically checked for pollutant emissions against stipulated
norms. Pollution Under Control (PUC) Certificate of all the vehicles shall be checked regularly and
the running of vehicles will be minimized during material loading / unloading operations.
➢ During the construction activity all construction workers will be provided appropriate PPE’s like
dust mask, ear plug, helmet, safety belt etc.
8.4.1.2 Water Environment

During the construction phase water will be sourced from the Tapi river. To maintain hygienic conditions at
the site, sufficient and good quality of sanitary facilities will be provided and existing sanitary facility will
be utilized. Proper care shall be taken during construction work and proper measures shall be ensured that is
does not create any obstruction / dips in the topography which can lead to accumulation of water within the
premises leading to undesirable consequences like health and hygiene problems etc.
8.4.1.3 Noise Environment

Following measures are proposed during construction period to mitigate adverse impacts:
• Construction equipment shall have noise control measures.
• Servicing of all construction vehicles and machinery shall be done regularly and during routine
servicing operations, the effectiveness of machineries and equipment will be checked and if found
defective it will be replaced
• Feasibility of putting up temporary barrier around areas with high noise levels shall also be
explored
• All the activities shall strictly conform to the noise standards specified in EP Act, 1986.
• Workers working near extreme noisy environment will be issued ear muffs/ear plugs and their
usage will be ensured.
• Noise monitoring shall be conducted at suitable locations at periodic intervals to check compliance
to the stipulated standards.
• The possibility of raising green belt along with construction activity will also be explored so as to
serve as a noise barrier.
8.4.1.4 Land Environment

Following steps have been proposed to take care of the impact of construction activity on project land area:
• After completion of civil works, contractor will be held responsible to clean all debris before
leaving the construction site and also to make necessary arrangements with scrap dealers to sell off
the waste scraps
• The waste from labor camps and administrative activities during construction will be disposed of
through municipal facility
• Other materials like paint, diesel, oil etc. will be properly stored and handled to prevent any spillage
on land.
• All the waste has to be collected and nothing to be dumped on land or water.
8.4.1.5 Solid Waste

During construction phase, construction debris like rubble, brick bats, debris, steel scrap, iron scrap,
wooden scrap, sand, gravel etc. will be generated as solid waste. Even though, these materials are inert in
nature, sustainable solid management approach will be required to manage these solid wastes.
These materials will be properly sorted and will be used within the premises for filling up the of low-lying
areas. Wooden scrap, steel scrap will be given to scrap dealers.
On completion of civil work, all debris and scraps etc. will be completely removed from site in order to
avoid any incompatibility with future use.
8.4.1.6 Ecology
The proposed modification will be done in the existing premises. During construction phase site clearance
is required. The company hosts a well-developed green belt in the periphery to arrest the pollutants during
construction phase.
8.4.1.7 Socio-Economic
During the construction phase, the major positive socio-economic impact is anticipated to occur in the
sphere of generation of permanent and temporary employment of very substantial numbers. Local people
from nearby villages of the site surroundings shall be employed for construction work to the maximum
extent possible and it will result in a positive socio-economic impact on the people
8.4.2 During Operation Phase

Considering the longer duration of the operation phase of any industry and its potential to create continuous
impact is quite important. The plant operating life will be primarily driven by the availability of raw
material in the longer term. Comprehensive and effective EMP has to be prepared and implemented to safe-
guard environmental concerns during operation phase of any unit.
8.4.2.1 Air Environment

Gaseous emission from the plant during the operation may lead to a reduction in air quality potential,
gaseous emission is of concern as it may cause general disturbance in the area and also have a potential
human health impact.
The air pollutants in the plant may be classified broadly into particulate matter and gases like Sulphur
dioxide, Oxides of nitrogen, BF gases, etc. from both utility and process emissions. The measures to control
the air pollution will ensure that the ambient air quality is as per the standards laid down for industrial areas
by Central Pollution Control Board.
The system proposed for air pollution control will positively provide an acceptable environment condition
in the working areas and abate air pollution in the surrounding area of the plant. The technological
equipment and processes have been selected with the above objectives. Depending on the quality of
emissions from different sources, suitable air pollution control system shall be provided.
Following measures are proposed to mitigate negative impact of operation phase of the project on the
surrounding air environment:
• Height of all the stacks shall be as per statutory requirement. All the stacks will have stack
monitoring facility (SMF) consisting of sampling port-hole, platform and access ladder.
• For the control measures of the air pollutants during operation phase, adequate stack height with
proper pollution control equipment will be provided to respective stacks.
• Idle running of vehicles will be minimized during material loading / unloading operations.
• Transport vehicles will be properly maintained to reduce air emissions.
• Vehicles will be periodically checked for pollutant emissions against stipulated norms.
• Proper maintenance of air pollution control equipment.
• A good housekeeping and proper maintenance will be practiced in the industry
• Regular maintenance of machinery’s in order to control emissions.
• Continuous Emission Monitoring Systems is provided to the existing stacks and in proposed stacks
it will be provided
ESP Photograph (Sinter Plant)
Bag House Photograph: (Bag Filters installed at SMP1, SMP2, Lime Plant 1, Lime Plant 2, Corex, Blast
Furnace, HBI, Plate Mill, Pipe Mill)
Also, monthly manual monitoring is being done for all Stacks by Third Party approved by NABL &
Recognized by MoEF&CC, New Delhi under Sec. 12 of Environmental Protection Act-1986 and reports
are being sent to GPCB & MoEF&CC regularly.
8.4.2.1.1 Control and Monitoring of Secondary Fugitive Emissions

Fugitive emissions from the proposed modification would be significant as there will be air pollution due to
activities like material handling, transfer points of materials and movement of vehicles, crushing of coal etc.
These operations generate large quantity of dust. Specific instances of fugitive dust generation include dust
blown by wind from the stockpile of raw-materials, the dust caused by vehicular traffic etc. good
housekeeping, proper maintenance, wetting of dusty areas, use of enclosed storage wherever feasible etc.,
would considerably reduce fugitive dust emissions.
For effective prevention and control of fugitive emissions, the M/s. AMNS India Limited has implemented
the following activities:
• Fume Extraction system has been modified and revived for efficient suction.
• Dust collection and extraction system has been strengthened.
• Bag house capacity is increased & filter bags have been replaced.
• Manual water sprinkling is going on, in & around plant as well as on roads.
• 7 Nos. of Road sweeping machines for effective road cleaning.
• Manual cleaning of the roads and the surrounding areas is enhanced by increasing additional
manpower to 270 nos. per day.
• Regular cleaning of the factory shed is being done to remove dust deposition.
• Enclosures are provided to all the loading and unloading operations, if possible.
• All transfer points are fully enclosed.
• Sprinkling of water to control airborne dust.
• Internal roads shall be paved on which the movement of raw materials or products will take place.
• Conveyor belt shall be covered.
• Regular maintenance of air pollution control equipment is done.
• Dust mask will be provided to the employee.
• Green belt will be developed around the plant to arrest the fugitive emissions.
• Regular training is given to the operating personnel and effectively maintaining the fugitive
emissions control systems.
• The fugitive emission will be monitored within plant area as per GPCB/CPCB guidelines,
8.4.2.2 Water Environment

The water is sourced from the Tapi river (Surface water source) and ground water will not be used, hence,
there shall be no impact on ground water due to plant operations. Further, a comprehensive rain water
recharge scheme has been adopted, this will improve the water table of the area.
To maintain hygienic conditions at site, proper and sufficient sanitary facility will be provided to the
construction workers. The generated sewage is treated in a sewage treatment plant and the treated water
shall be reused for greenbelt development, the sewage sludge, which is an excellent fertilizer, shall be used
as manure within the plant premises.
Water meter will be provided to ensure that, water consumption should not exceed than the committed
requirement. Further,
• 100 % reuse and recycling of water shall be carried out to reduce fresh water consumption.
• Raw materials shall be stored properly and all stockpiles will have concrete base or impervious
stable liner so that, leachate generation is negligible and hence no ground water contamination
• Rainwater harvesting will be carried out to recharge the ground water and shall be stored for future
use.
• Regular operation and maintenance of ETP will be done to achieve the GPCB norms.
• GPCB norms will be strictly followed for on-land irrigation.
8.4.2.2.1 Rain Water Harvesting Scheme

Rainwater harvesting is one of the most efficient and cost-effective ways of conserving and storing water
for later use. It is a simple process that primarily involves three steps: collecting accumulated rainwater
from roofs, ground and roads; storing it safely to avoid any contamination; and, finally, pumping it for
usage.

