August 2020 EIA-EMP REPORT REPORT NO: MEC/11/S2/E24V/EIA-EMP/2487/R-1 REV: 01
EXPANSION-CUM MODERNIZATION OF BOKARO STEEL PLANT FROM 4.5 MTPA TO 5.77 MTPA HOT METAL PRODUCTION CAPACITY AT BOKARO STEEL CITY, DIST. BOKARO, JHARKHAND BASELINE MOITORING PERIOD: MARCH 2018 TO MAY 2018 MECON LIMITED STEEL AUTHORITY OF INDIA LIMITED (A Govt. of India Enterprise) BOKARO STEEL PLANT Vivekananda Path (A Maharatna Company) PO. Doranda Dist – Ranchi, Jharkhand - 834002 Bokaro Steel Plant Dist – Bokaro, Jharkhand - 827001 CERTIFICATE NO: NABET/EIA/1619/RA 0068 August 2020 EIA-EMP REPORT REPORT NO: MEC/11/S2/E24V/EIA-EMP/2487/R-1 REV: 01
EIA-EMP REPORT FOR EXPANSION-CUM MODERNIZATION OF BOKARO STEEL PLANT FROM 4.5 MTPA TO 5.77 MTPA HOT METAL PRODUCTION CAPACITY AT BOKARO STEEL CITY, DIST. BOKARO, JHARKHAND
Category of project as per EIA Notification, 2006 Sl. No. 3(a) of Schedule - “Primary and Secondary Ferrous Metallurgical Industries”
QCI-NABET EIA Sector(s) involved: 08 – Metallurgical Industries (ferrous & non-ferrous) 11 - Coke Oven Plants
BASELINE MOITORING PERIOD: MARCH 2018 TO MAY 2018 (SUMMER SEASON)
Monitoring lab: MECON Ltd. (Inhouse) (CPCB recognition vide ltr. Nos. C-11012/81/2019-Tech/11427 dtd. 16-01-2020 & Gazette No. Legal 42(3)/87 dated 14-08-2014)
MECON LIMITED STEEL AUTHORITY OF INDIA LIMITED (A Govt. of India Enterprise) BOKARO STEEL PLANT Vivekananda Path (A Maharatna Company) PO. Doranda Dist – Ranchi, Jharkhand - 834002 Bokaro Steel Plant Dist – Bokaro, Jharkhand - 827001 CERTIFICATE NO: NABET/EIA/1619/RA 0068
National Accreditation Board for Education and Training (Member - International Accreditation Forum & Pacific Accreditation Cooperation)
QCI/NABET/ENV/ACO/20/1360 June 23, 2020
To
MECON Limited Vivekananda Path, P.O.Doranda, Ranchi, Jharkhand Pin 834002
Sub.: Extension of Validity of Accreditation till 22nd Sept, 2020 - regarding
Dear Sir/Madam
In view of the outbreak of Corona Virus (COVID-19) and subsequent lockdown declared for its control vide order dated 24th March 2020, issued by Ministry of Home Affairs, Govt. of India, NABET hereby extends the Validity of your Accreditation till 22nd Sept, 2020.
As soon as, NABET office opens/resumes its operation necessary action regarding issuance of certificate/extension of validity letters / other may be initiated, therefore, ACO to ensure their complete application with NABET, if applicable.
Meanwhile, you may enclose this with your EIA reports along with the certificate/validity letter. The EAC/SEIAA/SEAC/Other are hereby requested to consider the same as a valid document for the preparation of EIA/EMP report.
With best regards.
Sd/- (A K Jha) Sr. Director, NABET
Institute of Town Planners India, 6th Floor, 4-A, Ring Road, I.P Estate, New Delhi-1 10 002, India Tel. • +9 11 -233 23 4 1 6, 417, 18, 419, 420, 421 ,423 E-mail : [email protected] Website : www.qcin.org
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT CONTENTS
SN Description Page No. EXECUTIVE SUMMARY ES1 to ES10 1 INTRODUCTION 1 to 11 1.1 Purpose of the report 1 1.2 Identification of The Project and Project Proponent 1 1.2.1 Project Proponent 1 1.2.2 The Project 2 1.2.3 EIA consultant 2 1.3 Brief Description of The Project and Its Importance To The Country & Region 2 1.3.1 Importance of The Project 2 1.3.2 Alternative Sites Considered 3 1.3.3 Location of The Project 3 1.3.4 Nature and Type of the Project 10 1.3.5 Size of The Project 10 1.3.6 Industries Within 10 Km Radius of The Plant 10 1.4 Scope of Study 10 1.5 Basic Data Generation , Field Studies And Data Collection 11 1.6 Report Coverage 11 2 PROJECT DESCRIPTION 12 to 63 2.1 Introduction 12 2.2 Type of Project 12 2.3 Existing Statutory Compliances & Need For The Project 12 2.3.1 Existing EC, CTO & CTE of SAIL-Bokaro & their compliance status 12 2.3.2 Need for the proposed proposal 13 2.4 Location and Accessibility 14 2.4.1 Location 14 2.4.2 Infrastructure facilities 14 2.5 Size or Magnitude of Operation 14 2.6 Plant Details 15 2.6.1 Existing Plant Details 15 2.7 Proposed Project 19 2.8 Technology & Process Description 22 2.8.1 Coke Making - Coal Carbonisation 22 2.8.2 Sinter Making 29 2.8.3 New Pellet Plant 33 2.8.4 Hot Metal Production 35 2.8.5 Steel Melting Shops 37 2.8.6 Rolling mills 45 2.8.7 Refractory Material Plant (RMP) 47
CONTENTS Page I © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT SN Description Page No. 2.8.8 Oxygen production 47 2.8.9 Water Supply system 48 2.9 Environmental Pollution Mitigation Measures 50 2.9.1 Air pollution mitigation measures 50 2.9.2 Water Pollution Mitigation 51 2.9.3 Major green Initiatives undertaken at BSL 52 2.10 Project Site & Land Requirement 53 2.11 Raw Material Requirement 54 2.12 Water Requirement 56 2.13 Fuel Facilities 59 2.13.1 By product Gas Utilities (at 5.77 MTPA Hot metal stage) 59 2.13.2 Utilization of energy in off-gases 60 2.14 Power Requirement 61 2.15 Manpower 62 2.16 Proposed Schedule for Approval and Implementation 63 2.17 Project Cost 63 3 DESCRIPTION OF ENVIRONMENT 64 to 134 3.1 Introduction 64 3.1.1 General 64 3.1.2 Project Site & Study Area 64 3.2 Monitoring Schedule 64 3.3 Environmental Components and Methodology 65 3.4 Location and Geographical Settings 66 3.4.1 Topography 66 3.4.2 Drainage 66 3.4.3 Climate 67 3.4.4 Land Use 68 3.5 Hydrogeological Studies 70 3.5.1 Introduction 70 3.5.2 Hydrogeology 73 3.5.3 Conclusions 77 3.6 Baseline Data Generation/Establishment of Baseline for Environmental 78 Components 3.6.1 Micro-Meteorology 78 3.6.2 Atmospheric Inversion Level 82 3.6.3 Ambient Air Quality 82 3.6.4 Noise 86 3.6.5 Water Environment 88 3.6.6 Soil Characteristics 94 3.6.7 Traffic Density 96
CONTENTS Page II © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT SN Description Page No. 3.6.8 Biological Environment 104 3.6.8.1 Objectives of the study 104 3.6.8.2 Methodology of the Ecology Study 104 3.6.8.3 Ecology of Project area 104 3.6.8.4 Ecology of Study area 105 3.6.9 Socio-Economic Environment 114 3.6.10 Baseline status of Existing plant 121 3.6.10.1 Air Emissions 121 3.6.10.2 Work Zone Noise Levels 124 3.6.10.3 Effluent Quality 126 3.6.10.4 Solid Waste 127 3.6.10.5 Hazardous Wastes 128 3.6.11 Trace Metal / Toxic Metal / Toxic Content from Steel Plant Operations 130 3.6.11.1 Trace Metal Mercury, Arsenic and Fluoride content in Raw 131 Material 3.6.11.2 Trace metals in PM10 of Work Zone Air/ Fugitive emission 131 3.6.11.3 Trace metals in Particulate Matter of Stack emissions 132 3.6.11.4 Trace metals in PM10 of Ambient Air 133 3.6.11.5 Trace / Toxic Metal Content of Slag & Sludge 133 3.6.11.6 TCLP Studies of Waste Material (Slag & Sludge) 134 4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES 135 to 207 4.1 Introduction 135 4.2 Anticipated Environmental Impacts 135 4.3 Impacts & Mitigation Measures Due To Project Location 136 4.4 Impacts & Mitigation Measures Due To Project Design 136 4.5 Impacts & Mitigation Measures During Construction Phase 137 4.5.1 Land Use 137 4.5.2 Ambient Air Quality 137 4.5.3 Noise levels 138 4.5.4 Water Quality 139 4.5.5 Socio-economics of the area 139 4.5.6 Infrastructure facilities 139 4.6 Impacts and Mitigation Measures During Operation phase 140 4.6.1 Ambient Air Quality 140 4.6.2 Water Resources 154 4.6.3 Noise Environment 175 4.6.4 Ecological Features 178 4.6.5 Land Environment 179 4.6.6 Solid & Hazardous Waste and disposal 179 4.7 Additional Management Practices 182
CONTENTS Page III © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT SN Description Page No. 4.7.1 Rainwater Harvesting 183 4.7.2 Housekeeping 185 4.7.3 Greenbelt Development 185 4.7.4 Occupational Health & Safety 189 4.7.5 Occupational Health Services at BSL 197 4.7.6 Training Facilities 198 4.7.7 Corporate Social Responsibility 199 4.7.8 Corporate Environment Responsibility (CER) 204 4.7.9 Use of renewable energy sources 206 4.7.10 Energy Conservation Measures 206 4.7.11 Fly Ash Management 207 4.7.12 Stockpile Management 207 5 ANALYSIS OF ALTERNATIVES 208 to 212 5.1 Introduction 208 5.2 Alternative Technology / Process 208 5.2.1 New Coke Oven Battery 208 5.2.2 New Pellet Plant 209 5.2.3 New Sinter Plant 210 5.2.4 Upgradation of Steel Melting Shop (SMS) 211 5.3 Analysis of Site Alternatives 212 6 ENVIRONMENTAL MONITORING PLAN 213 to 225 6.1 Introduction 213 6.2 Environmental Aspects to be Monitored 213 6.2.1 General 213 6.2.2 Micro-Meteorology 214 6.2.3 Emissions and Air Quality 214 6.2.4 Noise Levels (Ambient and Work Zone) 214 6.2.5 Drainage System 214 6.2.6 Water & Wastewater Quality 215 6.2.7 Solid/Hazardous Waste Generation & Utilization 215 6.2.8 Green Belt Development 215 6.2.9 Rainwater Harvesting Facilities 216 6.2.10 House Keeping 216 6.2.11 Occupational Health & Safety 216 6.2.12 Laboratory Facilities 217 6.2.13 Socio-Economic Development 217 6.2.14 Interaction With Jharkhand State Pollution Control Board 217 6.3 Monitoring Plan 217 6.3.1 General 217 6.3.2 Performance Indicators 218
CONTENTS Page IV © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT SN Description Page No. 6.3.3 Environmental Monitoring Program 218 6.3.4 Progress Monitoring and Reporting Arrangements 224 6.3.5 Emergency Procedures 224 6.3.6 Interaction with Jharkhand State Pollution Control Board 225 6.4 Budgetary Provisions for Environmental Protection Measures 225 6.5 Updating of EMP 225 7 ADDITIONAL STUDIES 226 to 279 7.1 Risk Assessment 226 – 259 7.1.1 General 226 7.1.2 Brief Process Description 227 7.1.3 Applicability of the Rule 228 7.1.4 Description of Hazardous Substances 229 7.1.5 Hazard Identification 232 7.1.6 Hazard Assessment 233 7.1.7 Maximum Credible Accident Analysis (MCAA) 236 7.1.8 Consequence Analysis 237 7.1.9 Conclusion on MCA Analysis 251 7.1.10 Hazardous Events with Greatest Contribution to Fatality Risk 252 7.1.11 Summary & Conclusions of Risk Assessment 253 7.1.12 Recommended Risk Reduction and Mitigation Measures 253 7.1.13 On Site Emergency Plan 254 7.2 Socio-economic study 259 - 271 7.2.1 Objectives of the Study 259 7.2.2 Existing Socio-Economic Scenario 259 7.2.3 Methodology Adopted for the Study 260 7.2.4 Demographic Structure of the Surveyed Area 260 7.2.5 Basic Socio-Economic Conditions in the Study Area 262 7.2.6 Prediction of Socio-Economic Impacts 262 7.2.7 People’s Perception 263 7.2.8 Conclusions 268 7.2.9 Corporate Social Responsibility 270 7.3 Public Consultation 272 - 279 8 PROJECT BENEFITS 280 to 284 8.1 Introduction 280 8.2 Financial Benefits 280 8.2.1 Increase In Steel Production 280 8.3 Environmental benefits 280 8.4 Social Benefits 280 8.4.1 Improvements In Physical Infrastructure 280 8.4.2 Employment Potential 281
CONTENTS Page V © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT SN Description Page No. 8.4.3 Industrialization around Bokaro Steel Plant 283 8.4.4 Improvements In Social Infrastructure 284 8.5 Other Tangible Benefits 284 9 ENVIRONMENTAL COST BENEFIT ANALYSIS 285 10 EMP-ORGANISATIONAL SET UP & IMPLEMENTATION ARRANGEMENT 286 to 292 10.1 Organizational Policy 286 10.2 Organizational Setup 286 10.2.1 Administrative Set Up 286 10.2.2 System of reporting environmental non-compliances/infringements 287 10.2.3 Action plan for performance monitoring of pollution control equipment. 288 10.2.4 Laboratory Set Up 290 10.3 Functioning 290 10.3.1 Micro-Meteorology 291 10.3.2 Emissions and Air Quality 291 10.4 Implementation Arrangement 291 10.4.1 Institutional Implementation Arrangements 291 10.4.2 Co-ordination with Other Departments 291 10.4.3 Interaction with Jharkhand State Pollution Control Board 292 10.5 Training 292 10.6 Corporate Responsibility for Environment Protection (CREP) 292 11 SUMMARY & CONCLUSION 293 12 DISCLOSURE OF CONSULTANTS 294 to 298 12.1 Introduction 294 12.2 Profile Of EIA/EMP Consultant 294 12.3 Status Of Accreditation 297
CONTENTS Page VI © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT LIST OF DRAWINGS
SN. Description Drawing No.
1. Project site and study area area overlaid on Survey of India Toposheet MEC/11/S2/E24V/01
2. Physiography map of study area showing Air Quality monitoring stations MEC/11/S2/E24V/02 3. Drainage map of study area showing water and soil sampling locations MEC/11/S2/E24V/03 4. Land Use Land Cover map of the study area MEC/11/S2/E24V/04 5. Satellite Image Of The Study Area For LULC MEC/11/S2/E24V/05 6. General Layout showing greenbelt MEC/11/S2/E24V/LAY/01
CONTENTS Page VII © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT LIST OF ANNEXURES
Sn. Description Annexure No. 1. Terms of Reference 1.1 2. EC granted to Bokaro Steel Plant and amendments thereto 2.1(a) 3. Consent to Operate (CTO) & NOC (CTE) of existing Bokaro Steel Plant 2.1(b) 4. Recent compliance of CTO & NOC of Bokaro Steel Plant 2.1(c) 5. Updated implementation status of the facilities mentioned in the existing EC of BSL 2.1(d) 6. RO, MoEFCC's Certified Compliance report 2.1(e) Action Taken Report of BSL for closure of observations on Compliance of EC 7. 2.1(f) conditions 8. Linkage documents 2.2 Water Drawl Agreement of Bokaro Steel Plant & NOC from WRD, GoJ for 9. 2.3 development of Alternate Water Supply system Power Purchase Agreement(PPA) of Bokaro Steel plant 10. 2.4 with Damodar Valley Corporation(DVC) 11. Flood Zone Map of India 3.1 12. Raw AAQ Monitored Data In The Area 3.2 13. Need Assessment Study 3.3 14. Hazardous Waste Authorization of Bokaro Steel Plant 4.1 15. Air Quality model input/output 4.2 16. Approved Joint Action plan for Fly Ash Utilization (BSL & BPSCL) 4.3 17. Material Safety Data Sheets 7.1 18. Onsite emergency plan and Comprehensive HIRA with Disaster Management Plan 7.2 19. Safety procedures for hazardous gas handling 7.3 20. Public Consultation proceedings (original & authenticated English translation) 7.4 Integrated Quality, Environment, OHS & SA policy of Bokaro steel plant & overall 21. 10.1 Corporate Environmental Policy of SAIL 22. CREP Action Points and Compliance Status 10.2 23 MECON Lab certification from CPCB & recognition by MoEFCC 12.1
CONTENTS Page VIII © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT LIST OF TABLES
Table No. Details Page no. 1.1 Salient Features of Project Site & Its Environmental Sensitivity 4 1.2 GPS Coordinates of Project Site 5 1.3 Industries Located Within 10 Km Radius of the Project 10 2.1. Objective of proposed activities in expansion-cum-modernization of BSL 13 2.2. Product Mix after proposed expansion-cum-modernization 15 Existing Major Technological Units, products and their Capacities and changes 16 2.3. proposed in expansion-cum-modernization Status of facilities envisaged as per earlier EC as well as changes proposed in 19 2.4. existing configuration 2.5. Design parameters of Coke oven battery 22 2.6. Coal Consumption and coke production details for proposed coke oven 23 2.7. Salient features of proposed coke oven battery 23 2.8. Indicative characteristics of coal blend 24 2.9. Indicative coke and by-product yield of proposed coke oven battery 24 2.10 Indicative Coke characteristics 24 2.11 Typical technological parameters/features of envisaged CDCP 26 2.12 Clean Coke oven gas composition(indicative) 27 2.13 Broad design and operating parameters of new Sinter plant 30 2.14 Tentative raw material requirement and product output of new sinter plant 31 2.15 Tentative chemical composition & metallurgical properties of sinter 31 2.16 Tentative design parameters of new Kiln 32 2.17 Major facilities of proposed Pellet plant 33 2.18 Design and operating parameters of Pellet Plant 34 2.19 Envisaged Pellet Quality 35 2.20 Hot metal production envisaged & its breakup from installed BF complex 36 2.21 Technological parameters of the installed blast furnaces 36 2.22 Technological features of the existing SMS-I 37 2.23 Salient design details of existing BOF converters 38 2.24 Technological features of proposed modernized SMS-1 40 2.25 Design features of the proposed CCM 41 2.26 Debottlenecking activities envisaged in SMS-II complex 43 2.27 Production parameters of the existing SMS-II 44 2.28 Salient parameters related to productivity and mill utilization of HSM 46 2.29 Design parameters of the proposed 450 TPD shaft kiln 47 2.30 Oxygen Balance for Expansion to 5.77 MTPA Hot Metal (4.656 MTPA Crude steel) 48
CONTENTS Page IX © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table No. Details Page no. 2.31 Salient features of existing water supply system 49 2.32 Design parameters for the proposed raw water drawl system 49 2.33 List of existing Air Pollution Control (APC) Measures 51 2.34 Location of discharge points of outfalls from the plant 52 2.35 Land utilization of Bokaro Steel plant 53 Area requirement for new facilities envisaged under expansion-cum-modernization 54 2.36 of BSL 2.37 Major Raw Materials & Chemicals Consumed at BSL, Sources & transportation 54 Additional raw material required for the additional units of proposed expansion- 55 2.38 cum-modernization Existing water intake point as well as point of intake for proposed alternate water- 57 2.39 drawl & supply systems 2.40 Overall water requirement for BSL at 5.77 MTPA Stage 57 2.41 Fuel gas balance for BSL at 5.77 MTPA hot metal stage 59 2.42 Power requirement of existing facilities and generation of BSL 61 Additional Power Requirement of new units under proposed expansion-cum- 61 2.43 modernization Additional manpower requirement for the new units proposed expansion-cum- 62 2.44 modernization Tentative Implementation schedule of proposed activities in expansion-cum- 63 2.45 modernization of BSL 2.46 Indicative cost of proposed activities in expansion-cum-modernization of BSL 63 3.1. Environmental Components and Methodologies Adopted For the Study 65 3.2. Climatological data of IMD Dhanbad (Observation from 1951 to 1980) 67 3.3. Land use/Land Cover Pattern of the Study Area 69 3.4. Hydrogeological data of wells from the surrounding villages of the plant 77 3.5. Summarized Monitored Meteorological Data at BSL 78 3.6(a) Wind frequency distribution in Summer season (March-May, 2018)(Overall) 79 3.6(b) Wind frequency distribution in Summer season (March-May, 2018)(Day) 79 3.6(c) Wind frequency distribution in Summer season (March-May, 2018)(Night) 79 3.7. Ambient Air Quality (AAQ) monitoring stations 83 3.8. Methodology of sampling & equipment for analysis 84 3.9. Summarized Ambient Air Quality monitoring results 84 3.10 National Ambient Air Quality Standards, 2009 85 3.11 Ambient noise measurement stations 86 3.12 Summarized Ambient Noise level monitoring results 87 Ambient Air Quality norms in respect of noise (As per schedule III,Rule 3 of EP 87 3.13 (Rules))
CONTENTS Page X © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table No. Details Page no. 3.14 Location of Water Monitoring Stations 88 3.15 Surface Water Quality 89 3.16 Central Pollution Control Board (CPCB) Surface Water Quality Criteria 90 3.17 Ground Water Quality 92 3.18 Selection of Soil Sampling Locations 94 3.19 Physical & Chemical properties of Soil 94 3.20 Available Major Nutrients in Soil 95 3.21 Exchangeable Cations 96 3.22 Available Micronutrients 96 3.23(a to 99 - 103 f) Traffic density at various gates leading to steel plant 3.24 Plants planted within plant premises 105 3.25 List of Plants found in study area 106 3.26 Agricultural pattern and productivity in the area 109 3.27 Frequency Density of Protected Forest (PF) Along Damodar River 109 3.28 List of common trees/shrubs growing in and around Settlements 110 3.29 List of animal species in the study area 111 3.30 List of common birds found in the region 111 3.31 List of common planktons in study area 112 3.32 List of Fishes found in the study area 113 3.33 Common hydrophytes in the study area 113 3.34 List of Towns & Villages within Study Area 115 3.35 Brief profile of Bokaro district 115 3.36 Demographic Profile of Population in the Area (2011 Census) 116 3.37 Occupational Structure in the Area (2011 Census) 117 3.38 Presence of school in the study area (gradewise) 118 3.39 Schools with tap water, toilets and electricity facilities 119 3.40 Irrigation source &facilities 119 3.41 Health Care systems 120 3.42 Status of electrification 121 3.43(a) Stack emissions from Different Units of BSL 122 3.43(b) Fugitive Emissions Status (Work Zone) 124 3.43(c) Fugitive Emissions from Coke Oven battery 124 3.44(a) Work Zone Noise levels 125 3.44(b) Noise level at the Boundary of the Plant 126 3.45 Quality of various Outfalls at the Boundary line of the plant 126
CONTENTS Page XI © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table No. Details Page no. 3.46 Quality of Treated Sewage at Oxidation Pond Outlets 126 3.47 BOD Plant Effluent Analysis 126 3.48 Plant Outlets 127 3.49 Solid waste generation from existing plant (2017-18) 127 3.50(a) Hazardous waste generation from existing plant (2017-2018) 128 3.50(b) Typical composition of Hazardous waste generated 129 3.51 Method of analysis of Trace / Toxic Metal for Different Type of Samples 130 3.52 Results of Mercury, Arsenic and Fluoride content in Raw Material 131 3.53 Results of Metal analysis in Work zone air/fugitive emission 131 3.54 Results of trace metal analysis in Stack emission 132 3.55 Results of Metal Analysis in Ambient Air 133 3.56 Results of Trace Metal Content of Slag & Sludge by acid digestion 134 3.57 Results of TCLP studies for Slag & Sludge samples 134 4.1 Expected Stack Emissions from Proposed units 142 4.2 Comparative pollution loads before and after the present Proposal 143 4.3 Estimated fugitive emissions from proposed units 144 4.4: Meteorological data used as input for Air quality modelling 146 4.5 Expected GLCs from various units of BSL 147 4.6 Cumulative AAQ Values at various receptor points after expansion 148 4.7 Air pollution control measures in the proposed units 153 4.8: List of Water Pollution Control Systems 174 4.9: Resultant Noise Levels at Nearby Villages due to proposed Project 176 Generation & Action plan for 100% Utilization / disposal of Solid Wastes from 179 4.10 proposed expansion-cum-modernization of BSL Hazardous waste generation & Action Plan for disposal from proposed expansion- 180 4.11 cum-modernization of BSL 4.12 Major components of the Biogas plant facility 181 4.13 Action Plan for Management of Solid Waste at BSL 181 4.14 Location and Area for Rainwater Harvesting System 183 4.15 Tree Plantation by BSL in Nearby Villages During 2017 187 4.16 Most Common safety issues 190 4.17 Periodicity of the PME 197 4.18 Occupational Health Services Performances (2011-2018) 198 4.19 Training imparted on Environmental Awareness During 2017 - 18 199 4.20 Details of CSR Expenditure for FY 2016-2017 203 4.21 CSR Budget & Expenditure (2017-18) 204
CONTENTS Page XII © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table No. Details Page no. 4.22 Focus area wise CER Expenditure Plan 205 4.23 Energy Conservation Measures at BSL 206 6.1 Additional Stacks to be monitored after the Implementation of the proposed project 214 6.2 Green Belt Development by BSL 215 6.3 Equipment available with the Laboratory 217 6.4 (A) Environmental Monitoring Plan 219 6.4 (B) Environmental Monitoring Plan for the Performance Indicators 222 6.5 Reporting System for Environmental Monitoring Plan 224 6.6 Cost of Environmental Protection Measures (Rs. Crores) 225 7.1 List of Major Hazardous Substances to be Stored /Handled 228 Threshold Quantity &Identified Hazardous Substances to be Handled as per 228 7.2 MSIHC Rules, 1989& Subsequent Amendments 7.3 Type of Hazards Associated With Identified Hazardous Chemicals 232 7.4 Preliminary Hazard Analysis 234 7.5 Probable Release&Accident Scenarios Identified as per MCAA 238 7.6(a) Effect of Different Over-Pressures on Human Life& Property 239 7.6(b) Relation Between Heat Radiation Intensity, Time &Effect on Man 239 7.7 Results of Consequence Analysis 240 7.8 Worst Case Hazard Extents for Identified Hazardous Facilities 242 7.9 Hazardous Events Contributing to Risk and their Risk Ranking 252 7.10 Distribution of Landholding in the Study Area 264 7.11 Cropping Intensity Bokaro, District 264 7.12 Cropping Pattern of the Study Area 264 7.13 Cropping intensity, Net Return & investment 264 7.14 Demand Functions for Food and Non-food Items 265 7.15 Source-wise Distribution of Family Consumption 267 7.16 Fitted Consumption Function 268 7.17 Peoples’ Perception on the Project 269 7.18 Public Hearing Action Plan 273 8.1 Decadal Growth in Demographic Pattern in Study Area 282 12.1 List of Major Equipment at Environmental Laboratory 295 12.2 List of Computer models for Environmental Studies 296 Details of sectors accorded to MECON under the QCI-NABET scheme for 12.3 297 accreditation of EIA consultant organization 12.4 Brief description of the Functional Area Experts of MECON 298
CONTENTS Page XIII © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT LIST OF FIGURES
Figure Details Page no. No. 1.1 Location of Project Site (Index Map) 6 1.2(a) Location of Project on SOI Toposheet 7 1.2(b) Location of Project on Google Earth 8 1.3 Photographs of Proposed site of Pellet & Coke Oven plant 9 2.1. Process Flow Sheet of Existing Bokaro Steel Plant 18 Process-cum-material Flow Sheet of Bokaro Steel Plant after proposed expansion- 2.2. 21 cum-modernization plan 2.3. Existing (Tenu Canal) and Proposed water supply system for Bokaro Steel Plant 50 Water balance diagram at 4.5 MTPA Hot metal production stage and after 2.4. proposed expansion-cum-modernization programme (at 5.77 MTPA hot metal) of 58 BSL 3.1. Annual &Summer Season Wind Rose at IMD’s Dhanbad Observatory 68 3.2. Breakup of Land use 69 3.3. Hydrogeological map of Bokaro District 71 3.4. Drainage map of Bokaro District 72 3.5. Depth to water level (Pre-monsoon-2015) of Bokaro District 74 3.6. Depth to water level (Post-monsoon-2015) of Bokaro District 75 3.7. (a) Wind Rose (Overall) 80 3.7. (b) Wind Rose (Day) 81 3.7. (c) Wind Rose (Night) 81 3.8. Diurnal variation of average height of Inversions for Summer Season 82 3.9. (a) Existing Solid waste generation 128 3.9. (b) Existing Solid waste utilization for last three years 128 4.1 (a) Isopleths of PM over 10km area around BSL 149 4.1 (b) Isopleths of SO2 over 10km area around BSL 150 4.1 (c) Isopleths of NOx over 10km area aroundBSL 151 4.1 (d) Isopleths of Fugitive dust over 10km area around BSL 152 4.2 Scheme of BOD plant at BSL 158 4.3 Scheme of ETP of CRM complex in BSL 164 4.4 Scheme of TTP of CRM complex in BSL 167 4.5 Indicative Scheme of ZLD in BSL 171 4.6 Indicative Scheme of ZLD in BSL 173 4.7 Noise levels on account of the project only at different distances from the plant 176 4.8. Scheme for Rainwater harvesting structures in CRM-II 184
CONTENTS Page XIV © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Figure Details Page no. No. 4.9. Cumulative Plantation in last 5 years 186 BSL’s Policy for Quality, Environment, Occupational Health Safety and Social 4.10 191 Accountability 7.4 Preliminary Hazard Analysis 234 7.1(a to c) Hazard Extents For Thermal Fire Radiation Effects 243 - 246 7.1(d to Hazard Extents For Vapour Cloud Explosion Effects In Identified Hazardous 247 - 248 e) Facilities Hazard Extents For Toxic Cloud Dispersion Effects In Identified Hazardous 7.1(f) 249 Facilities 7.2 Safe Distances From Hazardous Installations Of BSL To Nearest Habitations 250 7.3 Educational status among the respondents 263 7.4 Occupational Structure of the Study Area 266 7.5 Consumption Pattern in the Study Area 267 7.6 Proceedings of Public hearing conducted for the project on 08.12.2018 272 8.1 Decadal Growth in Demographic Pattern in Study Area 282 10.1 Organizational Chart of Environmental Control Department 287 Standard Operating procedure for reporting environmental non-compliances to 10.2 288 higher management at Bokaro Steel Plant 10.3 Action plan for performance monitoring of pollution control equipment 288 10.4 Continuous emission, effluent & ambient air quality monitoring systems at BSL 289
CONTENTS Page XV © 2020 MECON Limited. All rights reserved &29(5$*(2)725 32,176 STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Index : ToR Coverage In EIA Report
Sl. No. ToR Chapters Pages Remarks ANNEXURE 1: STANDARD TOR IN RESPECT OF INDUSTRY SECTOR 1 Executive Summary Executive Summary ES1 – ES10 2 Introduction i Details of the EIA Consultant including Chap.1 Clause 1.2.3 2 xThe EIA/EMP Report has been prepared by NABET accreditation MECON Limited, a CPSE under the Ministry of Steel, Govt. of India. MECON Ltd. is accredited by QCI/NABET for preparing EIA/EMP reports in 17 sectors, including “Metallurgical industries (ferrous & non-ferrous) – both primary and secondary” vide their certificate no. NABET/EIA/1619/RA 0068 (validity up to 22-09-2020). Brief accreditation details of the EIA consultant, MECON Limited is given in Clause 1.2.3. Chap.12 Clause 12.2 & 294-298 xDisclosure of EIA Consultant-MECON limited with 12.3 profile and status of QCI-NABET accreditation is indicated in Chap. 12, Clauses 12.2-12.3 ii Information about the project proponent Chap.1 Clause 1.2.1 1 Project is being implemented by Bokaro Steel Plant, which is an integrated steel plant operated by Steel Authority of India Ltd. (SAIL). SAIL is a PSU under the Ministry of Steel, Govt. of India. iii Importance and benefits of the project Chap.1 Clause 1.3.1 2 – 3 xThe project will facilitate Bokaro Steel Plant in increasing its production and improve its performance parameters (both economic & environmental). The increased production will contribute to the Steel Production in the country as per National Steel Policy to bridge the gap between demand and supply. The project will also generate employment. Details of importance of the project mentioned in Chap.1 Clause 1.3.1.
Chap. 8 Clause 8.2 to 8.4 280 - 284 xBenefits of the project including Economic benefits, social benefits as well as environmental benefits are discussed at Chap. 8 in Clause nos. 8.2 to 8.4 3 Project Description i Cost of project and time of completion. Chap. 2 Clause 2.17 63 xEstimated Project Cost – Rs.5219.1 Crores. Details mentioned at Chap. 2 Clause 2.17. Chap. 2 Clause 2.16 63 xAll components will be implemented within 42 months. Details of proposed schedule for implementation mentioned at Chap. 2 Clause 2.16. ii Products with capacities for the proposed Presently Plant’s installed capacity is 5.77 MTPA of project. Hot Metal. Production is presently limited to 4.5 MTPA of Hot Metal & ~4.2 MTPA of steel due to production bottlenecks. On implementation of the project, the production capacity will be 5.77 MTPA Hot Metal & 4.656 MTPA of Steel. Chap. 2 Clause 2.5 14 – 15 xDetails of products with capacities at proposed 5.77 MTPA hot metal stage is summarized in Table 2.2 in Clause 2.5. Chap. 2 Clause 2.7 21 xDetails of proposed products and their process- cum-material flow mentioned at Fig. 2.2 in Clause 2.7.
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Sl. No. ToR Chapters Pages Remarks iii If expansion project, details of existing Chap. 2 Clause 2.6.1 15 – 17 xExisting Plant’s installed capacity is 5.77 MTPA of products with capacities and whether Hot Metal. Production is presently limited to 4.5 adequate land is available for expansion, MTPA of Hot Metal & ~4.2 MTPA of steel due to reference of earlier EC if any. production bottlenecks. Details of existing products and their capacities are indicated in Clause 2.6.1, Table 2.3.
Chap. 2 Clause 2.10 53 xThe proposed project is an expansion-cum- modernization project and its activities will be carried out entirely within BSL’s plant premises, for which adequate space is available. No additional land acquisition is required. Details of project site and land requirement is mentioned in Chap. 2 Clause 2.10.
Annexure 2.1(a) xBSL’s earlier EC has been granted for production of 5.77 MTPA hot metal (& 4.606 MTPA steel). Earlier ECs attached at Annexure 2.1(a). iv List of raw materials required and their source Chap. 2 Clause 2.11 54 - 56 The entire requirement of iron ore sourced from along with mode of transportation. SAIL’s captive mines. Part of the requirements of limestone, dolomite and coal met from SAIL’s mines or sourced from indigenous as well as foreign suppliers. Some of the raw materials (e.g. mill scales) generated in house) >99% of raw materials received at plant site by rail. v Other chemicals and materials required with Chap. 2 Clause 2.11 54 – 56 xList of Raw Materials & other chemicals required quantities and storage capacities by the existing plant as well as proposed unit along with their sources and transportation mode indicated in Clause 2.11.
Chap.7 Clause 7.1.2 227-228 xHazardous chemicals required to be stored/ handled at BSL for the proposed project mentioned at Clause 7.1.2 Table 7.1. vi Details of Emission, effluents, hazardous Chap. 3 Clause 3.6.10 121-129 xAir emissions from stacks, fugitive emissions as waste generation and their management. well as work zone air quality of existing plant is indicated in Clause 3.6.10.1. Effluent generation
from existing plant is mentioned in Clause 3.6.10.3. Solid & hazardous waste generation
from existing plant is mentioned in Clauses 3.6.10.4 & 3.6.10.5. Chap. 2 Clause 2.9.1 & 50-52 2.9.2 xDetails of existing management measures for air emissions and effluent is mentioned in Clauses 2.9.1 & 2.9.2. Existing Hazardous waste
management is mentioned in Chap.3 Clause 3.6.10.5. Chap. 4 Clause 4.6 140-181 xGeneration of Emissions, effluents and solid & haz. wastes from BSL after implementation of proposed project as well as their proposed management measures is given in Clause 4.6.1 (air emissions), Clause 4.6.2 (effluents) and Clause 4.6.6 (Solid & Hazardous wastes). vii Requirement of water, power, with source of Chap. 2 Clause 2.12 56 – 58 xTotal future water requirement – 17000 m3/hr. supply, status of approval, water balance Potable water requirement (plant & township - diagram, man-power requirement (regular 6800 m3/hr. Water drawn from Damodar River. and contract). BSL has permission for drawl of 23140 m3/hr of water. Water balance diagram given as Fig. 2.4.
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Sl. No. ToR Chapters Pages Remarks Chap. 2 Clause 2.14 61 – 62 xPower demand of expanded plant expected to be 416 MW. 302 MW supplied by captive power plant operated by Bokaro Power Supply Co. Ltd. Balance will be supplied by DVC. Power supply being augmented by solar power.
Chap. 2 Clause 2.15 62 xBSL’s existing manpower – 13269. Addl. Requirement – 785 (of which upto 99 executives will be regular & upto 686 non-executives will be contract employees). Addl. Requirement will be met from existing manpower as well as fresh recruits. viii The project proponent shall furnish the Chap. 2 Clause 2.12 56 xThe project does not draw ground water. requisite documents from the competent Permission for drawl of water from Damodar River authority in support of drawl of ground water enclosed as Annexure 2.3. and surface water and supply of electricity. Chap. 2 Clause 2.14 61 xAgreement with DVC for purchase of power is attached as Annexure-2.4 ix Process description along with major Chap. 2 Clause 2.8 22 – 50 xTechnology and process description along with equipment and machineries, process flow major equipment and machineries described in
sheet (Quantitative) from raw material to Clause 2.8. products to be provided. Clause 2.7, Fig. 2.2 21 xProcess flow sheet is shown in Clause 2.7 Fig. 2.2 x Hazard identification and details of proposed Hazards due to production and/or storage of safety systems. flammable, toxic and/or suffocating gases, production & handling of hot materials in the process, handling & utilization of corrosive liquids, handling of steam, production & handling of liquid oxygen, nitrogen & argon, operation of various machinery have been discussed as part of HIRA for the existing as well as proposed projects.
Chap. 7, Clause 7.1.5 & 232 – 236 xThe Hazard identification & assessment for the 7.1.6 proposed projects is mentioned in Clauses 7.1.5 & 7.1.6. Proposed preventive measures are summarized in Clause 7.1.6 Table 7.4.
Chap.7, Clause 7.1.12 253 – 254 xOverall risk reduction & mitigation measures recommended for the project are mentioned in Clause 7.1.12. xi Expansion/modernization proposals: a Copy of all the Environmental Clearance(s) Chap. 2 Clause 2.3.1 12 BSL has been accorded EC on 16.10.2008 by including Amendments thereto obtained for Annexure MoEFCC for expansion of its capacity from 4.0 MTPA the project from MOEF&CC/SEIAA shall be 2.1(a),(b),(c),(d),(e) & (f) to 7.0 MTPA of crude steel vide memo no. J- attached as an Annexure. A certified copy of 11011/99/2007-IA II(I). Extension of the EC was the latest Monitoring Report of the Regional accorded for a period of five years w.e.f. 15.10.2013 Office of the Ministry of Environment, Forests vide memo no. J- 11011/99/2007-IA.II(I) dtd. and Climate Change as per circular dated 30th 24.01.2014. Further, this EC (valid until 14.10.2018) May, 2012 on the status of compliance of has been granted an amendment by MoEFCC for conditions stipulated in all the existing modifications in some existing plant facilities of BSL environmental clearances including along with reduction of overall plant production Amendments shall be provided. In addition, capacity to 4.606 MTPA Crude Steel (5.77 hot metal) status of compliance of Consent to Operate vide MoEFCC letter F.No J-11011/99/2007-IA.II(I) for the ongoing /existing operation of the dated 28.11.2014. project from SPCB/PCC shall be attached with the EIA-EMP report. In addition, BSL has been granted EC amendment vide MoEFCC’s letter J-11011/99/2007- IA II(I) dated 13.12.2017 for development of an alternate water
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Sl. No. ToR Chapters Pages Remarks pipeline system for drawl of raw water from Damodar river. Copy of all the Environmental Clearance(s) including Amendments thereto obtained from MOEF&CC as well as CTO and CTE/NOC granted for the project are attached as Annexure-2.1(a)& 2.1(b) respectively. Recent CTO & CTE/NOC compliances are attached as Annexure-2.1(c). b In case the existing project has not obtained Not Applicable 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, Chap 2, Clause 2.10 53 Bokaro Steel Plant Located at Bokaro Steel City in Taluka / Tehsil, District and State, Chas Block of Bokaro District, Jharkhand. Proposed Justification for selecting the site, whether project will be implemented entirely within existing other sites were considered. steel plant’s premises. Since the project envisages expansion-cum-modernisation of existing plant, no alternate sites were considered. Ii A topo-sheet of the study area of radius of 10 Drg. No. MEC / 11 / S2 / xToposheet enclosed as Drg. No. MEC / 11 / S2 / km and site location on 1:50,000/1:25,000 E24V / 01 E24V / 01. scale on an A3/A2 sheet. (including all eco- xNo eco-sensitive or environmentally sensitive sensitive areas and environmentally sensitive Chap. 1, Clause 1.3.3, 3 - 4 place located in study area. Table 1.1 indicates places) Table 1.1. environmental sensitivity. iii Co-ordinates (lat-long) of all four corners of Chap. 1, Clause 1.3.3 5 Given in Table 1.2 the site. iv Google map-Earth downloaded of the project Chap. 1, Clause 1.3.3, 8 Enclosed as Fig 1.2(b) site. Fig 1.2(b) v Layout maps indicating existing unit as well Drg. No. 53 Enclosed as Drg. No. MEC/11/S2/E24V/LAY/01. as proposed unit indicating storage area, MEC/11/S2/E24V/LAY/01 Land requirement mentioned at Chap. 2, Clause 2.10 plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate. vi Photographs of the proposed and existing (if Chap.1 Clause 1.3.3, Fig. 9 Enclosed as Fig. 1.3 applicable) plant site. If existing, show 1.3 photographs of plantation/greenbelt, in particular. vii Land-use break-up of total land of the project Chap. 2, Clause 2.10 53 Bokaro steel plant is spread over 6973.68 ha area. site (identified and acquired), The proposed project will be implemented entirely government/private – agricultural, forest, within the plant’s existing premises (i.e. no Forest wasteland, water bodies, settlements, etc Land is involved and no additional land will be shall be included (not required for industrial acquired). area). viii A list of major industries with name and type Chap. 1 Clause 1.3.6 10 The industries around BSL include Thermal Power within study area (10km radius) shall be Plant, Coal Mine, Coal Washeries, Cement Plant, incorporated. Land use details of the study LPG Bottling plants etc. located in study area. Listed
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Sl. No. ToR Chapters Pages Remarks area. in Table 1.4 ix Geological features and Geo-hydrological Chap. 3, Clause 3.5 70 - 77 Details of the Geology & hydrogeology of the study status of the study area shall be included. area given in referred clause. x Details of Drainage of the project up to 5km Chap. 3, Clause 3.4.2 66 – 67 xThe drainage pattern of the area is mostly radius of study area. If the site is within 1 km dendritic. The Damodar River, which flows from radius of any major river, peak and lean west to east is the principal drainage channel of season river discharge as well as flood the area, and is about 2.5 km north of BSL plant occurrence frequency based on peak rainfall boundary. The plant is at an altitude of 226 – 241 data of the past 30 years. Details of Flood m a.m.s.l, whereas Damodar River flows at 141 – Level of the project site and maximum Flood 165 m a.m.s.l. Another small perennial tributary of Level of the river shall also be provided. the Damodar, the Garga, flows from west to east (mega green field projects) south of the plant and then towards the north east of the plant at altitude of 244 m – 186 m a.m.s.l. Details of drainage mentioned in Clause 3.4.2. Drg. MEC/11/S2/E24V/03 xDrainage map of study area Annexure-3.1 xFlood zone map of the area indicating the project site is not near any flood zone. xi Status of acquisition of land. If acquisition is Chap. 2, Clause 2.10 53 Project will be implemented entirely within the not complete, stage of the acquisition process existing premises of Bokaro Steel Plant. No land and expected time of complete possession of acquisition needed. Hence no R & R involved. the land. vii R&R details in respect of land in line with state Government policy 5 Forest and Related Issues (if applicable) i Permission and approval for the use of forest Chap.2 Clause 2.10 53 Not Applicable as project will be implemented entirely land (forestry clearance), if any, and within the existing premises of Bokaro Steel Plant. No recommendations of the State Forest Forest Land involved. Department. (if applicable). ii Land use map based on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha). iii Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted. iv The projects to be located within 10 km of the Chap. 3 Clause 3.6.8 104 There is no Biosphere Reserve, Ramsar Site, National Parks, Sanctuaries, Biosphere National Park, Wild Life Sanctuary, Tiger Reserve, Reserves, Migratory Corridors of Wild Elephant Reserve or Wildlife Corridor in study area. Animals, the project proponent shall submit the map duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden- thereon. v Wildlife Conservation Plan duly authenticated Chap. 3 Clause 3.6.8.4 106 Not applicable. None of the animals found in the by the Chief Wildlife Warden of the State study area are listed in Schedule I of the Wild Life Government for conservation of Schedule I Protection Act, 1972. fauna, if any exists in the study area. vi Copy of application submitted for clearance Not Applicable under the Wildlife (Protection) Act,1972, to the Standing Committee of the National Board for Wildlife 6 Environmental Status i Determination of atmospheric inversion level Chap. 3, Clause 3.6.1 78 – 82 xMicro-meteorological attributes monitored at hourly
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Sl. No. ToR Chapters Pages Remarks at the project site and site-specific micro- intervals continuously during full summer season meteorological data using temperature, 2018 and Bokaro Steel City Township. relative humidity, hourly wind speed and direction and rainfall. Clause 3.6.2 82 xThe average atmospheric mixing height is seen to vary from a minimum of ~50m to a maximum of ~1500m during the study period in the study area, based on Atlas of Spatial Distribution of Hourly Mixing Depth over Indian Region published by CPCB for nearest Radio Sonde station at Ranchi. ii AAQ data (except monsoon) at 8 locations for Chap. 3, Clause 3.6.3 82 - 86 AAQ monitored at 8 locations, twice a week for PM10, PM2.5, SO2, NOX, CO and other twelve weeks during March – May, 2018.PM10, PM2.5, parameters relevant to the project shall be SO2, NOx, NH3, CO, O3, Ni, As, Pb, Benzene & collected. The monitoring stations shall be Benzo-a-Pyrene analysed. Concentrations of Zn, Cu, based CPCB guidelines and take into account Fe & Mn in PM10 also determined. the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. iii Raw data of all AAQ measurement for 12 Annexure 3.2 xRaw AAQ data enclosed as Annexure 3.2. weeks of all stations as per frequency given xSummary and analysis of AAQ data collected in the NAAQM Notification of Nov. 2009 along Chap. 3, Clause 3.6.3 82 mentioned in Clause 3.6.3 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 (60m Chap. 3, Clause 3.6.5 88 – 93 Surface water samples collected from 9 locations. upstream and downstream) and other surface Surface Water Quality has been compared with drains at eight locations as per Surface Water Quality Norms prescribed by CPCB. CPCB/MoEF&CC guidelines. v Whether the site falls near to polluted stretch Chap. 3, Clause 3.4.2 66 The stretch of the Damodar River falling within the of river identified by the CPCB / MoEF&CC. study area, is not classified as “Polluted”” by CPCB. [the “Polluted” stretch of Damodar River is located >40 km downstream of the study area]. vi Ground water monitoring at minimum at 8 Chap. 3 Clause 3.6.5 88 - 93 Ground water samples collected from 8 locations. locations shall be included. Ground Water Quality has been compared with drinking water norms of IS: 10500(2012), Amendment No. 1, July 2015. vii Noise levels monitoring at 8 locations within Chap. 3 Clause 3.6.4 86 - 88 Ambient noise levels measured at 7 locations. Noise the study area. levels at all locations were found to be within the relevant norms for residential as well as commercial types of areas. viii Soil Characteristic as per CPCB guidelines. Chap. 3 Clause 3.6.6 94 – 96 Top soil samples collected from 6 locations for physico-chemical analysis. ix Traffic study of the area, type of vehicles, Chap. 3 Clause 3.6.7 96 – 103 Analysis of the traffic pattern at the steel plant gates frequency of vehicles for transportation of shows that some heavy vehicles leave or enter the materials, additional traffic due to proposed plant, but only from certain specific gates only. Bulk of project, parking arrangement etc. the traffic is constituted by 2-wheelers and cars and these enter and / or leave the plant during shift changes. There are adequate and dedicated parking spaces for vehicles inside the plant. x Detailed description of flora and fauna Chap. 3 Clause 3.6.8 104 - 113 Study area comprises industrial areas, urban & rural (terrestrial and aquatic) existing in the study settlements, open cast coal mines and small patch of area shall be given with special reference to degraded forest. Only common species of plants and rare, endemic and endangered species. If animals (none listed in Schedule I of W.P. Act) found Schedule-I fauna are found within the study in area. area, a Wildlife Conservation Plan shall be prepared and furnished.
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Sl. No. ToR Chapters Pages Remarks xi Socio-economic status of the study area. Chap. 3 Clause 3.6.9 114 - 120 xBaseline socio-economic study was carried out along with needs assessment of the peripheral villages and residential areas. Details of Baseline Socio-economic status of the study area is mentioned in Clause 3.6.9
Annexure 3.3 xThe Need based assessment of the study area is attached as Annexure 3.3. 7 Impact Assessment and Environment Management Plan i Assessment of ground level concentration of Chap. 4 Clause 4.6.1, 140 - 153 Ground level concentrations of PM, SO2 & NOx on pollutants from the stack emission based on account of emissions from point as well as non-point site-specific meteorological features. In case sources have been estimated. US Environmental the project is located on a hilly terrain, the Protection Agency’s (EPA’s) AERMOD computer AQIP Modelling shall be done using inputs of code has been used to estimate atmospheric the specific terrain characteristics for dispersion and concentrations of the released determining the potential impacts of the emissions in the immediate vicinity of the proposed project on the AAQ. Cumulative impact of all sources. sources of emissions (including transportation) on the AAQ of the area shall be well 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 Chap. 4 Clause 4.6.2 154 – 155 No additional effluent shall be discharged into the effluent is proposed to be discharged into the local surface water bodies due to the proposed units. local drain, then Water Quality Modelling Implementation of Zero liquid discharge will also study should be conducted for the drain water reduce wastewater discharge from the plant. taking into consideration the upstream and downstream quality of water of the drain. iii Impact of the transport of the raw materials Chap. 4 Clause 4.6.1 140 - 153 All major external material movement, both incoming and end products on the surrounding as well as outgoing, is done by rail. Since the railway environment shall be assessed and provided. network serving BSL is electrified, hardly any diesel In this regard, options for transport of raw locomotive hauled trains serve BSL. Thus no impact materials and finished products and wastes of transportation of material is anticipated on the air (large quantities) by rail or rail-cum road environment due to the proposed project. Over and transport or conveyor-cum-rail transport shall above, it will be ensured that all internal transport be examined. vehicles are in good working condition, properly tuned and maintained to keep emission within the permissible limits and engines turned off when not in use to reduce pollution. Vehicles would be regularly maintained so that emissions confirm to standards of CPCB. iv A note on treatment of wastewater from Chap. 4 Clause 4.6.2 154 - 174 Effluents from Coke Oven & By-products plant treated different plant operations, extent recycled and in ETP. ETP consists of waste water collection tank, reused for different purposes shall be tar settling unit, dissolved air floatation unit included. Complete scheme of effluent equalization basin, flash mixer, clariflocculator, two treatment. Characteristics of untreated and stage activated sludge process with separate treated effluent to meet the prescribed clarifiers and trickling filter system followed by final standards of discharge under E(P) Rules. clarifier and chlorine contact tank. In addition, sludge thickener and sludge drying beds are also provided for dewatering of sludge generated. The treated effluent shall be used in coke quenching. A new ETP & Tertiary treatment plant (TTP) has also been
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Sl. No. ToR Chapters Pages Remarks envisaged for the CRM complex. v Details of stack emission and action plan for Chap.3, Clause 3.6.10.1 121 -123 xDetails of stack emission from existing plant is
control of emissions to meet standards. mentioned in Clause 3.6.10.1 Table 3.43(a).
Chap.2, Clause 2.9.1 50 xExisting process stacks provided with ESPs or Bag Filters or Wet Scrubbers or Battery Cyclones or Dry Fog Dust Suppression Systems or Fume Extraction Systems.
Chap.4, Clause 4.6.1 140 -153 xIn proposed units, combination of technological measures as well as pollution control equipment shall be used. vi Measures for fugitive emission control Chap.4, Clause 4.6.1, (B) 154 Plain water sprinkling systems has been provided all round raw material stockpiles to suppress fugitive dust. In enclosed spaces, dust extraction & filtration systems and dust suppression systems have been installed. The dust extraction & filtration systems comprise of suction hoods, fans, ducts and bag filter units with all accessories. Details of proposed mitigation measures for air pollution control and fugitive emission control are mentioned in Clause 4.6.1, (B) and Table 4.7. vii Details of hazardous waste generation and Chap. 3 Clause 3.6.10.5 128 – 129 xDetails of hazardous waste generation from
their storage, utilization and disposal. Copies existing plant and its management is mentioned in of MOU regarding utilization of solid and Clause 3.6.10.5
hazardous waste shall also be included. EMP Chap.4, Clause 4.6.6 179 – 181 xDetails of solid and hazardous waste generation shall include the concept of waste- from proposed project and its management minimization, recycle/reuse/ recover measures is mentioned in Clause 4.6.6. techniques, Energy conservation, and natural resource conservation. Annexure 4.1 xCopy of BSL’s Hazardous waste authorization is attached as Annexure 4.1. viii Proper utilization of fly ash shall be ensured Chap. 4, Clause 4.7.11 207 SAIL-Bokaro is not involved in coal-based power as per Fly Ash Notification, 2009. A detailed generation and hence no fly ash is being generated plan of action shall be provided. by BSL. Power generation is done by M/s BPSCL (Bokaro Power Supply Company Limited), a separate entity which has got separate CTO from JSPCB and separate EC from MoEF&CC.
During the 20th R-EAC(Ind-1) meeting held on 26th June, 2020, SAIL-BSL submitted a Joint Action Plan for management of Fly Ash (as approved by Boards of both SAIL-Bokaro & BPSCL) with a revised time- schedule of implementation by August 2024 as suggested by the Hon’ble committee. The progress report in this regard shall be submitted to the Regional Office, MoEFCC along with the six-monthly compliance report.
Annexure 4.3 xThe EAC recommended action plan with budget provisions is attached as Annexure 4.3. ix Action plan for the green belt development Chap.4, Clause 4.7.3 185 - 189 In 2017-18, green belt and plantations cover 1782.35 plan in 33 % area i.e. land with not less than ha. Presently another ~2,15,000 saplings have been 1,500 trees per ha. Giving details of species, planted over 141.64 ha (350 acres) of plantations, as width of plantation, planning schedule etc. budgeted during 2018-19 with a budgetary provision shall be included. The green belt shall be of Rs. 1.6 Crores. Thus the total area of green belt around the project boundary and a scheme and plantations is 1923.99 ha (i.e. 33.32% of the for greening of the roads used for the project project area (excluding water bodies)). The same will
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Sl. No. ToR Chapters Pages Remarks shall also be incorporated. be maintained for >80% survival and plantations in other areas will also be augmented. x Action plan for rainwater harvesting measures Chap.4, Clause 4.7.1 183 - 184 In BSL, the engineered storm water drainage system at plant site shall be submitted to harvest leads to the cooling ponds. The cooling ponds also rainwater from the roof tops and storm water serve as raw water reservoirs. Thus the surface run- drains to recharge the ground water and also offs are collected and used to augment the plant’s to use for the various activities at the project raw water supply, thus reducing the dependence on site to conserve fresh water and reduce the Damodar River. Since the cooling ponds’ bottoms water requirement from other sources. are earthen they also serve to artificially recharge the ground water table. In addition rain water well be collected over a 540 m x 165 m area over the CRM-II building and artificially recharged through 4 nos. recharging pits. xi Total capital cost and recurring cost/annum Chap.6, Clause 6.4 225 Estimated Capital costs of environmental protection for environmental pollution control measures and enhancement measures - Rs. 365 Crores. shall be included. Annual recurring costs of environmental conservation, pollution control and monitoring facilities for proposed units - be Rs. 91.4 Crores . xii Action plan for post-project environmental Chap.6, Clause 6.3.3 218 - 223 BSL is already monitoring micro-meteorology, air monitoring shall be submitted. quality, emissions, noise levels, water quality, effluent quality, soil quality and solid wastes as directed by JSPCB xiii Onsite and Offsite Disaster (natural and Man- Chap.7, Clause 7.1.13 254 - 259 xThe onsite emergency plan for the existing plant made) Preparedness and Emergency has been already prepared by BSL. The same will Management Plan including Risk Assessment be extended to the proposed units also. A detailed and damage control. Disaster management Hazard Identification & Risk Assessment (HIRA) plan should be linked with District Disaster has been carried out for the existing as well as Management Plan. proposed project. The summarised overall onsite emergency plan is detailed at Clause 7.1.13. Annexure-7.2 xThe updated Disaster Management Plan with unit- wise Onsite Emergency plan for major plant units is also included as part of the HIRA attached as Annexure-7.2. 8 Occupational Health i Details of existing Occupational & Safety Chap.4, Clause 4.7.4 189 – 196 xOccupational & Safety Hazards anticipated in the Hazards. What are the exposure levels of plant areas are mentioned in Clause 4.7.4. Workers above mentioned hazards and whether they are exposed to heat, dust, gases, noise and even are within Permissible Exposure level (PEL). very low temperatures (only in oxygen plant). The
If these are not within PEL, what measures occupational health & safety management the company has adopted to keep them practices of BSL are also indicated in Clause 4.7.4
within PEL so that health of the workers can (A to N) be preserved, Chap. 3, Clause 3.6.10.1 121 - 126 xWork zone air quality and noise levels are & 3.6.10.2 monitored and found to be within the PELs. The work zone levels of air emission and noise to which the working environment of the plant is affected is mentioned in Clause 3.6.10.1 & 3.6.10.2. ii Details of exposure specific health status Chap.4, Clause 4.7.5 197 - 198 All employees undergo a Pre-employment Medical evaluation of worker. If the workers’ health is Examination followed by a Periodical Medical being evaluated by pre designed format, Examination (PME). The periodicity of the PME is as chest x rays, Audiometry, Spirometry, Vision per the workers’ area of deployment. Annual Check- testing (Far & Near vision, colour vision and up of all BSL personnel with a daily maximum target any other ocular defect) ECG, during pre- of check-up of 60 persons a day. Periodical health placement and periodical examinations give check-up covers lung function test, audiometry, vision the details of the same. Details regarding last test, pathological test and bio-chemical test is being
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Sl. No. ToR Chapters Pages Remarks month analyzed data of abovementioned done. Various health awareness and training parameters as per age, sex, duration of programme are being organized. exposure and department wise. iii Annual report of health status of workers with Chap.4, Clause 4.7.5 198 The annual report of Occupational Health checkups special reference to Occupational Health and for last 07 years (till 2018) is mentioned in Clause Safety. 4.7.5 Table 4.18. iv Plan and fund allocation to ensure the Chap.4, Clause 4.7.4 189 – 196 xPlant has dedicated Safety Engg. Deptt. All regular occupational health & safety of all contract employees as well as contract employees undergo and casual workers. mandatory safety training. Safety Engg. Deptt. Ensures all safety procedures and protocols are followed. Periodical safety audits are conducted.
Chap.4, Clause 4.7.4 (N) 196 xAnnual budget for procurement of PPE, conducting safety trainings, safety audits and safety promotional activities is ~Rs.3 Crores. 9 Corporate Environmental Policy i Does the company have a well laid down Chap.10, Clause 10.1 286 The Quality, Environment, Occupational Health Safety Environment Policy approved by its Board of & Social Accountability Policy of Bokaro Steel Plant Directors? If so, it may be detailed in the EIA and Corporate Environmental Policy of SAIL is report. attached as Annexure 10.1. ii Does the Environment Policy prescribe for Annexure 10.1 xYes, the Quality, Environment, Occupational Health standard operating process / procedures to Safety & Social Accountability Policy of Bokaro bring into focus any infringement / deviation / Steel Plant at bullet pt. no. 7 takes into account the violation of the environmental or forest norms requirement for compliance of all national laws / conditions? If so, it may be detailed in the including those pertaining to the environment. EIA. Chap.10, Clause 10.2.2 287-288 xThe system of reporting environmental non- compliances is described at Clause 10.2.2. iii What is the hierarchical system or Chap.10, Clause 10.2.1 286-287 xBSL has a dedicated Environment Control Administrative order of the company to deal Department (ECD) which is responsible dealing with the environmental issues and for with environmental issues and for ensuring ensuring compliance with the environmental compliance with the environmental clearance clearance conditions? Details of this system conditions. The administrative setup of
may be given. Environement Control Department of SAIL-Bokaro
is detailed in Clause 10.2.1, Fig. 10.1.
Chap.10, Clause 10.2.2 287-288 xThe system of reporting environmental non-
compliances is described at Clause 10.2.2.
Chap.10, Clause 10.2.3 288-289 xThe system of performance monitoring of pollution control equipment is described at Clause 10.2.3 iv Does the company have system of reporting Chap.10, Clause 10.2.2 287-288 The system of reporting environmental non- of non-compliances / violations of compliances is described at Clause 10.2.2. environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report 10 Details regarding infrastructure facilities such Chap.4, Clause 4.5.6 139 Inside the plant, there are canteens, rest rooms with as sanitation, fuel, rest room etc. to be drinking water & toilet facilities. There is also a provided to the labour force during medical unit which is manned round the clock. These construction as well as to the casual workers facilities are available for BSL employees as well as including truck drivers during operation contractors’ employees. BSL’s employees are housed phase. in the plant’s township which has also necessary infrastructure / amenities. 11 Enterprise Social Commitment (ESC) To address the Public Hearing issues, 2.5% Chap.4, Clause 4.7.8 204-205 Ministry’s Office Memorandum vide F.No. 22-
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Sl. No. ToR Chapters Pages Remarks of the total project cost of 65/2017-IA.III dated 1st May 2018, an amount of Rs. (Rs……………….crores), amounting to 17.22 Crores has been earmarked for Corporate Rs…………………….crores, shall be Environment Responsibility (CER) based on public earmarked by the project proponent, towards hearing issues as well as need assessment based Enterprise Social Commitment (ESC). Distinct socio-economic study carried out for the project. The ESC projects shall be carved out based on CER amount has been distributed in activities based the local public hearing issues. Project on issues raised during the Public Consultation and estimate shall be prepared based on PWD Need based socio-economic assessment in the study schedule of rates for each distinct Item and area. schedule for time bound action plan shall be prepared. These ESC projects as indicated by the project proponent shall be implemented along with the main project. Implementation of such program shall be ensured by constituting a Committee comprising of the project proponent, representatives of village Panchayat & District Administration. Action taken report in this regard shall be submitted to the Ministry's Regional Office. No free distribution/donations and or free camps shall be included in the above ESC budget*
As per Ministry’s OM No. 22-65/2017-IA.III dated 1st May, 2018, fund allocation fro Corporate Environmental Responsibility (CER) shall be made for various activities therein. The details of fund allocation and activities for CER shall be incorporated in the EIA/EMP report. 12 Any litigation pending against the project Nil Presently there are no court cases pending against and/or any direction/order passed by any project. Court of Law against the project, if so, details thereof shall also be included. Has the unit received 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 Complied compliance of above TORs. 14 The TORs prescribed shall be valid for a Complied period of three years for submission of the EIA-EMP reports along with Public Hearing Proceedings (wherever stipulated). The following General Points shall be covered i All documents shall be properly indexed, Complied page numbered ii Period/date of data collection shall be clearly Complied indicated. iIii Authenticated English translation of all Complied material in Regional languages shall be x The original PH proceedings are issued by JSPCB in Hindi (local language). The provided. Authenticated English translation of the PH proceedings along with original PH proceedings are attached as part of Annexure-7.4. iv The letter / application for environmental Complied clearance shall quote the MOEF&CC file No.
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Sl. No. ToR Chapters Pages Remarks and also attach the file. v The copy of the letter received from the Complied Ministry shall be also attached as an annexure to the final EIA-EMP Report. vi The index of the final EIA-EMP report must Complied indicate the specific chapter and page no. of the EIA-EMP Report. vii While preparing the EIA report, the Complied instructions for the proponents and instructions for the consultantsissuedbyMOEF&CCvideO.M.No.J- 11013/41/2006-IA.II (I)dated 4th August, 2009, which are available on the website of this Ministry shall also be followed. viii The consultants involved in the preparation of EIA-EMP report after accreditation with Quality Council of India(QCl) National Accreditation Board of Education and Complied Training (NABET) would need to include a x MECON Limited is a QCI-NABET accredited EIA consultant in the EIA Sector (8) – certificate in this regard in the EIA-EMP Metallurgical industries (Ferrous & non-ferrous) with Certificate no. reports prepared by them and data provided NABET/EIA/1619/RA 0068 by other organization/Laboratories including their status of approvals etc. Name of the Consultant and the Accreditation details shall be posted on the EIA-EMP Report as well as on the cover of the Hard Copy of the Presentation material for EC presentation. ix ToRs’ prescribed by the Expert Appraisal All points have been complied, as briefed below: Committee (Industry)shall be considered for preparation of EIA-EMP report for the project x ToRs prescribed by the Expert Appraisal Committee (Industry) along with in addition to all the relevant information as additional specific ToR(s) issued as part of ToR amendment and other per the ‘Generic Structure of EIA ’given in observations issued by the Hon’ble EAC during subsequent EAC meetings as part Appendix III and IIIA in the EIA Notification, of EDS and ADS have been considered for preparation of this EIA-EMP report. 2006. Where the documents provided are in a language other than English, an English x The ‘Generic Structure of EIA ’given in Appendix III and IIIA in the EIA Notification, translation shall be provided. The draft EIA- 2006 has been adhered while preparation of the EIA report.
EMP report shall be submitted to the State x The original PH proceedings are issued by JSPCB in Hindi (local language). The Pollution Control Board of the concerned Authenticated English translation of the PH proceedings along with original PH State for conduct of Public Hearing. The proceedings are attached as part of Annexure-7.4. SPCB shall conduct the Public Hearing/public consultation, district-wise, as x The issues raised in the Public consultation and the commitments made by SAIL- per the provisions of EIA notification, 2006. Bokaro, summarized in a tabular chart with financial budget and time-schedule of The Public Hearing shall be chaired by an implementation, have been included as a separate section in Chap. 7.0 at Clause Officer not below the rank of Additional 7.3 of the EIA report. District Magistrate. The issues raised in the Public Hearing and during the consultation process and the commitments made by the project proponent on the same shall be included separately in EIA-EMP Report in a separate chapter and summarized in a tabular chart with financial budget (capital and revenue) along with time- schedule of implementation for complying with the commitments made. The final EIA report shall be submitted to the Ministry for obtaining environmental clearance
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Sl. No. ToR Chapters Pages Remarks
ANNEXURE 2: SECTOR SPECIFIC TOR (Integrated Steel Plants) 1 Iron/coal linkage documents along with the Chap. 2, Clause 2.11 54 Iron ore is sourced exclusively from SAIL’s mines status of environmental clearance of iron ore Part of the coking coal is sourced from BCCL and and coal mines some imported. SAIL’s mines have necessary environmental clearances. The rest of the raw materials are either purchased from indigenous suppliers or imported. 2 Quantum of production of coal and iron ore Chap. 2, Clause 2.11 54 Coal & iron ore are transported to the plant from coal & iron ore mines and the projects exclusively by rail from the mines, coal washeries or they cater to. Mode of transportation to the port as applicable. plant and its impact 3 For Large ISPs, a 3-D view i.e. DEM (Digital Chap. 3 Clause 3.4.2 66 The drainage of the study area in Digital Elevation Elevation Model) for the area in 10 km Model (DEM) is shown in Drg. MEC/11/S2/E24V/03. radius from the proposal site. MRL details of project site and RL of nearby sources of water shall be indicated. 4 Recent land-use map based on satellite Chap. 3 Clause 3.4.4 68 - 70 Land-use/Land cover pattern in the study area as imagery. High-resolution satellite image data interpreted from RESOURCESAT (IRS P6) LISS-IV having 1m-5m spatial resolution like dated 30-01-2017 satellite imagery. quickbird, 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 P2.5) present in the ambient Chap. 3 Clause 3.6.11 130 - 134 Samples of PM10 of twenty hours duration were air must be analysed for source analysis - collected on EPM 2000 filter papers from 8 locations. natural dust / RSPM generated from plant Trace metal levels are well within the maximum operations (trace elements) of PM10 to be permissible limits. carried over. 6 All stock piles will have to be on top of a Chap. 4 Clause 4.7.12 207 Will be complied. Coking coal and CDI coal are stable liner to avoid leaching of materials to stored in covered silos only. Thus there is no chance ground water. of surface or ground water contamination due to leachates / surface run-offs from coal stock-piles. In case of iron ore and fluxes, the stockpiles have been built over very thoroughly compacted soil which minimises percolation of leachates. The stock-pile areas are also sloped towards engineered storm water drainage systems routed through settling pits. All the surface run-offs are collected by the drains and the suspended solids are settled out. The clarified storm water is routed to the plant’s cooling ponds, which also function as raw water reservoirs. 7 Plan for the implementation of the Chap.10, Clause 10.6 292 Annexure-10.2 recommendations made for the steel plants in the CREP guidelines. 8 Plan for slag utilization Chap. 4, Clause 4.6.6 179 Entire quantity of BF slag is granulated and sold off to cement manufacturers. ~80% of the BOF slag is utilized for various purposes. 9 Plan for utilization of energy in off gases Chap. 2, Clause 2.13 59 - 60 Entire quantity of Coke Oven and BF Gas is utilized (coke oven, blast furnace) in the plant as fuel. Even surplus gas generated at the SMS, which is rich in CO, is sent to the captive power plant for generation of power and steam. COVERAGE OF TOR Page xiii © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. No. ToR Chapters Pages Remarks 10 System of coke quenching adopted with Chap. 2, Clause 2.8.1 22 - 29 BSL’s existing coke oven complex has 8 (of which 6 justification. are working at any given time) top charged batteries with every pair of battery sharing common facilities of a Wet quenching tower and coke wharf. Thus, the existing coke oven complex has only wet coke quenching facility. However, the new coke oven battery has been proposed to have a dry quenching system as the primary system for coke quenching with a wet quench tower as a standby system. The adoption of dry quenching system as the primary system for coke quenching was made on the characteristics of the dry quenching process that are attractive to air pollution control and bring about other advantages to the environment as a whole. 11 Trace metals Mercury, arsenic and fluoride Chap. 3, Clause 3.6.11.1 131 Arsenic content <3 mg/kg. Mercury content <0.05 emissions in the raw material. mg/kg; Fluoride content ~150 - ~153 mg/kg. 12 Trace metals in waste material especially Chap. 3, Clause 3.6.11.5 133 BF Slag, SMS Slag, BF Sludge, SMS Sludge slag. analysed for Cu, Cd, Cr, Pb, Ni, Zn, Mn & As. 13 Trace metals in water Chap. 3, Clause 3.6.5 88 - 93 Concentrations of Cu, Hg, Ni, Cd, Pb, Zn & Cr determined in Surface Water. Concentrations of As, Cu, Hg, Ni, Cd, Pb, Zn & Cr determined in Ground Water. 14 Details of proposed layout clearly Chap. 2, Clause 2.10 53 Layout of Bokaro Steel plant indicating the new demarcating various units within the plant. units/facilities as well as shops to be modernized/up- graded as part of the proposed project is depicted in DRG. MEC/11/S2/E24V/LAY/01 15 Complete process flow diagram describing The steel plant is based on the BF-BOF route. Part of each unit, its processes and operations, the hot metal produced is converted into cold-pigs. along with material and energy inputs and However most of the hot metal is refined to steel. The outputs (material and energy balance). steel is directly cast into slabs or ingots. The ingots 16 Details on design and manufacturing are rolled into slabs. The slabs are processed into hot process for all the units. rolled coils and cold rolled flat products. Chap. 2, Clause 2.7 Fig. 21 xProcess-cum-material flow diagram shown in 2.2 Clause 2.7 Fig. 2.2 Chap. 2, Clause 2.13.1 59 – 60 xFuel/Energy Balance shown in Clause 2.13.1 Table 2.41 Chap. 2, Clause 2.8 22 – 50 xTechnical details of design and process of all units is described in Clause 2.8. 17 Details on environmentally sound Chap.4, Clause 4.6.6 179 - 181 Sludge generated at the ETP of the Coke Oven & technologies for recycling of hazardous Byproduct Plant is charged into the coke ovens, materials, as per CPCB Guidelines, may be where it decomposes under temperature >1000°C. mentioned in case of handling scrap and However, BSL is not involved in direct recycling of other recycled materials. other hazardous wastes. 18 Details on requirement of energy and water Chap. 2, Clause 2.12 56 – 58 xBSL shall require 17000 m3/hr of water including along with its source and authorization from 6800 m3/hr as potable water. Water will be drawn the concerned department. Location of water from Damodar River at Tenughat dam, for which intake and outfall points (with coordinates). permission is already available with BSL. Details of water requirement and sources are mentioned in Clause 2.12 Chap. 2, Clause 2.12 (1) 57 xLocation of existing and proposed intake points indicated in Table 2.39. Chap. 2, Clause 2.14 61 - 62 xPresent electricity demand is 256.3 MW, which is expected to increase to 416 MW on completion of the proposed expansion cum modernization
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Sl. No. ToR Chapters Pages Remarks project. Power is supplied by the plant’s captive power plant (cap. 302 MW) which operated by BPSCL – joint venture company of SAIL & DVC. The balance power shall be supplied by DVC and augmented by solar power generation. 19 Details on toxic metal content in the waste Chap. 3, Clause 3.6.11.5 133 xAnalysis of Cu, Cd, Cr, Pb, Ni, Zn, Mn & As in BF material and its composition and end use Slag, SMS Slag, BF Sludge, SMS Sludge done. (particularly of slag). Chap.4, Clause 4.6.6 179-181 x100% BF slag is granulated and used for cement making while 80% of the SMS slag is utilized for brick making. 20 Details on toxic content (TCLP), details on Chap. 3, Clause 3.6.11.6 134 xTCLP studies carried out for Cu, Cd, Cr, Pb, Ni, toxic metal content in the waste material and Zn, Mn & As in BF Slag, SMS Slag, BF Sludge, its composition and end use (particularly of SMS Sludge. slag). Chap.4, Clause 4.6.6 179-181 x100% BF slag is granulated and used for cement making while 80% of the SMS slag is utilized for brick making.
ADDITIONAL SPECIFIC ToR ISSUED AS PART OF ToR AMENDMENT (Issued Vide Letter no. IA/JH/IND/153631/2020 dated 20/05/2020) Sl. No. ToR Chapters Pages Remarks 21 Coke Oven battery shall be equipped with Chap. 2, Clause 2.8.1, 25 Proposed Coke oven battery of 0.77 MTPA gross Coke Dry Quenching (CDQ) facility and the sub-para 3 coke capacity is proposed to have a dry quenching details shall be incorporated in the EIA system of 120 TPH capacity as the primary system report. for coke quenching along with provision of a Back pressure Turbine Generator of 6.5 MW & 55 TPH of steam at 8 kg/cm2.