To revive this practice of water management at the Hazira plant, the Utilities team at Hazira devised an
effective strategy to revamp the existing rainwater harvesting systems at the plant. For CY19, a CAPEX
was cleared to harvest at least 60% of the targeted water on a sustainable basis.
Design Data:
Average rain fall (of 100 years) at Hazira site = 1117 mm/annum [Data taken from
https://www.suratmunicipal.gov.in/TheCity/Weather]. Generally speaking, the rainfall in Hazira is 25-
30mm less than the city. Runoff coefficient for plant and AMNS Township considered is 0.5
Note:
• We have considered 100% plant area under the control of AMNS India, including plant sheds, all
sheds rundown and 100% township area with a belief that rain water can always be harvested from
every shed, every house and every road.
• It is also to be noted that AMNS India is perhaps one of the most compact plant vis-àvis the land
and its production capacity.
• The following catchment areas had been created for harvesting:
LOCATION AREA [M2]

AMNS TOWNSHIP ENTRANCE POND 1 8753
NAND VIHAR 9166
NEAR PLATE MILL POND 1 1838
NEAR PLATE MILL POND 2 [HED] 1680
NEAR NURSING HOME 1942
COFFEE SHOP 13880
POND 1 IN FRONT OF R & D BUILDING 603
POND 2 IN FRONT OF R & D BUILDING 707
POND BEFORE HSE OFFICE 2103
Thus, approximately 42281 m2 of area is used for harvesting. Each pond has a depth of at least 2m.
The table above shows all the rain water harvesting jobs that were completed [CY19 and CY20]. The ones
show in red font are proposed for completion in CY22-23. The first 4 harvesting projects were taken up in
CY2020 Fund of ₹1.39 Crores was allotted for procurement of pumps and pipes, digging of dredging of
small ponds and hot tapping on the running main water supply line. Shown below is the plan for additional
rain water harvesting

From strategy to execution

A detailed roadmap was prepared to harvest a million cubic meters of water over a period of two years. This
includes drafting of comprehensive guidelines for the design, installation, commissioning and operations of
the harvesting system. A substantial part of the implementation process was carried out during the
lockdown period, between March to June 2020, with an appreciable help from the Hazira township
administration making it a collaborative effort.
To achieve optimal efficiency in rainwater harvesting, more than two kilo meter of pipes were laid with 12
pumps, being installed at various places. Electrical and instrumentation installations are provided at places
where access is difficult.
An enduring commitment to sustainability

The utilities team has been managing the operations and maintenance of the entire rainwater harvesting
system and it has been ensured that not a single drop of water is wasted.
As a result, during the monsoon episode in Hazira in CY20, the team was able to harvest a record 81 crore
litres (or 8, 10,081 cubic meters) of rainwater by the end of September 2020 marking a 20% jump due to
the improvements made in the operations. In fact, the Hazira plant runs on rainwater for a total of six days
as the river water pumping was temporarily suspended at Variav due to the massive influx of algae.
With a return on investment of seven months, the utilities team has successfully saved more than INR 2.8
crores in the first year of operation. Our team has indeed set a benchmark by harvesting more than 8,00,000
cubic meters of rainwater in just one calendar year
Y-O-Y Harvesting and Savings [₹ Cr]

1000000 2.89 4.00
800000 3.00
1.50
600000 2.00
400000 0.13 0.14 0.31 0.34 0.09 0.29 0.00 0.00 0.13 0.44 1.00
200000 0.00
0 -1.00
CY09 CY10 CY11 CY12 CY13 CY14 CY15 CY16 CY17 CY18 CY19 CY20
[M3] 112200109780218150219089 50852 151179 0 0 50000 150000 463,01 810,08
Savings [₹ Cr] 0.13 0.14 0.31 0.34 0.09 0.29 0.00 0.00 0.13 0.44 1.50 2.89
[M3] Savings [₹ Cr]

8.4.2.3 Land Environment

All the waste generation from the plant activity will be properly disposed as per Hazardous Wastes
(Management and Handling) Rules and guidelines. The company ensures that the contamination due to the
spillage and washing water will be minimum. Washing water will be collected through appropriate channels
and taken to ETP for treatment. To avoid leaching, entire washing area will be paved. There shall be no
disposal of industrial effluent on land.
8.4.2.4 Management of Solid/Hazardous Waste

Management of all the wastes generated from the unit will be disposed as per Hazardous Wastes
(Management and Handling) Rules. Domestic waste generated from canteen will be converted into manure
and used for green belt development as company is implementing the same management for the existing
plant. The solid and hazardous waste generation along with their management is given chapter-2.
8.4.2.5 Noise Environment

During the operational phase of the plant, noise generation is anticipated to occur from rotating equipment,
plant machineries etc. and mechanical operation, stamping operation, crusher, screener in coke oven and
other plant. All machinery, equipment, pumps, DG sets, motors, unloading of raw materials etc. are also
noise generating units. However, implementation of the EMP for noise helps to ensure that the noise level is
maintained within the GPCB/CPCB standards. Following precautionary measures will be adopted to control
the noise level:
• Sophisticated and low noise generating equipment will be selected.
• Regular oiling and servicing of machineries will always be done
• Personnel working near noisy machines in different plant locations, will be provided with well-
designed ear muffs /plugs.
• Noise generating sources and their platforms will be systematically maintained to minimize the
noise
vibrations generated by them.
• Green belt will be developed to act as a noise barrier.
• Noise barriers/shields in the form of walls, beams will be provided around the units wherever found
feasible.
• Training to personnel will be imparted to generate awareness about effects of noise and importance
of using PPEs.
• It would be ensured that there would not be any operator near the noise generating equipment on
continuous basis.
8.4.3 Green Belt Development

Greenbelts are an effective mode of control of air pollution, where green plants form a surface capable of
absorbing air pollutants and forming a sink of pollutants. Leaves with their vast area in a tree crown,
absorbs pollutants on their surface, thus effectively reduce the pollutant concentration in the ambient air.
Often the adsorbed pollutants are incorporated in the metabolic pathway and the air is purified. Plants
grown to function as pollution sinks are collectively referred as greenbelts.
An important aspect of a greenbelt is that, the plants are living organisms with varied tolerance limit
towards the air pollutants. A green belt proves to be effective as a pollution sink only within the tolerance
limit of the constituent plants. Planting few, known pollutant sensitive species along with the tolerant
species along the green belt could help carry out an important function of the indicator species
Apart from the function as a pollution sink, the greenbelt would also provide other benefits like aesthetic
improvement of the area and granting suitable habitats for birds and animals.
8.4.3.1 Selection of plants for Greenbelts:

The main limitation of plants to perform the function of pollution removal are, plant’s interaction to air
pollutants, sensitivity to pollutants, climatic conditions and soil characteristics. While making choice of
plants species for cultivation in green belts, due consideration has been given to the natural factor of bio-
climate. Xerophyte plants are not necessarily good for greenbelts; owing to their sunken stomata they are
capable to withstand pollution by avoidance but are poor absorbers of pollutants.