REVISED DETAILS ISSUED AS PART OF EDS & ADS ISSUED DURING EAC MEETINGS (Online EDS dated 17.04.2019 and ADS dated 14.06.2019) Sl. No. Observations of the Hon’ble EAC Chapters Pages Remarks EDS(i) Closure report of non-compliances from Chap. 2, Clause 2.11, 54 The recent status of compliance issued by RO, Regional Office shall be furnished. Annexure 2.1(e) & 2.1(f) MoEFCC is attached as Annexure-2.1(e). The updated Action Taken Report (ATR) submitted to the RO, MoEFCC for closure of observations on EC compliance is attached as Annexure-2.1(f). EDS(ii) Authenticated English translation of the Annexure-7.4 The original PH proceedings along with the Public Consultation proceedings shall be (referred at Chap. 7, authenticated English translation has been included furnished. clause 7.3) as an annexure to the present report. The same is include as Annexure-7.4. EDS(iii) HIRA is not project specific and inadequate Annexure-7.2 The project specific HIRA for the proposed project and it has not covered all the hazards has been included as Annexure-7.2 to this EIA associated with the facilities and activities. report. Hazard identification for existing critical units Accordingly, DMP shall be incorporated with has also been briefly discussed in the EIA report. An the on-site emergency response systems. updated and comprehensive Disaster Management Plan along with unit-wise Onsite emergency plan is also included as part of Annexure-7.2. EDS(iv) Socio-economic study including need-based Chap. 7, Clause 7.2 259 – 270 xThe socio-economic study has been carried out assessment shall be furnished” CER table within the study area including the needs may be re-worked out and basis for CER assessment of the peripheral communities. The shall be evolved. needs of the peripheral communities is briefly summarized in Clause 7.2.7. Annexure 3.3. xThe Needs assessment carried out as part of the socio-economic study is attached as Annexure 3.3
COVERAGE OF TOR Page xv © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
REVISED DETAILS ISSUED AS PART OF EDS & ADS ISSUED DURING EAC MEETINGS (Online EDS dated 17.04.2019 and ADS dated 14.06.2019) Sl. No. Observations of the Hon’ble EAC Chapters Pages Remarks Chap. 4 Clause 4.7.8 204-206 xThe findings of the Need-based socio-economic study has been used along with the issues raised during public hearing to formulate the CER action plan with emphasis on specific areas as identified during the PH and the Need based socio-economic study. The reworked CER has been discussed at Chap.4, Clause 4.7.8. ADS(i) The project proponent had not clearly Annexure 2.1(d) xThe implementation status of the facilities presented the salient aspects of the envisaged in existing EC is briefly discussed in implementation status of the existing EC, Chapter-2 and the details are enclosed as associated conditions thereof and status of Annexure 2.1(d). compliance of the conditions. Annexure 2.1(e) xThe RO, MoEFCC issued the recent Certified EC Compliance report vide letter no. 103- 211/13/EPE/3948 dated 12.05.2020, highlighting various observations (attached as Annexure- 2.1(e)). Subsequently, SAIL-Bokaro submitted its Action Taken Report vide letter dated 11-08-2020
Annexure 2.1(f) xSAIL-BSL subsequently submitted its updated Action Taken Report after consideration of the comments from RO, MoEFCC vide letter no. ECD/EMS/01/2020-2021 dated 11-08-2020 for closure of observations on Compliance of EC conditions. The same has been attached as Annexure-2.1(f). ADS(ii) The Committee further noted the mismatch Annexure-1.1 SAIL-BSL had applied for amendment in ToR between plant configuration and contents of regarding correction in capacity of proposed coke the ToRs. Moreover, ToRs points have not oven, which has been granted by MoEFCC vide letter been adequately addressed in the EIA/EMP no. IA/JH/IND/153631/2020 dated 20/05/2020 (copy report. The project proponent requested for attached as part of Annexure 1.1) more time to address the lacunae in the present proposal, and sought additional time The present EIA-EMP report has been revised based to review and revise its proposal. on observations noted by the Hon’ble EAC (Industry- 1) during EC appraisal meeting held on 31-05-2019 and subsequent meetings held on 23-08-2019 & 26- 06-2020.
COVERAGE OF TOR Page xvi © 2020 MECON Limited. All rights reserved (;(&87,9(6800$5< STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT EXECUTIVE SUMMARY 1.0 INTRODUCTION
Steel Authority of India Limited (SAIL) is the leading steel maker in India and to fulfil its long term strategic goal of playing as a key partner in the Steel Market, SAIL have come up with a corporate plan for the expansion of their Bokaro Steel Plant (BSL) to enhance its present hot metal production capacity of 4.5 MTPA to 5.77 MTPA of hot metal along with addition of some new facilitating units as well as debottlenecking and up-gradation of existing facilities.
BSL had already been accorded EC on 16.10.2008 by MoEFCC for expansion of its capacity from 4.0 MTPA to 7.0 MTPA of crude steel. Further, this EC (valid until 14.10.2018 with one extension) had been granted an amendment by MoEFCC for modifications in some existing plant facilities of BSL along with reduction of overall plant production capacity to 4.606 MTPA Crude Steel (5.77 hot metal) vide MoEFCC letter F.No J-11011/99/2007-IA.II(I) dated 28.11.2014.
However, as some of the expansion cum modernization projects of BSL got delayed and expiry of validity period was nearing, BSL again approached MoEFCC seeking fresh TOR in the 29th meeting of EAC held during 12th to 14th March, 2018. During deliberations, BSL also requested the MoEF&CC to consolidate their earlier proposal for “Modernization of existing Bokaro Steel plant by addition of 2.0 MTPA Pellet plant & 0.768 MTPA Coke oven battery” along with the present proposal. The same was accepted and the Terms of reference (ToR) for the consolidated proposal was granted by MoEF&CC vide their letter No.J-11011/99/2007-IA-II(I) dated 10th April, 2018.
2.0 PROJECT DESCRIPTION
BSL proposes the following activities in its expansion-cum-modernization plan of existing integrated steel plant at Bokaro. Sl. Unit Existing Installed Capacity Proposed Capacity At Remarks No. 5.77 MTPA Hot Metal Stage 4.212 MTPA of gross Addition of new coke oven battery of 1 Coke Ovens 3.442 MTPA coke 0.77 MTPA gross coke capacity Addition of new Sinter Plant of 3.7 2 Sinter Plant 5.0 MTPA 8.7 MTPA of gross coke MTPA gross sinter capacity Installation of new 2.0 MTPA pellet 3 Pellet Plant - 2.0 MTPA of pellet plant 5.77 MTPA 4 Blast Furnace 5.77 MTPA NO CHANGE (Existing production limited to 4.5) (same as before) Steel Melting Stage-1 modernization of SMS-I to 1.5 MTPA 1.306 MTPA Shop - I capacity of 1.306 MTPA 5 Steel Melting Augmentation of SMS-II to 3.35 3.3 MTPA 3.35 MTPA Shop – II MTPA 7 working soaking pit 7 working soaking pit 6 Slabbing Mill NO CHANGE batteries batteries 7 Hot Strip Mill 4.5 MTPA 4.5 MTPA NO CHANGE Refractory Addition of New Kiln of 450 TPD 8 Materials 0.2449 MTPA 0.4091 MTPA (0.1642 MTPA) Plant 2700 TPD 3950 TPD Addition of 1 x 1250 TPD Oxygen 9 Oxygen Plant (1450 TPD Captive+ 1250 (1450 TPD Captive + 2 Plant (BOO) TPD BOO) x 1250 TPD BOO) 2.4 MTPA Cold Rolling Debottlenecking of existing CRM 10 (1.2 of CRM I&II+1.2 of CRM- 2.86 MTPA Mills – I, II& III complex to 2.86 MTPA III) EXECUTIVE SUMMARY Page ES1 of ES10 © 2018 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. Unit Existing Installed Capacity Proposed Capacity At Remarks No. 5.77 MTPA Hot Metal Stage ~17000 m3/hr (Design Raw Water capacity = 23000 m3/hr) Maximum drawl Alternate water pipeline system 11 Supply (Permission upto 23140 capacity of 23140 m3/hr along with Tenu Canal System m3/hr)
2.1 LOCATION OF THE PROJECT & LAND REQUIREMENT
Bokaro Steel Plant (BSL) is located in Bokaro District, Jharkhand with plant centre coordinates 23°40'51.73"N and86° 5'17.65"E. The existing plant is in operation over a total area of 6973.68 ha which is under possession of BSL of which 1199.99 ha is taken up by the cooling ponds and 360.17 ha is occupied by the slag dump. At present green belt and plantations cover 1923.99 ha (i.e. 33.32%). All the proposed units shall be set up within the existing premises of the steel plant (i.e. no additional land acquisition).
2.2 RAW MATERIAL REQUIREMENTS & SOURCES
At present 4.5 MTPA stage, the total raw material required is ~16.9 MTPA. The same shall increase to ~17.6 MTPA after proposed expansion cum modernization. The breakup of raw material required is as follows- Sl. Raw materials Quantity required at 4.5 Quantity requirement Source Mode of No. MTPA HM (TPA) at 5.77 MTPA HM (TPA) transportation 1 Lump Iron Ore 2196000 956300 SAIL’s Captive mines Rail 2 Iron Ore Fines 5450000 10785290 3 Manganese Ore 259000 - Not required - 4 Limestone 3301000 312260 SAIL’s Captive mines Rail 5 Dolomite 169000 363870 Captive mines/purchased from Bhutan Rail 6 Coking coal 4470500 4582667 BCCL & imported Sea/Rail 7 Coal (CDI) 1065800 577000 Imported Sea/Rail 8 Bentonite - 23760 Purchased from Kuchch region Road Total raw material 16911300 17601147 requirement (TPA) Sp. Raw material 4.03 3.78 Consumption (t/tcs)
2.3 FUEL REQUIREMENT
The proposed units will be fueled by Coke oven gas/BF gas/ BOF gas generated in-plant from existing Coke Oven complex, Blast Furnaces and SMS complex. It is estimated that after the proposed expansion-cum-modernization of BSL, ~11.3 lakh Nm3/hr of BF Gas, ~1.6 lakh Nm3/hr of CO Gas and ~48,300 Nm3/hr of BOF Gas will be generated of which the plant requirement is estimated to be ~8.7 lakh Nm3/hr of BF Gas, ~1.3 lakh Nm3/hr of CO Gas and 3381 Nm3/hr of BOF Gas. The balance gas will be exported to BPSCL’s power plant for power generation. The use of in-plant fuel sources and increase in use of renewable energy sources shall improve the specific energy requirement of BSL from from 6.67 Gcal/tcs (at 4.5 MTPA HM) to 6.5 Gcal/tcs (at 5.77 MTPA HM).
2.4 WATER REQUIREMENT
No additional water withdrawal is envisaged for the proposed expansion-cum-modernization plan apart from the existing allocation of 227 cusecs (~23000 m3/hr) from Damodar River. The water drawl from Damodar River for meeting all requirements of BSL after proposed expansion-cum- modernization project shall be ~17000 m3/hr and the existing water allocation of ~23000 m3/hr is EXECUTIVE SUMMARY Page ES2 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT sufficient to cater the future water requirement of BSL. Further, extensive recycling and water reuse is envisaged in the present proposal, which will ensure no additional fresh drawl of water is required. The specific water consumption will improve from existing 3.55 m3/tcs (at 4.5 MTPA HM) to 3.48 m3/tcs (at 5.77 MTPA HM).
2.5 POWER REQUIREMENT & SOURCES
The existing power requirement for operating the steel plant is about 256.3 MW (excluding losses). For the proposed expansion cum modernization, the additional power requirement is 63.8 MW (Modernized SMS-1: 22.4 MW Sinter Plant-II: 22.4 MW, Pellet plant: 16 MW and Coke Oven plant: 3.0 MW (i.e 9.5– 6.5 MW generated by BPTG)). The same shall be met from existing Power network of BSL, which is primarily sourced from Captive Power Plant (CPP) of BPSCL as well as purchased from Damodar Valley Corporation (DVC).
2.6 PROJECT COST AND MANPOWER REQUIREMENT
The total cost for the projects is estimated as Rs. 5219.1 Crores. An amount of Rs 365 Crores has been allocated for Environment Protection control measures.
Additional 785 personnel (99 executives as well as 686 non-executives) are required for the proposed project. This requirement will be fulfilled by suitable redeployment of existing manpower (mostly for executives) as well as external hiring of other employees, preferably from local skilled and semi-skilled population in the area. The executives will be mostly regular employees and the non-executives will be mostly on contract basis.
3.0 DESCRIPTION OF THE ENVIRONMENT
The baseline environmental data was generated during Summer season, 2018 (March, April & May, 2018) for air, water, noise levels and soil characteristics, by setting up of monitoring stations for meteorology and air quality. Samples were collected for water and soil quality. Further, existing ecological and socio-economic features were also studied. The collected data were analysed for identifying, predicting and evaluating environmental impacts. The maximum anticipated impacts were assessed and based on these an environmental management plan has been drawn.
3.1 MICRO METEOROLOGY
A meteorological station was set up in Township area. AS per the monitored data, it is observed that winds are predominantly coming from NNW, SSE and N directions during monitoring period. The overall (24 hours) predominant wind direction was NNW (6.84%), followed by SSE (4.76%) and N (3.58%) recorded during monitoring period. Calm conditions prevailed for 66.17 % of the time. Wind speeds were in the range of 0.44 - 2 m/s. The air temperature ranged from 17.0 °C to 43.4°C (Avg.: 30.4°C). The maximum solar radiation was 2 cal/cm2/min. Total 17 mm of rainfall was recorded; there were 5 “rainy days”.
3.2 AMBIENT AIR QUALITY
Ambient Air Quality (AAQ) was monitored at eight (8) monitoring stations. All values at all the monitoring stations were found well within the respective permissible limit for Industrial, Residential, Rural and Other Areas. The summarized results are as follows.
Pollutants (μg/m3) Range Average Norm # PM10 49-99 68-88 100 # PM2.5 27-59 35-47 60 EXECUTIVE SUMMARY Page ES3 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Pollutants (μg/m3) Range Average Norm # SO2 8-40 15-21 80 # NO2 23-63 31-45 80 CO** 149-2490 591-1103 4000 NH3 13.9-39.2 18-31.6 400 O3 36.1-90.1 50.4-67.7 180 Pb 0.003-0.036 0.009-0.019 1 Ni (ng/m3) 0.834-12.778 3.206-7.155 20 As (ng/m3) <1.84 – 1.89 <1.84 6 Benzene <2.08 <2.08 5 Benzo-a- Pyrene (ng/m3) <0.24 <0.24 1 Note:#24 hourly average **1 hour average
3.3 AMBIENT NOISE LEVELS
Ambient noise levels were measured at seven (7) different locations which included “Residential Areas” and “Commercial areas”. Noise levels at commercial areas ranged from 41.8 to 64.8 during day time and 37.8 to 48.3 during night time. Noise levels at residential areas ranged from 40.5 to 54.6 during day time and 38.1 to 44.8 during night time. Mean noise levels at all locations were found within their respective norms.
3.4 WATER ENVIRONMENT
Nine surface water and eight ground water samples were collected and analysed. All the surface water quality were found within the norms for Class B or Class C. The ground water quality at all monitoring stations were compared with drinking water norms IS:10500. In few locations total Dissolved Solids content and total hardness is exceeding the desirable limits, however, within the Permissible Limits. All other parameters are within the limits.
3.5 SOIL CHARACTERISTICS
To assess the quality of soil in and around the plant, soil samples were collected from six (6) locations for Physico-chemical analysis. The soil pH is in the range of 6.1-6.9. Conductivity ranged from 42 to 610 μs/cm. Availability of Nitrogen is ranging from 213 to 502 Kg/Ha while Phosphorus and Potassium vary from 1.1-11.5 Kg/Hectare & 90-549 Kg/Ha. Organic carbon content is found in the range of 1.2- 1.7 %.
Calcium and Magnesium constitutes the bulk of exchangeable cations in the tested soil samples whereas levels of exchangeable sodium and potassium are relatively low.
3.6 BIOLOGICAL ENVIRONMENT
The study area lies in the humid subtropical climatic zone and under Eastern Plateau & Hill region of the Agro-climatic Zone and within the Agro-climatic Zone (Eastern Plateau & Hill Region), the Agro- Ecological Zone is “Hot Sub-Humid Eco-Region” (Planning Commission).The area is plateau region interspersed with plain and small hillocks. Part of the study area is urban and industrial and the rest is rural and is covered with agricultural fields and small patches of forest along Damodar River towards North.
There are many stretches of forest within the study area. These forests are classified as Moist Peninsular Valley Sal Forests, sub-group of Northern Tropical Moist Deciduous Forests. In some
EXECUTIVE SUMMARY Page ES4 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT areas, Dry Deciduous Scrub Forests have developed due to biotic influences. The forests in general in the area are under high biotic influence and are under degraded state.
The forests are composed of Butea monosperma (Palas), the most dominant species followed by Bombax ceiba (Semal), Lagerstroemia parviflora (Sidha), Madhuca indica (Mahua) and Alangium salviifolium (Dhela).
Due to lack of suitable habitat, the only animals found in the vicinity of the project site are few rodents, small mammals, reptiles and birds. The forests in the study area are mostly degraded and too small to support viable populations of large mammals. No Schedule-I faunal species are found in the study area.
There is no Biosphere Reserve, Ramsar Site, National Park, Wild Life Sanctuary, Tiger Reserve, Elephant Reserve or Wildlife Corridor in study area.
4.0 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES
4.1 IMPACTS ON AMBIENT AIR QUALITY
The prediction of Ground level concentrations (GLC) of pollutants emitted from the proposed stacks have been carried out using AERMOD Air Quality Simulation model released by USEPA. The GLCs has been predicted over a 20 km X 20 km area with the location of the SMS1 as the center. GLCs have been calculated at every 500 m grid point.
The maximum GLCs for each grid point were predicted with respect to pollutants PM, SO2 and NOx. The maximum values are obtained within/very close to the plant. The predicted values are super imposed on existing AAQ data & found values are within the norms. After expansion, the maximum GLCs derived from the proposed new units are as follows- Pollutants Baseline Mean Additional GLCs Cumulative AAQ Norm AAQ AAQ station PM10 68-88 0.3-1.0 69.2-88.8 100 SO2 15-21 1.6-3.8 18.8-24.2 80 NO2 31-45 0.8-2.2 33.2-46.2 80 3 Values in μg/m Several pollution control equipment as ESPs/ Bag filters in stacks, fugitive emission control systems in new coke oven plant, dust suppression and dust Extraction systems while handling of raw materials are provided in the proposed units to control air emissions.
4.2 IMPACTS ON NOISE LEVELS
No impact on ambient noise levels are envisaged due to proposed expansion as acoustic enclosures, hoods, laggings and screens are provided in noise prone areas to the extent possible so that the sound pressure level in working areas are restricted below 85 dB(A) for 8 hours duty. Whenever this is not practicable, administrative and personnel protection measures like provision of rotation of workers to minimize exposure time as well as provision of ear muffs to workers exposed to high noise areas are envisaged.
4.3 IMPACTS ON WATER
No additional water withdrawal is envisaged for the proposed expansion-cum-modernization plan. Water used for services and other losses will be met through recycling of the effluents being generated by various other units of the Plant. Thus, no impact on existing water regime is envisaged. The effluents generated from these units will be recycled and reused. EXECUTIVE SUMMARY Page ES5 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
4.4 IMPACTS ON ECOLOGY
The proposed modernization and setting up of new project units will be carried out within the premises of the existing steel plant. No additional land will be acquired for the project. The area earmarked for the proposed project units are presently lying vacant. No impact on ecological environment is envisaged.
4.5 IMPACTS ON LAND ENVIRONMENT
As the proposed expansion will be within the premises of the existing steel plant and no additional land will be acquired for the project, no impact on the land use is expected.
4.6 ADDITIONAL MANAGEMENT PRACTICES
To ameliorate the adverse impacts of the project and for scientific development of the local environment, a comprehensive Environmental Management Plan (EMP) is prepared.
To supplement the existing underground water table and to reduce the fresh water consumption for the proposed project, BSL will provide rain water harvesting system for all new units.
BSL is committed to develop green belt in and around Bokaro Steel Plant. BSL has planted 45,73,150 trees so far covering 33.32 % of the plant area. In addition, BSL is carrying out tree plantations to the tune of ~1 Lakh trees every year through its Horticulture, Environment and CSR department for maintenance of the existing cover.
4.7 OCCUPATIONAL SAFETY & HEALTH PLAN
Safety is a prime concern for SAIL as well as BSL. The plant has a dedicated “Safety Engineering Department” headed by the General Manager (Safety). He is assisted by the Dy. General Manager (Safety). Safety officers under him will look after the safety activities in all the departments. This department regularly scrutinizes, supervises and ensures implementation of safe working practices in various departments of the company. Safety Engineering Department conducts Safety Training Programmes for all regular employees / contractual workers of BSL at various levels. Special Training Programmes by external safety experts on various topics are being conducted on different topics.
SAIL has a dedicated safety department at the corporate level - SAIL Safety Organization (SSO), which, monitors and guides the Promotion of safety and Occupational Health Services activities undertaken at different steel Plants/Units/Mines/Stockyards.
4.8 CORPORATE SOCIAL RESPONSIBILITY& CORPORATE ENVIRONMENTAL RESPONSIBILITY
Bokaro Steel Plant has always treated its periphery as a key stakeholder. The main objective of BSL's Community Development Programme has been to create synergy and synthesis of Industrial activities, Social infrastructure with the environment. Bokaro Steel Plant has established a separate department “CSR” for carrying out various activities under Corporate Social Responsibility. As part of corporate environmental responsibility SAIL-Bokaro will keep the financial provisions on various focus areas as identified by the issues raised during Public hearing and other community development projects.
EXECUTIVE SUMMARY Page ES6 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 5.0 ANALYSIS OF ALTERNATIVES
Alternative technologies for all the units have been taken into consideration and after sufficient reasoning suitable technologies have been chosen.
6.0 ENVIRONMENTAL MONITORING PROGRAMME (EMP)
To ensure the effective implementation of the proposed mitigation measures, elaborate arrangements were made for monitoring of various environmental parameters. Environmental aspects to be monitored include drainage systems, water quality, emissions and air quality, noise pollution, solid/hazardous waste utilization, green belt development, housekeeping & occupational health.
7.0 ADDITIONAL STUDIES
7.1 RISK ASSESSMENT & DISASTER MANAGEMENT PLAN
Risk assessment for hazardous gases to be handled as well as stored after the implementation of proposed modernization-cum-expansion project at BSL has been carried. The maximum hazard extent due to thermal effects of fire is 127 m, for explosion effects is 136 m and for toxic effects is 50 m. The nearest habitations are >2000 m away from the plant and no offsite hazard is anticipated on these habitations due to the proposed project. BSL is having a well-documented Onsite Emergency Plan for their existing plant covering all the chemicals / gases handled by BSL. During the current project, no additional chemical will be handled. BSL shall extend existing Onsite Emergency Plan for the proposed projects also.
7.2 SOCIO-ECONOMIC STUDY
Socio-economic survey was undertaken in all the villages identified in the study area. The unit of population like, Literate, illiterate, employed, unemployed, old age, youths, males and females were included in the survey. Needs and expectations of the villagers have also been studied as part of the Need based Assessment studies.
BSL already has made a widespread impact on the social and economic conditions of the people of the region in terms of direct and indirect employment, skill diversification, infrastructure development, business development etc. Over the years BSL has carried out excellent community development activities and now approaching towards implementation of sustainable development programmes.
7.3 PUBLIC CONSULTATION
Public Hearing for the proposed project was conducted on 08.12.2018 at Bokaro Club Limited, Sector-V in Bokaro Steel City, District Bokaro. A total of 130 numbers of representations/ queries/ suggestions/ views were received in connection with the project. Majority of the queries were related to concerns regarding pollution of the environment and other miscellaneous issues, infrastructure development related to water supply facilities and generation of employment opportunities. Technological aspects and health care commitments of BSL were also discussed. The Public hearing was successfully completed and all issues were addressed by BSL. Subsequently, a budgetary action plan has been prepared for addressing all the identified issues and needs of the villagers.
8.0 PROJECT BENEFITS
The proposed expansion will increase steel production which will contribute to achieving National Mission for Steel Production of 300 MTPA by the year 2030. This will also improve the revenue EXECUTIVE SUMMARY Page ES7 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT generation for the Central and State exchequer, besides reducing the Nation’s dependence on imports.
The proposed modernisation includes increase in sintering capacity, which will increase utilisation of iron ore fines (generated both at the plant and at SAIL’s captive iron ore mines), coke fines, lime fines and mill scales. The new pelletisation plant will enable utilisation of iron rich tailings from SAIL’s captive mines. These will reduce the dependence on iron ore lumps for hot metal production.
The new units will have modern pollution control systems and existing ESPs will also be revamped. Implementation of Zero Liquid discharge systems will also reduce discharge of wastewater from the plant. The specific PM load will decrease from 0.76 kg/tcs (at 4.5 MTPA HM) to 0.69 kg/tcs (at 5.77 MTPA HM). The specific water consumption will also decrease from 3.55 m3/tcs to 3.48 m3/tcs. The debottlenecking and modernization schemes will also improve productivity with improvement in energy efficiency, leading to improvement from 6.67 Gcal/tcs (at 4.5 MTPA HM) to 6.5 Gcal/tcs (at 5.77 MTPA HM).
The project shall also generate considerable direct and indirect employment. The employment generation will be 785 (permanent) and 2500 (temporary). Further, BSL is making major contributions for development of social infrastructure in the area, such as improvement of roads, improvements of health care facilities, improvement of education facilities, contribution to social and cultural events etc. The same shall continue. A total of Rs. 17.22 Crores has been allocated by BSL as Corporate Environmental Responsibility (CER) for development in peripheral villages. The CER implementation plan based on PH issues and Need based socio-economic assessment is as indicated below: Amount to be spent (in Rs. lakhs) Sl. No. Sector 1st yr. 2nd yr. 3rd yr. 4th yr. 5th yr. 6th yr. 7th yr. Total (A) Based on Need based Socio-economic assessment 1 For education: i Gyan Jyoti Yojana-Adoption of 15 of 8 8 8 8 8 8 8 56 Birhor Children ii Scholarships under CSR to support 1.5 1.5 1.5 1.5 1.5 1.5 1.5 10.5 technical education iii Repair & maintenance of BSL school 5 5 5 5 15 15 15 65 buildings where more than 80% non- BSL students are studying iv Support to two Schools run under 5 5 5 5 10 10 10 50 Mahila Samiti v Non-matriculate to Matriculation 8 8 8 8 8 8 8 56 drive for girls/ women 2 For Healthcare i Sarva Swasthya Kendra, Sector- V 2.5 2.5 2.5 2.5 2.5 2.5 2.5 17.5 ii Low- cost Sanitary Napkin project 2 2 2 2 2 2 2 14 3 For Livelihood Generation Providing infrastructure and financial 25 25 25 25 30 30 30 190 i support to Bokaro Pvt ITI established CSR Silk Yarn Reeling project to provide 3 3 3 3 3 3 3 21 ii skill development of women 4 For Sanitation
EXECUTIVE SUMMARY Page ES8 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Amount to be spent (in Rs. lakhs) Sl. No. Sector 1st yr. 2nd yr. 3rd yr. 4th yr. 5th yr. 6th yr. 7th yr. Total Maintenance of 105 toilets under 18.5 18.5 18.5 18.5 25.5 25.5 25 150 i SVA 5 Rural Infrastructure Development Miscellaneous civil work in 4 4 4 4 4 4 4 28 i peripheral villages and other sites SUB-TOTAL (A) 82.5 82.5 82.5 82.5 109.5 109.5 109 658 (B) Based on Public consultation issues Installation of hand-pumps in 10 10 10 10 10 10 5 65 6 peripheral villages through CSR Dept. Annual repair & maint. of hand- 4.32 5.34 5.34 5 15 15 15 65 pumps installed in peripheral 7 villages, construction of toilets through CSR Repair of roads within the Bokaro 50 50 50 50 50 50 50 350 8 Steel township by Town Administration dept. Infrastructural development as 76 76 76 76 76 76 76 532 well as financial support to Bokaro Balika Kalyan Vidyalaya as well as Bokaro Steel Kalyan 9 Vidyalaya. Additionally funding and operation of 8 different schools in township as well as peripheral areas. Repair & maintenance of roads in 2 2 2 2 2 2 2 14 10 peripheral villages (both PCC & pre- mix types) Greenbelt development in outside 4 4 4 4 4 4 4 28 11 plant area (near Garga Basin) Greenbelt development in 1.75 1.75 1.75 1.75 1 1 1 10 12 peripheral villages (including Satanpura village) SUB-TOTAL (B) 148.07 149.09 149.09 148.75 158 158 153 1064 GRAND TOTAL (A+B) 1722 Lakhs (i.e. 17.22 Crores)
9.0 EMP-ORGANISATIONAL SET UP AND IMPLEMENTATION ARRANGEMENT
BSL has given maximum importance for adopting latest state-of-the-art technologies for keeping the pollution to minimum levels. A separate Environment Control Division (ECD) was set up along with an Environmental Laboratory with latest monitoring instruments.
The ECD also co-ordinates with other departments like Occupational Health, Safety Management, Project Engineering, Horticulture, Social Welfare, CSR Department, Water Supply Department etc. and also do the liaison work with external agencies like State & Central Pollution Control Boards and SAIL Corporate Office.
EXECUTIVE SUMMARY Page ES9 of ES10 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT BSL has installed continuous online stack monitoring systems in all existing and provision of the same has been kept for in upcoming units. Also ambient air monitoring stations have been setup at eight locations around the plant.
10.0 SUMMARY & CONCLUSION
In the design phase of the Project, EIA was done to assess the possible impacts of the proposed Expansion-cum-modernization plan of BSL from 4.5 MTPA to 5.77 MTPA hot metal. In the plant design itself, latest state-of-art technology has been envisaged so as to achieve the desired air emissions and noise levels from plant operation levels. All new proposed facilities have been designed for “Zero Water Discharge”. Also, Zero Liquid discharge facilities are being proposed for recycling the waste water being discharged from outfalls. Further, all generated solid waste will be either recycled back into the steel plant operations or sold in open market for further use in cement making, road making etc.
Primary and secondary data were used to assess the environmental impacts of the proposed project. The introduction of state-of-art technology (including the technological mitigation measures) during the design has limited the associated environmental impacts of the Project. The implementation and monitoring of effectiveness of the environmental mitigation measures during the operation phase will be done by the Environmental Control Department of BSL.
EXECUTIVE SUMMARY Page ES10 of ES10 © 2020 MECON Limited. All rights reserved EIA-EMP REPORT STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
CHAPTER-1: INTRODUCTION
The present report is an EIA/EMP report for the proposed Expansion-cum-modernization of Steel Authority of India Limited’s (SAIL) Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand. The report is prepared as per the procedure specified in 14th September 2006 Notification of Ministry of Environment, Forest & Climate Change (MoEF&CC), Government of India and subsequent amendments thereto.
1.1 PURPOSE OF THE REPORT
In pursuance of Government of India policy vide Environmental (Protection) Act 1986, new projects or expansion of existing plant necessitates statutory prior environmental clearance in accordance with the objectives of National Environmental Policy (NEP) as approved by the Union Cabinet on 18th May, 2006 and MOEF&CC, EIA Notification dated 14.09.06, by preparing Environmental Impact Assessment (EIA) report. In view of the above, the EIA report has been prepared taking into consideration the requirement and guidelines of statutory bodies and also SAIL-Bokaro’s requirement.
The objective of the EIA study report is to take stock of the prevailing quality of environment, to assess the impacts of proposed industrial activity on surrounding environment and to plan appropriate environmental control measures to minimise adverse impacts and to maximise beneficial impacts of proposed project. The following major objectives have been considered: x Assess the existing status of environment. x Assess the impacts due to the proposed project. x Suggest pollution control and ameliorative measures to minimise the impacts. x Prepare an action plan for implementation of suggested ameliorative measures. x Suggest a monitoring programme to assess the efficacy of the various adopted environmental control measures. x Assess financial considerations for suggested environmental control plans. x Clearances from statutory authorities
1.2 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT
1.2.1 Project Proponent
SAIL is a public sector undertaking under Ministry of Steel, Government of India. SAIL is one of the leading steel makers in India. SAIL produces iron and steel at five integrated plants {Bhilai Steel Plant in Chattisgarh, Rourkela Steel Plant in Odisha, Bokaro Steel Plant in Jharkhand, Durgapur Steel Plant and IISCO Steel, Burnpur in West Bengal), three special steel plants {Salem Steel Plant in Tamil Nadu, Visvesvaraya Iron & Steel Plant in Karnataka, Alloy Steel Plant in West Bengal) and Ferro Alloys Plant at Chandrapur, Maharshtra. SAIL has its own captive mines for sourcing its entire requirements of iron ore and part of its requirements of other raw materials.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
1.2.2 The Project
To fulfil its long term strategic goal of playing as a key partner in the Steel Market, SAIL has come up with a corporate plan for the expansion of their Bokaro Steel Plant (BSL) to enhance its present hot metal production capacity of 4.5 MTPA to 5.77 MTPA of hot metal along with addition of some new facilitating units as well as debottlenecking and up-gradation of existing facilities.
The proposed project will be implemented at the Bokaro Steel Plant (BSL). Hence, BSL is the project proponent for the proposed project.
The proposed expansion-cum-modernization project, primarily includes Phase-1 up-gradation of SMS-1 to 1.306 MTPA, augmentation of existing SMS-2 to 3.35 MTPA, debottlenecking and augmentation of CRM complex to 2.86 MTPA, addition of a new 3.7 MTPA Sinter plant, a new 2.0 MTPA Pellet plant, a new 1.0 MTPA Coke Oven plant, a new lime-dolo kiln of 0.1642 MTPA, a new Oxygen plant of 1250 TPD and repair of Tenu canal along with development of an alternate system of drawl of raw water from Damodar river.
1.2.3 EIA consultant
The EIA/EMP report for the proposed Expansion-cum-Modernisation of Bokaro Steel Plant, located at Bokaro Steel City, Jharkhand, from 4.5 MTPA Hot Metal to 5.77 MTPA Hot Metal (BSL) has been prepared by MECON Limited, a Public Sector undertaking under the Ministry of Steel, Government of India.
MECON Limited is accredited by QCI/NABET for preparing EIA/EMP reports in 17 sectors, including “Metallurgical industries (ferrous & non-ferrous) – both primary and secondary” vide their certificate no. NABET/EIA/1619/RA 0068. This certificate is valid up to 22nd September, 2020. A copy of this NABET certificate is attached along with this EIA-EMP report.
1.3 BRIEF DESCRIPTION OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION
1.3.1 Importance of the Project
The Indian steel industry is poised for faster growth in the decades ahead as the industrial and economic development of the country gains pace. As per the review report of National Steel Policy approved by the Cabinet, titled “Transformation of the Steel Sector" published in 2017, the total steel consumption of finished steel has been estimated to touch 230 MT in 2030-31 (as per study carried out Ministry of Steel, INSDAG, MECON & based on the premise that 60-65 % of steel production in 2030-31 shall be coming through BF-BOF route and rest through EAF/IF route) from the existing production levels of 97.936 MT (in 2016-17 as per Annual report 2017 published by Ministry of Steel). Even after approximately doubling the production capacity, which currently stands at about130 MT of Crude steel, the per capita domestic consumption of 61 kg would continue to be substantially below the world average of 208 Kg per capita. There is good prospect of domestic steel consumption growing to 161 kg per capita by 2030-31. The national steel policy has set a target of 300 million tonne (MT) of steel production by 2030-31.Steel Authority of India, CHAPTER-1 INTRODUCTION Page 2 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Limited is well positioned to fulfil its role in the nation’s quest for higher growth and development in the new millennium.
Steel being a basic commodity for all industrial activities, quantum of its consumption is considered as an index of industrial prosperity. Since independence, there has been a substantial growth in the steel production in India from 1.5 MT in 1950-51 to about 128 MT in 2016-2017. Despite the above growth in the steel sector, the per capita finished steel consumption continues to remain at a level of about 61 kg per capita only, compared to 208 Kg per capita in the world. Further, with nearly 17% of the world population, India’s contribution is only of the order of 6.0% of world steel production (in 2016-2017). Hence, short-term and long-term strategies are necessary in planning the development of the steel industry in the country to improve the level of per capita steel consumption.
The growth of the steel industry significantly contributes to economic growth of the Nation as well as to the region as it generates employment both directly and also due to development of downstream industries. The infrastructural and other social amenities grow in the region leading to overall development of the region.
The project is needed to facilitate SAIL-Bokaro in meeting its production requirements and contribute to the Steel Production in the country as per National Steel Policy to bridge the gap between demand and supply.
1.3.2 Alternative Sites Considered
The modernization activities / additional facilities envisaged under proposed expansion-cum- modernization plan of Bokaro Steel plant (BSL) have been contemplated to facilitate Bokaro Steel plant in producing its envisaged production capacity of 5.77 MTPA hot metal. So, it is more feasible to have the facilities installed at minimum distance from the existing units of the plant. Also, the existing plant has sufficient land area to accommodate the new projects within the premises of the existing steel plant. So, the new Pellet plant, Coke Oven Battery, Sinter Plant, Oxygen plant and lime-dolo kiln are proposed to be setup within the existing plant boundary of Bokaro Steel Plant.
1.3.3 Location of the Project
The proposed expansion-cum-modernization plan will be carried out within the existing plant boundary of Bokaro Steel Plant (BSL), which is located in Bokaro Steel City, Sub-division Bokaro of Bokaro District in Jharkhand, between longitude 86°04’1.56”E to 86°08’38.27” E and latitude 23°38'45.38” N to 23°43'2.89” N. The site is approximately 100 km away in the ENE direction from Ranchi, the state capital of Jharkhand. The nearest Railway station i.e. Bokaro Steel City is approximately 3.0 km away. The nearest airport is Ranchi, which is about 90 km away. However Steel Authority of India Ltd. (SAIL) has its own airstrip at Bokaro itself. This airstrip is being upgraded to handle commercial flights.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
The salient features of the proposed project site and its environmental sensitivity is briefed in Table 1.1.
Table 1.1 Salient Features of Project Site & Its Environmental Sensitivity Sn Particulars Description 1. Project Location xBokaro Steel City, Chas tehsil of Bokaro District in Jharkhand x23°38'45.38” N to 23°43'2.89” N (Lat.) 2. Geographical Coordinates (Lat.& Long.) x86°04’1.56” E to 86°08’38.27” E (Long.) 3. Survey of India (SOI) Toposheet Reference xF45C1, F45C2, F45B13& F45B14 xPlain, barren land 4. Topography of project site xAltitude: 215 m to 243 m above MSL xAvg. annual rainfall: 1267.8 mm (as per IMD Atlas, Bokaro) 5. Climatic conditions xAnnual Temperature (min-max): 3°C to 45°C (as per IMD Atlas, Bokaro) xTotal plant area of Bokaro steel plant = 6973.68 ha. Proposed 6. Land details modernization-cum-expansion programmed will be carried out under existing plant premises. xNo additional water drawl required.The requirement of make-up water for BSL after the proposed modernization-cum-expansion has been estimated to be 9500 m3/hr (2,28,000 KLD) will be 7. Water requirement from the already allocated water supply for BSL. Source: Existing water supply system as well as by treatment & recycling of waste water from outfalls. xNo additional fuel is required for the proposed project. The total fuel requirement for BSL after this proposal will be met together from the existing & proposed fuel gas generation network. An additional 3200 kg/h of propane will be required for catering to 8. Fuel requirement the cutting requirements of SMS, Caster and auxiliary shops.
Source: CO gas & Mixed gas will be sourced from existing fuel gas network of BSL. Propane gas will be sourced locally. xThe additional power requirement for the proposed expansion- cum-modernization is 63.8 MW. 9. Power requirement Source: From Captive Power Plant (CPP) of BPSCL as well as purchased from Damodar Valley Corporation (DVC) ENVIRONMENTAL SENSITIVITY xNH-32 (~7 Km , S) 10. Nearest State/National Highway xNH-23 (~2.5 Km, S 11. Nearest Railway station xBokaro Steel City R.S (~3.0 km, SW) xRanchi Airport (~90 km, SW) 12. Nearest commercial airport xBokaro Air strip xNo Wildlife sanctuary/National Park/ Biosphere reserve is Ecologically sensitive areas (Wild Life present within 10km study area from the proposed site. 13. Sanctuary National Park / Biosphere Reserve etc.) xNo notified ecologically sensitive area present within 10 k of the area. 14. RF / PF in Project Site xNo forest land within the Project Site. Within 10km: xProtected Forest (PF) along Damodar River (degraded) 15. RF / PF In Study Area xProtected Forest (PF) near Nara (degraded) xPatches of open scrub forests WATER BODIES: 16. Nearest River / Dam xDamodar River,~6.5 km (N) CHAPTER-1 INTRODUCTION Page 4 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sn Particulars Description xGarga Nadi, ~4.0 km (S) xGarga Reservoir, ~ 4.5 km (SW) xZone III (Moderate Damage Risk Zone) as per Seismic Zone 17. Seismic Zone India Map IS:1893 (Part I) 2002 xBokaro Steel City, ~1km (E) 18. Densely populated or built-up area xChas, ~5km (E) xNo private land acquisition required. Proposed activity 19. Land Acquisition & R&R Issue envisaged within existing premises of Bokaro Steel Plant. Hence, no R&R issues. Source: 1. Survey of India Toposheet Nos. F45C1, F45C2, F45B13 & F45B14, Google Earth Imagery and Wikimapia 2. http://www.jharkhand.gov.in/web/bokaro, https://bokaro.nic.in/
The area is devoid of any greenery and the general topography of the area is plain with slight undulation. Land development will be as per detailed engineering for the project.
The location map (index map) is shown in Fig. 1.1. The GPS locations of corners of the project site are given in Table 1.2. The location of the existing Bokaro Steel plant overlaid on Survey of India toposheets, indicating the GPS coordinates of the project site is shown in Fig.1.2(a).The project site marked on Google Earth is shown in Fig. 1.2(b). The study area covering 10 km radius around the proposed project area is shown on toposheet in Drg. MEC/11/S2/E24V/01. Site photographs of the same are shown in Fig. 1.3.
Table 1.2: GPS Coordinates of Project Site Sl. No. Units Corner Index Latitude (N) Longitude (E) 1 23.648171 86.097261 2 23.660658 86.098098 3 23.656157 86.126024 4 23.643593 86.127401 5 23.653438 86.132405 6 23.6636 86.134035 7 23.672185 86.141441 8 23.684881 86.136062 9 23.669725 86.127826 10 23.672497 86.119806 11 23.676861 86.12166 1. Existing plant 12 23.677257 86.111948 13 23.682149 86.120791 14 23.693739 86.111709 15 23.683609 86.10456 16 23.685806 86.098749 17 23.708662 86.099514 18 23.707113 86.084929 19 23.713811 86.088884 20 23.716504 86.074024 22 23.702888 86.067058 23 23.697579 86.068851 24 23.662091 86.08686 Source: Preliminary Survey conducted during site visit on 09.07.2018.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Fig 1.1: Location of Project Site (Index Map)
xLocated in Eastern Jharkhand xDistrict: Bokaro xLatitude: 23°38'45.38” N to 23°43'2.89” N xLongitude: 86°04’1.56” E to 86°08’38.27” E xSite Topography:Plain, barren land xElevation: 215 to 243m above MSL xTemperature: 3°C (Min) / 45°C (Max) xAnnual Rainfall: 1267.8 mm (avg.)
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Fig 1.2(a): Location of Project on SOI Toposheet
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Fig. 1.2(b): Location of Project on Google Earth
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Fig. 1.3 : Photographs of Proposed site of Pellet & Coke Oven plant
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
1.3.4 Nature and Type of the Project
The proposed plant falls under Category ‘A’ (Sl.No. 3 (a) of Schedule: "Primary and Secondary Ferrous Metallurgical Industries") of the “List of projects or activities requiring prior Environmental Clearance” of MoEF&CC’s EIA notification 2006 and its subsequent amendments. The proposed project intends to expand its existing production capacity to 5.77 MTPA of hot metal and 4.656 MTPA of crude steel by modernising existing facilities such as SMS complex and CRM complex as well as installing new facilitating units such as Coke oven battery, pellet plant, sinter plant, oxygen plant and lime-dolo kiln. The existing production process is crude steel production via BF-BOF route.
1.3.5 Size of the Project
The proposed expansion-cum-modernization plan will enable existing Bokaro Steel Plant (BSL) to produce 5.77 MTPA of hot metal and consequently, 4.656 MTPA of Crude Steel. The detail of all products to be manufactured from the proposed expansion-cum-modernization units of BSL is given in Chapter-2 of the report.
1.3.6 Industries Within 10 km Radius of the Plant
Damodar Valley Corporation (DVC) had set up a 6 x 130 MW coal based thermal power plant at Chandrapura during the 1960s. This plant is about 5 km north-east of the site of Bokaro Steel Plant. Subsequently other industries have also come up in the area. The industries within a 10 km radius of Bokaro Steel plant are mentioned in Table 1.3 below: Table 1.3: Industries Located Within 10 Km Radius of the Project Sn Name of Industry Dist. & dir. from BSL Capacity Type of Industry 1. Chandrapura TPS ~5.3 km NE 630 MW Coal based Power plant 2. Dugda Coal Washery ~8.1 km NE 3 Mt/yr Coal washery 3. Dalmia Cement East Ltd. ~0.7 km W 2.1 Mt/yr Cement Plant 4. LPG Bottling Plant of IOCL ~0.7 km W NA LPG Bottling Plant 5. IOCL’s POL Storage Terminal ~1.5 km W NA Oil storage terminal 6. LPG Bottling Plant of HPCL ~1.5 km W NA LPG Bottling Plant 7. BIADA Industrial Area ~1.7 km W NA Small-scale ancillary industries 8. Selected Dhori OCP ~5.8 km NNW 11 Mt/yr (Peak) Open cast coal mine Source: Google Earth Imagery, Wikimapia and Observations made during survey of study area
1.4 SCOPE OF STUDY
SAIL-Bokaro had submitted the application for TOR along with the Form-I as per the guidelines laid down by MoEF&CC for conducting environmental studies specified in Notification dated 14.09.06. Based on the information provided by SAIL-Bokaro, the Terms of Reference (TOR) were issued during the 29th meeting of the Expert Appraisal Committee (Industry-1) of Ministry of Environment, Forest & Climate Change (MoEF&CC) held during 12th to 14th March, 2018 for preparation of EIA/EMP report for “Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal of M/s Steel Authority of India Ltd. at Bokaro Steel City, at Bokaro Dist., Jharkhand. During deliberations, BSL also requested the MoEF&CC to consolidate their earlier proposal for “Modernization of existing Bokaro Steel plant by addition of CHAPTER-1 INTRODUCTION Page 10 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
2.0 MTPA Pellet plant & 0.768 MTPA Coke oven battery” along with the present proposal, which was accepted and the Terms of reference (ToR) for the consolidated proposal was granted by MoEF&CC vide their letter No.J-11011/99/2007-IA-II(I) dated 10th April, 2018. The same is attached as Annexure 1.1. An amendment to the issued ToR for correction in Capacity of proposed coke oven battery and the final configuration of Coke oven complex at 5.77 MTPA Hot metal stage was requested by SAIL-Bokaro vide their online ToR Amendment proposal no. IA/JH/IND/153631/2020 dated 20/05/2020, which was accorded by the MoEFCC vide letter no. F. No. J-11011199/2007-IA. II (I) dated 13th July, 2020. An additional specific ToR point has been issued as part of the ToR amendment and the same is also attached as Annexure 1.1.
The present report also includes revised details as sought by the Hon’ble EAC committee vide EDS (Essential details sought) dated 17.04.2019 and ADS (Additional details sought) dated 14.06.2019. The coverage of the EDS and ADS points have also been included in the “ToR Coverage” of this report and the details have been annexed/updated appropriately in the present report.
1.5 BASIC DATA GENERATION, FIELD STUDIES AND DATA COLLECTION
This report has been prepared based on one full season baseline environmental data monitored during Mar’18–May’18(summer) by field study, which includes meteorological conditions, ambient air, water & soil quality, noise and Traffic density. Site survey has been conducted for studying ecology, socio-economic conditions, land use, etc. Secondary data is also collected from concerned State/Central govt. agencies and departments. The collected data have been analysed for identifying, predicting and evaluating impacts of proposed project, and maximum anticipated impacts are assessed for suggesting suitable environmental management plan.
1.6 REPORT COVERAGE
This report contains information on existing environment and evaluates predicted environmental and socio-economic impacts of proposed plant. A detailed coverage of background environmental quality, pollution sources, anticipated socio-environmental impacts and mitigation measures, environmental monitoring programme, project benefits, environmental monitoring plan and other related aspects have been covered. The report including this Introduction chapter contains: x Project Description x Description of the Environment x Anticipated Environmental Impacts and Mitigation Measures x Analysis of Alternatives (Technology & Site) x Environmental Monitoring Program x Additional Studies: Risk Assessment Studies x Additional Studies: Social Impact Assessment & Public Consultation x Project Benefits x Environmental Management Plan (EMP) x Summary & Conclusion x Disclosure of Consultant engaged
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT CHAPTER 2: PROJECT DESCRIPTION
2.1 INTRODUCTION
Bokaro Steel Plant (BSL), a unit Steel Authority of India Limited (SAIL), is an integrated steel plant producing iron and steel based on BF-BOF route. The rated production capacity of BSL as per existing Environmental Clearance (EC) is of 5.77 Million Tonnes Per Annum (MTPA) of hot metal and 4.606 MTPA of steel. The existing production capacity of BSL is 4.5 MTPA of hot metal (and 4.2 MTPA of steel).
In view of modernizing and improving the existing facilities of Bokaro Steel Plant (BSL) for achieving the rated production capacity, BSL has contemplated the up-gradation of existing units, execution of debottlenecking activities as well as addition of some new facilities in the proposed expansion-cum-modernization programme from 4.5 MTPA to 5.77 MTPA hot metal capacity (and 4.2 MTPA to 4.656 MTPA steel production).
2.2 TYPE OF PROJECT
The present proposal involves modernization of existing SMS-1, up-gradation of existing SMS-2, debottlenecking of existing CRM complex, addition of a new Sinter plant with a new lime kiln, Coke oven battery, Pellet plant and Oxygen plant (on BOO basis) along with development of an alternate water supply system (without increasing the water withdrawal capacity from existing permitted quantity).
These proposed changes in plant configuration shall take place within the premises of existing BSL and is coming under “Metallurgical Industries”. The expansion-cum-modernization of BSL falls under Category ‘A’ [Sl. No. 3(a) of Schedule: “List of projects or activities requiring prior environmental clearance”] in connection with Environment (Protection) Act, 1986.
2.3 EXISTING STATUTORY COMPLIANCES & NEED FOR THE PROJECT
2.3.1 Existing EC, CTO & CTE of SAIL-Bokaro & their compliance status:
Bokaro Steel plant (BSL) has already been accorded EC on 16.10.2008 by MoEFCC for expansion of its capacity from 4.0 MTPA to 7.0 MTPA of crude steel vide memo no. J-11011/99/2007-IA II(I). Extension of the EC was accorded for a period of five years w.e.f. 15.10.2013 vide memo no. J- 11011/99/2007-IA.II(I) dtd. 24.01.2014. Further, this EC (valid until 14.10.2018) has been granted an amendment by MoEFCC for modifications in some existing plant facilities of BSL along with reduction of overall plant production capacity to 4.606 MTPA Crude Steel (5.77 hot metal) vide MoEFCC letter F.No J-11011/99/2007-IA.II(I) dated 28.11.2014.
In addition, BSL has been granted EC amendment vide MoEFCC’s letter J-11011/99/2007- IA II(I) dated 13.12.2017 for development of an alternate water pipeline system for drawl of raw water from Damodar river. Copy of all the Environmental Clearance(s) including Amendments thereto obtained from MOEF&CC as well as CTO and CTE/NOC granted for the project are attached as Annexure-
CHAPTER-2 PROJECT DESCRIPTION Page 12 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2.1(a) & 2.1(b) respectively. Recent CTO & CTE/NOC compliances are attached as Annexure- 2.1(c).
Most of the facilities envisaged as part of the existing EC of BSL have been installed/implemented. The updated implementation status of the facilities mentioned in the existing EC of BSL is attached as Annexure-2.1(d). SAIL-BSL has also been taking proactive steps for compliance of conditions of its existing EC. The recent certified status of EC compliance from RO, MoEFCC is attached as Annexure-2.1(e) of this report. SAIL-BSL has subsequently submitted its updated Action Taken Report after consideration of the comments from RO, MoEFCC vide letter no. ECD/EMS/01/2020- 2021 dated 11-08-2020 for closure of observations on Compliance of EC conditions (attached as Annexure-2.1(f)).
2.3.2 Need for the proposed proposal:
Post EC amendment granted on 28.11.2014, BSL has been progressively installing the different projects of the amended expansion-cum-modernization program, which are presently at an advanced stage of implementation. However, for completion of phase-1 up-gradation of SMS-1 and installation of the new Sinter plant-II of 3.7 MTPA capacity, more time is required as inordinate delay has occurred because of procedural delays in design & engineering activities as well as site clearance activities necessary for enabling subsequent construction activities for SMS-1 up- gradation as well as installation of Sinter Plant-II.
In addition to the above, only (01) one out of the (02) two 1250 TPD Oxygen plants envisaged originally during the expansion of Bokaro Steel plant from 4 MTPA to 7.0 MTPA (which was later reduced to 4.606 MTPA steel via modification of existing EC) could be installed. The other 1250 TPD Oxygen plant (BOO basis) has been included in the presently proposed expansion-cum- modernization program as a fresh project in view of increased requirement of oxygen for envisaged production capacity of 5.77 MTPA of hot metal.
It is also proposed to improve the performance of existing steel-making as well as downstream facilities by execution of some of the modernization/debottlenecking schemes which will modernize the existing SMS-I steel making facility to 1.306 MTPA production capacity and augment the existing facility of steel making at SMS-II from 3.3 MTPA to 3.35 MTPA resulting in an increase in overall production capacity of steel to 4.656 MTPA. Debottlenecking of existing CRM complex will also augment the production capacity of cold rolled products from 2.4 MTPA to 2.86 MTPA.
In addition to the above, a new 2.0 MTPA Pellet plant is also being envisaged for gainful utilization of iron ore fines generated at SAIL captive mines as well as ferruginous wastes generated within the existing Plant. A new coke oven battery is also being envisaged to meet the shortfall of BF coke required for production of 5.77 MTPA hot metal.
Further, the development of alternate water pipeline system, as envisaged as part of existing EC accorded to BSL, will require more time to complete due to delays in project execution activities. In view of the above, BSL proposes to include the aforementioned activities in the proposed expansion-cum-modernization program.
CHAPTER-2 PROJECT DESCRIPTION Page 13 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT A summary of the objectives of the present expansion-cum-modernization proposal is listed in Table 2.1 below.
Table 2.1. Objective of proposed activities in expansion-cum-modernization of BSL Need for inclusion in Activity/Facility proposed at BSL plant Type of activity Status of completion present proposal Overall up-gradation of SMS-1(1.5 MTPA to Stage 1, Envisaged in earlier Included in present proposal MODERNIZATION 3.156MTPA) (Stage -1 - 1.306 MTPA) EC. Not yet completed due to delay in installation New Sinter Plant-II (3.7 MTPA) with Lime- Envisaged in earlier EC. Not Included in present proposal NEW FACILITY Dolo kiln (450 TPD) completed due to delay in installation Envisaged in earlier EC. Not Included in present proposal New Oxygen Plant (1250 TPD) NEW FACILITY installed. as fresh proposal Envisaged in earlier EC. Not Included in present proposal Alternate Water pipeline NEW FACILITY completed due to delay in installation Performance improvement by Included in present proposal SMS-II (3.30 MTPA to 3.35 MTPA) MODERNIZATION debottlenecking as fresh proposal Existing CRM complex (2.4 MTPA to 2.86 Performance improvement by Included in present proposal MODERNIZATION MTPA) debottlenecking as fresh proposal Included in present proposal New Pellet Plant (2.0 MTPA) NEW FACILITY Freshly envisaged as fresh proposal Included in present proposal Coke Oven Battery (0.77 MTPA gross coke) NEW FACILITY Freshly envisaged as fresh proposal
2.4 LOCATION AND ACCESSIBILITY
2.4.1 Location
Bokaro Steel Plant is located at Bokaro Steel City in Bokaro District of Jharkhand. The plant is located between latitudes 23°38'45.38” N to 23°43'2.89” N and longitudes 86°04’1.56” E to 86°08’38.27” E.
2.4.2 Infrastructure facilities
The National Highway No. 32 joining Gobindpur and Dhanbad to Jamshedpur passes about 7 km to the west of Bokaro Steel plant (BSL) while National Highway No. 23 joining Chas and Nauhata (Odisha) passes about 2.5 km away from BSL on the Southern side. The site is approximately 100 km E-NE of Ranchi city, the state capital of Jharkhand. The nearest commercial airport is Ranchi Airport which is about 90 km away from Bokaro Steel City.However, Steel Authority of India Ltd. (SAIL) has its own airstrip at Bokaro itself, which is being upgraded to handle commercial flights.The nearest railway station is Tupkadih on South-Eastern Railway’s Muri – Chandrapura BG line, which runs parallel to the steel plant’s western boundary but the nearest major Railway station with higher footfall is Bokaro Steel City Station.
2.5 SIZE OR MAGNITUDE OF OPERATION
Existing Bokaro Steel Plant is spread over 6973.68 ha of land. The proposed expansion-cum- modernization project will be implemented entirely within the plant’s existing premises (i.e. no land acquisition is envisaged).
CHAPTER-2 PROJECT DESCRIPTION Page 14 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The proposed expansion-cum-modernization programme of BSL shall enhance production capacity from 4.5 MTPA to 5.77 MTPA of hot metal and improve processing capability of downstream facilities.
BSL intends to maintain production of flat products based on the-state-of-the-art technology, i.e. production of hot rolled coils either through conventional slab caster – hot strip mill route or through thin slab caster-hot strip finishing train route.
Moreover, the existing SMS facilities will be revamped and modernized for better productivity and sustainable operations. Eventually, dependence on hot rolled coil production through ingot– slabbing mill route will also be reduced as per the expansion programme. Further, existing CRM facilities will be debottlenecked by removing obsolescence in exiting process technology for cold rolled production. BSL has also given emphasis on production of slabs through additional conventional slab caster in order to fulfill the requirement of slabs for the existing hot strip mill.
Keeping the above points in view, revamping / augmentation measures as well as addition of new facilities have been proposed. The indicative product mix after proposed expansion-cum- modernization is presented in Table 2.2 below:
Table 2.2. Product Mix after proposed expansion-cum-modernization Sl. No. Item Annual production (MTPA) 1 HOT METAL 5.77 2 CONTINUOUS CAST SLABS 4.656 3 SALEABLE STEEL 3.1 Directly from Existing Hot Strip Mill - HR Coils/Sheets/Plates 1.86 3.2 Existing CRM Complex - CR Coils/Sheets 1.03 3.3 CRM III complex - CR Coils/Sheets 0.95 3.4 CR Galvanized Plain/ Corrugated Sheets (Existing CRM) 0.17 3.5 CR Galvanealed &Galvanized Coils/Sheets (CRM-III Complex) 0.25
2.6 PLANT DETAILS
Bokaro Steel plant has already been granted environmental clearance for 4.5 MTPA to 5.77 MTPA Hot metal production (and 4.2 MTPA to 4.606 MTPA steel). Majority of the facilities envisaged then have been installed. However, owing to ageing of downstream facilities as well as obsolescence of their existing technologies, BSL’s production capacity is limited to about 4.5 MTPA of hot metal and ~4.2 MTPA steel at present. In view of the above, many new facilitating units as well as modernization/up-gradation of existing facilities has been proposed to enable the production of 5.77 MTPA hot metal and subsequently 4.656 MTPA of continuous cast slabs (Steel). A brief discussion of the existing facilities at BSL and the proposed changes is given in the succeeding paragraphs.
2.6.1 Existing Plant Details
BSL is having an installed production capacity of 5.77 MTPA of hot metal. However, it is limited to a production capacity of 4.5 MTPA hot metal through CO-BF-BOF-CCP route due to unavailability of processing capacity of downstream facilities. The details of all existing facilities at BSL are mentioned in Table 2.3 as follows. CHAPTER-2 PROJECT DESCRIPTION Page 15 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 2.3. Existing Major Technological Units, products and their Capacities and changes proposed in expansion-cum-modernization Sl. Department Units / Facilities installed as per existing Product(s) Existing Installed PROPOSED CHANGES IN FINAL CAPACITY AT STATUS OF PROPSOSED No. EC accorded to BSL valid upto 14.10.18 & Capacity EXPASNION-CUM- 5.77 MTPA HOT CHANGES all amendments thereof MODERNIZATION OF BSL METAL STAGE FROM 4.5 TO 5.77 MTPA HM Addition of new coke oven 8 (only 6 available) batteries of 69 ovens 4.212 MTPA of gross 1 Coke Ovens Coke 3.442 MTPA battery of 0.77 MTPA gross Fresh proposal. each. 5.0 m tall; coke coke capacity Addition of new Sinter Plant of Envisaged in earlier EC but 2 x 252 m2 sintering m/c + 312 m2 sintering 5.0 MTPA 8.7 MTPA of gross 2 Sinter Plant Gross sinter 3.7 MTPA gross sinter yet to complete. Included in m/c (Installed cap.as per existing EC= coke 6.9) capacity this proposal due to delay Installation of new 2.0 MTPA 3 Pellet Plant - - - 2.0 MTPA of pellet Fresh proposal. pellet plant 4 x 2000 m3 useful volume + 1 x 2586 m3 5.77 MTPA 5.77 MTPA 4 Blast Furnace Hot metal NO CHANGE - useful volume (Existing production limited to 4.5) (same as before) 5 (3 operating) converters of 100/130 + 5 Stage-1 modernization of Envisaged in earlier EC but Steel Melting Shop - I nos. 130 t LD Convertors + casting ingots of Ingot steel 1.5 MTPA SMS-I to capacity of 1.306 1.306 MTPA yet to complete. Included due diff. sizes + soaking pits MTPA to delay 5 2 x 300 t LD Convertors + 2x 300 t Ladle Steel Melting Shop – II Ingot steel + cast Augmentation of SMS-II to furnace + 2 nos. double strand casting 3.3 MTPA 3.35 MTPA Fresh proposal. Continuous Casting Shop slabs 3.35 MTPA machines 1250 mm Universal Reversing Mill + 7 no. of 7 working soaking pit 7 working soaking pit 6 Slabbing Mill Rolled slabs NO CHANGE - working Soaking Pit batteries batteries batteries 4 x 260 t reheating furnaces (Walking beam Hot Rolled (HR) 7 Hot Strip Mill type) + Tandem Mill + HR coil conveying 4.5 MTPA NO CHANGE 4.5 MTPA - Coils system HR shearing lines + HR slitting lines + HR Hot Rolled Coil Finishing HR plat/Sheet 8 sheet/plate packaging line + HR Slit coil - NO CHANGE - - (HRCF) complex HR Slit coil packaging line 3 nos. 270 t/d Lime Kilns (Rotary) + 1 nos. Addition of New Kiln of 450 9 Refractory Materials Plant Lime, Dolomite 0.2449 MTPA 0.4091 MTPA Fresh proposal. 270 t/d Dolomite Kilns (Rotary) TPD (0.1642 MTPA) 10 Oxygen Plant 4 x 450 TPD Air separation units (only 2 Oxygen, 2700 TPD Addition of 1 x 1250 TPD 3950 TPD Envisaged in earlier EC but CHAPTER-2 PROJECT DESCRIPTION Page 16 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. Department Units / Facilities installed as per existing Product(s) Existing Installed PROPOSED CHANGES IN FINAL CAPACITY AT STATUS OF PROPSOSED No. EC accorded to BSL valid upto 14.10.18 & Capacity EXPASNION-CUM- 5.77 MTPA HOT CHANGES all amendments thereof MODERNIZATION OF BSL METAL STAGE FROM 4.5 TO 5.77 MTPA HM operational) + 1 x 550 TPD ASU Nitrogen, Argon (1450 TPD Captive+ 1250 Oxygen Plant (BOO) (1450 TPD Captive + 2 yet to complete. Included in + 1250 TPD Oxygen plant (BOO) TPD BOO) x 1250 TPD BOO) this proposal as fresh proposal CRM-I&II : Pickling lines I & II + Hood xPickled Coils, Annealing furnaces + 1 x 4 Stand Reduced Coils, Tandem Cold Mill + 1 x 5 Stand Annealed Coils, Tandem Cold Mill + Single Stand Cold Rolled Skin Pass Mills + CR Shearing (CR) Coils, Lines + CR Slitting Lines + TMBP Coils, Electrolytic Cleaning Line + CR Sheets, CR Continuous Annealing Lines + Slit Coil, GP Twin stand Temper Mill + Hot Dip Coils / Sheets 2.4 MTPA Cold Rolling Mills – I, II& Debottlenecking of existing 11 Galvanizing Line + Galvanised (1.2 of CRM I&II+1.2 of 2.86 MTPA Fresh proposal. III CRM complex to 2.86 MTPA Sheet Shearing Lines + Coil CRM-III) Corrugating Lines xReduced Coils, CRM-III : Coupled Pickling & Tandem Mill + Annealed Coils, Electrolytic Cleaning Line + Bell CR coils, Annealing furnaces + Skin Pass Galvanised Iron Mill + Hot Dip Galvanizing Line + & Annealed Tension leveller & Inspection line coils, GI/GA + Coil packaging lines coils ~17000 m3/hr (Design Maximum drawl Envisaged in earlier EC but Raw Water Supply capacity = 23000 m3/hr) Alternate water pipeline 12 Tenu Canal from Damodar River Water capacity of 23140 yet to complete. Included due System (Permission upto 23140 system along with Tenu Canal m3/hr to delay m3/hr) A brief schematic of the process flow of Bokaro Steel Plant (BSL) is shown in Fig. 2.1 below.
CHAPTER-2 PROJECT DESCRIPTION Page 17 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig. 2.1. Process Flow Sheet of Existing Bokaro Steel Plant
CHAPTER-2 PROJECT DESCRIPTION Page 18 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 1. Existing Process:
The process of iron and steel production at BSL at present is briefly explained in subsequent paragraphs.
Metallurgical coal, both Indian and Imported, are charged into Coke Ovens to produce coke which is charged in Blast Furnaces along with Iron ore, sinter and fluxes. From the volatile matter evolved in Coke ovens Ammonia, Tar, Naptha are separated. Chemicals like Naphthalene and Benzol are recovered.
Gases evolved in Coke Oven, Blast Furnace and LD Convertors are cleaned in Gas Cleaning Plant. The cleaned coke oven gas, blast furnace gas and LD Gas are used either singly or mixed together as fuel in various shops. Excess LD gas is stored in gas holders after cleaning.
Most of the hot metal from blast furnaces (BFs) is taken in ladles/Torpedo Ladle to LD Convertors where high purity oxygen is blown into the hot metal to convert it into steel. A minor proportion of the hot metal from the BFs is cast into pigs, which is a saleable product. The slag from the BFs is granulated and sold off to cement manufacturers.
The liquid steel produced in LD Convertors is cast into ingots and slabs through Continuous Casting route. The ingots are further routed to slabbing mill for conversion to slabs. The slabs are fed to the Hot Strip Mill for rolling to Hot Rolled (HR) Coils. Part of the HR Coils is sent to the Cold Rolling Mill (CRM) Complex for further processing into cold rolled products.
Magnitude/capacities:
The production capacities of existing major technological & auxiliary facilities as well as proposed changes in the proposed expansion-cum-modernization programme are given in Table 2.3 above.
2.7 PROPOSED PROJECT
The proposed expansion-cum-modernization program envisages installation of freshly proposed new facilitating units along with the present proposal as well as modernization/up-gradation of existing facilities which were envisaged in the earlier expansion programme for which BSL has already obtained EC. The summary of facilities envisaged as per existing EC, status of implementation as well as changes proposed as part of the present expansion-cum-modernization programme is presented in Table 2.4 below.
Table 2.4.Status of facilities envisaged as per earlier EC as well as changes proposed in existing configuration SN UNITS/ CAPACITY OF CAPACITY OF UNITS STATUS OF CHANGES FINAL PRODUCTS UNITS AT 4.5 AFTER EXPANSION EXISTING PROPOSED AS PER CONFIGURATION MTPA HOT METAL FROM 4.5 TO 5.77 MTPA FACILITIES REVISED AT 5.77 MTPA HOT STAGE HOT METAL CONFIGURATION METAL (AS PER EXISTING EC FOR, VALID PRODUCTION UPTO 14.10.2018 & ALL CAPACITY AMENDMENTS THEREOF) Addition of 0.77 MTPA Coke Oven 1. 3.442 MTPA 3.442 MTPA Completed. gross coke Coke oven 4.212 MTPA Complex battery* 2. Blast Furnace 4.5 MTPA 5.77 MTPA Completed. NO CHANGE FROM 5.77 MTPA
CHAPTER-2 PROJECT DESCRIPTION Page 19 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT SN UNITS/ CAPACITY OF CAPACITY OF UNITS STATUS OF CHANGES FINAL PRODUCTS UNITS AT 4.5 AFTER EXPANSION EXISTING PROPOSED AS PER CONFIGURATION MTPA HOT METAL FROM 4.5 TO 5.77 MTPA FACILITIES REVISED AT 5.77 MTPA HOT STAGE HOT METAL CONFIGURATION METAL (AS PER EXISTING EC FOR, VALID PRODUCTION UPTO 14.10.2018 & ALL CAPACITY AMENDMENTS THEREOF) Complex EXISTING EC SMS-1: 1.5 MTPA SMS-1: 1.306 MTPA SMS-I up-gradation SMS-1 upgradation delayed. included. 3. SMS Complex SMS-2: 2.7 MTPA SMS-2: 3.3 MTPA 4.656 MTPA SMS-2 expansion SMS-2 proposed to be Total: 4.2 MTPA Total: 4.606 MTPA completed. upgraded to 3.35MTPA - Universal Slabbing Mill - Universal Slabbing Universal Slabbing Universal Slabbing with 7 no. soaking pit NO CHANGE FROM 4. Slabbing Mill Mill with 7 no. Mill with 7 no. soaking Mill with 7 no. batteries to be phased out EXISTING EC soaking pit batteries pit batteries retained soaking pit batteries after SMS-1 upgradation Existing plant: 5.0 MTPA Sinter Plant New Sinter Plant of 3.7 5. 6.9 MTPA New Sinter plant: 3.7 MTPA New sinter plant of 3.7 8.7 MTPA Complex MTPA Total: 8.7 MTPA MTPA delayed. Addition of 2.0 MTPA 6. Pellet Plant - - - 2.0 MTPA Pellet plant New Kiln of 0.1642 7. Lime-Dolo Kiln 0.2449 MTPA 0.5358 MTPA Expansion deferred. 0.4091 MTPA MTPA NO CHANGE FROM 8. Hot Strip Mill 3.2 MTPA 4.5 MTPA Completed 4.5 MTPA EXISTING EC 9. CRM complex 1.2 MTPA 2.4 MTPA Completed Increase by 0.46 MTPA 2.86 MTPA 2700 TPD (1450 TPD captive plant & 1x1250 TPD BOO 3950 TPD Tot. Capacity: 3950 TPD Installation of 1250 TPD plant) already (2700 TPD existing 10. Oxygen Plant - (1450 TPD captive plant + Oxygen Plant on BOO installed. + 1250 TPD 2x1250 TPD BOO plant) Basis now included. BOO(new)) Other 1250 TPD BOO plant not installed. Tenu Canal along with Tenu Canal along Water supply - alternate water pipeline Project delayed Project Included with alternate water system system pipeline system NOTE:*Throughput of envisaged Coke Oven battery is 1.0 MTPA
Overall process flow of BSL after proposed expansion-cum-modernization is shown in Fig.2.2.
CHAPTER-2 PROJECT DESCRIPTION Page 20 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig. 2.2. Process-cum-material Flow Sheet of Bokaro Steel Plant after proposed expansion-cum-modernization plan
CHAPTER-2 PROJECT DESCRIPTION Page 21 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The details of changes in technology and process envisaged in all the aforementioned facilities are described in subsequent section.
2.8 TECHNOLOGY & PROCESS DESCRIPTION
Bokaro Steel Plant is following the conventional and well-established CO-BF-BOF-CCP route of steel making. Iron ore lumps, sinters and coke (made from coking coal) and fluxes such as limestone, dolomite are the major raw materials. The crude steel produced from the steel making shops is cast into slabs which are rolled into hot rolled coils as well as cold rolled products, both galvanized/galvanealed as well as normal cold rolled products.
The planned expansion will include de-bottlenecking and rebuilding / modernization of existing facilities and addition of some new facilitating units.
A brief technological description of all facilities (existing as well as new) and modernization schemes envisaged in some of the existing facilities is described in succeeding paragraphs.
2.8.1 Coke Making - Coal Carbonisation
1. Existing Coke making facilities:
The coke oven complex at Bokaro Steel Plant consists of 8 by-product recovery type coke oven batteries.These batteries are of compound, regenerative with partial recirculation of waste gases, twin flue, under jet type.
Each battery has 69 ovens in single block, compound, regenerative with partial recirculation of waste gases, twin-flue, under jet type. The oven dimensions (cold) of the existing batteries are as
under: Table 2.5.Design parameters of Coke oven battery Parameter Details Total length 15040 mm Total height 5000 mm Average width 410 mm Oven taper, mm 40 mm Useful volume 27.3 m3 Gas collecting main 2 Charging holes 3
Due to ageing, old batteries are being rebuilt /repaired on regular basis. Because of this, only six (6) out of eight (8) batteries are in operation most of the time. This in turn is resulting short-fall of BF grade coke supply to Blast Furnaces.
As per on-going expansion plan of BSL with targeted HM production of 5.77 MTPA, there will be a shortfall of BF coke even after the rebuilding of existing batteries. BF coke requirement will be 3.328 MTPA for which installation of Battery No. 9 is necessary.
2. Proposed Stamp charge battery:
The proposed stamp charge battery having coal throughput of approx. 1 million ton per year will be installed along with Coke Dry Cooling Plant (CDCP), Back Pressure Turbine Generator (BPTG),
CHAPTER-2 PROJECT DESCRIPTION Page 22 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT DM water plant and By-product plant. Wet quenching of coke has also been considered as a standby facility to facilitate boiler inspection of CDCP plant as per the statutory requirement. Required blended coal will be received from the existing coal handling network for Battery No.9 after suitable modification/extension/addition. Produced gross coke will be processed in new coke sorting plant to convert it into BF coke, nut coke and breeze coke.BF coke will be dispatched to all the furnaces by connecting to the existing BF coke conveyors. Similarly, breeze coke will be dispatched to both SP-1 and SP-2.
The proposed battery will be stamp charge, twin flue, under jet, compound, regenerative heating type with partial recirculation of waste gases system. This Battery will have 92 ovens in two blocks of 46 ovens each. The ovens will be 5 m to 5.5 m tall, 14 m long (max) and have average width of 500 mm (min). Battery will be provided with two sets oven machines. The enhancement of coal handling unit, coke processing unit and conveyors will be suitable for operating one new stamp charge coke oven battery along with the existing batteries, to meet the overall coke demand of the BF complex.
The proposed battery will be provided with two sets (1W+1S) of oven machines i.e., stamping cum charging cum pushing machine, coke transfer car, charging gas transfer car, self-propelled coke bucket car and one set of coke electric loco& coke quenching wagon.
A 120 TPH single chamber Coke Dry Cooling Plant (CDCP) along with DM water plant has been envisaged for cooling of hot coke. A Back Pressure Turbine Generator (BPTG) of around 6.5MW power generation potential with about 55tph of steam at 8kg/cm2 has also been included. Wet quenching of coke has also been considered as a standby facility to facilitate boiler inspection of CDCP plant as per the statutory requirement.
Further, a dedicated new By-product Plant of 50000Nm3/h gas handling capacity for removal of tar, naphthalene, ammonia, sulphur has also been envisaged.
New Coke Oven Battery (proper):
The battery will operate for 24 hours a day, 365 days a year. Coal consumption and coke production and coke quality for proposed battery are as indicated below.
Table 2.6.Coal Consumption and coke production details for proposed coke oven Parameter Envisaged Dry Coal charge 1.02 (min) MTPA Quantity of dry Coke Produced (@76%) 0.77 25mm to 80mm BF coke (dry) @70% 0.71 (-) 25mm breeze coke (dry) 0.06
The indicative salient features of the stamp charge battery are:
Table 2.7.Salient features of proposed coke oven battery Parameter Envisaged No. of ovens/battery 46 +46 Oven dimensions (cold) Height of ovens, mm 5000 (min.) to 5500(max.)
CHAPTER-2 PROJECT DESCRIPTION Page 23 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Parameter Envisaged Length of ovens, mm 14000 (max.) Avg. width of ovens, mm 500 (min.) to 550(max.) Oven taper, mm 20 (min.) Coal cake weight (dry), t 31.5 (BD=1.0) Coking period, hrs 25 (max.) No of pushing per day 90 (max.) Pushing sequence 5-2 Heating system Twin flue, under-jet, compound, regenerative type with re-circulation of waste gases
The indicative characteristics of coal blend to be charged into the proposed coke oven battery are
as follows: Table 2.8.Indicative characteristics of coal blend Parameter Envisaged Ash content 11-12% Sulphur content 0.57 to 0.58% Phosphorus 0.092 to 0.093% Moisture content 9-11% (avg.) Volatile matter 24 to 26% CSN 4.5 (min.) to 6.5 (max.) Ro (Mean Reflectance 1-1.05 -3.15 mm coal size 90% (min.) -0.5 mm coal size 50% (max.)
The coke yield and by-product yield is as shown below:
Table 2.9.Indicative coke and by-product yield of proposed coke oven battery Parameter Envisaged Oven pushing/day 90 (max.) Dry Bulk density of blend 1t/m3 (min.) Cake volume 31.0 m3 Yield of run-off oven coke from dry coal 76% charge Yield of 25 mm to 80 mm BF grade coke 70% from dry coal charge Yield of (-) 25 mm coke from run-off oven 7.9% coke (dry) Yield of coke oven gas per ton of dry coal 320-340 Nm3 charge Yield of Tar per ton of dry coal charge 32 kg Gas 45000Nm3/h (max.) Tar 37000TPA (max.)
The tentative quality of coke produced is as follows:
Table 2.10. Indicative Coke characteristics Parameter Envisaged Ash content 14-15% Moisture content < 0.5% Volatile matter 0.8% M40 84% (min.) M10 5.5% (max) CSR 65 (min.) CRI 25 (max.)