Character of plants mainly considered for affecting absorption of pollutant gases and removal of dust
particle are as follows.
• For absorption of Gases:
Tolerance towards pollutants are at a concentration, that are not too high to be instantaneously lethal.Longer
duration of foliage, Freely exposed foliage, Adequate height of crown, Openness of foliage in canopy Big
leaves (long and broad laminar surface), Large number of stomatal apertures
• For Removal of Suspended Particular matter
o Height and spread of crown.
o Leaves supported on firm petiole
o Abundance of surface on bark and foliage
o Roughness of bark
o Abundance of auxiliary hairs
o Hairs or scales on laminar surface
o Protected Stomata
Table 8.1 Recommended Plant Species for Green Belt Development along the Boundary of as a wind
barrier as well as to prevent dust pollution
Plant Species Habit Tolerance Limit Stomatal Index Mode of Regeneration

Acacia auriculiformis Tree Tolerant 10.9 Seeds
Acacia leucophloea Shrub T 12.01 Seeds
Ailanthus excelsa Tree T 13.01 Seeds, shoot, root cuttings
Alstona scholaris Tree T 15.23 seeds
Azadirachta indica Tree T 29.2 Seeds
Bauninia recemosa Tree T 25.68 Seeds
Bauhinia acuminata Tree T 22.31 Seeds
Bauhinia purpurea Tree T 23.58 Seeds
Bambusa vulgaris Tree/ Shrub T Cutting
Bougainvillea spectabilis Shrub T 32.53 Cutting
Caesalpinia pulcherrima Tree T 29.09 Seeds and Cuttings
Callistemon citrinus Small tree T 127.49 Seeds
Cassia javanica Tree T seeds
Cassia siamea Tree T 21.2 Seeds
Clerodendrum inerme Shrub T 18.02 Seeds/cuttings
Delonix regia (Gulmohur) Tree Sensitive 14.38 Seeds /stem cutting
Dendrocalamus strictus Shrub/ tall T - Seeds/stem cuttings
grass
Hibiscus rosa-sinensis Small tree T 23.32 stem cutting
Ixora arborea Small tree T 17.3 stem cutting
Ixora rosea Small tree T 20.30 Stem cutting
Kegelia Africana Small tree T 12.90 Seeds
Lantana camara shrub T 12.13 Seeds/cuttings
Lowsonia intermis Shrub T 17.0 Seeds/cuttings
Mangifera indica Tree S 30.77 Seeds/ budding/grafting
Melia azadirachta Tree T Seeds /stem cutting
Nerium indicum Shrub T 15.7 Cutting
Peltophorum pterocarpum Tree T 16.78 Seeds
Polyathia longifolia Tree Sensitive 22.27 seeds
Prosopis cineraria Tree T 18.1 Seeds/root suckers

Plant Species Habit Tolerance Limit Stomatal Index Mode of Regeneration

Syzygium cumini tree T 20.60 Seeds
Tecoma satans Shrub T 23.08 Seeds/ cuttings
Terminalia catapppa Tree T 20.9 seeds
Thespesia populneoides Tree T 29.81 Seeds/ cuttings
Thevetia peruviana Shrub T 27.8 Seeds
T: Tolerant S- sensitive, (--) =Not available Sources: CPCB (March, 2000) Guidelines for developing
green belts PROBES/75/1999-2000
8.4.3.2 Roadside Plantation

Roadside plantation plays a very important role in making the area greener, increasing the shady area,
increasing aesthetic value and for the eco-development of the area. The approach roads to project site,
colony, etc. can be planted with flowering trees. Trees are planted to increase the aesthetic value as well as
shady area along the roads. The list of the selected plant species provided for roadside plantation is
provided in the following table.
Table 8.2 Species for Plantation along the roadside

Sr. No. Based on Color Sr. No. Based on Color
Yellow Flowered Trees
1. Acacia auriculaeformis 10. Erythrina parcelli
2. Acacia baileyana 11. Laburnum anagyroides
3. Acacia dealbata 12. Michelia champaca
4. Acacia decurrens 13. Parkinsonia aculeata
5. Acacia implexa 14. Peltophorum pterocarpum
6. Anthocephalus chinensis 15. Pterocarpus dalbergioides
7. Bauhinia tomentosa 16. Schizolobium excelsum
8. Cassia calliantha 17. Tabebuia spectabillis
9. Cassia fistula 18. Thespesia populnea
Red Flowered Trees
1. Brownea grandiceps 5. Saraca asoca
2. Erythrina blakei 6. Spathodea campanulata
3. Erythrina laurifolia 7. Wrightia coccinea
4. Erythrina variegate 8.
Scarlet Flowered Trees
1. Barringtonia acutangula 5. Callistemon lanceolatus
2. Brassia actinophylla 6. Delonix regia
3. Brownea coccinea 7. Stenocarpus sinuatus
4. Butea monosperma
Pink Flowered Trees
1. Bauhinia purpurea 5. Hibiscus collinus
2. Cassia javanica 6. Kleinhovia hospital
3. Cassia nodosa (Red) 7. Lagerstroemia speciosa
4. Cassia renigera
Blue Flowered Trees
1. Bolusanthus speciosus 2. Jacaranda acutifolia
White Flowered Trees
1. Albizia lebbeck 6. Magnolia pterocarpa
2. Bauhinia acuminate 7. Mesua ferrea
3. Calophyllum inophyllum 8. Millingtonia hortensis
4. Kydia calycina 9. Mimusops elengi
5. Magnolia grandiflora 10. Plumeria alba

8.4.3.3 Guidelines for plantation

The plant species identified for greenbelt development shall be planted using pitting technique. Width of
the green belt in the available land area may prove to be difficult for many industries to attain for one or
more reasons. Hence, it shall be decided to have a green belt in places available around the industry
(source-oriented plantation) as well as around the nearby habitable area (receptors-oriented plantation).
The choice of plants for green belt should include, shrubs and trees. The intermixing of trees and shrubs
should be such that the vertical foliage area density is almost uniform.
The pit size has to be either 45 cm x 45 cm x 45 cm or 60 cm x 60 cm x 60 cm. Bigger pit size will be
considered at marginal and poor-quality soil. Soil used for filling the pit should be mixed with well
decomposed farm yard manure or sewage sludge at the rate of 2.5 kg (on dry weight basis) and 3.6 kg (on
dry weight basis) for 45cm x 45 cm x 45 cm and 60 cm x 60 cm x 60 cm sized pits respectively. The filling
of soil has to be completed by at least 5-10 days before actual plantation. Healthy saplings of identified
species should be planted in each pit with the commencement of monsoon. Provision for regular and liberal
watering of the plants during the summer period during the commissioning stage of the plant shall be
arranged from the local available resources. After the proposed plant becomes operational, the authorities
responsible for plantation will also make adequate measures for the protection of the saplings.
The trees and shrubs selected from the above-mentioned list shall be planted based on the availability,
plantation shall be done as a greenbelt of 10-20 m width around the plant boundary. The plantation will be
in the recommended pattern as below:
3rd Tire plantation management

Tire Habit Height in meter Rows
st
1 Tire (Towards boundary) Trees 10-20 3
2nd Tire (Middle layer) Small tress 5-10 meter 2
3rd Tire (Towards Plant) Shrubs 1-5 meter Thick pattern
8.4.3.4 Location wise total area under Greenery Development:

AM/NS. Hazira Campus is divided under two categories of greenery for maintenance i.e. 1. Prime
Locations and 2. Sub Prime Locations.
Highly intense landscape with continuous and direct interaction areas of people are termed as the prime
location like AM/NS House Surrounding, All main offices & houses of AM/NS Township etc.
The areas where minimum people interaction occurs and where less attention is required are termed as sub
prime locations like green belt areas and fellow areas require minimum attention.
Table 8.3 Existing Developed Green Belt Details at AMNS

Sr. No. Particulars Plant Township
1. Total Area (Hectare) 670 100
2. Trees Planted (Nos.) 226745 60684
3. Green Belt developed Area (Hectare) 136.047 72.82
4. % of Greenbelt (Green Belt Area to Total Area) 20.30% 72.82%
Table 8.4 Type of Tree & Coverage

Plant Township
Sr. Type of Tree Nos. % Land Area Sr. Type of Tree Nos. % Land Area
No. Cover No. Cover
1. Peltophorum sp. 67000 30% 1. Peltophorum sp. 19000 31%
2. Neem 3000 1.32% 2. Neem 700 1%
3. Kadamb 100 0.04% 3. Kadamb 200 0.30%
4. Siris 1500 0.66% 4. Siris 500 0.80%

5. Putranjiva 1700 0.74% 5. Putranjiva 450 0.70%

6 Paras Pipal 45800 20% 6 Paras Pipal 5500 9%
7 Ashoka trees 300 0.13% 7 Ashoka trees 500 0.80%
8 Pipal 200 0.08% 8 Pipal 300 0.40%
9 Indian banyan tree 100 0.04% 9 Indian banyan tree 50 0.08%
10 Mango 500 0.22% 10 Mango 7600 12.52%
11 Amaltas 500 0.22% 11 Amaltas 1500 2.47%
12 Jambul / Black plum 900 0.39% 12 Jambul / Black plum 1200 2%
13 Date Palm 100 0.04% 13 Date Palm 80 0.13%
14 Bottle Palm 150 0.06% 14 Bottle Palm 30 0.04%
15 Casurina -Saru 45000 19.84% 15 Casurina -Saru 16000 26.36%
16 Rain Tree 28000 12.34% 16 Rain Tree 750 1.23%
17 Spathodia 800 0.35% 17 Spathodia 500 0.80%
18 Tabubia 2000 0.88% 18 Tabubia 300 0.40%
19 Alastonia - 700 0.30% 19 Alastonia - 500 0.80%
Saptaparni Saptaparni
20 Coconut 50 0.02% 20 Coconut 80 0.13%
21 Guava 150 0.06% 21 Guava 450 0.74%
22 Chikoo 395 0.17% 22 Chikoo 750 1.23%
23 Eucalyptus 22000 9.70% 23 Eucalyptus 2043 5%
24 Foxtail Palm 500 0.22% 24 Foxtail Palm 700 1.15%
25 Adensonia 0 0% 25 Adensonia 1 0.00%
26 Badam 5000 2.20% 26 Badam 1000 1.64%
Total 226445 Total 60684
Table 8.5 Proposed Green Belt Area to be developed

Sr. No. Particulars Plant Township
1. Total Area (Hectare) 670 100
2. Trees to be Planted (Nos.) 145000 38566
3. Green Belt to be developed Area (Hectare) 66 18
4. % of Greenbelt (Green Belt Area to Total Area) 10% 18%
Table 8.6 Type of Tree with ht. & Age:

Plant Township
Sr. Type of Tree Ht. in Age of Sr. Type of Tree Ht. in Age of
No. ft. Tree No. ft. Tree
1. Peltophorum sp. 15 - 20 40 - 50 1. Peltophorum sp. 15 - 20 40 - 50
2. Neem 20 - 30 70 - 90 2. Neem 20 - 30 70 - 90
3. Kadamb 15 - 20 50 - 60 3. Kadamb 15 - 20 50 - 60
4. Siris 15 - 20 30 - 50 4. Siris 15 - 20 30 - 50
5. Putranjiva 15 - 20 30 - 50 5. Putranjiva 15 - 20 30 - 50
6 Paras Pipal 15 - 20 40 - 50 6 Paras Pipal 15 - 20 40 - 50
7 Ashoka trees 15 - 20 30 - 50 7 Ashoka trees 15 - 20 30 - 50
8 Pipal 25 - 30 100 Plus 8 Pipal 25 - 30 100 Plus
9 Indian banyan tree 25 - 30 30 - 50 9 Indian banyan tree 25 - 30 30 - 50
10 Mango 15 - 25 30 - 50 10 Mango 15 - 25 30 - 50
11 Amaltas 15 - 20 30 - 50 11 Amaltas 15 - 20 30 - 50
12 Jambul / Black plum 15 - 25 40 - 50 12 Jambul / Black plum 15 - 25 40 - 50
13 Date Palm 10 - 15 30 - 50 13 Date Palm 10 - 15 30 - 50
14 Bottle Palm 15 - 20 30 - 50 14 Bottle Palm 15 - 20 30 - 50

15 Casurina -Saru 25 - 35 30 - 50 15 Casurina -Saru 25 - 35 30 - 50

16 Rain Tree 25 - 30 30 - 50 16 Rain Tree 25 - 30 30 - 50
17 Spathodia 15 - 20 30 - 50 17 Spathodia 15 - 20 30 - 50
18 Tabubia 15 - 20 30 - 50 18 Tabubia 15 - 20 30 - 50
19 Alastonia - 15 - 20 30 - 50 19 Alastonia - 15 - 20 30 - 50
Saptaparni Saptaparni
20 Coconut 10 - 20 30 - 50 20 Coconut 10 - 20 30 - 50
21 Guava 10 - 20 30 - 50 21 Guava 10 - 20 30 - 50
22 Chikoo 10 - 20 30 - 50 22 Chikoo 10 - 20 30 - 50
23 Eucalyptus 25 - 35 30 - 50 23 Eucalyptus 25 - 35 30 - 50
24 Foxtail Palm 15 - 20 30 - 50 24 Foxtail Palm 15 - 20 30 - 50
25 Adensonia 15 - 20 100 Plus 25 Adensonia 15 - 20 100 Plus
26 Badam 15 - 20 30 - 50 26 Badam 15 - 20 30 - 50
Table 8.7 Greenbelt Details (Existing) & Proposed Greenbelt Plan

Location Total Area Existing Greenbelt area Proposed Greenbelt Total Greenbelt area
(Ha) area (Ha) (Ha)
Plant 670 117 17 % 66 10 % 183 27 %
Township 100 53 53 % 18 18 % 71 71 %
Total (Ha) 770 170 22% 84 11 % 254 33 %
8.4.3.5 Action Plan for Greenbelt Details

A Budgetary-outlets for the development of greenbelt is given in table-8.7.
Table 8.8 Greenbelt Details (Existing) & Proposed Greenbelt Plan

Particular Details
Greenbelt Area to be developed 734262 Sq. Mt
Greenbelt Area in Ha 73.426 Ha
No. of Trees to be planted 183566 Nos.
Cost for Greenbelt Development 6.22 Crores
Table 8.9 Service Cost and Maintenance Cost

SPR (Service Cost)
A Providing Manpower and Equipment
Sr. No. Description of work or Material Unit Qty Rate Amount
Cr
1 Cleaning of area by removing/cutting of unwanted Sq. Mt 734262 10 0.73
bushes, removal of slags and unwanted scrap
materials, and marking for tree plantation etc.
2 Excavator for Pit digging for tree plantation along Hours 2448 1200 0.29
boundary wall. 2'x2'x2':
3 Dumper for loading, unloading of excavated soils. Hours 2448 400 0.10
4 Filling pits with provided soil after mixing it with Nos 183566 10 0.18
manure and medicines
5 Planting provided sapling in the middle of filled Nos 183566 5 0.09
pits
6 Maintenance of greenbelt for 365 Days Nos 183566 20 0.37
7 Providing Water through Tankers for one year Trips 17622 470 0.83
Total A 2.60
PR (Material Cost)
B Providing Materials for Greenbelt
1 Yellow soils M3 39650 700 2.78