CHAPTER-2 PROJECT DESCRIPTION Page 24 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 3. Coke Quenching:
The existing coke oven complex of BSL has 6 working top charged batteries with every pair of battery sharing common facilities of a Wet quenching tower and coke wharf. However, at any point of time, 2 batteries are shut down for repairs/rebuilding. Thus, the existing coke oven complex has only wet coke quenching facility.
However, the new coke oven battery has been proposed to have a dry quenching system as the primary system for coke quenching with a wet quench tower as a standby system.
The adoption of dry quenching system as the primary system for coke quenching was made on the characteristics of the dry quenching process that are attractive to air pollution control and bring about other advantages to the environment as a whole. These include: x substantial reduction of air pollution caused by coke quenching x curtailment of air pollution—especially soot and tarry smoke particles—during the hot coke push and during transportation to the quench tower x elimination of water pollution associated with wet quenching x improvements in the working environment and the surrounding community x removal of wet quenching equipment that may tempt coke plant and steel mill operators to dispose of polluted water during wet quenching x recovery of substantial amounts of waste heat energy and production of steam/power, reducing overall energy consumption x Dry quenching also produces a greater amount of coke that has superior quality than coke produced by wet quenching. x Dry quenching equipment can be flexibly located. As because the hot coke can be transferred further at a higher rate of speed (because of the closed coke transport cars), dry quenching equipment does not necessarily have to be immediately adjacent to the coking batteries.
In view of the above, dry coke quenching system has been envisaged for BSL’s new coke oven battery. However, a wet quenching system as a standby has also been envisaged. The technological description of the overall proposed quenching system for the new coke oven battery is detailed in paragraphs below.
Coke Quenching system in proposed new coke oven battery:
Coke pushed from the oven will be at around 1050°C temperature. For quenching this hot coke, two types of quenching systems will be provided. The primary system will be based on single chamber Coke Dry Cooling Plant (CDCP) and the stand-by system will be based on conventional wet quenching.
Coke Dry Cooling Plant (CDCP):
Dry cooling of coke produces a stabilized metallurgical coke of better strength & low moisture which is useful for blast furnace. Hot coke at temperature of 1050°C pushed from oven will be
CHAPTER-2 PROJECT DESCRIPTION Page 25 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT received in the coke bucket. Hot coke will be discharged into a single cooling chamber of 120TPHcapacity (5 ovens per hour) with the help of a coke bucket lifter.
Sensible heat of hot coke will be recovered with the circulation of inert nitrogen and producing steam.
The CDCP will primarily comprise of the technological units viz., cooling chamber (refractory lined steel vessel) with matching waste heat boiler followed by backpressure turbine to handle the steam, dust recovery& transportations system, feed water storage & supply to waste heat boiler, ventilation facilities and a new DM water plant and other related facilities.
The typical technological parameters/features of CDCP envisaged is indicated below:
Table 2.11. Typical technological parameters/features of envisaged CDCP Description Unit Value Dry cooling chamber No. 1 Chamber capacity tph 120 Temperature of coke charged in the chamber °C 950-1050 Temperature of coke after cooling °C <180 Temperature of circulating gas before entering cooling °C 150-160 chamber Pressure of steam generated Bar(g) 66 Temperature of steam generated °C 500 Cycle time min 500 Generation of steam from boiler Tph 55 Daily working system of CDQ Hr. 24 Annual working of CDQ Day 345 Annual maintenance Day 20
Standby Wet Quenching:
Conventional wet quenching system will be provided as a stand-by system to CDCP, when CDCP boiler will be under annual shut down for boiler maintenance & inspection as per IBR requirement. The quenching system will consist of quenching tower, vapour suppression, spraying system at top, quenching pump house, settling pond etc. Settling pond will have EOT crane grab bucket for removing the coke breeze from the pond. The removed breeze will be loaded into a ground bunker which drains the water. Then the same grab crane will load it into a truck/ dumper for transporting to final dumping place. Treated waste waters from the BOD plant of COB#9 will be supplied to the settling pond of the wet quenching station as make up water for quench station evaporation losses. Settling pond of quenching station will be have suitable designs which prevent overflow or drainages from it to escape to any other sewerage system and the quench water will be exclusively re-circulated under “zero-discharge” concept.
4. By-Product Plant
A new By-product plant (BPP-2) will be installed to clean the raw coke oven gas generated from battery with removal of tar, ammonia, hydrogen sulphide and naphthalene. Production of clean coke oven gas is estimated to be 50000 Nm3/h (approx.) with a net calorific value of 4200
CHAPTER-2 PROJECT DESCRIPTION Page 26 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Kcal/Nm3. Clean Coke oven gas composition &tentative output quantities will be as mentioned
below (indicative): Table 2.12. Clean Coke oven gas composition(indicative): Clean Coke oven gas composition Composition of cleaned Coke Oven Gas % by volume Hydrogen 52 to 59 Carbon monoxide 6 to 7 Carbon dioxide 3 to 4 Oxygen 0.3 to 0.7 Methane 24 to 28 Nitrogen 4 to 7 CnHm 1.5 to 2.5 Tentative Output quantity Tar 37000 tpa (max) Sulphur 1220 tpa (max)
The major technological units of the proposed BPP are as follows:
x Gas Condensation Plant (GCP) comprising of Primary Gas Coolers (4 x 25000 Nm3/h of each), Electrostatic Tar Precipitators (3 x 35000 Nm3/h of each), decanters for Tar & sludge, different tanks for flushing liquor, crude tar, gas condensate, tar storage etc. and exhausters.
x Ammonia & Hydrogen Sulphide removal comprising of H2S Scrubbing Unit (counter current flow of ammonia contained in de-acidified water of 50,000 Nm3/hr), NH3 Scrubbing Unit of 50,000 Nm3/hr, COMBI scrubbing Unit of 50,000 Nm3/hr and Distillation Unit with H2S and NH3 Stripper as well as Ammonia Cracking & Sulphur Removal via Sulphur recovery unit for recovery of Sulphur from H2S and decomposition of Ammonia and HCN based on Claus process. The unit mainly consists of Claus Kiln (vapour burner & crack reactor with catalyst), waste heat boiler, Claus reactor (with catalyst), sulphur condenser, sulphur storage tank, sulphur palletizing unit, heat exchangers. x Naphthalene scrubber using solar oil (50000 Nm3/h) comprising of naphthalene stripping column (1 no.), condenser, rich solar oil pre-heater, lean solar oil coolers, lean solar oil pumps, separator etc.
5. Benzol Storage Facility
New benzol storage facility will be installed near the existing tar storage tanks in front of existing Benzol Recovery Plant to accommodate the existing benzol storage facility working presently. Storage of 3000m3 will be created by installing four tanks of 750 m3 capacity each. Tanker loading facilities will be provided.
6. Coal Preparation & Handling
Existing coal handling plant has been provided with 81 silos of 2500 ton capacity each. Required coal blend is prepared on the conveyors below the silos through belt feeders. These silos have been installed in three rows of 27 nos. each.
CHAPTER-2 PROJECT DESCRIPTION Page 27 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 11 nos. of existing silos will be allocated to COB#9 by splitting the conveyors below. Out of these, 6 nos. of coal silos in combination will be allocated for PCI/non coking coal. The tail portion of these two conveyors will be extended and drives will be provided in new junction houses. Flap gates and chute will be provided for transporting high HGI coal to intermediate hopper and PCI/non coking coal having low HGI to primary hammer crusher. Two nos. of primary hammer crushers (1W + 1S) of 200tph capacity each will be installed. The crushed coal will be fed into a conveyor for coal blend as per requirement. The crushed coal and high HGI coal from intermediated hopper through vibro feeder will be transported to the secondary crusher house for crushing of coal blend. Three nos. of secondary hammer crushers (1W + 2S) of 600tph each will be installed. Secondary crusher will receive coal through reversible shuttle conveyor. The coal blend will be crushed to minimum 90% (- 3 mm and (-) 0.5 mm would be limited to max. 50%. The crushed and blended coal from the secondary crushers shall be transported to new coal tower using a series of new coal conveyors. This new coal conveying route passes over the existing coal conveyor with provisions for catering to existing batteries also. Coal blend supply conveyer shall be equipped with moisture meter and conveyer scales at an appropriate location.
7. Pollution Control
The details of technological implementation from environmental considerations are as follows: Parameter Envisaged details BOD Plant / Capacity 50 m3/hr. Pollution Control facility in Coal Handling Route Dust Suppression/ Extraction system has been proposed along with the proposed Battery( DFDSS) Pollution Control facility in Coke Handling Route Dust Suppression/ Extraction system has been proposed along with the proposed Battery. Fugitive Emission Control Measures: Control of Emission through Doors, PLD ¾ Air cooled spring loaded diaphragm type doors with self- sealing arrangement. ¾ Machine mounted door & door frame cleaner. ¾ Hydro jet cleaner of 600 bar pressure ¾ Mechanized frame cleaner ¾ Hydraulic governors to control fluctuation of collecting main pressure to +1mmWC. Control of Emission through Lid, PLL ¾ Water seal in U- tube connecting mechanism in the oven top. ¾ Manual Lid Luting arrangement Control of Emission through Off takes, PLO ¾ Ceramic rope sealing at the base socket of AP ¾ Water sealed ascension pipe cap ¾ Proper sealing arrangement between IV & goose neck ¾ Arrangement for easy cleaning of goose neck For control of Charging Emission ¾ High pressure Ammonia Liquor Aspiration system for on main charging ¾ Gas collecting main along with U-tube facility in
CHAPTER-2 PROJECT DESCRIPTION Page 28 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Parameter Envisaged details CGT car for transferring gas to adjacent oven for easy evacuation of gas during on- main charging. ¾ Speedy coal cake charging along with the hood for extracting the gases ¾ Provision of charging frame in SCP car For control of Pushing Emission ¾ Land based pushing emission control system to prevent charging time emission ¾ Computerized Heating control system For control of Quenching Emission ¾ New quenching tower will be erected that will have grit arrestor and vapour spray system Stack Emission Control PM control ¾ Improved design of Battery Anchorage ¾ Door frame to keep in contact with armour frame through ceramic rope ¾ Load transfer through buckstay to heating through liner bricks and not through central axis of the wall ¾ Proper location of intermediate springs transferring the load on armour frame from buckstay to ensure positive load during regular operation ¾ Improvement in quality of refractories & mortar particularly with reference to porosity, bulk density & residual quartz.
SO2 Control As the percentage of sulphur in coal blend is less, so
SO2 level will always be less than stipulated norm. NOx Control Provision of re-circulation of waste gases in flues CO Control ¾ Proper combustion by control of Air & gas mixture ¾ Temperature & combustion monitoring on regular basis ¾ Monitoring through computerised heating control system. Monitoring System Stack Emission On-line Continuous stack monitoring system for PM,
SO2, NOx and CO
Details of pollution control measures envisaged is elaborated in Chapter-4 of this EIA-EMP report.
2.8.2 Sinter Making
Bokaro Steel Plant (BSL) is equipped with 2 (two) Nos. of 252 m2sinter machine and 1 (one) no. of 312 m2 sinter machine in its existing sinter plant. The existing sinter plants are operating at a lower productivity level, which is insufficient to meet the requirements for envisaged hot metal production
CHAPTER-2 PROJECT DESCRIPTION Page 29 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT level of 5.77 MTPA. The present average gross sinter production over last few years from the existing sinter plant is approx. 5.0 MTPA.
1. Proposed new Sinter Plant:
In view of meeting the sinter deficit at the targeted hot metal production level of 5.77 MTPA, a new sinter plant of 360 m2 area has been proposed to meet the sinter requirement of Blast Furnaces. The rated sinter production from the new sinter machine will be 3.7 MTPA gross sinter based on rated productivity of 1.3 t/m2/h with machine utilization of 90.4% over calendar year. The reasons for selection of 360 m2 new sinter plant are as follows: x without pellet, 70% sinter charge in BF burden is possible x with new Sinter plant, any shut down in any of the existing sinter machine will not significantly affect % sinter in BF burden for targeted hot metal production of 5.77 MTPA after phase-I expansion x Installation of new sinter plant can be taken up independently without relating to BF shut down x Logistics of sinter feed to BF stock house will improve significantly x Better environmental control with new sinter plant
The proposed Sinter plant with sinter machine with 360 m2 grate area shall have annual production capacity of 3.7 MTPA of gross sinter. This is based on annual average productivity of 1.3 t/m2/hr working for 330 days (7920 hours) in a year. The design capacity will however be based on 1.4 t/m2/hr. This will take care of any short fall in production on annual basis due to reduction in working days, quality of raw materials.
The major design and operating parameters of the proposed operating parameters is as follows:
Table 2.13. Broad design and operating parameters of new Sinter plant Parameter Unit Value No. of sinter machines x area No. x m2 1 x 360 Productivity, rated t/m2/h 1.3 Annual sinter production (gross ) MTPA 3.70 Size of finished sinter mm 5 - 40 Annual working regime days/ yr. 330 No. of working hours/ day hrs /day 24 Under-grate suction mm WC 1650 Sinter M/c bed height (including 30 to40 mm 700 mm hearth layer) Cooler type - Circular(deep bed dip rail) Avg. temperature of cooled sinter deg.C < 100 Dust content in exhaust gases at stack mg/ Nm3 Below 50
The sinter plant will consist of the following main technological units: x Storage and Proportioning unit x Mixing unit x Nodulising unit x Sintering and cooling unit
CHAPTER-2 PROJECT DESCRIPTION Page 30 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Cold sinter crushing unit x Cold sinter screening unit x Waste gas cleaning unit x Plant dedusting unit x Junction houses & galleries x Pneumatic handling systems x Emergency sinter storage unit
The above units will be interconnected by conveyor galleries & junction houses for conveying sinter mix, finished sinter, hearth layer, sinter return fines and plant waste. In addition to the main technological units, services facilities like electrics, instrumentation and automation, air conditioning, ventilation, water supply, compressed air, gas, pollution control etc. catering to the above units shall also form a part of the sinter plant complex. The tentative raw material requirement and product output is as follows:
Table 2.14. Tentative raw material requirement and product output of new sinter plant Input TPA Output TPA Iron ore fines 3040290 B.F. Sinter 3700000 Limestone 193140 IPRF 1764230 Dolomite 316350 Hearth layer 569130 Mill scale 39960 Losses 1080740 Flue dust 23310 Calcined lime 66600 Coke breeze 233100 Hearth layer 569130 Return fines 2134230
The tentative chemical composition & metallurgical properties of sinter is as follows: Table 2.15. Tentative chemical composition & metallurgical properties of sinter Constituents Value (%) Fet 57.2 FeO 9.0 SiO2 4.5 Al2O3 2.5 CaO 7.0 MgO 1.9 Basicity (CaO / SiO2) 1.55 ISO tumbler index (+) 6.3 mm 76 (min.) Reducibility Index (RI) 65 (min.) RDI 28 (max.)
Raw Material & Finished Sinter Handling and Transportation
Incoming raw material such as iron ore fines, lime stone, dolomite etc. shall be received by railway wagons. Existing railway network of BSL will be utilized for receipt of incoming rakes. The rakes/ wagons are tippled in the existing and the proposed raw material tipplers. After tippling, the materials shall be conveyed by existing & proposed conveyors to the new storage beds (3 nos.), to be located besides flux storage yard.
CHAPTER-2 PROJECT DESCRIPTION Page 31 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Three new beds with stacker, barrel reclaimer, stacker cum reclaimer, transfer car etc. have been envisaged for the same. From material storage yard to sinter plant, material will be transported by overhead conveyor.
Sinter from new sinter plant shall be discharged by belt conveyor to the outgoing conveyor of existing sinter storage unit of SP-I for feeding to BF 3, 4 and 5.
2. Proposed New Shaft Kiln:
Installation of new Sinter plant shall require augmentation of existing Raw Material Handling System (RMHS) and dedicated sinter storage & dispatch system to feed sinter to all the BFs. One new Lime Shaft Kiln shall also be installed to meet the lime requirement.
Lime stone of size (+) 25mm to (-) 55mm will be received by existing belt conveyer from RMHP to existing weigh batcher of RMP and it will be stored in the existing 2*200 tons bunkers of phased out Rotary Kiln # 7 from where the same will be conveyed by conveyor to storage bunker at limestone storage unit. 2 nos. 250t capacity each of storage bunker is envisaged for lime stone. From the storage bunker, the materials will be fed to individual weigh hopper through belt conveyor for feeding the measured quantities materials to the kiln through skip hoist/ belt conveyer. The kiln will be fired with fuel to generate heat of calcination temperature of 1100°C-1150°C.
Produced lime will be stored in the hopper placed below the kiln and shall be discharged by vibratory feeder to the belt conveyors (1W+1S).
Lime storage, crushing & screening unit shall have screening facility for (+)/ (-) 10mm lime with bypassing arrangement. The crushed lime fines shall be screened to (-) 2mm and conveyed by belt conveyor to lime fines storage & despatch unit.
The waste gas which is coming out from kiln shall be cleaned in waste gas cleaning system to vent out the clean gas to the atmosphere. The dust load at clean gas let out to atmosphere will be <50mg/Nm3 at normal temperature. The dedusting system will be provided at all transferring points of materials for Limestone Storage Unit; Lime Storage, Crushing & Screening Unit and Lime fines storage & Despatch Unit to keep dust free atmosphere in lime kiln area.
The tentative design parameters taken into consideration while designing the Shaft Kiln is as
follows: Table 2.16. Tentative design parameters of new Kiln Parameter Unit Value Capacity of new Shaft Kiln TPD 450 Nos of Kiln Nos. 1 Temperature (Burning Zone) °C 1150 Type of kiln Twin Shaft, Parallel flow, Regenerative. Method of charging to new Shaft Kiln Skip/ Belt conveyor
In addition, various pollution controls as well as environmental friendly facilities have also been envisaged for the proposed lime kiln such as: x One independent Bag Filter based gas cleaning system with a self-supported chimney for the Lime Shaft Kiln for waste gas cleaning.
CHAPTER-2 PROJECT DESCRIPTION Page 32 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Suitable waste heat recovery system shall be provided. x Dust Extraction (DE) Systems for Lime Stone Storage Unit and Lime storage & Dispatch Building for new sinter plant with - Dust extraction hoods, branch ducts with manual dampers, header ducts for extraction of fugitive dusts at various material handling points like conveyor discharge, conveyor receiving, lime stone/lime storage bunker feeding points, screen feeding and discharge points, skip feeding & discharge points, lime crushers including duct supports, dust cleaning hatches with covers, etc. - Pulse jet Type bag filter with accessories and dust storage silo - Self-supported stack of suitable height.
2.8.3 New Pellet Plant
It is proposed to setup a new Pellet plant of 2.0 MTPA capacity in BSL’s premises for gainful utilisation of the iron fines generated at SAIL’s captive mines as well as ferruginous wastes generated at the existing plant. The Pellet plant shall be based mostly on the beneficiated iron ore fines received from SAIL’s captive iron ore mines.
BSL will follow the well-established travelling grate process of pelletisation for pellet making. Beneficiated Iron ore fines, Limestone, Dolomite, coke breeze and bentonite are the major raw materials. The main steps in manufacturing process are as follows:
1. Pelletisation-Travelling grate process:
Pelletizing is the agglomeration of very fine (<75μm), often beneficiated raw materials into spherical products of preferably 9–16mm diameter with defined properties for transportation and further processing in blast furnaces or direct reduction furnaces. However, it is different from sintering process in the way that while the former uses coarser fines of the order of ‘mm’, the micro fines (also called ultra-fines) of the order of ‘micron’ is unsuitable for production of sinter are utilised in pelletisation. In this process, beneficiated iron ore is crushed, proportioned and mixed with fines of limestone, dolomite and bentonite with coke breeze and fed to disc pelletizers to prepare green pellets. These green pellets are charged from one end into the travelling grate for induration via four major zones of drying, preheating, firing and cooling and after that the finished pellets are sent to the Blast furnace as BF burden.
The Pellet plant complex will consist of one Travelling grate machine (for induration) of 348 m2 induration machine area along with associated service facilities. The pellet plant is slated for production of 2.0 MT pellets per annum at a rated productivity of 18 t/m2/day. About 500x400 m2 (20 Ha) land will be required for the Pellet Plant.
The major facilities of the proposed Pellet Plant proper are mentioned in Table 2.17:
Table 2.17. Major facilities of proposed Pellet plant S.No. Facility Purpose Development of two no. Beds- 22& 23 at RMHP along with 1. Raw Material Storage required facilities like stacker, reclaimer, conveyors etc. for
CHAPTER-2 PROJECT DESCRIPTION Page 33 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT S.No. Facility Purpose stacking and reclaiming. One new raw material conveyor to transport the reclaimed raw materials to storage bunkers at Pellet Plant site. Bin/Bunker for storage of Beneficiated Iron Ore Fines, Limestone, Dolomite, Coke Breeze and Bentonite. Covered shed storage for bentonite. Drying and Grinding of Iron Ore fines to pellet feed size (<45 microns-80%). 2. Ball Mill and Rotary drier Crushing and Grinding of Limestone, Dolomite, Coke Breeze to pellet feed size. Proportioning and Mixing of Ground Raw Material with ground 3. Proportioning and mixing unit beneficiated iron ore fines. 4. Disc Pelletizers Production of green pellet 5. Induration unit Heat hardening and cooling of green pellets Hearth Layer separation/ Pellet 6. Hearth Layer separation/ Cooled Pellet screening screening Cooled pellets after separation for hearth layer shall go the Pellet storage bunkers (Capacity- 600 tons). From these Pellet storage and dispatch to bunkers, pellets shall come on weigh feeder and then shall be 7. BFs. transported to PSD-1 through new series of conveyors. From PSD-1, pellets shall be feed to all Blast Furnaces through existing conveying system. Mixing and boosting station for BF To supply mixed gas at required pressure and temperature as 8. gas and CO gas process gas to Burners in Induration unit of Pellet Plant. Dust abatement facilities (ESP, bag 9. Pollution control filter, dust suppression system etc.) Electrics, instrumentation 10. As per requirement & automation 11. Laboratory facilities Testing of raw material and pellets
The basic design and operating parameters as indicated in Table-2.18 have been envisaged for the proposed pellet plant.
Table 2.18. Design and operating parameters of Pellet Plant S.No. Item description Unit Quantity 1. No. of induration machine x area No. x m2 1 x 348 2. Productivity (Rated) t/m2/day 18 3. Annual pellet production t/yr 2,000,000 9-16 (92%) 4. Size of finished pellet mm +16 (5%) -9 (3%) 5. Annual working regime d/y 320 6. Gaseous energy consumption for ignition / ton of pellet kCal/ t-Pellet 260,000 7. Electric power consumption Kwh/t-pellet 60 8. Compressed Air consumption m3/t-pellet 2.7 9. Dust content in exhaust gases at stack mg/Nm3 50 SPECIFIC RAW MATERIAL CONSUMPTION 10. Iron Ore Fines kg/t of Pellet 1100 11. Limestone kg/t of Pellet 20 12. Dolomite kg/t of Pellet 20 13. Coke Breeze kg/t of Pellet 15 14. Bentonite kg/t of Pellet 8
CHAPTER-2 PROJECT DESCRIPTION Page 34 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2. Dust Abatement Facilities
The Pellet Plant comprising various process units, accessories and handling facilities will be provided with adequate dust suppression and dust extraction facilities to restrict the particulate emission level within acceptable limits i.e. 50 mg per N cum. The systems will consist of water spraying facilities, mechanical gas cleaning equipment, dust recycle arrangement and exhaust stack. Exhaust gas from drying and grinding system will be cleaned using fans, ductings, suction hoods, cyclones, bag filters, ESPs etc., as applicable.
The indurating furnace gas will be made to pass through electrostatic precipitator (ESP) before being released to the atmosphere. Dust content in the work zone shall be limited to 5 mg/N cum over and above the prevailing dust level.
The solid waste that is the dust generated in the system will be recycled back to the system itself or will be sent to iron ore fines bed for sintering.
3. Pellet Quality:
Envisaged Pellet Quality is as given below:
Table 2.19. Envisaged Pellet Quality CHEMICAL (TYPICAL): Fe SiO2 + Al2O3 Basicity ~64% ~ 4% ~0.5% MECHANICAL & METALLURGICAL PROPERTY:
Sl. No. Item Value Size 9-16mm 92% min 1. +16mm 5% max -9mm 3% max 2. Porosity 24-28% 3. Cold Crushing Strength 250 kg/pellet (min) 4. ASTM tumbling index (+6.35 mm) 92% (min) 5. Abrasion Index (-0.6 mm) 4% (max) 6. JIS swelling index 18% (max) 7. JIS reducibility 70 % min 8. Compression strength after Reduction 30 kg / p
2.8.4 Hot metal production
At present there are five blast furnaces in the existing Blast Furnace complex of BSL having useful volume 2000 m3 each (B.F 1,3,4&5) and 2586 m3 (B.F 2). As per assessment by BSL, the hot metal production capacity will be 4.8 MTPA till commission of new sinter plant and 4thseries of conveyors. After commissioning of the above facilities, the hot metal capacity will be 5.77 MTPA from the existing blast furnaces.
At 4.0 MTPA stage, BSL had installed 5 BFs of 2000 m3 useful volume for an overall installed production capacity of 4.5 MTPA of hot metal. Out of the 5 BFs, one BF (BF-2) was upgraded to
CHAPTER-2 PROJECT DESCRIPTION Page 35 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT increase the installed potential capability of production to 5.77 MTPA of hot metal as per earlier expansion programme to 5.77 MTPA of hot metal (EC for this had already been granted to BSL).
However, the above target of 5.77 MTPA was envisaged subject to fulfilment of the following: x Installation of 4th series conveyor for BF highline charging x Up-gradation of SP-1 x Installation of a new sinter plant SP-2 x Up-gradation of SMS-I for crude steel production of 3.1 MTPA fromSMS-1
Since, the above facilities have not been incorporated yet, BSL has limited the hot metal production capacity to 4.5 MTPA. The existing hot metal production is limited to about 4.0 MTPA to 4.5 MTPA owing to deficit in iron-bearing burden as well as reduced production capacity of downstream facilities.
The breakup of hot metal production envisaged from the existing Blast furnace complex is as follows:
Table 2.20. Hot metal production envisaged & its breakup from installed BF complex Envisaged Hot metal Envisaged Hot metal BF No. Useful volume (m3) production (TPD) production (TPA) 1 2000 3000 1050000 2 2586 4500 1575000 3 2000 3000 1050000 4 2000 3000 1050000 5 2000 3000 1050000 Total 5770000
All the blast furnaces operate with sized iron ore, sinter, coke, coal dust, fluxes and additives. The hot metal produced is transferred to Steel Melting Shops (SMS) for desulphurization and then charged in BOF. A part of hot metal is sent to pig casting machine for cold pigs production as and when SMS is not in a position to accept the hot metal.
The Technological parameters of the installed blast furnaces are given in Table 2.21below.
Table 2.21. Technological parameters of the installed blast furnaces Parameter Unit Design Value BF1,3,4,5 BF2 Gross hot metal Production TPD 3000 4500 Useful Volume m3 2000 2586 Intensity Of Coke Burning kg/m3/day 835 968 Slag Rate kg/thm 331 320 Working Days / year day/yr 350 350 BF Gas generation / THM Nm3 1576 1520 BF Gas CV Kcal/Nm3 841 883 Productivity t/d/m3(UV) 1.5 1.74 CDI – Dry (rate) kg/thm 55 67 Operating Top Pressure atm 1.0 1.3 Hot Blast Temp °C 950 1200 Source: 1. Annual Statistics of BSL 2017-18 2. Composite Project Feasibility Report of BSL’s expansion to 7.0 MTPA steel, 2006
CHAPTER-2 PROJECT DESCRIPTION Page 36 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The present proposal does not envisage any change in equipment/production technology in the existing Blast furnaces. However, the up-gradation of downstream facilities and installation of facilitating units as envisaged in the present proposal of expansion-cum-modernization will enable the existing Blast furnaces to achieve the targeted production capacity of 5.77 MTPA of hot metal.
2.8.5 Steel Melting Shops (SMS)
There are two steel melting shops (SMS) at Bokaro Steel Plant viz. (SMS-I) and SMS-II. SMS-I is based on BF – BOF – Ingot Casting route producing ingot steel, whereas SMS-II is based on BF – BOF – Continuous Casting route producing continuously cast slabs (CC slabs). The ingots produced at SMS-I are further rolled in Slabbing Mill to produce slabs. Both rolled slabs and CC slabs are finally sent to Hot Strip Mill (HSM) to produce hot rolled (HR) coils.
1. Existing SMS-I :
SMS-I consists of 5 Basic Oxygen Furnaces (BOF) / converters each of 100/130 t capacity out of which 3 converters are in operation at any given time. This creates logistics problems in hot metal charging, scrap charging and other related operational activities.
The overall modernisation of SMS-I has been envisaged in two stages: x Stage-1: Phasing out of ingot casting and introduction of 100% continuous casting x Stage-2: Expansion of capacity by introduction of endless thin slab casting with direct rolling facility.
The brief technological features of the existing SMS-I are given below.
Table 2.22. Technological features of the existing SMS-I Parameter Quantity No. of BOF converters 5 (3 operating) Heat size of BOF converters 100 / 130 t. Working volume of each converter 90.7 m3 Casting of liquid steel Ingot casting No. of ingot casting platforms 4. No. of scrap yards 2 No. of Mould yard 1 No. Of mould cleaning & cooling bays 2 No. of stripper yard 1 No. of Hot metal mixers 2 x (1300 t each) Hot metal ladle capacity 140 t Steel teeming ladle capacity 130 t Gas cleaning system Open combustion with waste heat boiler, wet scrubber, ID fan, etc.
The working volume of each converter is 90.7 m3 which, at nominal heat size of 100 t, provided a specific volume of 0.907 m3 per tonne of liquid steel. After the heat size was raised to 130 t, the specific volume came down to 0.697 m3 per tonne. Salient design details of existing BOF converters are given below:
CHAPTER-2 PROJECT DESCRIPTION Page 37 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 2.23. Salient design details of existing BOF converters Parameter Quantity No. of BOF converters 5 (3 operating) Heat size of BOF converters 100 / 130 t. Working volume of each converter 90.7 m3 Casting of liquid steel Ingot casting No. of ingot casting platforms 4. No. of scrap yards 2 No. of Mould yard 1 No. Of mould cleaning & cooling bays 2 No. of stripper yard 1 No. of Hot metal mixers 2 x (1300 t each) Hot metal ladle capacity 140 t Steel teeming ladle capacity 130 t Open combustion with waste heat Gas cleaning system boiler, wet scrubber, ID fan, etc.
Each converter is equipped with an independent system of gas cooling. The system consists of a cooling hood consisting of uptake and down take sections comprising of main boiler, evaporator-I &II and economizer sections to cool down the exhaust gas and recovery of steam. This cooled gas is finally cleaned in a venturi scrubber before being led to the stack through the ID fan. The waste heat boiler & GCP system is designed for a maximum blow rate of 320 Nm3/minute.
Mixer bay is located by the side of the existing SMS-I. There are 2 nos of hot metal mixers in this bay. The hot metal from the blast furnaces are received in this bay and poured into the mixer for storage. The hot metal is discharged into the mixer ladle and transferred with the help of railway locomotive to the converter bay for charging into the converter.
There is no facility of pre-treatment of hot metal or secondary refining of steel at SMS-I. After tapping from BOF converters, the liquid steel is teemed into moulds to produce ingots of various sizes. For this purpose, stripper yard, mould provided.
Slag from the converter is dumped into slag pot placed on a transfer car below the converters. The slag pot is transferred from the converter bay to slag yard located at a distance of about 500 m from SMS-I building with the help of railway locomotive.
2. Proposed modernization of SMS-1:
There has been gradual decline in production from SMS-I over the years. This steady decline in productivity is attributable to various reasons such as obsolescence of technologies and ageing of plant & equipment. The major issues contributing to poor productivity at SMS-I are enumerated below: x Poor logistics of 5 Converter Shop as modern converter shops are mostly designed with not more than 3 converters out of which 2 or 3 are in operation at any given time, which is not the case for existing SMS-1 x Low specific volume of BOF converters due to poor blow and temperature condition leading to slopping and spitting, which is mostly attributed to higher slag volume.
CHAPTER-2 PROJECT DESCRIPTION Page 38 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Problems with Waste Heat Boilers which are over 30 years old and are prone to breakdowns leading to various issues as leakage of flue, high energy requirement, delayed availability of steam for injection etc. x Constraints in Slag Disposal from BOF Converters, i.e. operational delays due to non- availability of slag pots x Ingot Casting Technology which is an obsolete and uneconomical technology suffering from several drawbacks including low yield, high energy consumption, inferior quality of finished steel and offering hardly any possibility of process automation.
To overcome the aforementioned issues, the proposed modernization of SMS-1 involves the following: x Replacement of 1 out of 5 nos. of existing BOF converters with a new BOF converter of 130 t (max.) heat size and higher specific volume. For this purpose, the shell of the converters along with its tilting gear & drive system will be replaced. x Suppressed combustion system in the new BOF converter replacing waste heat boilers. Gas recovery system with new gas holder (1 no.). x Secondary emission control system in the new BOF converter. x Oxygen blowing lance system with handling & maintenance system. x Combined blowing facilities including valve stand, piping etc. in new BOF converter. x New self-propelled steel transfer cars (2 nos.) for BOF converters x New self-propelled steel transfer car heats from CCS to BOF converters (1 no.) for handling of return x Modification of existing self-propelled steel transfer cars (2 nos.) x New steel ladles (10 nos.) with slide gate system. x Ladle Tilter (1 no.) x Replacement of Ladle Pre-heaters (2 nos.) to suit the new steel ladles. x Self-propelled slag pot transfer cars (2 nos.). x One new slag bay including all associated facilities like EOT cranes, slag transport system, etc. to handle the slag pot. Existing slag pots will be utilised. x Lime / flux addition system from both sides of the BOF converter. Presently there are facilities for flux addition from one side of the converter. x Replacement of 2 nos magnet cranes in Scrap Yard No. 1 x Modification of existing teeming cranes (2 nos.) and HM crane (1 no.) for lifting of the new steel ladles. x New Ladle Furnace of double track swivelling roof type (1 no.). x New single strand conventional slab caster (1 no.) with all associated facilities like cooling water system, power sub-station, utilities and gas facilities, EOT cranes and other material handling facilities. x Cooling water system for the existing SMS-I will be augmented to suit the new requirement of the shop. x Diversion of existing rail tracks to create space for the new shops.
CHAPTER-2 PROJECT DESCRIPTION Page 39 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x New rail tracks inside CCS for slab transfer to HSM. Laying of rail tracks at Scrap Yard No.1 for revival of rail linkage. Goods cum Passenger Elevator at BOF Shop.
The major technological features of proposed main facilities and production plan are as follows:
Table 2.24. Technological features of proposed modernized SMS-1 TECHNOLOGICAL FEATURES: BOF Converters : No. of BOF converters 1 nos. Heat size 130 t (max.); 125 t (avg.) Oxygen blowing rate 36,000 Nm3/h (max), at 10-12 kg/cm2. Tap to tap time 50 minutes. Gas collection system Suppressed combustion system. Slag disposal Self-propelled transfer car. Secondary Refining Unit: Ladle Furnace type 1 x 130 t; Double track swivelling roof type. Heating rate 3° C – 5° C per minute Alloy addition system Ferro alloy and flux feeding arrangement (FAFA) and wire feeding device Gas cleaning system Gas collecting through ladle hood, duct & ID fan and cleaning through venture scrubbers. Continuous Caster: Conventional Slab caster 1 x 1 strand. Slab thickness 200 - 250 mm Slab width 950 – 1650 mm. Length of slab 7500 – 10500 mm. Casting time 40 - 50 minutes (Depending on steel grade)
Apart from the replacement of one no. of BOF converter in SMS-1, the other facilities envisaged in the modernization plan are as follows: x New Slag Yard Self-propelled slag pot transfer car with provision of placing 1 slag pots of 16 m3 on each car and new track- 2 Nos Slag Pot Stands - 10 Nos. Lime coating unit- 1 No. Dozer- 1 No. Pay Loader (1 m³) - 1 No. x Ladle Furnace for secondary refining– 1 No.double track swinging roof type Ladle Furnace x Continuous Casting Machine (CCM) - 1 No. equipped with state-of-the art, high productivity continuous slab casting machine and auxiliary facilities for production of crude steel consisting broadly of Ladle Turret, Ladle slide gate lance, Shroud manipulator, Tundish & Tundish car, Dummy Bar System, Torch Cutting Machine (TCM) x Handling Equipment (Cranes, Hoists etc.) x Goods cum Passenger Elevator in BOF Shop
CHAPTER-2 PROJECT DESCRIPTION Page 40 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The production planning from the envisaged facilities is as follows: x Tap to tap time :50 minutes x No. of heats/day : 34 x Heat weight (liquid steel) : 125 t (avg.); 130 t (max.). x No. of working days available : 320 days/year per converter x Production capability of BOFs :1.306 MTPA of liquid steel (after modernization) x Production from new Caster :1.306 MTPA of CC slabs
Out of 34 heats required per day to achieve target annual production, the modernised BOF converter will produce about 28 heats per day. For production of balance heats, the existing converters will be used.
Ingot casting will be phased out and 100% continuous casting of liquid steel will be introduced. However, ingot casting route will be retained during stabilisation period. The proposed slab caster will receive liquid steel from any of the operating BOF converters after secondary refining.
A brief description of the additional facilities envisaged in the proposed modernization is as follows:
Ladle Furnace
1 no. new double track swinging roof type Ladle Furnace will be installed in the PQ bay of new CCM shop for secondary refining of liquid steel. Ladle Furnace shall broadly consist of following equipment / system: x Water Cooled Ladle Roof Complete with Supporting System x Roof Lifting Arrangement x Electrode Nippling and Storage Stand / Station: x Ferro Alloy Feeding Arrangement (FAFA) x Ladle Transfer Cars (2 nos). Transfer car track will be extended up to AB bay of existing SMS-I shop. x Arc Heating System consisting Electrode Masts and Electrode Holder and Clamp System x Hydraulic System x Centralized Lubrication System x Wire feeding system x Temperature measurement and sampling Lance x Inert Gas Stirring System
Continuous Casting Machine (CCM)
The proposed Continuous Casting Shop in SMS-1will be equipped with state-of-the art, high productivity continuous slab casting machine and auxiliary facilities for production of crude steel. The salient design features of the proposed CCM are as below:
Table 2.25. Design features of the proposed CCM Sl.No. Description Design feature 1. Ladle Turret Ladle Turret with lifting / lowering, rotating and Weighing facility, equipped with
CHAPTER-2 PROJECT DESCRIPTION Page 41 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl.No. Description Design feature ladle cover manipulator. 2. Ladle stream protection Ceramic shroud 3. Tundish Refractory lined, suitable for hot lining 4. Tundish stream protection Through submerged entry nozzle 5. Tundish transfer car 2 nos. overhead cantilever design with lifting /lowering and weighing facility 6. Type of mould Plate mould, straight, multi ta er / parabolic design 7. Mould lubrication Casting powder for closed casting 8. Mould level control Eddy current type 9. Mould oscillating Hydraulic design, adjustable stroke, oscillation mechanism frequency linked to casting speed 10. Secondary cooling Multi zones, high-pressure automatically controlled spray/air mist cooling system, dynamic control of cooling water flow w.r.t.casting speed 11. Withdrawal and Multi point straightening, hydraulic pinching, modular design straightening unit 12. Dummy bar Chain link type bottom fed 13. Strand cutting device Oxy-propane torch cutting machine 14. Marking unit Automatic Slab marking machines 15. Slab discharge By EOT crane
Gas Cleaning & Recovery System
The production of steel in the BOF converter releases fumes rich in Carbon monoxide laden with a significant amount of dust with high temperature. In order to utilize the calorific value of the gas and to suppress air pollution, each converter is to be fitted with a Gas Cleaning Plant which will collect and treat the released fumes called BOF gas, for further utilisation in the steel plant. In the Gas Cleaning Plant (GCP), hot gases will be collected above the converter mouth using suppressed combustion system, cooled through a hood and cleaned at a scrubbing installation and either recovered in a gas holder or let out to the atmosphere after combustion in a flare stack. The Gas Cleaning Plant will achieve the collection of gas without complete combustion by means of automatic adjustment of the suction rate to the flow rate of gas produced by blowing, periodically throughout the entire sequence of operation. The BOF gas is generated during blowing period only. The hot and dust laden gases leaving the BOF converters (called BOF gas) are collected largely un-burnt with the help of an adjustable (raising &lowering) skirt ring arranged between the cooling stack & converter mouth. Skirt and cooling stack will be cooled by soft water to bring down the temperature of the gases to about 1000°C. Then these gases are cooled further and at the same time, cleaned by a two stage venturi scrubbers. The non-combustion control of the system is achieved by controlling the gas pressure in the hood by means of throat dampers in the secondary venturi of the two stage scrubbers. Dust content in the gases will be reduced to less than 100 mg/Nm3.
Secondary Emission Control System
The proposed Converter will be provided with Dog House consisting of sliding doors at the charging side, swing/sliding doors at the tapping side. The top and the sides of the Converter will also be suitably closed. The Dog House shall have suitable fume collection ducts to effectively capture he fumes during hot metal charging, puffing during blowing and tapping operation.
CHAPTER-2 PROJECT DESCRIPTION Page 42 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The collected fumes will be taken to the inlet of ESP through MS fabricated duct along the shop building. The dust laden fumes, after cleaning in the ESP will be released to the atmosphere through a chimney via. ID Fan. Similarly, suitable fume collection hoods will be installed to capture the fumes from the hot metal mixture and will be taken to the header duct going to the inlet of ESP along the shop building.
Further, suitable dust collection hoods will be installed to capture the fugitive dusts from the various material transfer points of the ferro-alloys and flux feeding system and will be taken to the header duct going to the inlet of ESP along the shop building. One no. self -supported stack shall also be provided of suitable height.
BOF Gas Holder
The cleaned BOF gases shall be exported to a revamped gas holder (50,000 m3volume) or flared through a flare stack by means of a three way valve. Flaring / export of gas will be carried out depending upon the operational regime of the plant. The gas recovered in to the holder will be further cleaned (from 100mg/Nm3 to less than 5 mg/Nm3) in Electrostatic Precipitators (ESP).The final cleaned gases will be boosted by gas boosters before connecting to existing BF gas mains.
After a 3-way valve, in the gas holder direction, the gas goes through a safety hydraulic non return valve. A common collector carries the gas in to the gas holder of 50,000 m3 capacity. The gas from the holder will be cleaned in ESPs. Finally gas is exported to main fuel network by means of gas booster. The revamped gas holder will be of dry fabric seal type.
3. Existing SMS-II:
SMS-II was initially designed for 1.5 MTPA of ingot steel production based on100% ingot casting. In the year 97-98, SMS-II was provided with 100%continuous casting with addition of a 2 x 2 strand Continuous Casting Department (CCD) parallel to BOF shop and not in line to the shop due to space constraints, which improved its production capacity to 2.16 MTPA of cast slabs.
However, in 2007-2008, it was observed that the production capacity could be increased to 2.85 MTPA Cast slabs on improving existing shop practices and better in-plant material movement and the same was included in the earlier expansion programme of BSL. Additionally, a new Ladle Furnace was also envisaged in the earlier expansion programme. These schemes improved the production capacity to 3.3 MTPA of cast slabs.
Debottlenecking of existing SMS-II:
On assessment by BSL, it was realised that some debottlenecking activities could further enhance the production capacity to 3.35 MTPA cast slabs. The schemes/activities for debottlenecking of SMS-II as envisaged in the present expansion-cum-modernization proposal are as follows:
Table 2.26. Debottlenecking activities envisaged in SMS-II complex Sl. No. Debottlenecking activities envisaged 1 Transfer of hot metal to SMS-II by use of torpedo ladles envisaged 2 Facilities envisaged are new track for optimized Torpedo ladle movement along with Torpedo ladle heating system & tilting system, EOT crane etc.
CHAPTER-2 PROJECT DESCRIPTION Page 43 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. No. Debottlenecking activities envisaged 3 Installation of HMDS (Hot Metal desulphurization) 4 New BOF Gas holder, ESP & Booster Fan complex
The production parameters of the existing shop are summarized below:
Table 2.27. Production parameters of the existing SMS-II TECHNOLOGICAL FEATURES: No. of BOF converters 2 nos. Heat size 300 t (max.) Hot metal mixers 2 x 2500 t Ladle Furnace 2 x 300 t Argon Rinsing unit 1 x 300 t SMS-II CCD: Average heat size, t 285 Average tap-to-tap time, min 1/2 & 2/2 Converter operation 60/65 One converter and one caster operating, days 100 Two converters and two casters operating, days 250 No. of. heats/day during one converter and onecaster operation 23 No. of heats/day during two converter operation 37 Total No. of heats/year 11550 Average No. of heats/day (yearly average) 33 Total production of Cast Slabs per year, MTPA 3.3
The additional facilities for debottlenecking of SMS-II are briefly described in succeeding paragraphs.
Hot Metal Desulphurisation
Hot metal desulphurisation station is required to bring down the sulphur content in hot metal received from blast furnaces, which will improve quality of steel product. Desulphurisation of hot metal will be carried out in the converter hot metal charging ladles of 300 t capacity prior to charging into BOFs.
Desulphurisation facilities are planned in a separate building adjacent to the mixer shop. The facilities have been planned for 100%desulphurisation of hot metal. The desulphurisation building will be equipped with hot metal ladle handling cranes and reladling pits for torpedo. The desulphurisation facility will be based on co-injection process. Calcium and magnesium based reagent will be used for desulphurisation of hot metal. Nitrogen will be used as the carrier gas during injection.
New Gas Holder, ESP and Booster Fan
The capacity of the Gas Holder will be 80,000m3, having working pressure in range of 200+50 mmWC. The envisaged volume of recovered gas (34,200 Nm3/hr) will require installation of two streams of ESP & Booster Fan. It is proposed to install a new stream of ESP & Booster Fan of similar capacity i.e. 30000 Nm3/h with all necessary piping work in addition of existing two streams.
CHAPTER-2 PROJECT DESCRIPTION Page 44 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2.8.6 Rolling mills
BSL produces both hot rolled as well as cold rolled products. For production of these, BSL has Slabbing mills, Hot strip mills and Cold rolling mills already under operation. After completion of all phases of earlier expansions, BSL has a Universal Slabbing mill, a 4.5 MTPA Hot strip mill with Hot rolled coil finishing lines and a CRM complex of 2.4 MTPA of Cold rolled products. x The present capacity of existing HSM is 4.5 MTPA and there is no change envisaged as part of the proposed expansion-cum-modernization plan. x The existing Slabbing mills operate with 7 batteries of soaking pits and the same shall continue after the proposed project. x The existing CRM complex of 2.4 MTPA has been assessed and debottlenecking activities have been identified, which would improve the production capacity of the complex to 2.86 MTPA of cold rolled products.
A brief discussion of the existing units and changes proposed is discussed in subsequent paragraphs.
1. Slabbing mill:
Slabbing Mill transforms ingots into slabs by rolling them in its 1250 mm Universal Four-High Mill. The maximum rolling capacity of the Mill is ~4 MTPA. There are only 7 groups of working soaking pit batteries, with 4 pits of 160 TPA capacity each.
The shop also has Hot and Cold Scarfing Machines and 2800 T Shearing Machine. Controlled heating in Soaking Pits, close dimensional accuracy during rolling and hot and cold scarfing help produce defect-free slabs.
No changes are envisaged in the present proposal in the slabbing mills and these will be in continued operations after the proposed expansion-cum modernization plan, till the stabilization of overall modernization of SMS-I (Both phase-1 and phase-2) is achieved.
2. Hot Strip Mill:
The existing Hot Strip mill had been built under two stages at 4.0 MTPA Steel production capacity of plant and then modernized in the subsequent modernization-cum-expansion programme of BSL. The existing facilities after both the stages of implementation are described below: x 4 nos. of walking Beam type Reheating Furnaces of charging rate 300 T/Hr. x 7 nos. of Modernised finishing stands of Tandem type with Hydraulic AGC x 4 nos. of Hydraulic coilers
Additionally, a Hot rolled Coil finishing complex with two (02) shearing lines and one (01) slitting line is also present.
The salient parameters related to productivity and mill utilization are given in the table below.
CHAPTER-2 PROJECT DESCRIPTION Page 45 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 2.28. Salient parameters related to productivity and mill utilization of HSM Sl.No. Parameters Values/description 1. Capacity of HSM-HR coils (t) 45,00,000 2. Slab Tonnage (t) 4,615,400 3. Yield (%) 97.4% 4. Mill utilization (%) 88% 5. Furnace capacity (t/hr) 757.5 6. No. of Reheating furnaces 4 7. Type of Reheating furnaces Top and bottom fired walking beam type furnace 8. Fuel Mixed Gas of CV = 2300 kcal/Nm3 9. Slab discharge Temperature 1250°C 10. Slab thickness range 1.6 mm-16 mm 11 Width range 900mm -1850 mm
The present proposal doesn’t envisage any change in the production capacity of the existing HSM of 4.5 MTPA (HR Coils).
3. Cold Rolling Mill complex:
The existing Cold Rolling Mill (CRM) complex had been built under two stages at 4.0 MTPA Steel production capacity of plant and then augmented by addition of a new CRM-III in the subsequent modernization-cum-expansion programme of BSL. The existing facilities after both the stages of implementation are described below: x CRM-I&II - 2 nos. of Continuous Pickling lines I & II - Hood Annealing furnaces - 1 x 4 Stand Tandem Cold Mill + 1 x 5 Stand Tandem Cold Mill - 2 nos. of Single Stand Skin Pass Mills - 5 nos. CR Shearing Lines - 3 nos.CR Slitting Lines - 1 no. of Electrolytic Cleaning Line - Tower type Continuous Annealing Lines - 1 no. Twin Stand Temper / DCR Mill - 1 no. Hot Dip Galvanizing Line with 1 no. Galvanised Sheet Shearing Line & 1 no. Galvanised Sheet Corrugation Line - Acid regeneration plant I&II
x New CRM-III - Coupled Pickling & Tandem Mill - Electrolytic Cleaning Line - Bell Annealing furnaces - Single Stand 4-Hi Skin Pass Mill - Hot Dip Galvanizing Line with electrolytic cleaning & differential Zn coating - Tension Leveller & Inspection Line with Combination of Walking Beam conveyor, Coil shuttle car & Coil Transfer car
CHAPTER-2 PROJECT DESCRIPTION Page 46 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT - Coil packaging lines for GI/GA Coils and CR coils each - Acid regeneration plant-III In order to remove debottlenecks in the existing CRM complex (CRM-I,II&III), BSL envisaged the following activities: x Process overhauling & up gradation of PL-II x Up-gradation of Pickling Line-1 (PL-I) welding machine x Addition of 12 Nos Bell Annealing furnaces x Addition of HDGL line x 3 crane replacement for improved shop movement x Replacement of TM-1, Stand- 3 & 4 transformer and system x Replacement of TM – 1 hydraulic system
The above mentioned activities are envisaged to remove the existing production debottlenecks by removing obsolescence from the unit and improving the shop productivity of CRM I&II to 1.66 MTPA, hence increasing the total production of the CRM complex from 2.4 MTPA to 2.86 MTPA.
2.8.7 Refractory Material Plant (RMP)
Existing Refractory Material Plant (RMP) is has 6-nos. of Rotary Kilns of capacity 270 TPD each to meet the present flux requirements of BFs, SMS and for production of Calcined dolomite. However, at a time only 4 are available for operation to meet the existing flux requirements.
Under Sinter Plant, one no. of new Shaft Kiln of capacity 450 TPD has been envisaged to meet the lime requirement of 250 tpd (@ 20 kg/t of gross sinter).Extra 200 TPD lime shall be available for use in other SMS to meet the requirement of lime.
Installation of proposed new Sinter Plant shall also require augmentation of Raw Material Handling System (RMHS) and dedicated sinter storage & dispatch system to feed sinter to all the BFs.
The brief design parameters of the proposed 450 TPD shaft kiln is as follows:
Table 2.29. Design parameters of the proposed 450 TPD shaft kiln Sl.No. Parameters Values/description 1. Capacity of new Shaft Kiln) 450 TPD 2. Temperature (Burning Zone) 1150°C 3. Type of kiln Twin Shaft , Parallel flow, Regenerative. 4. Temperature (preheating zone) 500°C– 450°C 5. Temperature (burning zone) 1050°C– 1150°C 6. Temperature (discharge zone) <100°C 7. Fume Temperature 120°C– 130°C 8. Method of charging to new Shaft Skip/ Belt conveyor) Kiln
2.8.8 Oxygen production
The Oxygen demands of Bokaro Steel Plant (BSL) is met by Captive Oxygen Plant and BOO oxygen plant. The installed capacity of Captive Oxygen Plant was 2350 TPD with all the five Air Separation Units (ASU) working. The capacity of BOO Oxygen Plant is 1250 TPD.
CHAPTER-2 PROJECT DESCRIPTION Page 47 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
The designed capacity of ASU-I, II, IV & V is 450 TPD each and ASU-III is 550 TPD. ASU-I & II of Captive Oxygen Plant have outlived their design life and were written off by BSL in March, 2010. Now the installed capacity of Captive Plant is 1450 TPD. Hence the total installed capacity of oxygen production is 2700 TPD including 1250 TPD of BOO plant.
ASU-III & IV of Captive Oxygen Plant were commissioned in 1978-79 and ASU-V was commissioned in 1988. These units have developed several defects resulting in lower production and compromise in purity. Due to deteriorated conditions of ASU III, IV & V, production from these units has reduced drastically w.r.t their designed capacity of 550TPD, 450TPD& 450 TPD respectively. However it is envisaged that with rectification of problems, production of 350 TPD, 250 TPD & 350 TPD can be achieved from ASU Ill, IV & V respectively.
As per Oxygen balance indicated in table below for planned steel production after expansion to 5.77MTPA hot metal & 4.656 MTPA crude steel the total short fall of Oxygen is 34250 Nm3/h (1175 TPD).
Table 2.30. Oxygen Balance for Expansion to 5.77 MTPA Hot Metal (4.656 MTPA Crude steel) stage Unit Production considered Oxygen requirement (Nm3/hr) SMS 4.656 MTPA 34550 (@65 Nm3/ton) (SMS-I: 1.306 MTPA, SMS-II: 3.35 MTPA) BF 5.77 MTPA hot metal 57100 Miscellaneous @5.77 MTPA hot metal stage 6600 (@10 Nm3/ton) Total Oxygen requirement @ 5.77 MTPA HM stage: 98250 Nm3/hr Existing production capacity: 64000 Nm3/hr (2200 TPD) Shortfall of oxygen: 34250 Nm3/hr (~1175 TPD)
In view of the above, BSL is contemplating a 1250 TPD Oxygen Plant on BOO basis. This will be a green field project and land (120m x 195m approx.) for setting up this Plant is readily available besides the exiting BOO Plant. Power shall be made available from MSDS-7 and make-up water shall be made available from Supply Canal. One oxygen supply line from the BOO plant shall be connected to existing supply header for BF blast enrichment. Another oxygen supply line from the BOO plant after suitable pressure reduction at BOO plant will be connected to existing supply header for SMS II. There will not be any effluent & waste generation from the plant.
2.8.9 Water Supply system
For fulfilment of raw water requirement, BSL has an agreement with Government of Jharkhand for drawl of 227 cusecs (i.e. 23140 m3/hr) of water from Damodar River. Water requirement of BSL plant & township is fulfilled by Tenughat dam on Damodar River. Water is supplied through a gravity canal (i.e. Tenu canal) which is about 35 km long.
1. Existing Raw Water Drawl System:
Water from Tenughat Dam is released through a separate exclusive gate into the Tenu canal. This canal discharges into Cooling Pond-I of BSL which serves as are circulating basin for the plant.
CHAPTER-2 PROJECT DESCRIPTION Page 48 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The Canal is mainly built with earthen embankments, has PCC lining along the full length and has intermittent civil structures like RCC aqueducts or cross drainages over the nalas, small seasonal rivers, low lying land etc. It also caters to the irrigation as well as public needs of the adjoining areas.
The salient features of the existing system are as follows:
Table 2.31. Salient features of existing water supply system Sl. No. Feature Quantity(m3/hr) 1 Maximum withdrawal permission 23140 2 Original capacity of canal 23000 3 Requirement of BSL Plant & Township 19500 4 Present flow received at Cooling Pond - I 16800 to 17500 5 Minimum withdrawal permission 15291
The existing canal is more than 40 years old. Its condition has deteriorated considerably. At many places the canal lining is damaged. The problem is more pronounced at junction points of aqueducts and main canal.
Heavy siltation has taken place over the entire length of the canal leading to lowering in withdrawal capacity. The long stretch of the canal makes continuous monitoring difficult leaving the stretch open to potential threat of unnoticed breaches. This has happened on several occasions in the past.
In view of the above, BSL is contemplating major repair including strengthening of embankment, relining of damaged parts, repair of aqueduct joints and other such deficiencies. However, a repair of such magnitude will require shutdown for minimum six (06) months whereas the emergency storage available at BSL in cooling ponds-I &II is for 7 days only.
In this condition, it is imperative to create an alternate facility for supply of raw water from Damodar to Cooing Pond -I. Hence, drawing water from Baidhmara weir near Bokaro, as an alternate source of raw water, was found out to be most suitable and feasible. BSL has already obtained permission from Jharkhand government for water from Baidhmara weir and release of corresponding quantity from drawl of Tenu dam.
2. Proposed alternate water drawl system:
The design parameters for the proposed raw water drawl system are as follows:
Table 2.32. Design parameters for the proposed raw water drawl system Sl. No. Feature Proposed 1 Capacity of system 19500 m3/ hr 2 Intake source Baidhmara weir on Damodar river 3 River bed level at weir 159.75 m 4 Weir crest level 164.00 m 5 Minimum water level 164.00 m 6 Maximum water level 184.00 m 7 Discharge point level 219.00 m 8 Water depth in river in dry weather 4-5 m 9 Dry weather flow 40-50 cumec (1,44,000 to 1,80,000 m3/hr)
CHAPTER-2 PROJECT DESCRIPTION Page 49 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. No. Feature Proposed Fore bay (200 mm) +Sump (10m x 30m) + 10 Intake type Suction Chamber (10m x 30m) 11 RCC Side wall for sump protection Minimum 20 m long from sump Two parallel pipe line of dia 1000 mm & 1400 m approx. 5 kms each. Out of total 5 km, 4.0kms 12 Pipeline shall be buried &0.5 kms on trestles. 13 Power supply 33 kV line from DVC at doorstep 14 Railway Crossing One (01) 15. Energy dissipater at discharge point Spillway
Sealing gates & bar screens have been envisaged at the entry of Intake well for isolation & screening purpose. Between intake well &individual suction chamber of pumps, flow passages at different levels have been envisaged which shall be opened/closed through stage gates as per river water level chambers. This will help in reducing the siltation of the chambers
The existing water supply system and the proposed water system are indicated in Fig. 2.3 below.
Fig. 2.3. Existing (Tenu Canal) and Proposed water supply system for Bokaro Steel Plant
2.9 ENVIRONMENTAL POLLUTION MITIGATION MEASURES
2.9.1 Air pollution mitigation measures
In an integrated Steel plant, air pollutants are generated at different stages of production. Air pollutants may be particulate matter, sulphur dioxide, oxides of nitrogen etc. The pollutants may be released as point source emission or fugitive emission. In order to reduce the impacts on ambient environment, all efforts have been made to adopt latest state of art technology and to install adequate pollution control measures for different processes and de-dusting stacks and for different fugitive emission sources.
CHAPTER-2 PROJECT DESCRIPTION Page 50 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT During the construction phase of the proposed project, appropriate mitigation measures have been implemented to reduce the impact on these activities in ambient air quality. For operation stage of the plant, several APCs have been installed to limit the emission levels within the prescribed norms. Details of the existing & proposed Air Pollution Control Devices in the Integrated Steel Plant are given in Table 2.33.
Table 2.33. List of existing Air Pollution Control (APC) Measures Sl. Department Existing Air pollution Control equipment No. ESP Bag Wet Battery DFDS Fume extraction filter scrubber cyclone system EXISTING FACILITIES 1 Refractory material plant 6 40 - - - - (RMP)* 2 Sinter Plant** 3 - 34 5 - - 3 Blast Furnace 3 - - 10 1 - 4 SMS-1 , SMS-2 - 23 - 17 - - 5 Coke oven - - 6/10 - 4 - 6 Foundries - - 23 23 - - 7 Cold Rolling Mill - - - - - 2 8 Slabbing Mill - - 1 - - - Note: *All ESPs of RMP are undergoing revamping. **All Cyclones to be replaced by ESPs Source: ECD, BSL
The air pollution control facilities envisaged in proposed facilities is mentioned in Chapter-4 of this report.
2.9.2 Water Pollution Mitigation
Wastewater discharges from an integrated steel plant can be broadly divided into two parts - Non- contact water discharges and contact water discharges.
Water is used in a series of heat exchangers in coke oven gas treatment, blast furnaces, basic oxygen furnaces, and rolling operations and boilers. This non-contact water is generally contaminated with high dissolved solids comprising of salts of calcium and magnesium which were originally present in the raw / feed water. Due to repeated re-circulation and high temperature, concentration of these salts starts increasing, necessitating bleeding off of some part of circulating water.
Water is also used for contact cooling i.e. quenching, Coke oven gas treatment, slag handling etc. This contact water discharges may be contaminated with different pollutants and need to be treated prior to discharges.
A number of water pollution control measures are already under implementation at Bokaro Steel Plant. A few measures are enumerated as follows:
1. Coke Oven & By-Product Plant:
Existing Coke Oven complex has Effluent treatment plant (ETP), commonly called as Biological Oxidation and De-phenolisation Plant (BOD Plant). It is designed to remove contaminants from the
CHAPTER-2 PROJECT DESCRIPTION Page 51 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT effluent such as Oil & Grease, Ammonia, Phenol, Thiocyanate, Cyanide etc. The BOD plant treated waste water is fully used in coke quenching. The details of the existing as well as proposed ETP are elaborated in Chapter-4 of this report.
2. Local recirculation system:
These are the localised recirculating systems serving a particular area, such as x GCPs of BF - Return water from precipitations and scrubbers of GCPs come to radial settling tanks for settlement with coagulants (Ferrous sulphate and lime). Clarified water is cooled in cooling towers and supplied back to GCPs. Settled sludge in radial settling tanks is pumped to Dredge pump house for further pumping to Metallic sludge compartment. x Primary gas coolers of Coke ovens: Water from coolers are cooled in cooling towers and taken to the suction chamber for further pumping to gas coolers. x Final gas coolers: Here cooling is done by direct contact with gas. Return water is taken to tank for allowing naphthalene, Tar etc. to separate out and clear water is taken to cooling towers and from cooling towers to pump house for further use. x Slag Granulation Plant: Return water is taken through filter media and settling tank for separation of floating and settleable solid and pumped back for reuse.
3. Other Facilities: x Pig Casting Machine: Used water is taken through settling tanks for settlement of lime and clarified water goes to cooling pond. Sludge is removed by Grab crane. x Slag Ladle Spraying: Suspended materials are separated in settling tank and over flow water goes to cooling pond. x Ingot Mould cooling and Hydraulic cleaning: Return water goes to settling tank for clarification and overflows to cooling pond. Settling matters are removed by grab crane.
Presently, there are two outfalls at BSL which discharge treated effluents of approximately 550 m3/hr to Damodar River. The coordinates of the two outfall discharge points are indicated in Table
2.34 below. Table 2.34. Location of discharge points of outfalls from the plant Sl. No. Outfall description Coordinate of discharge point Latitude Longitude 1 Outfall-1 (OF-1) 23° 44.256'N 86° 5.270'E 2 Outfall-2 (OF-2) 23° 43.513'N 86° 8.310'E
However, to conserve water, BSL is implementing schemes for recycling water flowing in its two outfalls. Most of the water is pumped back to the water re-circulatory systems, like cooling ponds and sludge compartments, by which the effluent discharged through the outfalls have been drastically reduced over years. The details of the water pollution control measures envisaged as well as under implementation are detailed in Chapter-4 of this report.
2.9.3 Major green Initiatives undertaken at BSL
BSL has been investing in adoption of green and clean technologies for becoming a sustainable and clean production facility. Some of the major initiatives undertaken are as under:
CHAPTER-2 PROJECT DESCRIPTION Page 52 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Steam Ageing of LD Slag for use as an alternative rail ballast. x First steel plant to introduce Biodiesel in Locomotives. x Use of plastic flakes in road making. x Steel slag-Fly ash bricks. x Use of solar energy through initiatives mentioned hereunder: - Installation of 65 nos. (18 W) of LED based solar lighting system for area lighting around ED(W) building. - Roof- top solar PV units on BPSCL plant building of 2x50 KWp - Roof-top solar units on BSL buildings of 2.0 MWp - Greenfield ground mounted solar PV plant of 20 MWp
The details of hazardous waste generation (existing as well as anticipated) and its management is elaborated in Chapter-4 of this report.
2.10 PROJECT SITE & LAND REQUIREMENT
The proposed expansion-cum-modernization plan is being carried out entirely within the existing Bokaro Steel plant premises. The existing plant is in operation over a total area of 6973.68 ha which is under possession of BSL. Proposed units will be located entirely within the existing plant premises for which sufficient space is available.
The proposed project shall not involve any land acquisition i.e. the question of Resettlement & Rehabilitation of land oustees and diversion of Forest Land does not arise. The existing vegetation of the areas identified for the proposed units comprises of shrubs, grasses, herbs and a few small trees. Therefore no large-scale tree felling will be necessary.
Of total area under possession of BSL, i.e. (6973.68 ha), 1199.99 ha is taken up by the cooling ponds and 360.17 ha is occupied by the slag dump. Thus, the actual plant area is 5413.52 ha. At present green belt and plantations cover 1923.99 ha (i.e. 33.32%). During 2019 – 20 another 141.64 ha of plantations are proposed to be added. Thus the total area of green belt and plantations shall increase to 2065.63 ha. The brief land utilization of the plant area is given in Table 2.35 below: Table 2.35. Land utilization of Bokaro Steel plant Sl. No. Type of Land utilization Area (in ha) 1. Major Plant facilities (including greenbelt) – (A) 5413.52 2. Cooling ponds – (B) 1199.99 3. Slag dump – (C) 360.17 4. Greenbelt area (included in Sl 1 & 3) 1923.99 Total area under possession of BSL ( A+B+C ) 6973.68
The modernization/debottlenecking projects under the proposed expansion-cum-modernization plan of BSL will be carried out within the respective existing units of the plant. The new facilities under BSL’s expansion-cum-modernization plan are proposed in the vacant and unutilized areas adjacent to existing units of the plant. The area requirement for these new facilities within the existing plant complex is given in Table 2.36 below.
CHAPTER-2 PROJECT DESCRIPTION Page 53 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 2.36. Area requirement for new facilities envisaged under expansion-cum- modernization of BSL Units Dimension (m) Area requirement (m2) Area (ha) New Sinter plant 360 x 315 113400 11.34 New Pellet Plant 500 x 400 200000 20 New Coke Oven 400 x 450 180000 18 New Oxygen Plant 120 x 195 23400 2.34 Total area required within the plant 51.68
The indicated area of ~52 ha required for the expansion-cum-modernization programme is available within the existing plant premises of BSL.
The layout of Bokaro Steel plant indicating the new units/facilities as well as shops to be modernized/up-graded as part of the proposed expansion-cum-modernization programme is depicted in DRG. MEC/11/S2/E24V/LAY/01.
2.11 RAW MATERIAL REQUIREMENT
The existing raw material and other chemical requirement of Bokaro Steel plant, their sources & mode of transportation is presented in Table 2.37 below:
Table 2.37. Major Raw Materials & Chemicals Consumed at BSL, Sources & transportation Sl. Raw Material Quantity Source(s) Mode of transportation No. (t) 1 Iron Ore Lumps 2307446 Mines of RMD-SAIL (Bolani, Kiriburu, Rail 2 Iron Ore Fines 3915575 Meghahatuburu, Gua, Kalta, Rail Manoharpur) 3 Coking Coal 701767 Mines / washeries of BCCL, CCL, Rail RMD-SAIL 2775802 Imported from Australia, New From ports and transported via Rail Zealand, Mozambique, Indonesia, USA, Canada 4 CDI Coal 225578 Imported From ports and transported via Rail 5 Middling Coal 1710287 Indigenous Rail 6 Furnace Oil 11483 Public Sector Oil Companies Road via oil Tankers 7 Limestone (BF 399560 Indigenous (Khanabhanjari, Rail/road Grade) Jaisalmer) 42278 Imported From ports and transported via Rail 8 Limestone (SMS 485869 Indigenous (Jaisalmer) Rail Grade) 53668 Imported From ports and transported via Rail 9 Ferro-alloys 30690 Indigenous & Imported Rail 10 Dolomite chips 63352 Indigenous Rail 11 Dolomite Lumps 188706 Indigenous Rail (BF Grade) 223739 Imported from Bhutan Rail 12 Dolomite Lumps 191887 Indigenous Rail (SMS Grade) 132502 Imported from Bhutan Rail 13 Sand 15408 Indigenous Rail 14 Quartzite 1147 Indigenous Rail 15 Sulphur 7279 Imported Rail 16 Hydrochloric acid 4117 Generated In-house In-plant movement 17 Propane gas 1576.6 Locally purchased Road via Gas Tankers 18 CBM Gas 2094 ONGC-Parbatpur Pipe/ Road via Gas Tankers
CHAPTER-2 PROJECT DESCRIPTION Page 54 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. Raw Material Quantity Source(s) Mode of transportation No. (t) 19 Copper ~200 Locally purchased Rail/road 20 Aluminum 7393 Indigenous Rail/road 21 Nickel ~83 Imported Rail/road 22 Zinc 3500 Indigenously purchased Rail/road TOTAL 13502987 Source: Annual Statistics (2017 – 18) of Bokaro Steel Plant
The total raw material requirement estimated at 4.5 MTPA hot metal production is estimated as 16911300 TPA (as per CPFR for 4.0 to 7.0 MTPA of crude steel expansion program of BSL).
The additional raw material required for the additional units proposed as part of the proposed expansion-cum-modernization plan of BSL, alongwith their sources and transportation is as follows:
Table 2.38. Additional raw material required for the additional units of proposed expansion-cum-modernization Additional Consumer requirement (t) Total additional Raw material New Stamp New Pellet New Sinter Source Mode of transportation requirement charged battery plant Plant Coal 10,20,000 - - 10,20,000 Transported via railway wagons Coke Breeze - 31,680 2,33,100 2,64,780 In-plant Coke breeze generated at Coke generation Ovens, BSL shall be transported via overhead conveyors. Iron Ore Fines - 25,00,000 30,40,290 55,40,290 SAIL’s captive iron Will be received via Railway ore mines wagons at RMHP and shall be stacked in new two nos. of bed-22 & 23. Limestone - 47,520 1,93,140 2,40,660 SAIL’s captive Will be received via Railway and limestone mines shall be stacked at Bed No.-21 and other (Common with Sinter Plant-II) indigenous which is divided in two parts- one sources for Limestone and another for Dolomite. Dolomite - 47,520 3,16,350 3,63,870 Tulsidamar Dolomite received via Railway mines/purchased shall be stacked at Bed No.-21 from Bhutan (Common with Sinter Plant-II) Bentonite - 23,760 - 23,760 Purchased from Direct supply to Pellet Plant by Kuchch region of railways. Gujarat Calcined Lime - - 66,600 66,600 In-plant Transported via overhead generation from conveyors new Lime Kiln Flue dust - - 23,310 23,310 In-plant Transported via overhead generation conveyors Mill scales - - 39,960 39,960 In-plant In-plant transportation generation
The total raw material requirement at 4.5 MTPA HM stage and 5.77 MTPA HM Stage is as follows: Sl. Raw materials Quantity required at 4.5 Quantity requirement at Source Mode of No. MTPA HM (TPA) 5.77 MTPA HM (TPA) transportation 1 Lump Iron Ore 2196000 956300 Captive mines Rail 2 Iron Ore Fines 5450000 10785290 Captive mines Rail 3 Manganese Ore 259000 - Not required - 4 Limestone 3301000 312260 Captive mines Rail 5 Dolomite 169000 363870 Captive mines/purchased from Bhutan Rail
CHAPTER-2 PROJECT DESCRIPTION Page 55 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. Raw materials Quantity required at 4.5 Quantity requirement at Source Mode of No. MTPA HM (TPA) 5.77 MTPA HM (TPA) transportation 6 Coking coal 4470500 4582667 BCCL & imported Sea/Rail 7 Coal (CDI) 1065800 577000 Imported Sea/Rail 8 Bentonite 23760 Purchased from Kuchch region Road Total raw material 16911300 17601147 requirement (TPA) Sp. Raw material 4.03 3.78 Consumption (t/tcs)
As observed from the above tables, the major raw material requirement for Bokaro steel plant comprises of iron ore lumps & fines, coking coal and middling coal, fluxes such limestone and dolomite, as well as other chemicals/fuels. Almost all of the major incoming raw material such as Coal, Iron ore fines, Lime, Dolomite, etc. is transported through rail route, excluding scrap, fuel oil, spares & tools as well as construction material, which are mostly received via road vehicles. The outgoing materials such as some amount of Granulated slag, some amount of Hot rolled coils and other materials are also dispatched by road vehicles.
For the supply of domestic coal, MoU have been signed with the following: x Bharat Coking Coal Limited (BCCL) for supply of washed coking coal(indigenous) to BSL x Coal India Limited (CIL)/BCCL for supply of midling coal to BPSCL (for power generation)
The same are attached as Annexure 2.2.
BSL also imports part of its coking and CDI coal from Australia, USA, New Zealand, Mozambique and Indonesia. BSL sources its iron ore and fluxes from SAIL’s captive mines (such as Kiriburu, Meghataburu, Manoharpur, Bolani, Gua, Kalta and Barsua). Limestone is received from SAIL mines at Khanabhanjari and purchased from Jaisalmer. Some quantity is imported. Dolomite is received from SAIL’s Tulsidamar mines and purchased from Bhutan in open market.
2.12 WATER REQUIREMENT
The overall water drawl by BSL for meeting all requirements at 5.77 MTPA hot metal production stage is estimated to be 17000 m3/hr. Of this, 1850 m3/hr of water will be used by BSL for steel production, 3250 m3/hr will be used by BPSCL for power generation, 150 m3/hr of water will be required by Pellet plant and Oxygen plant (BOO basis), and 50m3/hr will be used for construction works and other miscellaneous purposes. The plant drinking water requirement is estimated to be 6800 m3/hr.
1. Source:
There will be no groundwater drawl for the project as BSL already has permission for use of water from Damodar River for all its purposes. The water will be sourced from existing water source i.e. Damodar River via Tenu canal or alternate water pipeline system (when Tenu canal is not available for use due to repairs/ maintenance). BSL has permission for withdrawal of 227 cusecs (i.e. 23,140 cum/hr) from Damodar River accorded by Water Resource Department (WRD), Govt. of Jharkhand (GoJ) and the copy of the agreement is provided as Annexure 2.3. The NOC from WRD, GoJ has
CHAPTER-2 PROJECT DESCRIPTION Page 56 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT also been granted to BSL for permitting the development of the proposed alternate water supply system and the same is also attached at aforementioned Annexure-2.3.
The location of existing water intake point as well as point of intake for proposed alternate water- drawl & supply systems is indicated in Table 2.39 below:
Table 2.39. Existing water intake point as well as point of intake for proposed alternate water- drawl & supply systems Geographical Coordinates Description of intake point Location of Intake Point Latitude Longitude Existing water intake point of Tenu canal drawing from 23° 43.461'N 85° 50.281'E Tenu Canal Tenughat dam on Damodar River Intake point of proposed Alternate Intake point before Baidhmara 23° 43.802'N 86° 6.818'E Water supply system Weir on Damodar River
2. Makeup Water Supply System:
The total water drawn via Tenu canal (or via the alternate water pipelines) will be stored in Cooling ponds. The total recirculation from cooling ponds through pump house #1 is 70000 m3/hr and that through pump house #2 is 60000 m3/hr, totaling to 130,000 m3/hr of cumulative recirculation flow.
There is evaporation and seepage loss of around 5% of total recirculation flow and process water losses which will include waste water outflow of around 700 m3/hr. To arrest the waste water outflow, zero discharge schemes are under implementation at BSL.
The overall water requirement of BSL for all purposes will be 17000 m3/h as indicated in table 2.40:
Table 2.40. Overall water requirement for BSL at 5.77 MTPA Stage Area Quantity (m3/hr) Consumer Shops xSteel production 1850 xPower generation (BPSCL) 3250 xOxygen Plant & Pellet Plant (both on BOO basis) 150 xConstruction works 50 Seepages from Cooling Ponds(CP) & Sludge Compartments 3500 Evaporation Losses 2900 Plant drinking water 6800 Subtotal 18500 Wastewater recycled back to CPs 1500 Total water requirement at 5.77 MTPA HM 18500 - 1500 = 17000
The above includes the drinking water requirement of 6800 m3/hr. As indicated above, the total water required at 5.77 MTPA stage will be 17000 m3/hr.
The existing specific water consumption of BSL is 3.55 m3/tcs, which will improve to 3.48 m3/tcs at 5.77 MTPA hot metal production, after the implementation of proposed plan.
Water balance diagram for the proposed plant at 4.5 MTPA Hot metal production stage and after completion of proposed expansion-cum-modernization programme (at 5.77 MTPA Hot metal) is shown in Fig. 2.4 below.