2 Tree saplings 3' height of required species Nos. 183566 25 0.46
3 Cell rich (Organic Fertilizers) Kg 367131 8 0.29
4 Bamboos for stacking the newly planted trees Nos. 183566 5 0.09
Total - B 3.6
Grand TOTAL 6.22
Figure 8.1 Layout for existing and proposed
8.4.4 Conservation Measures for Peacock /Indian Peafowl and White-rumped Vulture
8.4.4.1 Peacock /Indian Peafowl
Conservation through Habitat Improvement and Awareness.
• Habitat improvement program shall be undertaken through plantation of suitable tree species in the
surrounding villages. While selecting the tree/ shrub species care shall be taken for beery plants
which attract these birds.
• This tree will provide the shelter for these birds for escaping from the predators.
• During summer period, villagers are encouraged to use the old earthen pots which can be filled with
water for the birds to drink.
• Summer is the time when these birds are facing shortage of feeds, thereby supplying the feeds like
Bajri, Juwar, Maize to the identified surrounding villages with good population of Indian peafowls
will positively fix the problem of food shortage.
• The proponent can directly supply these feeds to the villages directly or by funding to the NGOs
active in this mission.
• Yearly Fund allocation towards Conservation through Habitat Improvement and Awareness
program.

Conservation measures Proposed Conservation measures Yearly allocation in

Indian Rupees
Conservation through Habitat Plantation of suitable tree species in the surrounding Part of Green belt fund
Improvement villages. allocation
Supplying the feed like Bajri, Juwar, Maize to the 50,000.00-
identified surrounding villages
Provision of Earthen pots for water during summer
months
8.4.4.2 White-rumped Vulture

Recommended Conservation Measures
• In-situ conservation:
• Establishing feeding centers in the nearby area by Procuring and providing uncontaminated
carcasses with Diclofenac at feeding centers.
• Nature Club, Surat, along with Forest department, has already started VULTURE FEEDING SITE
at Hazira region.
• Population of feral dogs, are major threat and competitors for vultures at this site. The fencing
around this feeding site may discourage these feral dogs entering the feeding site.
• The project proponent can contribute a portion of their CSR fund for this major course.
• Framers and people engaged in cattle farming should voluntarily stop Diclofenac treatment on
cattle. If treated they should be obliged for the safer disposal of Diclofenac contaminated carcasses.
Other measures:
• Conduct population surveys and review periodically till self-sustaining populations are established.
• Publicity campaigns in all relevant media, targeting users of veterinary formulations, school
students, and the general public, on ecological significance of vultures.
• White-rumped Vultures (Gyps bengalensis) build their nests on tall palms, Borassus flabellifer
(Tad). These palms grow in plenty in Hazira region. Due to the recent land use change of the area,
these palms were cut for the conversion of farmlands to Mango and Chikku orchards. This
phenomenon may create a situation of reduction in suitable nesting and brooding sites for Vultures.
This may force vultures to discard this habitat.
• Awareness program in the villages surrounding Hazira region is required to be conducted to
encourage farmers to retain some of these palms along the boundary of their fields for nesting and
brooding sites for Vultures.
Conservation measures Yearly allocation in

Indian Rupees
Contribution for Vulture 50,000.00/-
Feeding Site
8.4.5 Socio-Economic Aspects

Environment Management Plan is required for ensuring sustainable development. It should not affect the
surrounding environment adversely. The Environment Management Plan aims at controlling pollution at
source with the available and affordable technology followed by treatment measures. Waste minimization
and waste recycling measures are emphasized to maximize the positive impacts which includes, giving
more employment to local people, providing educational facilities, improving health facilities and
improving CSR activities through respective personnel.
8.4.6 Occupational Health and Safety

• All health and safety measures such as safety appliances, training, safety awards, posters, slogans
will be undertaken.
• Occupational health and safety standards/guideline will be followed and implemented.
• Personal Protective Equipment (PPE) like ear muff/plugs will be provided to the workers
• Facilities like drinking water and toilets will be provided to the employees.
• The fire and safety equipment will be properly utilized and maintained regularly.
• The health of the workers shall be checked regularly by a well-qualified doctor and proper records
will be kept for each worker.
• Details of exposure specific health status evaluation of worker along with annual report of existing
project is enclosed as annexure-19 and annexure 20.
• Infrastructure facilities such as rest room, sanitation facility etc. will be provided in all the plants
for the casual workers.
• Annual report of health status of workers is/shall be carried out.
• A separate area having facilities like truck parking, canteen/dining, rest room, wash room, first aid,
communication facility, ATM, safety training centre, studio etc. is allocated for truck drivers.
• A layout map showing infrastructure facilities for truck driver is shown in following figure-8.2.
• Plan and fund allocation to ensure the occupational health & safety of all contract and casual
workers is given in table 8.10.
Figure 8.2 Layout for Infrastructure Facilities for Truck Drivers
8.4.7 Concept of Waste-Minimization, Recycle/Reuse/Recover Techniques, Energy Conservation,

And Natural Resource Conservation
The possibility of reuse/ recycle and other cleaner production options for reduction of wastes is given
below.
Waste-minimization:
• Process optimization by using latest technology equipment.
• Proper control over the materials used in the manufacturing process
• Improved operating and maintenance procedures and process equipment modification
Recycle/reuse/recover:
Solid Waste:
• Dust collected from air pollution control equipments like bag filters, ESPs and dust from gas
cleaning plant of BF plant will be reused as input material in sinter plant.

• Tar sludge from effluent treatment plant will be mixed with coal blend and will be charged in the
coke oven batteries.
• Granulated slag are being sold to authorized vendor for reuse.
Liquid waste:
• Washing water from shop floor, chemical dosing system, main pump house will be reused in pump
house of slag granulation.
• Floor washing from Complex will be used as makeup water for coke quenching after treatment.
• Cooling tower blow down shall be reused for slag quenching/ cooling of Slag.
• Wastewater, ascension pipe water sealing drainage, centrifugal cooling & floor washing water from
coke oven complex will be used as make up water for coke quenching after removal of pollutants in
ETP (BOD Plant) plant.
Energy Conservation:
• Reduction in usage of traditional light bulbs with LED bulb means reduction in usage of 1/4th of
the total energy consumption.
• Use of solar street lights in entire complex
Natural Resource Conservation:

• To conserve ground water, rain water harvesting will be carried out to store rain water for future
use and also to recharge the ground water before it gets evaporated.
8.5 Environmental Management Department

It is necessary to have a permanent organizational set up to ensure its effective implementation. Hence,
company has a well experienced team consisting of officers from various departments to co-ordinate the
activities concerned with management and implementation of the environmental control measures. This
team undertakes the activities of monitoring the stack emissions, ambient air quality, noise level etc. either
departmentally or by appointing external agencies wherever necessary.
Regular monitoring of environmental parameters is being carried out to find any deterioration in
environmental quality and also to take corrective steps, if required, through the involvement of the
respective internal departments.
The existing Environmental Management Department also collects data about health of workers, green belt
development etc. An organogram of the Environmental Management Department (EMD) is presented in
following figure 8.3
Figure 8.3 Hierarchy in EHS

8.6 Environmental Policy

M/s. AMNS has a combined health, Safety and environment policy which is given as figure-8.3.
Figure 8.4 Health, Safety and Environment (HSE) Policy
8.7 Reporting System to The Directors