CHAPTER-2 PROJECT DESCRIPTION Page 57 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig. 2.4. Water balance diagram at 4.5 MTPA Hot metal production stage and after proposed expansion-cum-modernization programme (at 5.77 MTPA hot metal) of BSL
CHAPTER-2 PROJECT DESCRIPTION Page 58 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2.13 FUEL FACILITIES
At present, the main gas producing facilities at Bokaro Steel plant are the five blast furnaces, the coke- oven batteries and BOFs. After present ongoing expansion, there will be an additional coke oven battery no 9 added to the existing coke oven complex.
The generated gases at these plants, BF gas, Coke-oven gas and BOF gas have considerable calorific value. These gases are used as fuel by different consumers of the steel plant. The major consumers are the stoves of the blast furnaces, under firing of Coke-oven batteries and reheating furnaces and other units of Rolling Mills. Surplus gases are used in the Power Plant owned by BPSCL (a JV company of DVC and SAIL). These fuel gases, after being cleaned in respective Gas Cleaning Plants, are distributed to different consumers through piping network. The details of the gas utilities for the plant at 5.77 MTPA hot metal stage is mentioned in subsequent paragraphs.
2.13.1 By product Gas Utilities (at 5.77 MTPA Hot metal stage):
Gas network pressure will be 1000 - 1200 mmWC for BF gas and 600 - 800 mmWC for CO gas. Calorific values considered for different byproduct fuel gases are as follows: x BF Gas - 914 Kcal/Nm3 x CO Gas - 4250 Kcal/Nm3 x BOF Gas - 2000 Kcal/Nm3
Byproduct fuel gas balance for BSL at 5.77 MTPA hot metal stage based on specific generation and consumption of various technological / process units is furnished in Table 2.41 below. Surplus available byproduct fuel gases will be diverted to JV power plant.
Table 2.41. Fuel gas balance for BSL at 5.77 MTPA hot metal stage Annual Output/ Hourly Fuel Supply/ Consumption Name of shop / unit Input (MTPA) BF gas CO gas BOF gas Generation Blast Furnace 5.770 11,26,872 - - Coke Oven –Coal throughput 4.480 - 1,63,731 - SMS 4.775 - - 48,300 Total Generation 11,26,872 1,63,731 48,300 Consumption Blast Furnace 5.770 4,91,242 19,950 - Coke Oven-Gross coke output 3.442 2,31,289 30,444 - Sintering Plant & Pellet Plant 10.700 4,397 4,017 - SMS 4.775 - 3,049 - Continuous Casting Shop 4.775 - 4,354 - Mills Area 4.656 50,286 45,573 - Lime + Dolo Plant 0.764 16,763 15,192 - Miscellaneous Requirement - 56,344 8,187 2,415 Losses - 22,537 1,637 966 Total consumption + Losses 8,72,858 1,32,403 3,381 Net Balance 2,54,014 31,328 44,919 (to BPSCL power plant) All figures are in Nm3/hr
CHAPTER-2 PROJECT DESCRIPTION Page 59 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT For optimum use of fuel gases, BF gas enriched with Coke-oven gas and BOF gas has been envisaged to be used by most of the consumers. Additionally around 3200 kg/hr of propane will be required for catering to the cutting requirements of SMS, Caster and auxiliary shops on as-on-when basis.
The overall energy consumption shall improve from 6.67 Gcal/tcs (at 4.5 MTPA HM) to 6.55 Gcal/tcs (at 5.77 MTPA HM).
2.13.2 Utilization of energy in off-gases
Steel production processes typically dispose large volumes of speciality gases, which have significant energy content. Three different process stages – from coal to steel – provide three different gas types: coke oven gas (COG), blast furnace gas (BFG) and converter gas/BOF gas (BOFG).
The fuel availability of Bokaro Steel plant after completion of the proposed expansion-cum- modernization plan indicates generation of 1126872 Nm3/hr of BFG (CV=914 Kcal/Nm3), 163731 Nm3/hr of COG (CV=4250 Kcal/Nm3) and 48300 Nm3/hr of BOFG (CV=2000 Kcal/Nm3). This amounts to a total availability of approx. 6943 x 103 Gcal/hr of energy available from the off gases generated from the plant processes.
Coke Oven Gas:
COG is normally used in coke oven battery heating, heating in other furnaces such as in SMS and Blast furnace as well as Hot strip mill and sometimes for power generation. Coke oven gas is also mixed with BF gas and/or converter gas before being used as fuel in the furnaces.
BF gas:
BFG is generally being used mixed with either coke oven gas or converter gas or both as a fuel in various furnaces of the steel plant. BF gas without mixing and without preheat is used in BF stoves, soaking pits, normalizing and annealing furnaces etc.
Mixed gas:
For optimum use of these fuel gases, Low calorific BF gas is also enriched with coke-oven gas for use by most of the consumer units of the plant. These gases are mixed at various gas mixing stations to meet the demand of mixed gas. At BSL, existing mixed gas consumers are 3 coke oven batteries along with the proposed new coke oven battery as well as Cold rolling mills. The proposed new sinter plant, associated new kiln and Pellet plant will also utilize mixed gas as fuel for their heating purposes. Mixed gas will also be used in Blast Furnace Stoves, Coke Ovens Batteries and Reheating furnaces.
BOF gas:
BOFG/converter gas is mostly boosted & mixed with BF gas network for further distribution. It is also used to produce process steam in SMS. At present, due to its similar heating value to coal for power plant, most of the BOF gas is exported to BPSCL for generation of power. CHAPTER-2 PROJECT DESCRIPTION Page 60 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2.14 POWER REQUIREMENT
The existing power requirement for operating the steel plant is about 256.3 MW (excluding losses). This is partly fulfilled by power sourced from BPSCL Captive power plant (operated on surplus fuel gas from BSL) and balance is imported from DVC. The power requirement of existing facilities and generation is shown in Table 2.42 below:
Table 2.42. Power requirement of existing facilities and generation of BSL
SN SHOPS POWER(MW) 1 BPSCL generation 156 2 BPSCL aux. consumption 33.33 3 Available BPSCL power 122.67 4 DVC import 140.61 5 Total available power 263.28 6 RMP 2.52 7 RMHP 0.89 8 CO and BPP 7.39 9 Sinter Plant 27.97 10 Blast Furnace 11.57 11 SMS-1 3.87 12 SMS-2 6.12 13 CCS 11.62 14 Slabbing Mill 2.97 15 Hot Strip Mill 32.21 16 HRCF 1.17 17 CRM 24.76 18 Water Supply 19.11 19 Oxygen Plant (Captive) 15.42 20 Air Services 11.14 21 Auxiliary Shops 2.45 22 Gas Facility 1.81 23 TBS 0.37 24 Construction 0.77 25 INOX Oxygen Plant 29.43 26 Township 38.2 27 Vertical Pump 4.54 LOSSES 6.98 TOTAL CONSUMPTION 256.3 Source: DNW department, BSL
The additional power required for the proposed expansion-cum-modernization is approximately ~64MW. The breakup of additional power requirement is given in Table 2.43 below:
Table 2.43. Additional Power Requirement of new units under proposed expansion-cum-modernization New units Power requirement (MW) Power Generation (MW) Coke Oven plant 9.5 6.5* Pellet plant 16** Sinter plant 22.4** Modernized SMS-1 22.4** Net total requirement for proposed activities 70.3 – 6.5 = 63.8 Note: *Generated from proposed Back pressure Turbo generator **Considering a power factor of 0.85 in Jharkhand Source: FR of individual units
CHAPTER-2 PROJECT DESCRIPTION Page 61 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The present maximum power generation capacity of BSL’s captive power plant i.e. BPSCL is 302 MW of power besides 660 TPH of steam. The Plant has 9 boilers (5 boilers each of 220 TPH, 3 boilers each of 260 TPH capacity and 1 boiler of 300 TPH) and 7 turbine generators (one 12 MW back Pressure Turbine Generator (TG), 2 TGs each of 55MW capacity, 3 TGs each of 60 MW capacity and one 36 MW Back Pressure Turbine Generator.
After present expansion-cum-modernization plan, the power requirement for existing facilities at higher production levels (i.e. at 5.77 MTPA stage) is estimated to be 352 MW and an additional 63.8 MW for the new facilities totals to approx. 416 MW of power requirement at 5.77 MTPA hot metal production stage. This can be met by the existing BPSCL plant of 302 MW with an additional power import requirement of about 114 MW which can be sourced from DVC. The agreement with DVC for purchase of power is attached as Annexure-2.4.
Additionally, the above power availability will be augmented by installation of envisaged 2.0 MWp of Roof-top solar units on BSL buildings (ADM/ BGH/ HRD/ BOKARO NIWAS/ ED(W) & PPC building of Bokaro Steel Plant) as well as a 20 MWp Greenfield ground mounted solar PV plant, which will make available 22 MW of solar power for utilization within the steel plant.
2.15 MANPOWER
As on date, BSL’s existing manpower strength is 13269 employees comprising of 1958 executives and 11311 non-executives.
Of the above, 11041 persons (1393 executives + 9648 non-executives) are deployed in the Works Division, 2138 persons (509 executives + 1629 non-executives) are deployed in the Non-Works Division and 90 persons (56 executives + 34 non-executives) are deployed in the Projects Division.
The additional manpower requirement for the new units proposed as part of the expansion-cum- modernization plan is as follows:
Table 2.44. Additional manpower requirement for the new units proposed expansion-cum-modernization Manpower requirement (Nos.) New units Executive Non-executive Total Coke Oven plant 54 406 460 Pellet plant 20 130 150 Sinter plant 24 136 160 Alternate Water supply system 1 14 15 Net total requirement for proposed activities 99 686 785
The above additional requirement of 785 personnel (99 executives as well as 686 non-executives) will be fulfilled by suitable redeployment of existing manpower (mostly for executives) as well as external hiring of other employees, preferably from local skilled and semi-skilled population in the area. The executives will be mostly regular employees while the non-executives will be primarily hired on contractual basis.
BSL’s employees are presently housed in BSL’s township which has all amenities including schools, hospital, shopping centres, banks, parks & playgrounds, places of worship, clubs and even a zoo. The same facility shall be extended to the new employees. CHAPTER-2 PROJECT DESCRIPTION Page 62 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2.16 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION
The proposed expansion-cum-modernization aims at enhancing the present production capacity of 4.5 MTPA to 5.77 MTPA of hot metal, by addition of new units as well modernizing and augmenting the existing units. To achieve the increase in production, the envisaged new units and major up-gradation/modernization schemes are to be implemented as per the tentative time schedule as indicated in Table 2.45 below.
Table 2.45. Tentative Implementation schedule of proposed activities in expansion-cum-modernization of BSL Activity/Facility proposed at BSL plant Tentative Time schedule Stage -1 of overall up-gradation of SMS-1 (1.306 MTPA) 31 months from Stage-2approval New Sinter Plant-II (3.7 MTPA) along with Lime-Dolo kiln 30 months after placement of order (450 TPD) 30 months from the effective date New Oxygen Plant (1250 TPD) of Agreement Alternate Water pipeline 15 months from stage II approval. New Pellet Plant (2.0 MTPA) 25 months after Stage II approval Coke Oven Battery (0.77 MTPA gross coke) 42 months after Stage-II approval
2.17 PROJECT COST
The estimated total cost for the proposed expansion-cum-modernization project is about Rs. 5219.1 Crores. The breakup of the total cost is as mentioned in Table 2.46 below:
Table 2.46. Indicative cost of proposed activities in expansion-cum-modernization of BSL Activity/Facility proposed at BSL plant Indicative Cost (in Crore Rs.) Stage -1 of overall up-gradation of SMS-1 (1.306 MTPA) 1154.18 New Sinter Plant-II (3.7 MTPA) along with Lime-Dolo kiln 1034.01 (450 TPD) Alternate Water pipeline 87.82 New Pellet Plant (2.0 MTPA) 891.62 Coke Oven Battery (0.77 MTPA gross coke) 2051.47 Total estimated project cost 5219.1 Note: Oxygen plant is proposed to be on BOO basis and no capital investment will be made by BSL for the same.
CHAPTER-2 PROJECT DESCRIPTION Page 63 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT CHAPTER-3: DESCRIPTION OF THE ENVIRONMENT
3.1 INTRODUCTION 3.1.1 General
EIA is the most important aspect of overall environment management strategy. EIA needs a datum on which the prediction can be done. Information on the existing baseline environmental status is essential for assessing the likely environmental impacts of the proposed project. For studying the existing baseline environmental status the following basic steps are required: x Delineation of project site and study area. x Delineation of the environmental components and methodology x Identification of study period. x Delineation of the location of proposed project and description of its surroundings based on secondary data. After delineation of the above for the present case, various environmental attributes such as physiography and drainage, meteorology, air quality, water quality, soil quality, noise levels, ecology and socio-economic environment etc. have been studied/monitored in order to establish baseline for different environmental components.
3.1.2 Project Site &Study Area
The existing Bokaro Steel Plant along with its existing facilities where the proposed activities are concentrated is designated as the project site. The study area or buffer zone for the present study is taken as 10km radius around the proposed plant site. The location of the project site&10km buffer zone is marked in Drg. MEC/11/S2/E24V/01.
The study area is located between Latitude 23°38' N to 23°42' N and between Longitude 86°02' E to 86°10’ E can be located in the Survey of India Topo-sheet No. 73I/I& 73I/2. The study area is situated in Eastern part of India. In general, the areas falling in Bokaro District are characterised by a long stretches of flat land with isolated hills and hillocks presenting a gently flat topography. The general elevation varies from 215 to 243 m above MSL. The area is seismically stable and falls under the Seismic Zone III – as per Seismic Zone India Map IS:1893 (Part-I)-2002, BIS,GOI, referred as Moderate Damage Risk Zone and the seismic intensity as expressed in Modified Mercalli Intensity Scale (MSK) is category-VII, which is referred to as Moderate Damage Risk Zone. The physiographic features of the study area are shown in Drg.MEC/11/S2/E24V/02.
3.2 MONITORING SCHEDULE
Site monitoring has been carried out for three months from March, 2018 to May, 2018(summer season, 2018) to study the above mentioned environmental attributes.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 64 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 3.3 ENVIRONMENTAL COMPONENTS AND METHODOLOGY
The environmental components studied and the methodologies followed for the preparation of EIA report are given in Table 3.1.
Table 3.1. Environmental Components and Methodologies Adopted For the Study Sl. Environmental Area Parameters Methodology* No. Components 1. Study Area/project Air Meteorology Field Monitoring Site x Ambient Air Quality (prescribed parameters by CPCB). x Pb, As & Ni in PM10 x Benzene & Benzo(a)Pyrene Noise Levels 2. Study Area/project Water Water Quality: Field Monitoring Site x Ground water (parameters as per IS:10500) x Surface water (as per CPCB’s Surface Water Quality Criteria 3. Study Area/project Soil Soil Quality (Physico-chemical Field Monitoring Site characteristics) 4. Study Area/project Ecological features Flora & Fauna Field Study / Site Secondary Data 5. Study Area/project Socio-economic Parameters related to Social / Field Study (Public Site features Economic aspects Consultation by questionnaire survey) / Secondary Data 6. Study Area/project Geology & x Formation of Rocks Field Monitoring / Site Hydrology x Water use & impact Secondary Data 7. Study Area/project Work Zone Air x Stack Emissions Field Monitoring Site x Parameters related to work zone air quality x Work Zone Noise 8. Study Area/project Water x Effluent Quality at Outlet of Effluent Field Monitoring Site Treatment Plant (parameters as per Integrated Iron & Steel Plant – waste water discharge standard) x Water Quality at plant outfalls (parameters as per Integrated Iron & Steel Plant - waste water discharge standard) 9. Study Area/project Soil x Soil Quality near Solid Waste Field Monitoring Site Dumping Area 10. Study Area/project Ecological Flora and fauna Field Study / Site Features Secondary Data 11. Interface of Study - Traffic density study Field Monitoring Area and Project Site
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 65 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 3.4 LOCATION AND GEOGRAPHICAL SETTINGS 3.4.1 Topography
The study area forms a part of the edge of the Chhotanagpur Plateau. The area is mostly flat, gently rolling at places and is dotted by hills and hillocks which rise 40 to 80 m above the surrounding areas. The area is mostly covered with soil and is strewn by graded valleys and winding streams. At places the sandstone and laterite is exposed from the slightly elevated grounds in comparison to areas covered with soil, which are mostly with settlements or agriculture. Bokaro Steel Plant is located about 2.5 km south of Damodar River with an elevation of 215 to 243m, sloping gently upwards from the Damodar River (at about 180m above MSL) towards the North. The proposed units are coming within the existing plant boundary and the area is already in Industrial use. Topography of the study area is shown in Drg.MEC/11/S2/E24V/03.
3.4.2 Drainage
The drainage pattern of the area is mostly dendritic. The Damodar River, which flows from west to east is the principal drainage channel of the area, and is about 2.5 km north of BSL plant boundary. The perennial tributaries of the Damodar River in the southern part of the area are Garga and Ijri. BSL is located between the Damodar and the Garga. A small reservoir, Garga Reservoir, has been constructed across the Garga River to supply water to Bokaro.
The Damodar River originates in the Palamau Hills in Jharkhand and flows through Jharkhand and West Bengal before meeting the Hooghly River (the western-most distributary of the River Ganga) in Howrah District of West Bengal, downstream of Kolkata. It flows from the west to the east along the northern edge of the study area and with the Barakar River, trifurcates the Chota Nagpur Plateau. The Garga Nadi is a perennial stream which flows from west to east in the southern part of the study area but eventually turns towards the North to flow into the Damodar River, which is about 1km away from BSL plant boundary. The drainage of the study area is shown in Drg. MEC/11/S2/E24V/03.
There is no major river within 1 km from the project site. The details of the rivers found within 5km of the plant boundary and RL details w.r.t. the plant are as follows: x BSL Project Site: 226 m to 241m amsl x Rivers/streams within 5km from : 1. Damodar River (~2.5 km) (at 141m-165m amsl) 2. Garga stream (~1.0 km) (at 186m-244m amsl) x Major Reservoir: Garga Reservoir (2.5 km) (at 244m amsl)
The main source of water for existing Bokaro Steel Plant is Tenughat Dam, which has been built across the Damodar River. Tenughat Dam has live storage of 224 million m3. Water flows by gravity from Tenughat Dam to BSL through ~35 km long Tenu Canal. A small masonry dam, Garga Dam, has been built across river Garga (a small river in the Bokaro district) by Bokaro Steel Plant about 5 km in the SSE of the plant to supply water to the township.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 66 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT River Damodar was known for its severe floods in the past. However, the development of Damodar Valley Corporation’s integrated river basin management has moderated floods in the area to about 53% - 80%. So, there is no possibility of flood waters entering the plant. The Flood Zone map of area as given in Annexure 3.1 substantiates that Damodar River flowing near to plant site is not coming under the flood zone.
3.4.3 Climate
The study area lies in the tropic monsoon region. Climate of the region is characterized by hot summers and cool winters. The summer season (March-May) is very hot and the temperature is in the range of 18.5°C to 45°C followed by monsoon which lasts from the first week of June to the end of September. The mean annual rainfall as recorded at IMD’s Dhanbad observatory (~36 km NE of BSL) is 1374 mm (72.7 rainy days) of which 1130 mm (~82.2%) occurs during the monsoon season. July is the wettest month (rainfall - 342.8 mm) followed by August. The winter season (December-February) is cold and the temperature goes down to 2°C in the season. The wind direction is predominantly from W, NW & N during winter and W& NW during most of the other seasons. During winters, temperature is in the range of 3.0°C to 35.0°C.
Annual percentage frequency of wind blowing from for day and night based on nearest IMD data i.e. IMD Dhanbad is presented in the Table 3.2 below. IMD data are recorded only in the morning and evening and is represented in 8 quadrants. As indicated in the IMD publication, data recorded in the morning represents day time wind direction and the data recorded in the evening represents night time data. In general, annual predominant wind directions are about 10-12% from W & NW directions and 5-15% from E-SE directions. During summer season, the winds are predominantly from W, NW & SE. The historical climatological data as collected from nearest IMD station at Dhanbad is presented in Table 3.2 below.
Table 3.2. Climatological data of IMD Dhanbad (Observation from 1951 to 1980) N NE E SE S SW W NW Calm IMD Annual Mean Day 5 7 5 14 4 10 17 8 30 (% no. of days wind from) Night 5 6 5 15 4 4 7 14 40 Overall 5 6.5 5 14.5 4 7 12 11 35 Predominance Sequence 6th 5th 6th 1st 7th 4th 2nd 3rd (Annual) Day (avg) 2 3 3 15 5 13 23 9 25 Summer Season Night (avg) 5 6 4 15 3 6 11 22 29 (March, April & May) Overall (avg) 3.5 4.5 3.5 15.0 4.0 9.5 17.0 15.5 27.0 Predominance Sequence 7th 5th 7th 3rd 6th 4th 1st 2nd (Summer)
The Annual and Summer season Wind rose diagrams at IMD’s Dhanbad observatory is shown in Fig. 3.1.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 67 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 3.1. Annual &Summer Season Wind Rose at IMD’s Dhanbad Observatory
3.4.4 Land Use
Satellite imagery contains detailed records of features on ground at the time of satellite overpass. An image interpreter systematically examines the images for generating the information required. Other supporting materials such as published maps and reports from various sources will increase the accuracy of the interpretation. The chain of process in visual interpretation of the shape and pattern in an image begins with detection. There are certain fundamental characteristics seen on images which aid in the visual interpretation of satellite imagery. These are tone/colour, size, shape, texture, pattern, location, association, resolution and season. Visual interpretation is subjective and differs from person to person and also upon the season, scale, spectral bands, spatial resolution, overall image contrast and quality of the data. The land use/land cover of the region is presented in the land use &land cover map enclosed. The major classifications of the land use/land cover are vegetation cover, settlements, agricultural land, local water body, and river & road connectivity.
Land Use & Land Cover Classification
Land-use/Land cover pattern in the study area as interpreted from RESOURCESAT (IRS P6) LISS-IV satellite imagery is shown in Drg.No. MEC/11/S2/E24V/04 and given below in Table 3.3 and Fig 3.2.The satellite image of the area is attached as Drg.No. MEC/11/S2/E24V/05. The study area as per the satellite imagery covers 20.5% built-up, 64.4% cultivation & fallow area, 2.9% open forests, 2.9% open areas, 4.4% water bodies, 3.4 % scrubland and 1.5% waste-land. The detailed land use/land cover of the region within 10 km radius buffer area is described below:
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 68 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.3. Land use/Land Cover Pattern of the Study Area Sn. Type of Land Use Area (sq Km) Percentage Land Use 1 BUILT-UP AREA 121.95 20.5% 2 CULTIVATION & CURRENT FALLOW 382.99 64.4% 3 OPEN FOREST 17.38 2.9% 4 OPEN LAND 17.12 2.9% 5 POND 13.18 2.2% 6 RESERVOIR 2.4 0.4% 7 RIVER 10.63 1.8% 8 SCRUBLAND 20.18 3.4% 9 WASTELAND 8.67 1.5% Total 594.5 100%
Fig 3.2. Breakup of Land use
Built-up area: The built-up area in the study area refers to the settlements both urban and rural with all infrastructural facilities like roads, railways, markets etc. along with the plant establishment. The built-up area in the study area consists of 20.5% of the total land cover.
Cultivation & current fallow land: The cultivation & current fallow land covers the land area of about 64.4% of the total area. Some part of the land has been kept as current fallow where grasses are grown. This may be attributed to rain fed agricultural practice. These agricultural lands are used for seasonal agricultural practice.
Forest Land / Vegetation Cover: The forests in the area are primarily degraded open forest in nature and covers 2.9% of the total land within 10 km buffer area. The vegetation is the green vegetation planted by local habitants mostly and some are part of the natural vegetation of the area surrounding the settlements. It is present in patches throughout the study area. This vegetation is observed in patches because it includes the type of plantations like social forestry, orchards and gardens. These also include the natural mixed vegetation along the roadside or empty lands and the vegetation which remains after the clearance of vegetation for agricultural use with increased population and settlements. A few open/social forests consisting mostly of palash, primarily to the North and North western side of the plant area are also included in this vegetation cover.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 69 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Scrubland, Wasteland & Open area: The scrubland in the area is limited to 3.4% of the total area and nearly 1.5% of the area is wasteland. The area also has open, vacant areas comprising almost 2.9% of the area.
Rivers: The River Damodar is the main natural surface water body of the study area. The river is flowing from west to east. A small Garga Nadi is also found within the study area. Rivers cover about 1.8 % of the total study area.
Other water bodies: Besides Damodar River, there are canals and tanks in the study area. Garga Reservoir is the major reservoir in the area which primarily supplies drinking water. Bokaro Steel Plant has two Cooling Ponds; Cooling Pond 1, the larger of the two is located on the north-eastern side of the plant, Cooling Pond 2 is located on the eastern side of the plant. These constitute 2.6% of the total study area.
3.5 HYDROGEOLOGICAL STUDIES 3.5.1 Introduction
The rapid technological advances of industrialization in recent years have resulted in increased pollution of the environment. The waste products of industries, many of them still unidentified, which pollute our land, air and water, persist in the environment and react with one another in complex ways to affect the life cycles of plants, animals and human beings. Water resources, more perhaps than any other, illustrate the interaction of all parts of the environment. Everything that man injects into his environment, ultimately finds its way into the ground water.
Industrialization of an area will have direct bearing on the land and groundwater. The demand of water particularly for domestic purpose (due to population influx) increases manifold and they are generally met from the groundwater. Hence, there is always a thrust on the groundwater balance. In addition, industrialisation of an area also leads to contamination of natural resources like groundwater if the untreated effluent comes into contact with groundwater once they are discharged on the surface. Due to infiltration and permeability of the soil, the effluent ultimately finds its way to groundwater table. Hence, a detailed study is required well before starting of any industrial activities of an area to understand the existing condition of groundwater occurrence, movement and groundwater balance for future planning to utilise the resources in a sustainable manner. If it is not planned, in the early stage of development, the industrialisation will have major negative impacts on the existing resources particularly on water supply. In order to study the impact of activities due to proposed project, hydrogeological study was carried out in the month of May, 2018 at Bokaro and surrounding 10 km radius. The hydrogeological map of Bokaro district is shown in Fig. 3.3.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 70 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 3.3. Hydrogeological map of Bokaro District
Basin/Sub basin: Damodar basin is the main basin of the district. The sub basins like Ijri, Gobai, Konar, Bokaro etc. are mainly confined in the area.
Drainage: The Damodar River is the most important river in the district which flows from West to East in the Central part of the district. The major tributaries of Damodar are Konar and Jamuniya. The minor tributaries of the Damodar River are Isri, Gobai, Tasharkhan, Kadwa, Khanju etc. The drainage system is mainly confined to weak zones viz. joints, fractures and faults. Drainage map of Bokaro District is shown in Fig. 3.4.
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Geomorphology: The Bokaro district is part of Chhotanagpur Plateau. It is highly undulating and hilly all over the district. The regional slope of the district is towards east and controls the alignment of the tributaries of Damodar river. The hill ranges trending WNW – ESE. The average elevation of the undulating pediplain ranges from 200 – 350m above MSL. The highest hill prominent block is Gomia. The northern and western parts of the district are having hilly ranges. Chas and Chandankiyari are low upland where cultivation is practiced.
Geology: Geologically the area is comprises with Archean rocks of meta-sediments, limestone, Phyllites, Chotanagpur granite gneisses. In eastern, northern and western part has Gondwana rock formation of occur in patches. Major part of the area covers granite gneiss and Gondwana rocks. Ground water occurs in unconfined in the weathered zone of the granitic gneiss and semi-confined to unconfined in the shale, sand and coal bearing area of Gondwana rocks formations. The generalized stratigraphic succession of the Bokaro/Dhanbad district is as follows: Quaternary Soil / Alluvium Triassic To Lr. Lower Gondwana Raniganj sub-group or upper coal measures ironstone shales subgroup or Carboniferous group Barren measures, Barakar sub-group or lower coal measures Talchirs Later post-Dharwar injection Complex Streaky, injection, augen and sillimanite gneisses. Rapakiwi textured gneisses and epidiorites. Earlier post-Drarwar Intrusives Granites, pegmatites, aplites and some quartz veins. Meta-dolerites and meta- norites with or without olivine Dharwar Gneisses, amphibolites, epidiprites and hornblends – schists. Quartzites (granulite and schistone), granulites and calc gneisses, Micaceous schists Source: Report on NATIONAL AQUIFER MAPPING AND MANAGEMENT PLAN for parts of Bokaro, Ramgarh and Dhanbad Districts, Jharkhand, 2016 by CGWB
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Texturally the soils of Bokaro district have been classified into four classes as: a) Stony and Gravelly: These are low grade soils having an admixture of cobbles, pebbles and gravels, generally found at the base of the hills. b) Sandy Soils: It is found near the stream beds containing 60% sand and is easily drained. These are poor in respect of fertility and require heavy manuring. c) Loamy Soils: This consists of mostly detritus of decomposed rocks and vegetable matter. It is suitable for cultivation. Normally these are found in valleys near the hills. d) Clayey Soils: These soils are found near tank beds. These are sticky soils. Their water bearing capacity is very high. The area is very fertile but crop yielding capacity improved with addition of sand, lime and organic manures etc.
3.5.2 Hydrogeology
Groundwater in the district is mainly replenished by the atmospheric precipitation. Influent seepages from canal, streams and other surface water bodies, also contribute to the groundwater in the district. The hydrogeological condition of the district is very complicated due to vide variability of geology, topography, drainage and mining activity.
Fissured Formation: Based on the degree of consolidation the fissured formation can be further sub divided into two namely:- (i) Consolidated Formation: Groundwater occurs in the area under confined to semi confined conditions. The fracture, lineaments are found to be an effective factor in facilitating groundwater movement and storage.
(ii) Semi Consolidated Formation: Groundwater occurs in this formation under confined to semi confined condition. These are found in the central part of the district.
Porous/ Unconsolidated Formation: It occupies the low laying area covered with recent alluvium deposited mainly by Damodar, Konar and Jamunia rivers. The ground water occurs in these areas under water table condition.
Aquifer geometry: The aquifer geometry for shallow and deeper aquifer has been established through hydro geological studies, exploration, the surface and subsurface geophysical studies in the district covering all geological formations. The aquifer can be divided into two zones – shallow and deeper aquifer. (i) Shallow aquifer – The shallow aquifers are being taped through dug wells, dug cum bore wells or shallow bore wells drilled to the depth of 60 m. The weathered mantle and shallow fractures constitute the shallow aquifers. The thickness of weathered mantle varies from 5 to 25 mbgl. The well inventory data suggest that the maximum depth of dug well in granite gneiss and Gondwana is 17 m and 25 m respectively. Exploration in granite gneiss
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(ii) Deeper aquifers: Achaeans meta-sedimentary, the granites, intrusive metabasics and the Lower Gondwana sedimentary constitute the productive aquifer. The first three come under consolidated Formation and the last one under semi consolidated Formation.
Depth to Water Level:
As per Report on NATIONAL AQUIFER MAPPING AND MANAGEMENT PLAN for parts of Bokaro, Ramgarh and Dhanbad Districts, Jharkhand, 2016 of CGWB, Ground water regime is monitored through 46 ground water monitoring wells that includes 42 dug wells and 4 purposes built Piezometers established in the study area. With the field data, maps were prepared for visual interpretation of the behaviors of the ground water levels. Depth to ground water level were demarcated into various zones in the ranges of less than 2 m, 2-5 m, 5-10 m, 10-20 m, 20-40 m, and more than 40 m. The description of depth to water levels during pre-monsoon and post monsoon is as follows:
Depth to Water level (Pre-monsoon 2015): Depth to ground water level during May 2015 ranges from 3.54 mbgl to11.6 mbgl. Minimum depth to water level 3.54 mbgl recorded at Bermo/Phusro in Bokaro district and maximum depth to water level 11.6 mbgl recorded at Chas block in Bokaro district. Depth to water level map (Pre-monsoon 2015) is shown in Fig. 3.5.
Depth to Water level (Post-monsoon 2015): During month of November 2015 (post- monsoon) depth to water level varied from 2.2 m bgl to 8.7 m bgl. Minimum depth to water level 2.2 mbgl recorded at Thakurgora, in Mandu block of Ramgarh district and maximum depth to water level 8.7 mbgl recorded at Jaina-mohr, Chas block of Bokaro district. Depth to water level map (Post-monsoon 2015) is shown in Fig. 3.6. Fig 3.5. Depth to water level (Pre-monsoon-2015) of Bokaro District
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Fig 3.6. Depth to water level (Post-monsoon-2015) of Bokaro District
Water Level Trend: Rainy season is the only recharge period in the Bokaro district. Most observation wells show rising trend in the district. These are the localized rising patches in the area. The pre and post monsoon observations at Jaina More, Chas is showing falling trend > 0.2m/yr (as per CGWB Ground Water Information Booklet, Bokaro Jharkhand – 2013).
Ground Water Resources: As per CGWB’s Ground Water Information Booklet, Bokaro Jharkhand – 2013, Groundwater resource assessment has been carried out based on the recommendations of Ground Water Estimation Committee Report 1997 (GEE, 1997). All blocks of the districts are falling under “Safe” Category except Chas which falls under semi critical category. The stage of Ground water development varies from 13.56% to 75.52 %.
Ground Water Quality: The aforementioned CGWB’s report mentions that to evaluate the quality of groundwater, samples were collected from 5 locations in the district. These samples were considered to assess the chemical quality of ground water and its suitability for drinking and irrigation purposes. The samples represent the quality of phreatic zone or shallow zone. The EC value varies from 455 – 1421 μS/cm. The constituents are under permissible limit as per the Indian Standard of Drinking Water (BIS- 10500 – 91). The pH value of groundwater indicates its alkaline nature. The total CaCO3 value varies from 170 – 420 mg/l. Almost all the constituents are within tolerance limits as per the drinking water norms.
Status of Ground Water Development There is sufficient scope for shallow as well as deep bore wells in the district. Jharkhand State Government has constructed a number of bore wells to minimize the scarcity of drinking water
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Ground Water Management Study Ground Water Development: The shallow and medium dug-wells are suitable extraction structures in the district. It is necessary for drinking as well as irrigation purpose. The stage of groundwater development in the district is 31.31% only. Thus there is sufficient scope for development through dug wells, shallow and medium bore wells. Construction of dug cum bore well structure is also suitable for enhancing the yield of dug well, which is economical. The groundwater development varies in different places depending on the availability of favourable locations.
Groundwater potential available for the groundwater development, considering the groundwater draft has been worked out as per norms of groundwater Estimation Committee 1997 (GEC – 1997). Groundwater recharge, annual groundwater availability, annual draft, net groundwater balance and stage of groundwater development have been evaluated. The total groundwater draft for irrigation in the district is 5203.99 ham. The net annual groundwater availability and the existing groundwater draft for all uses is 25408.41 ham and 7956.10 ham respectively. As per CGWB’s report, the stage of ground water development in Chas block (buffer area for the present study) is “Semi-critical”. The same is shown in the figure below:
Water Conservation and Artificial Recharge: The total irrigation potential created is 10039 hectare and potential utilized 6526 hectare only as per 4th MI census. During rainy season, most of the rain water goes as runoff. At many places shortage of water is observed in the district. Construction of water conservation structures will help to arrest run off, recharge the aquifer and retain the soil moisture. Contour bunding, check dam, gulley plug and percolation tanks are suitable structures in the hard rock areas. In mines area, water can be stored in the pond.
Ground Water Related Issues and Problems: During summer season the dug wells dry up. The deeper groundwater level has been observed at Chas in Bokaro District (Jharkhand). The groundwater is contaminated with fluoride in two blocks (Chas and Chandankiyari). Iron is also found above desirable limit. Trace elements like Mn & Zn are found above permissible limit around industrial area. [Ref. “Groundwater Information Booklet, Bokaro district, Jharkhand State”; Pub. CGWB, 2013]
Water levels in the study area: About 17 wells have been inventoried in the buffer zone and data like total depth, depth to water and their location were collected during the study around the BSL. The hydrogeological details of the measured wells are shown in the Table: 3.4 below. In each village minimum of two and maximum of three wells have been measured and measured levels were used for preparing the groundwater contour map. From the data, it is evident that water levels fluctuation is in the range of 6.1 m bgl to 8.4 m bgl.
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Well Water Level below ground level Name of the village no. (in feet) In mbgl 1 House of Rajesh Agrawal, Balidih, Bokaro 20’ 2” 6.1 2 Temple near Bokaro Railway Station 24’ 7” 7.5 3 House of Prahlad Mahto, Sector -9, Ramdih, Bokaro 24’ 5” 7.4 4 House of Nandlal Hazam, Tupkadih 20’ 2” 6.1 5 House of Baleshwar Majhi, Village Shibutar, Bokaro 23’ 4” 7.1 6 House of Nasiruddin, Village Maheshpur, Bokaro 20’ 8” 6.3 7 House of Jasim, Village Maheshpur, Bokaro 22’ 1” 6.7 8 House of Goutam Majhi, Village Shibutar, Bokaro 20’ 9” 6.3 9 Temple, Sector–II D, Bokaro 20’ 2” 6.1 10 House of Prabhakar Kumar, Village – Tentulia 21’ 8” 6.6 11 House of Sanjay Kumar, Village – Tentulia 24’ 7” 7.5 12 House of Binood Nayak, Tupkadih 22’ 1” 6.7 13 House of Naresh Mahto, Tupkadih 22’ 5” 6.8 14 House of Subodh Majhi,Village Bansgora 24’ 5” 7.4 15 House of Ajay Majhi, Village Bansgora 27’ 6” 8.4 16 House of Rupesh Mahto, Sector - 9 20’ 8” 6.3 17 House of Pradeep Mahto, Sector - 9 25’ 4” 7.7
Even though the measured wells are regularly used for domestic consumption, there is no remarkable fluctuation in the water table is observed/ reported in terms of draw down. Several villagers in the study area reported that no fluctuation in water table is observed even during peak summer. In general, the measurement of water table level indicates that in most of the villages the aquifer is recharged immediately by the interconnectivity of the aquifer and higher storitivity due to properties of the rocks. The phreatic aquifer provides sufficient yield which meets the villager’s day to day consumption. This may be as a result of (i) Continuous recharge of groundwater either by rain or by the river (ii) Extraction/draft of groundwater is lesser than or equal to the recharge quantity.
Non-existence of dug wells continuously creates problem in giving continuity of measured water table. This intermediate gap of non-availability of wells impedes the groundwater map of the study area. Hence, the groundwater table map prepared for district by Central Ground Water Board has been collected and are depicted above for pre monsoon and post monsoon season respectively.
3.5.3 Conclusions
1) The existing groundwater is in water table condition encountered at an average depth of 6.1 m bgl to 8.4 m bgl and in phreatic aquifer condition.