Details for reporting non-compliances / violations of environmental norms to the Board of Directors of the
company is given in the figure-8.5
Figure 8.5 Reporting System

Compliance status of the existing unit of the company, with respect to various conditions given in the
Consolidated Consent & Authorization (CC&A) order of the Gujarat Pollution Control Board (GPCB) is
given in annexure 21. A note on compliance to the recommendations mentioned in CREP guidelines is
enclosed as annexure-22.
8.8 Budgetary provision for EMP

A budget has been allocated by the management for environmental management plans for proposed
modification. The details of capital and recurring cost per annum earmarked for pollution control /
monitoring like operation and maintenance of pollution control equipment, greenbelt development and its
maintenance etc. is given as table 8.9 below.
Table 8.10 Break up cost for Environment Pollution Control Measures

Total 1682.26 377.95

Chapter – 9
Analysis of Alternatives (Technology & Site)
This project is a modification of existing plant by installing Auxiliary Facilities without increasing Plant
Capacity. Hence evaluation of alternate site is having no significance
Further, it is ensured that the technology adopted are all the latest available in this field to ensure
compliance of all environmental rules and regulations.
M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat 9-1

Chapter – 10
Environmental Cost Benefit Analysis
It is Modification in Existing Plant by installing Auxiliary Facilities without increasing Plant Capacity and
hence, Environmental Cost Benefit Analysis not recommended.
.

Chapter – 11
Summary and Conclusion
11.1 Name of the Project
Modification in existing plant by installing auxiliary facilities without increasing plant capacity by M/s.
ArcelorMittal Nippon Steel India Limited.
11.2 Location of the Project


b) Village : Hazira
d) District : Surat
e) State : Gujarat
Table 11.1 Surrounding Salient Features and Environmental Setting

Headquarter
11.3 Details of earlier ECs

Table 11.2 List of EC Year wise
Year of EC
Granted
capacity 1190 meter
2008

Year of EC
Granted
J-11011/714-A/2008-IAII(I)
Pellets Plant (4 MMTPA), HBI/DRI (1.85 MMTPA), COREX
2025)
11.4 Products and Capacities

Table 11.3 List of Product
No. 2016
in 2016 in 2020
Crude Tar (By – TPA 52,200 63,000 1,15,200
Product)
Sulphur (By – TPA 1,700 1,980 3,680
Product)
Product)
5 Air Separation
Oxygen Liquid Nm3/hr 2,950 500 3,450 2950 in operations
1(EAF) (4Nos.)
Furnace (BoF) (3
Nos.)
(4 EAF& 4LF)

No. 2016
in 2016 in 2020
(Lime / Dolime)
& Long Product -
HRC
Wire Rod 0.7 0 0.7
15 Caster Shop
Caster
16 CRM
Coils/Sheets
Jetty
Based Power Plant
19 Pipe Mill
received from SPCB)
increase in the steelmaking capacity


15 CRM-2
CR Coils/Sheet 2.2
for Special grades)
Coke oven gas
11.5 Project Requirement

11.5.1 Land Requirement
Existing land 770 ha will be utilized for the proposed modification project i.e. no additional land is required
for proposed modification.
Table 11.4 Details of Land Breakup

4 Admin area 15.00
7 Open Area 25.00
12 OHC area 4.00
Total 770.00

11.5.2 Major Raw Material Requirement:

Details of major raw material requirement, its source and transportation details is presented in following
table.
Table 11.5 List of Raw Materials

Existing Units
Mod. I to VI)
Flux 140 KT 140 KT
1480 KT
External fines
as per
requirement
Flux
external)
(Recovery Type)
Lime 271 KT 271 KT
(Note: Scrap
can be replaced
by HBI/DRI)
Lime 300 KT 300 KT
(Note: Ideal
mix.,In case of
lower hot metal,
additional HBI,
CDRI required
Coke: 355 KT, 355 KT,
Coal: 2900 KT 2900 KT
(Lime/ Dolime)
(Lime/ Dolime)
11 CPP - - -
Product -HRC


(CSP Casters INI)
16 CRM-1 HRC 1500 KT 0.0 2000 KT
Existing Jetty
Recovery Based
Power Plant
HRC 300 KT 300 KT
Plant - (1000 TPD)
Pulverized coal
TPD) - Lime and
Dolime
TPD) - Calcined
Lime
Catcher /Dust
separation unit-150
TPD
Plant - 100 KL &
Pickling Line-3
TPD
towers (Mod 1 to
Mod 6)
plant
Normalizing KTPH
Furnace
machine plates:
Tower
Plant for 500 MW
CCPP
Special grades)
CPC 850 TPA 850 TPA
17 SMP-1 fume - -

Extraction System
upgradation
VPSA to utilize
Corex gas and
going forward Coke
oven gas
Pretreatment
Station Outside
Shop (KR
Technology)
interconnection
between PKL-3 &
ARP-2
grades Aluminium
CPC 850 TPA 850 TPA
11.5.3 Water Requirement

Existing:
used for the industrial purposes.
Proposed:
river.
reject water would be generated. RO reject will be disposed to TSDF. There are three STPs dedicated to
treat the domestic effluent generated. Treated water will be used for plantation inside the premises.
11.5.4 Power Requirement

additional (337 MW) will be availed from 400 KV- PSOCL (National Grid).
11.5.5 Fuel Requirement

Coal, Coke & NG will be used as a fuel.

11.5.6 Manpower Requirement

The manpower requirement after proposed modification will be 15270 nos.
11.6 Process Description

The integrated steel plant consists of a number of unit processes.

EAF/CONARC
temperatures

temperature
temperatures.
irrigation use.
three Phases
Phase 1:
Mill (CTCM)
Phase 2:
mill (PLTCM)


(CGL-3)
Phase 3:
11.7 Project Cost

Total capital cost of the proposed modification project would be approx. Rs. 6413.13 crores. Capital and
recurring cost of the environmental control measures would be 1682.26 and 377.95 crores respectively.
11.8 Estimated time of Completion

Estimated time of completion of the project is 34 months.
11.9 Site Selected for the project

Our existing project site is located in Hazira, which is inside the notified Hazira industrial area of Gujarat.
11.10 Baseline Environment

Primary baseline environmental monitoring studies were conducted during post-monsoon season of Oct
2020 to Dec 2020 in a study area of 10 km radial distance from the project site.
11.10.1 Ambient Air Quality

11.10.2 Ground Water Quality Monitoring

11.10.3 Surface Water Quality Monitoring

samples.

11.10.4 Background Noise Level

Ambient noise levels monitoring was done at day as well as night time. At Industrial area maximum noise
levels recorded during the day time 65.0 Leq dB(A) and during night time 51.0 Leq dB(A).
area are well within the prescribed limits as prescribed by the CPCB. The main sources of noise identified
in the industrial zone are vehicular traffic, industrial and commercial activities.
11.10.5 Soil Quality

11.10.6 Land Use Pattern

Land use within 10 km radius of the study area has been determined with the help of satellite imagery, and
broadly consists of settlements, Industrial, Tank/River/reservoir, Agriculture, land with scrub, Mud plot,
water logged area, airports, mangroves. Predominant land use is water bodies classified as tank/river, sea
i.e. 55.8 percent.
11.10.7 Socio-Economic Study

Total population of the study area as per year 2011 census was 84075, out of which 54253 were male and
29,822 were female.
11.10.8 Biological Environment

In the project area, the wild animals as well as other fauna are not seen except domestic animals. The study
area doesn’t include any part of National Park or wild life sanctuary.
11.11 Anticipated Environmental Impacts & Mitigation Measures

Anticipated adverse environmental impacts due to the proposed modification project during construction
and operation phase, and its mitigation measures are given below:
11.11.1 Air Environment

Construction phase involves site cleaning, excavation, construction, grinding, cutting, erection or
installation of equipment & machinery, transportation and material handling. These activities result in
emission of pollutants like dust, PM10, SO2 and NOx and fumes, into the atmosphere of the surrounding
area.
• Regular checking and maintenance of vehicles will be carried out
The impact of such activities would be temporary and restricted to the construction phase only and will be
confined within the project premises.
During operation phase, major air emissions are anticipated as gaseous emissions (PM, SO2 and NOx) from
a single or small group of stacks. Fugitive dust emission will be due to raw materials handling, loading and
unloading of raw materials and finished goods, conveying and feeding point, vehicular movements,
crushing & screening operations etc. The ISCST3 scientific model has been used to predict ground level
concentration due to proposed project and due to cumulative impact, which is as follows.

Sr. Maximum Ground Level Concentration

Parameters
No. Due to Proposed Project Due to Cumulative Impact
• Adequate pollution control equipments like bag filter, ESP scrubber etc. along with online
• Periodic checkup of all APC equipment to ensure proper functioning.
11.11.2 Water Environment

river.
Impact of ground water and its mitigation measures

For the proposed modification project entire water will be sourced from surface water source and hence
there will be no impact on ground water due to water consumption requirement. However, rain water
harvesting practice will be followed to improve ground water condition.

During the industrial activities there may be a chance of contamination in ground water by leachate
generation from spillage of hazardous chemicals, storage of raw materials, finish products and solid waste.,
etc. following mitigation measures for avoiding contamination of ground water will be implemented.
11.11.3 Noise Environment

level.
plant operation.

- Use of adequate noise control measures such as mufflers, silencers, anti-vibration pad for equipment
- Use of earmuff and earplugs to the operators, etc. would be provided.
- Housing / casing shall be provided for all noise generating machines.
- Regular maintenance of equipments.
- Limiting activity within day hours
- Regular monitoring of noise level
By these measures, it is anticipated that noise levels in the plant will be maintained below the stipulated
standard prescribed by the pollution control board.
11.11.4 Soil Environment - Solid / Hazardous Waste Management

construction and operation activities.
During operation phase of the project, there will be generation of solid and as well as hazardous wastes.
Plant wise details of hazardous waste generation and disposal method/Management is given in following
table.
Table 11.6 Details of Solid Waste generation and its management

Fines
1 Pellet Fines 902
Corex
4 Mill Scale 150
/ CSP
palletization
palletization
Material.
Material.
Slag
Granulated Slag
(IM)
sub base material
13 SMP I & II Steel Slag 1651 material
villagers
sub base material
De Spherization
(HMDP) Slag


Dust and Sludge

machine
sinter plant
activities
22 BF BF Dust 52
Refractories
High Alumina
30 SMP I & II 2
Grog
Coal Fines
Non-PCI Corex
coal fines
Table 11.7 Details of Hazardous Waste generation and its management

modification
(TPA)
Micropelletization
Vendors.
Sludge)

modification
(TPA)
Drums vendor.
CHWIF.

approved TSDF site.
approved TSDF site
batteries
wool TSDF site
/Year
Vendor.
TSDF site
TSDF site
11.11.5 Ecological Environment

Keeping in view, the importance of biological component of total environment due to the proposed project,
biological characterization of terrestrial and aquatic environments, changes in species diversity of flora and
fauna in terrestrial as well as aquatic systems were studied for impact analysis. The details of flora/fauna
species and the wildlife habitat in the area covering 10 km radius have been collected to determine the
existence of rare and/or endangered species. Few populations of Peacock or Indian peafowl (Pavo cristatus)
were reported from some villages of the study area and conservation plan has been prepared to protect the
same. Moreover, development of greenbelt will help to improve ecological environment of the area and
hence, no major impact on ecological environment will be anticipated.
11.11.6 Socio-Economic
The proposed modification project will generate job opportunities, both direct and indirect due to
development of ancillary industries. During the construction phase, the project will generate substantial
employment and income. Hence, this will improve socioeconomic status of the area but increased in-
migrated population may create impact on culture of the area.
11.12 Environmental Monitoring Programme

The environmental monitoring points shall be decided considering the environmental impacts likely to
occur due to the operation of proposed modification project as, the main scope of monitoring program is to
track, timely and regularly, the change in environmental conditions and to take timely action for the
protection of environment. The monitoring points/location and significant parameters analyzed as per
follows.

4. CRM Office,
5. AMNS
Township,
2. West Station
3. South Station
4. North Station
Environment
(Fugitive)
Effluent


Colour, Taste, pH, Turbidity,
Total Dissolved Solids, Total
Hardness as CaCO3, Alkalinity,
Residual Chlorine, Chloride as
Cl, Heavy Metals & Other
Parameters : Calcium as Ca,
Magnesium as Mg, Oil & Grease
(Mineral Oil), Phenolic
Compound as C6H5OH,
Hexavalent Chromium as Cr+6,
Cadmium as Cd, Copper as Cu,
Zinc as Zn, Iron as Fe, Lead as
Pb, Mercury as Hg, Selenium as
Se, Aluminium as Al, Manganese
as Mn, Arsenic as As, Sulphate
as SO4, Cyanide as CN, Boron as
B, Fluoride as F, Nitrate Nitrogen
as NO3 , Anionic Detergents as
MBAS, Bacteriological :
Coliform, E. Coli.
Manganese, Sodium,
Molybdenum, Selenium, Arsenic,
Mercury, Barium, Aluminium,
Silver, Stannous, Cobalt, Boron.
Building Conductivity, C: N Ratio,
Organic Carbon, N, P, K, Na, Ca,
Mg, CEC, Cl, Fe, Mn, Cu, Zn, B,
Mo.
Phenolic compounds.
and outside plant
Monitoring
Urin, RBS, etc.
check-up both are
same.

11.13 Additional Studies

11.13.1 Public Hearing
incorporating the compliance of Terms of References issued by Ministry of Environment, Forest and
Climate Change vide letter No. F. No. J11011/44/2004-IA. II(I) dated 8th February, 2021.
11.13.2 Risk Assessment

A detailed risk assessment and consequence analysis has been carried for all the plant operations for the
proposed modification project. A disaster management plan for entire complex is available. The
responsibilities of the officers include identification of the hazardous conditions and unsafe acts of
employees and advice on corrective actions, conduct safety audit, organize training programs and provide
professional expert advice on various issues related to occupational health and safety.
Safety training is being provided by the safety officer with the assistance of experts. In addition to regular
employees, all contractor labors are/will attend safety training.
11.13.3 Occupational Health Monitoring

Potential occupational hazardous work places are being monitored regularly. The health of employees are
being monitored at regular intervals for early detection of any ailment due to exposure to noise, heat,
respirable dust and hazardous chemicals. The audiometry and lung function tests will also be included in
this surveillance program. Company has a detailed occupational health management plan to address the
occupational diseases.
11.14 Project Benefits Corporate Social Responsibility (CSR)

The budgetary allocation for the CSR activities is 1600.00 lacs for five years. CSR activities includes
Education, Health & Sanitation, Infrastructure Development, Sustainable Livelihood, Sports and Youth
Development and Environment projects etc. Moreover, this project will add income of the government
through different type of taxes, excise duty etc.
11.15 Environmental Management Plan

The Environmental Management department is being done regular monitoring of different monitoring
parameters. Mitigation of environmental impacts has to be implemented according to the suggestions and
will be monitored regularly to prevent any lapse. The company will undertake various training programme
for improving the performance of the working personnel. Special training will be arranged in regular
intervals to combat emergency scenarios that may occur during the plant operation.
11.15.1 Cost of EPCM

Cost for Environment Pollution Control Measures (EPCM) is given in below table:
Total 1682.26 377.95
11.15.2 Green Belt Development

Existing greenbelt is developed in the area of 170 ha. And further area of about 84 ha. will be earmarked for
the development of green belt. After establishment, total greenbelt area will be 254 ha. Total 1,83 566 nos.
of trees will be planted at plant boundary, road side, around offices & buildings and in the open land.
11.16 Conclusion
The proposed modification plant facilities will have insignificant impact on the local environment.
However, with the implementation of the proposed pollution control and environment management
measures, better impacts anticipated. Further, development of this project will have many beneficial
impacts/effects on various socioeconomic aspect.
Thus, in view of extensive benefits from the project and controllable adverse environmental impacts, the
proposed modification project will be most advantageous to the region and will definitely improve the
regional, state and national economy.

Chapter – 12
Consultant Engaged
Environmental Impact Assessment (EIA) Study for the proposed modification project of M/s.
ArcelorMittal Nippon Steel India Limited, Surat, Gujarat was conducted by,
Name : M/s. Shree Green Consultants

Address : 505 SNS Platina, Near Reliance Market, Opp. Shrenik
Residency, Vesu, Surat, 395007, Gujarat, INDIA,
Phone : 9712916775
E-mail : info@shreegreen.com
Website : www.shreegreen.com
Status of accreditation with : NABET/EIA/2124/IA0072 validity till February 24, 2024
QCI/NABET
Shree Green Consultants (SGC) Surat - Gujarat is an aggressive service provider in Environment sector
with a focus on balancing Industrialization and environment. We are here to help companies and
organizations to address environmental challenges and identify green opportunities in an effective and
efficient way. Our core strength is our team of exceptionally competent and committed people who see
themselves as partners with our clients by building long term relationships based on providing cost
effective, industry specific and environmentally friendly solutions to our clients.

12.1 Accreditation Certificate issued by QCI NABET

Functional area experts and assistance to FAE involved in the EIA study for M/s. ArcelorMittal Nippon
Steel India Limited, Surat, Gujarat is as follow:
12.2 Functional Area Experts Involved in the EIA

Name of EIA FUNCTIONAL AREA EXPERTS INVOLVED
Coordinator /
Assignment Head
FUNCTIONAL AREA NAME/S
involved
LU (Land Use) Mr. Pritresh Kiritbhai Patel
EIA Coordinator: Associate: Ms. Alpaben Bariya
Dr. Smitha Rajesh AQM (Meteorology, Air Dr. Smitha Rajesh
Quality Modeling & Associate: Ms. Alpa Bariya
Associate: Prediction) Mr Abhay Kakkad
AP (Air Pollution Monitoring, Dr. Smitha Rajesh
Prevention & Control) Associate: Ms. Joslin Jose
WP (Water Pollution Dr. Smitha Rajesh
Monitoring, Prevention, & Associate: Mr. Satyendra Singh
Control) Ms. Rizwana Mesaniya
EB (Ecology & Biodiversity) Dr. Manoj Eledath
Associate: Mr. Satyendra Singh
SE (Socio-Economy) Dr. Rumjhum Ray Chaudhuri
Associate: Mr. Rajesh Patel
Mrs Lalita Kumai
NV (Noise & Vibration) Associate: Mr. Haneesh Panicker
Ms Alpaben Bariya
Ms Unnati Randeria
HG (Hydrology, Ground Mr. Ravikant Sharma
Water & Water Conservation) Associate: Ms Joslin Jose
GEO (Geology) Mr. Ravikant Sharma
RH (Risk Assessment & Mr. Amidala Chinnikrishna Sundhararajulu
Hazard Management) Associate: Mr. Parixit Ghelani
SHW (Solid & Hazardous Dr. Smitha Rajesh
Waste Management) Associate: Ms. Unnati Randeria
Mr Abhay Kakkad
SC (Soil Conservation) Associate: Mr. Vishal Vadodaria
Ms. Joslin Jose
12.3 Laboratory Involved for Baseline Monitoring & Other Analysis

Sr.
Name of Laboratory NABL Registration Status Role
No.
NABL certified laboratory,
Shreegreen environmental Certificate No. T-2227 and Baseline environmental Monitoring
1.
Laboratories MOEF&CC accredited and Analysis
laboratory under EPA 1986

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Draft Environmental Impact Assessment & EMP Report

(Oct - 2020 to Dec - 2020)

M/s. ArcelorMittal Nippon Steel India Limited

27th KM, Surat-Hazira Road, Hazira-394270

Proposed Modification in Existing Plant by installing Auxiliary Facilities

Shree Green Consultants

Mobile No.: 9712916775

M/s. ArcelorMittal Nippon Steel India Limited

27th KM, Surat-Hazira Road, Hazira-394270

Proposed Modification in Existing Plant by installing Auxiliary Facilities

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-1

Location of the Project

a) Industrial Estate : Hazira Notified Industrial Area

Surrounding Salient Features and Environmental Setting

Details of earlier ECs

Products and Capacities

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-3

Sr. No. Facility Unit Proposed Capacity

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-4

Details of Land Breakup

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-5

List of Raw Materials

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-8

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-9

Estimated time of Completion

Site Selected for the project

Ambient Air Quality

Ground Water Quality Monitoring

Surface Water Quality Monitoring

Background Noise Level

Anticipated Environmental Impacts & Mitigation Measures

Sr. Maximum Ground Level Concentration

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-12

Impact of ground water and its mitigation measures

Impact on ground water quality and mitigation measures:

Soil Environment - Solid / Hazardous Waste Management

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-13

Details of Solid Waste generation and its management

Shot blasting Will be sent to TSDF Site.

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-14

Details of Hazardous Waste generation and its management

8 Contaminated cotton rags 0 300 300 Collection, Storage, Transportation

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-15

Environmental Monitoring Programme

Sr. Area of Sampling Locations Parameters to be Analyzed Frequency of

Occupational Health Monitoring

Project Benefits Corporate Social Responsibility (CSR)

Environmental Management Plan

Green Belt Development

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-19

મેસસસ આસેલરમમત્તલ મિપ્પોિ સ્ટીલ ઇન્ડિયા લલમમટેિ

હજીરા િોટટફાઇિ ઔદ્યોલિક એટરયા, િામ: હજીરા, તાલુકો: ચોયાસસી,

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-1

ક) ઔદ્યોલિક વસાહત : હજીરા નોફટિાઇિ ઔદ્યોલિક એફરર્ા

આસપાસની મખ્ર્ લાક્ષલિકતાઓ અને પર્ાયવરિીર્ માહીતી

૧ નજીકન િામ હજીરા પ્રોજેક્ટ સાઇટ્થી દ્ક્ક્ષીિ ફિશામાાં

૩ નજીકનો નેશનલ હાઇવે એનએચ-૬ / પ્રોજેક્ટ સાઇટ્થી ૦.૧ કીમી

૮ આકે લોજીકલ સાઇટ નથી ૧૦.૦૦ કીમીની મિજ્ર્ામા આવેલ નથી

૯ રાજ્ર્ની સીમાાંફકતરે ખા નથી ૧૦.૦૦ કીમીની મિજ્ર્ામા આવેલ નથી

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-2

પ્લાડટના નામ અને તેની ક્ષમતા

M/s. ArcelorMittal Nippon Steel India Limited, Surat, Gujarat E-4

પ્રોજેક્ટની માટેની આવશ્ર્કતાઓ

જમીનના ભાિની મવિતો

Arcelormittal Nippon Steel India Limited Srt73 Eia1 Tds & All Details

Arcelormittal Nippon Steel India Limited Srt73 Eia1 Tds & All Details