2) Taping of groundwater is not envisaged for the project hence the existing groundwater equilibrium will not be affected due to plant operation.
3) The terrain is favourable for groundwater recharge; hence the authorities are planning for groundwater recharge from the proposed plant structures.
4) Plant operation shall not have any impact on drainage pattern and the existing pattern is expected to remain as it is.
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The establishment of baseline for different environmental components in the study area and at the project site has been done by conducting field monitoring for baseline data generation. The data generation was carried out covering Meteorology, Ambient Air Quality, Noise Levels, Water Quality, Soil, Ecology and Socio-economic features. Besides additional data/information regarding water availability, ecology, demographic pattern and socio-economic conditions were collected from various central and state government agencies.
3.6.1 Micro-Meteorology
Meteorology plays a very important role in the environmental impacts of industrial project. Meteorological conditions govern the dispersion (and hence dilution) of air pollutants. Hence Meteorological studies form an integral part of environmental impact assessment studies.
A meteorological station was set up at Bokaro Steel Plant Township. The meteorological data was generated hourly during the monitoring period. The location of the meteorological data monitoring stations is marked in Drg. No.MEC/E24V/11/S2/02.The following parameters have been recorded: x Wind speed x Wind Direction x Atmospheric Temperature x Relative Humidity x Solar Radiation x Cloud Cover x Rainfall
Table 3.5 gives the summary of meteorological data collected during the monitoring period. Tables 3.6(a), (b) and (c) give the monitored wind frequency distribution for overall, day and night hours. Overall day, Day time (0600 hrs.– 1800 hrs.) and night time (1800 hrs. – 0600 hrs.) Wind-rose diagrams have been prepared and presented as Figs.3.7 (a), (b) and (c)
respectively. Table 3.5. Summarized Monitored Meteorological Data at BSL Solar Radiation Wind Speed (m/sec) Temperature (oC) Relative Humidity (%) Rainfall (mm) (Cal/cm2/min) Period No. of Rainy (Mar- Max. Min. Avg. Max. Min. Avg. Max. Min. Avg. Max. Max. Min. Avg. May’18) days 2.1 <0.4 0.4 43.4 17.0 30.4 96 10 55.5 17 05 2.0 0.0 0.3
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Wind Direction Wind Speed Ranges (m/s) Sum (towards) 0.44 – 2.0 2.0 – 3.0 3.0 – 5.0 5.0 – 6.0 >6.0 N 3.58 0.00 0.00 0.00 0.00 3.58 NNE 0.14 0.00 0.00 0.00 0.00 0.14 NE 0.23 0.00 0.00 0.00 0.00 0.23 ENE 0.45 0.00 0.00 0.00 0.00 0.45 E 0.32 0.00 0.00 0.00 0.00 0.32 ESE 0.41 0.00 0.00 0.00 0.00 0.41 SE 1.95 0.05 0.00 0.00 0.00 1.99 SSE 4.62 0.14 0.00 0.00 0.00 4.76 S 3.40 0.09 0.00 0.00 0.00 3.49 SSW 1.45 0.00 0.00 0.00 0.00 1.45 SW 1.00 0.00 0.00 0.00 0.00 1.00 WSW 1.18 0.00 0.00 0.00 0.00 1.18 W 2.58 0.00 0.00 0.00 0.00 2.58 WNW 2.49 0.00 0.00 0.00 0.00 2.49 NW 2.94 0.00 0.00 0.00 0.00 2.94 NNW 6.84 0.00 0.00 0.00 0.00 6.84 Sum % 33.56 0.27 0.00 0.00 0.00 33.83 Calm (Wind speed <0.44 m/s or <1.6 km/hr) = 66.17% (in % of times)
Table 3.6. (b): Wind frequency distribution in Summer season (March-May, 2018) (Day)
Wind Direction Wind Speed Ranges (m/s) Sum (towards) 0.44 – 2.0 2.0 – 3.0 3.0 – 5.0 5.0 – 6.0 >6.0 N 4.17 0.00 0.00 0.00 0.00 4.17 NNE 0.09 0.00 0.00 0.00 0.00 0.09 NE 0.36 0.00 0.00 0.00 0.00 0.36 ENE 0.63 0.00 0.00 0.00 0.00 0.63 E 0.54 0.00 0.00 0.00 0.00 0.54 ESE 0.54 0.00 0.00 0.00 0.00 0.54 SE 3.26 0.09 0.00 0.00 0.00 3.35 SSE 8.70 0.27 0.00 0.00 0.00 8.97 S 6.25 0.18 0.00 0.00 0.00 6.43 SSW 2.54 0.00 0.00 0.00 0.00 2.54 SW 1.81 0.00 0.00 0.00 0.00 1.81 WSW 2.08 0.00 0.00 0.00 0.00 2.08 W 4.26 0.00 0.00 0.00 0.00 4.26 WNW 4.17 0.00 0.00 0.00 0.00 4.17 NW 4.98 0.00 0.00 0.00 0.00 4.98 NNW 9.15 0.00 0.00 0.00 0.00 9.15 Sum % 53.53 0.54 0.00 0.00 0.00 54.08 Calm (Wind speed <0.44 m/s or <1.6 km/hr) = 45.92 % (in % of times) Table 3.6. (c): Wind frequency distribution in Summer season (March-May, 2018) (Night) Wind Direction Wind Speed Ranges (m/s) Sum (towards) 0.44 – 2.0 2.0 – 3.0 3.0 – 5.0 5.0 – 6.0 >6.0 N 2.99 0.00 0.00 0.00 0.00 2.99 NNE 0.18 0.00 0.00 0.00 0.00 0.18 NE 0.09 0.00 0.00 0.00 0.00 0.09 ENE 0.27 0.00 0.00 0.00 0.00 0.27 E 0.09 0.00 0.00 0.00 0.00 0.09
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Fig 3.7. (c)-Wind Rose (Night)
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 81 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT From Table 3.6 above, it can be concluded that during summer season, 2018 at Bokaro Steel Plant area, wind was mostly blowing from North-North-West (NNW) and South-South-East (SSE). Overall, the predominant wind direction was found to be North-North-West (NNW), which prevailed for 6.84% of the time, followed by South-South-East (SSE), which prevailed for 4.76% of the time, followed by North (3.58%); calm conditions prevailed for 66.17% of the time. During day time predominant wind direction was found to be NNW (prevailing for 9.15% of the time) followed by SSE (8.97%) and S (6.43%); calm conditions prevailed for 45.92% of the time. During night time the predominant wind directions were found to be NNW (4.53%), N (2.99%) and W &SW (0.91% each); calm conditions prevailed for 86.41% of the time. During the monitoring period the predominant wind speeds were mostly in the range of 0.4 m/s– 2.1 m/s.
3.6.2 Atmospheric Inversion Level
The knowledge of thermal inversion of the atmosphere is very useful in interpretation of pollution measurement data and particularly so in recognizing the responsibility for pollution episodes (growing emission or meteorology).
The average atmospheric mixing height is seen to vary from a minimum of about 50m to a maximum of about 1500m during the study period in the study area, based on Atlas of Spatial Distribution of Hourly Mixing Depth over Indian Region published by CPCB for nearest Radio Sonde station at Ranchi. Graph showing the variation of average mixing depth during the pre- monsoon (Summer) season is shown in Fig 3.8.
Fig 3.8. Diurnal variation of average height of Inversions for Summer Season
HOURLY AVG. MIXING DEPTH (SUMMER SEASON) Hourly Avg. Mixing depth (in m) 1600 1500 1500 1500 1500 1500 1400 1200 1000 1000 1000 1000 1000 800 700 600 500 400 200 200 Average Hourly Mixing depths Mixing Hourly Average 100 0 50 50 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 Hour of day (IST) Source: Atlas of Spatial Distribution of Hourly Mixing Depth over Indian Region published by CPCB for nearest Radio Sonde station at Ranchi
3.6.3 Ambient Air Quality To quantify the effects of existing and proposed activities it is necessary to initially evaluate the existing air quality in and around the existing plant. Present ambient air quality has been determined quantitatively through a planned field monitoring. The ambient air quality was evaluated in terms of Particulate Matter (PM10, PM2.5), Sulphur-di-oxide (SO2), Oxides of CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 82 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Nitrogen (NO2), Carbon Monoxide (CO), Ammonia, (NH3), Ozone (O3), Benzene (C6H6), Polynuclear Aromatic Hydrocarbons (PAH), Lead (Pb), Nickel (Ni) and Arsenic (As) in PM10. . Chemical characterization of PM10 was also carried out for Zn, Cu, Fe& Mn concentrations.
Location of Ambient Air Quality (AAQ) Monitoring Stations
To assess the ambient air quality, eight numbers of ambient air quality monitoring stations have been set up. Table 3.7 gives the list AAQ monitoring stations. The location of stations has been shown in Drg. MEC/11/S2/E24V/02.
For selection of the monitoring stations, data published by Indian Meteorological Department (IMD) of their observatory at Dhanbad has been utilized to identify the probable locations. The Climatological Atlas of India lists the IMD Dhanbad station to be established in 1956at office of Commissioner, Coal Mines Welfare Organization at 23°47’ N latitude and 86°26’ E longitude.
Station locations were decided by running screening model using wind direction & speed, atmospheric stability, stack details such as temperature, volume, velocity etc. of the existing stacks. As indicated earlier, the annual predominant wind directions in the study area in general are from the sectors between South and East-South-East as well as from sectors between North and West-North-West. All predominant downwind sectors are considered for fixing up the monitoring stations. 8 AAQ monitoring stations were selected for the present study.
Table 3.7. Ambient Air Quality (AAQ) monitoring stations Sl. Stn. Direction& Distance from Location Latitude Longitude No. Code center of project (km) 1. A1 TA Building 4.5 km, E 23°39'55.69"N 86° 8'28.04"E 2. A2 Garga Dam Pump House 4.7 km, SSW 23°38'14.08"N 86° 4'53.69"E 3. A3 Sector – XII 6.8 km, SE 23°37'35.45"N 86° 8'27.29"E 4. A4 Bokaro Niwas 7.3 km, E 23°39'38.88"N 86°10'9.23"E 5. A5 Slag Granulation Plant, CISF Barrack 4.3 km, NNW 23°42'31.57"N 86° 4'29.56"E 6. A6 Bokaro Industrial Area, Baladih 5.8 km, W 23°40'13.44"N 86° 2'34.72"E 7. A7 Near Air Strip 8.3 km, ESE 23°38'2.19"N 86°10'4.84"E 8. A8 Sector-IX 8.2 km, NE 23°41'56.84"N 86°10'37.62"E
Ambient air quality (AAQ) monitoring schedule As mentioned earlier, EIA report has been prepared based on data generated in the Summer season, 2018. At all monitoring stations, i.e. from A1 to A8, samples were collected twice a week for twelve weeks. Samples of 24 hourly duration were collected for PM10, PM2.5, SO2,NO2andNH3in PM10whereas for CO and O3hourly samples were taken; four-hourly samples were collected for benzene. Lead (Pb), Nickel (Ni) and Arsenic (As), Benzo(a)Pyrene (BaP) and Polynuclear Aromatic Hydrocarbon (PAH) content of PM10were also determined. CO, O3, NH3, Pb, Ni, As, BaP and PAH in PM10 and Benzene in ambient air were analysed in selected samples at all the locations. Chemical characterization of PM10 was also carried out for Zn, Cu, Fe & Mn concentrations.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 83 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Methods of Sampling and Analysis
The methods of sample collection, equipment used and analysis procedure as followed are
given in Table 3.8.
Table 3.8. Methodology of sampling & equipment for analysis Sl. Parameters Instrument/ Apparatus used Method followed Reference No. Sulphur dioxide RDS with Impinger Improved West & Gaecke IS 5182 Part 2 2001, 1 (SO2) tubes, spectrophotometer Method (Reaffirmed 2017) Nitrogen Oxides RDS with Impinger Jacobs & Hochheiser Modified IS 5182 Part 6 2001, 2 (NOx) tubes, spectrophotometer (Sodium Arsenite) Method (Reaffirmed 2017) Particulate matter Respirable Dust Sampler IS 5182 Part 23 2006, 3 Gravimetry (PM10) (RDS),balance (Reaffirmed 2017) Particulate Matter PM2.5 Sampler (Fine dust NAAQS Monitoring 4 Gravimetry (PM2.5) sampler), balance & Analysis Guidelines 5 Ammonia Spectrophotometer Indophenol Method APHA Edition 21st NAAQS Monitoring 6 Carbon Monoxide CO Analyzer NDIR Method & Analysis Guidelines IS 5182 part 9, 7 Ozone Ozone analyzer UV photometric 1974 (Reaffirmed 2014) Nickel AAS Method after sampling on 8 AAS, RDS IS 5182 part 10, 1999 EPM 2000 F.P. AAS Method after sampling on 9 Arsenic AAS, RDS IS 5182 part 10, 1999 EPM 2000 F.P. AAS Method after sampling on 10 Lead AAS, RDS IS 5182 part 10, 1999 EPM 2000 F.P. Adsorption & Desorption IS 5182 part 11, 11 Benzene Benzene Sampler followed by GC 2006 (Reaffirmed 2017) Benzo(a)Pyrene Solvent extraction IS 5182 part 12, 12 RDS, Particulate Phase (BaP) followed by HPLC 2004 (Reaffirmed 2014)
Ambient Air Quality Results
The summarized results of ambient air quality monitoring are given in Table 3.9. The results have been compared with the National Ambient Air Quality standards given by Central Pollution Control Board. The detailed results are attached as Annexure 3.2.
Table 3.9. Summarized Ambient Air Quality monitoring results
Pollutants A1 A2 A3 A4 A5 A6 A7 A8 NAAQS (μg/m3) TA Garga Dam Pump Sector – Bokaro Near SGP, CISF Bokaro Industrial Near Air Sector-IX Norms Building House XII Niwas Barrack Area, Baladih Strip
PM10# Max 95 85 99 92 93 98 95 98 (Detection limit= 5 μg/m3) Min 57 49 55 55 52 60 67 68 100 Mean 77 68 80 78 78 88 86 87 μg/m3 C98 95 84 98 90 92 97 95 97 PM2.5# Max 51 42 58 55 57 59 56 57 (Detection limit= 5 μg/m3) Min 31 27 35 33 32 36 32 32 60 Mean 40 35 44 43 42 46 47 44 μg/m3 C98 50 41 55 54 54 57 54 55 SO2# Max 30 20 27 30 34 31 40 28 (Detection limit=4 μg/m3) Min 11 8 8 11 13 13 12 9 80 Mean 19 15 17 19 21 21 20 19 μg/m3 C98 25 20 22.4 29.3 32.3 30.6 30.2 26.4 NO2# Max 52 46 44 54 54 59 63 55 80 (Detection limit=10 μg/m3) Min 24 23 24 29 30 29 30 33 μg/m3
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 84 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Pollutants A1 A2 A3 A4 A5 A6 A7 A8 NAAQS (μg/m3) TA Garga Dam Pump Sector – Bokaro Near SGP, CISF Bokaro Industrial Near Air Sector-IX Norms Building House XII Niwas Barrack Area, Baladih Strip Mean 36 31 34 39 41 42 45 42 C98 46.6 42 41.2 51.3 50 51.3 57.1 54.3 CO** Max 1601 1349 1487 2287 1715 2253 2490 2158 4000 (Detection limit=57 μg/m3) Min 153 159 163 201 149 158 152 159 μg/m3 Mean 823 696 726 919 591 1062 1103 813 NH3 Max 30.6 24.1 28.2 31.9 26.1 34.3 39.2 27.2 400 (Detection limit=4.2 μg/m3) Min 18.0 13.9 15.5 16.1 15.5 19.0 26.3 13.9 μg/m3 Mean 27.4 18.0 23.1 24.3 22.6 26.3 31.6 24.3 O3 Max 64.0 73.5 59.6 80.4 64.8 72.4 90.1 82.1 180 (Detection limit=20 μg/m3) Min 37.9 43.0 37.9 57.6 36.1 41.0 42.0 46.5 μg/m3 Mean 54.5 63.8 50.4 66.7 55.6 55.0 65.9 67.7 Pb Max 0.014 0.014 0.022 0.036 0.021 0.017 0.022 0.028 (Detection limit=0.001 Min 0.009 0.003 0.016 0.010 0.011 0.012 0.012 0.007 1 μg/m3 3 μg/m ) Mean 0.012 0.009 0.019 0.019 0.015 0.014 0.018 0.017 Ni (ng/m3) Max 8.435 5.855 4.554 5.947 5.168 6.216 12.778 7.643 20 (Detection limit=0.69 ng/m3) Min 2.337 2.845 1.319 2.230 4.932 1.942 4.090 0.834 ng/m3 Mean 4.948 4.385 3.206 4.572 5.067 4.675 7.155 4.267 As (ng/m3) Max 1.89 <1.84 <1.84 <1.84 <1.84 <1.84 <1.84 <1.84 (Detection limit=1.84ng/m3) Min <1.84 <1.84 <1.84 <1.84 <1.84 <1.84 <1.84 <1.84 6ng/m3 Mean ------Benzene Max <2.08 <2.08 <2.08 <2.08 <2.08 <2.08 <2.08 <2.08 (Detection limit=2.08 Min <2.08 <2.08 <2.08 <2.08 <2.08 <2.08 <2.08 <2.08 5μg/m3 μg /m3) Mean ------Benzo-a- Pyrene Max <0.24 <0.24 <0.24 <0.24 <0.24 <0.24 <0.24 <0.24 (ng/m3) Min <0.24 <0.24 <0.24 <0.24 <0.24 <0.24 <0.24 <0.24 1ng/m3 (Detection limit=0.24 ng/m3) Mean ------Note:#24 hourly average **1 hour average
Table 3.10. National Ambient Air Quality Standards, 2009 Concentration in Ambient Air Sl. Time Weighted Ecologically Sensitive Area Parameter Industrial, Residential, No. Average (Notified by Central Rural & Other Areas Government) Annual* 50 20 1 Sulphur Dioxide (SO2) ; (μg/m3) 24 Hours** 80 80 Annual* 40 30 2 Nitrogen Dioxide (NO2) ; (μg/m3) 24 Hours** 80 80 Annual* 60 60 3 Particulate Matter, PM10; (μg/m3) 24 Hours** 100 100 Annual* 40 40 4 Particulate Matter, PM2.5; (μg/m3) 24 Hours** 60 60 8 Hours ** 02 02 5 Carbon Monoxide (CO); (mg/m3) 1 Hour ** 04 04 8 Hours ** 100 100 6 Ozone (O3) ; (μg/m3) 1 Hour ** 180 180 Annual* 100 100 7 Ammonia (NH3) ; (μg/m3) 24 Hours** 400 400 Annual* 0.50 0.50 8 Lead (Pb); (μg/m3) 24 Hours** 1.0 1.0 9 Arsenic (As); (ng/m3) Annual* 06 0.6 10 Nickel (Ni); (ng/m3) Annual* 20 20
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 85 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Concentration in Ambient Air Sl. Time Weighted Ecologically Sensitive Area Parameter Industrial, Residential, No. Average (Notified by Central Rural & Other Areas Government) 11 Benzene (C6H6) ; (μg/m3) Annual* 05 05 12 Benzo(a)Pyrene (BaP); (ng/m3) Annual* 01 01 *Annual arithmetic mean of minimum 104 measurements in a year at a particular site taken twice a week 24 hourly at uniform intervals **24 hourly or 08 hourly or 01 hourly monitored values, as applicable, shall be compiled with 98% of the time in a year. 2% of the time, they may exceed the limits but not on two consecutive days.
It is observed that PM10, PM2.5, SO2, NO2, CO, NH3, O3, Pb, As and Ni at all the locations are within the NAAQS norms. In case of PM10 and PM2.5, the maximum values at A3, A6 and A8 locations are close to the norms, however, are well within the limits. Average values of PM10 and PM2.5 are in comfort zone. Higher values of PM10 concentration at A3 (Sector – XII) & A8 (Sector XI, Community Center) may be attributed due to higher vehicular movement as these areas are of commercial importance. Also, A6 is located in Balidih Industrial Area higher values of PM10 & PM2.5 can be attributed due to additional industrial activity in the area.
All values of Poly Aromatic Hydrocarbon (PAH) in PM10 and Benzene in ambient air were found below the detection limits of measurement.
Chemical Characterization of Particulate Matter
Chemical characterization of particulate matter was also done at all AAQ stations &the results are compared with the characterization of particulate matter within the plant area as well as raw material area, as detailed separately in Section 3.6.11.
3.6.4 Noise
In order to determine the existing noise levels in the study area, noise monitoring was conducted at nearby villages of existing plant.
Ambient noise levels
Ambient noise levels were measured at seven (7) locations which are listed in Table 3.11.These locations are marked in Drg. MEC/11/S2/E24P/02. Leq noise level was measured at one hour intervals for 24 hours during the monitoring period once at all seven locations. The results are summarized in Table 3.12. The results have been compared with the norms given in Table 3.13. Table 3.11. Ambient noise measurement stations Direction & Distance Sl. Stn. Location from center of Latitude Longitude Type No. Code project (km) 1. N1 Bokaro Niwas 6.3 km, E 23°39'38.88"N 86°10'9.23"E Residential area Sector – XII, 2. N2 5.2 km, SE 23°38'26.42"N 86° 8'44.40"E Residential area Community Centre Commercial 3. N3 TA Building 3.5 km, E 23°39'55.69"N 86° 8'28.04"E Area Slag Granulation 4. N4 5.3 km, NNW 23°42'31.57"N 86° 4'29.56"E Residential Area Plant, CISF Barrack
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 86 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Direction & Distance Sl. Stn. Location from center of Latitude Longitude Type No. Code project (km) City Center, Sector Commercial 5. N5 3.6 km, ESE 23°39'59.46"N 86° 8'34.53"E IV Area 6. N6 Sector-IV B 3.8 km, E 23°40'20.49"N 86° 8'43.27"E Residential Area Commercial 7. N7 Air Strip 5.2 km, SE 23°38'41.34"N 86° 8'58.95"E Area
Table 3.12. Summarized Ambient Noise level monitoring results Noise Level (dB(A)) Stn. Type of Description Day (0600 – 2200 hrs.) Night (2200 – 0600 hrs.) Code area Min Max Mean Min Max Mean N1 Bokaro Niwas Residential 41.2 54.4 52.1 38.1 44.6 40.7 Sector – XII, N2 Residential 40.5 53.6 51.7 38.2 44.8 40.3 Community Centre N3 TA Building Commercial 41.8 64.8 62.9 37.8 45.2 41.0 Near Slag Granulation N4 Residential 44.0 54.6 51.4 38.6 43.5 40.5 Plant, CISF Barrack N5 City Center, Sector IV Commercial 50.1 64.8 61.6 37.8 46.2 42.0 N6 Sector-IV B Residential 44.1 53.8 51.9 38.9 43.7 41.2 N7 Air Strip Commercial 49.7 64.7 62.8 38.3 48.3 43.4
Table 3.13. Ambient Air Quality norms in respect of noise (As per schedule III, Rule 3 of EP (Rules)) Type of area Day (0600 – 2200 hrs). Night (2200 – 0600 hrs). Industrial Area 75 70 Commercial Area 65 55 Residential Area 55 45 Silence Zone 50 40 Note: All values are in dB(A).
Noise levels at all locations were found to be within the relevant norms for residential as well as commercial areas.
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Water quality monitoring was carried out with the following objectives: x To collect baseline data on existing water quality. x To assess the impact, if any, of the proposed facilities on water quality of receiving water bodies. x To assess the raw water quality to be used by the proposed project.
Selection of Sampling Locations
A total of seventeen (17) water-sampling locations were selected for the present study covering nine (9) surface water and eight (8) ground water. Locations of samples were selected considering up gradient and down gradient of proposed project.
Water monitoring locations is marked in Drg. No. MEC/11/S2/E24V/03.
Methodology
In order to study the existing water quality within the study area, grab samples of ground water and surface water were collected from the locations indicated in Table 3.14. Samples were analysed for different physico-chemical and bacteriological parameters as per 23rd edition of "Standard Methods for the Examination of Water and Waste Water" published by American Public Health Association (APHA), 2017. In absence of any norms for ground water, the analysis results of ground water samples were compared with Drinking Water Specification - IS:10500 whereas the analysis results of all surface water samples were compared with CPCB Water Quality Criteria for Surface Water.
Table 3.14. Location of Water Monitoring Stations Direction & Distance Stn. Date of Sn Location from center of project Latitude Longitude Code Sampling (km) Surface Water Raw Water (Tenu 1. SW1 4.5 km, NW 23°42'49.31"N 86° 4'18.53"E 14.04.2018 Canal) U/s of Damodar 2. SW2 8.6 km, NNW 23°45'37.62"N 86° 0'47.34"E 14.04.2018 River (Fusro Bridge) D/s of Damodar 3. SW3 River 7.1 km, NE 23°43'43.41"N 86° 8'37.67"E 14.04.2018 (Chandrapura) Garga River near 4. SW4 6.0 km, SE 23°37'31.32"N 86° 8'24.67"E 14.04.2018 Birsabasa Bridge Garga River before 5. SW5 meeting with 9.6 km, ENE 23°42'44.78"N 86°11'34.64"E 14.04.2018 Damodar D/s of Damodar 6. SW6 10.6 km, ENE 23°43'1.23"N 86°12'4.59"E 14.04.2018 (Telmuchu Bridge) 7. SW7 Pump House-I 1.85 km, NW 23°41'8.41"N 86° 5'51.71"E 14.04.2018 8. SW8 Pump House-II 2.1 km, ESE 23°40'31.60"N 86° 6'39.13"E 14.04.2018 9. SW9 Garga Reservoir 5.0 km, SW 23°38'6.90"N 86° 4'50.32"E 14.04.2018 Ground Water
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 88 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Direction & Distance Stn. Date of Sn Location from center of project Latitude Longitude Code Sampling (km) Mahuar village – 10 GW1 3.3 km, NE 23°41'11.70"N 86° 7'46.50"E 14.04.2018 Dug well Balidih village – 11 GW2 3.9 km, WSW 23°39'52.50"N 86° 4'10.30"E 14.04.2018 Hand pump Maheshpur village – 12 GW3 4.55 km, N 23°42'51.00"N 86° 7'0.58"E 14.04.2018 Dug well Shibutar – Hand 13 GW4 pump (D/s of Dump 5.4 km, NNW 23°43'15.60"N 86° 5'48.90"E 14.04.2018 yard) Tupkadih village – 14 GW5 7.5 km, NW 23°43'17.90"N 86° 2'59.40"E 14.04.2018 Dug well Bansgoda village - 15 GW6 3.7 km, S 23°38'26.49"N 86° 6'10.30"E 14.04.2018 Dug well Bari Cooperative, 16 GW7 4.1 km, SSE 23°38'15.42"N 86° 7'12.01"E 14.04.2018 Tentuliya - Dug well Ramdih more, 17 GW8 6.1 km, ENE 23°41'46.40"N 86° 8'44.20"E 14.04.2018 Sector IX - Dug well
Results of Surface Water Quality Analysis
The result of analysis of Surface Water is given in Tables 3.15. The surface water quality was compared with CPCB norm for surface water, as given in Table 3.16. All the surface water quality results were within the norms for Class B (Surface water for Organised Outdoor Bathing) or Class C (Surface water which can be used as drinking water source after conventional treatment and disinfection). These waters are suitable only for “Propagation of Wildlife & Fisheries” (i.e. Class D) and “Irrigation, Industrial Cooling, and Controlled Waste Disposal” (i.e. Class E).
Table 3.15. Surface Water Quality Sl. Parameters SW3 SW2 SW4 SW5 SW6 SW1 U/s of Garga River Garga River SW8 SW9 No. D/s of D/s of Damodar SW7 Raw Water Damodar near before Pump House- Garga Damodar (Telmuchu Pump House-I (Tenu Canal) River (Fusro River Birsabasa meeting with II Reservoir Bridge) Bridge) (Chandrapura) Bridge Damodar 1 pH Value 7.5 7.4 7.6 7.5 7.3 7.4 7.8 7.6 7.5 Dissolved Oxygen (as O2), 2 6.4 6.2 6.1 5.2 5.4 5.8 6.6 6.5 6.2 mg/l 3 BOD, 3 days at 27°C, mg/l 1 2 2 3 3 3 1 1 2 4 Iron (as Fe), mg/l, Max. 0.071 0.055 <0.05 0.197 0.234 0.05 0.135 <0.05 0.051 5 Chloride (as Cl), mg/l, Max. 24 26 28 51 71 32 24 39 18 6 Fluoride (as F) mg/L, Max. 1.25 1.1 1.29 1.35 1.36 1.38 1.38 1.39 1.35 7 Calcium (as Ca), mg/l, Max. 21 27 29 40 43 30 22 27 22 Magnesium (as Mg), mg/l, 8 11 15 18 17 17 14 12 9 9 Max. 9 Sodium (as Na), mg/l 10.4 12.4 12 23.3 22 16.6 12 12.4 14.4 10 Potassium(as K), mg/l 2.3 12.5 7.5 7 15 7 6.5 10 3.3
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 89 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. Parameters SW3 SW2 SW4 SW5 SW6 SW1 U/s of Garga River Garga River SW8 SW9 No. D/s of D/s of Damodar SW7 Raw Water Damodar near before Pump House- Garga Damodar (Telmuchu Pump House-I (Tenu Canal) River (Fusro Birsabasa meeting with II Reservoir River Bridge) Bridge) (Chandrapura) Bridge Damodar 11 Copper (as Cu), mg/l, Max. <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Manganese (as Mn), mg/l, 12 <0.01 0.054 <0.01 0.101 0.219 <0.01 <0.01 <0.01 <0.01 Max. Sulphate (as SO4), mg/l, 13 21 68 70 31 46 54 39 30 11 Max. 14 Nitrate (as NO3), mg/l 9.2 6.5 24.4 28.0 37 37 12.6 14 15 15 Cyanide(as CN), mg/l, <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 16 Mercury (as Hg), mg/l, Max. <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 17 Nickel (as Ni), mg/l, Max. <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 18 Lead (as Pb), mg/l, Max. <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 19 Zinc (as Zn), mg/l, Max. <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 <0.10 Chromium (as Cr), mg/l, 20 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Max. Total Coliform organisms, 21 220 480 380 580 630 460 140 170 320 MPN/100ml 22 Sodium Absorption Ratio 0.46 0.48 0.43 0.78 0.71 0.63 0.51 0.53 0.65 23 Free Ammonia (as N) mg/l 0.02 <0.01 0.01 <0.01 <0.01 <0.01 0.02 <0.01 0.01 Electrical Conductivity, 24 216 327 329 453 512 348 253 288 240 μmhos/cm 25 Boron, mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05
Table 3.16. Central Pollution Control Board (CPCB) Surface Water Quality Criteria Sl. No. Parameters Class A Class B Class C Class D Class E 1. pH 6.5–8.5 6.5–8.5 6.0-9.0 6.5–8.5 6.5–8.5 2. Dissolved oxygen (as O2), mg/l, min 6 5 4 4 - 3. BOD, 5 days at 20q C, max 2 3 3 - - 4. Total coliform organism, MPN/100 ml, max 50 500 5000 - - 5. Free ammonia (as N), mg/l, max - - - 1.2 - 6. Electrical conductivity, Pmhos/cm, max - - - - 2250 7. Sodium absorption ratio, max. - - - - 26 8. Boron (as B), mg/l, max. - - - - 2 Class A: Drinking water source without conventional treatment but after dis- Class B: Outdoor bathing (organised) infection Class C: Drinking water source after conventional treatment and after disinfection Class D: Propagation of Wild life and Fisheries Class E: Irrigation, Industrial Cooling, and Controlled Waste Disposal Below E: Not meeting A, B, C, D & E Criteria
Results of Ground Water Quality Analysis
The results of ground water quality are given in Table 3.17. In absence of any specific norms for Ground Water Quality, the results have been compared with drinking water norms of IS: 10500(2012), Amendment No. 1, July 2015. Most of the parameters at all the eight locations are within the respective norms. Total Dissolved Solids content is exceeding the “Desirable Limits” at GW2, GW4,GW5, GW6 and GW7,but within “Permissible Limits”. At GW1, GW2, GW3, GW4, GW5, GW6 & GW7, Total hardness is higher than “Desirable Limit” but within the “Permissible Limit”. At GW2, GW5 and GW7, Calcium content is exceeding the “Desirable CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 90 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Limits” but not the “Permissible Limit”. Similarly at GW2, GW3, and GW7, magnesium is exceeding the “Desirable Limits” but not the “Permissible Limit”. Fluoride is exceeding “Desirable Limit” at GW2, GW4, GW6, GW7 and GW8 but within “Permissible Limit”. Total alkalinity at GW5 & GW7 is slightly higher than the desirable limits but well within the permissible limits.
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Table 3.17. Ground Water Quality Norms* Locations GW4 GW7 Permissible GW3 GW5 GW6 Sl. Requirement GW1 GW2 Shibutar – Bari GW8Ramdih Parameters limits in the Maheshpur Tupkadih Bansgoda No. (desirable Mahuar village Balidih village Hand pump Cooperative, more, Sector absence of village – Dug village – Dug village - Dug – Dug well – Hand pump (D/s of Dump Tentuliya - Dug IX - Dug well limits) well well well alternate source yard) well A ORGANOLEPTIC AND PHYSICAL PARAMETERS 1 Colour, Hazen Units (max) 5 15 <5 <5 <5 <5 <5 <5 <5 <5 2 Odour Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 3 pH value 6.5 to 8.5 No Relaxation 6.5 6.9 7.0 7.4 7.5 7.2 7.1 7.4 4 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 5 Turbidity, NTU, Max. 1 5 <1 <1 <1 <1 <1 <1 <1 <1 6 Total Dissolved Solids, mg/l, max. 500 2000 370 748 336 546 734 538 582 224 Total Hardness(as CaCO3), mg/l, 7 200 600 220 372 216 284 464 308 356 108 max B GENERAL PARAMETERS CONCERNING SUBSTANCES UNDESIRABLE IN EXCESSIIVE AMOUNTS 8 Aluminium (as Al ), mg/l, Max 0.03 0.2 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 9 Boron (as B), mg/l, max. 0.5 1 <0.05 <0.05 <0.05 <0.05 <0.05 0.355 0.155 0.234 10 Calcium (as Ca), mg/l, max. 75 200 74 93 35 64 136 75 88 26 11 Chloride (as Cl),mg/l, max. 250 1000 96 162 61 94 202 70 93 39 12 Copper (as Cu), mg/l, max. 0.05 1.5 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 13 Fluoride (as F), mg/l, max. 1 1.5 0.26 1.25 0.96 1.37 0.93 1.26 1.37 1.36 14 Iron (as Fe), mg/l, max. 1 No Relaxation <0.05 <0.05 <0.05 0.078 <0.05 0.488 0.064 0.179 15 Magnesium (as Mg), mg/l, max. 30 100 9 34 31 30 30 29 33 11 16 Manganese (as Mn), mg/l, max. 0.1 0.3 <0.01 <0.01 <0.01 <0.01 <0.01 0.059 0.058 <0.01 17 Nitrate (as NO3), mg/l, max. 45 No Relaxation 38 35 44 28 35 40 36 20 18 Phenolic compounds, mg/l, max. 0.001 0.002 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001
19 Sulphate (as SO4), mg/l, max. 200 400 27 52 22 109 56 75 62 31
20 Total Alkalinity( as CaCO3), mg/l 200 600 92 104 112 140 214 180 228 64 21 Zinc (as Zn), mg/l, max. 5 15 <0.1 <0.1 <0.1 <0.1 <0.1 0.355 0.155 0.234
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Norms* Locations GW4 GW7 Permissible GW3 GW5 GW6 Sl. Requirement GW1 GW2 Shibutar – Bari GW8Ramdih Parameters limits in the Maheshpur Tupkadih Bansgoda No. (desirable Mahuar village Balidih village Hand pump Cooperative, more, Sector absence of village – Dug village – Dug village - Dug – Dug well – Hand pump (D/s of Dump Tentuliya - Dug IX - Dug well limits) well well well alternate source yard) well C PARAMETERS CONCERNING TOXIC SUBSTANCES 22 Cyanide (as CN), mg/l, max. 0.05 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 23 Lead (as Pb), mg/l, max. 0.01 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 24 Mercury,(as Hg), mg/l, max. 0.001 No relaxation <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 25 Nickel (as Ni ), mg/l, max. 0.02 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 26 Total Arsenic (as As), mg/l, max. 0.01 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Total Chromium (as Cr), mg/l, 27 0.05 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Max. * compared with Drinking Water Specification IS: 10500 (2012), Amendment no. 1, June'2015 Note:- BDL is Below Detectable Limit ; Minimum Detectable Limit For parameters tested are as under: (Al-0.01,As-0.01,B-0.05,Cr-0.01,Cu-0.01,Fe-0.05,Pb-0.01, Mn-0.01, Zn-0.1,) (Unit - mg/l) (NTU - NephelometricTurbidity Units; MPN - most probable number) * Requirement (Desirable limits) ** Permissible limits in the absence of alternate source ***Throughout any year, 95 % of samples should not contain any coli-form organism and that no sample should contain more than 10 MPN/100 ml of coli-form organism and further no coli-form organism should be detectable in any two of the consecutive samples.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 93 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 3.6.6 Soil Characteristics
Selection of Sampling Locations
The soil sampling locations were selected with the following objective: x To assess the background / baseline soil quality of the region. x To assess the impact (if any) of existing Steel Plant air emissions, effluent discharge and solid waste on soil of the study area
To assess the quality of soil in and around the plant, soil samples were collected from six (6) locations for Physico-chemical analysis. Table 3.18 lists the soil sampling stations which are also marked in Drg. MEC/11/S2/E24P/03.
Table 3.18. Selection of Soil Sampling Locations Direction &Distance Sl. Stn. Type of Location from center of project Latitude Longitude No. Code Land (km) 1. S1 Behind slag dump area 5.36 km, NW 23°42'49.47"N 86° 4'25.07"E Agricultural 2. S2 Near Shibutar village 5.5 km, NNW 23°43'17.73"N 86° 5'48.74"E Agricultural 3. S3 Near Mahuar Village 3.5 km, ENE 23°41'12.07"N 86° 7'42.44"E Agricultural 4. S4 Near Balidih Village 4.5 km, W 23°40'24.97"N 86° 4'14.78"E Barren 5. S5 Near City Park, Sector-III 5 km, ESE 23°39'8.71"N 86° 9'14.40"E Plantation 6. S6 Near electrical loco shed 2.7 km, W 23°39'41.51"N 86° 5'20.82"E Industrial
Methodology
In order to have an idea about the baseline soil quality in the study area, samples of top soil were collected from the six locations once during the study period (March-May, 2018) from 15- 20 cm depth. The soil samples collected were marked, brought to laboratory, air-dried under the shed, powdered & passed through 2 mm sieve and further analysed for different physico- chemical characteristics following methodology given in “Soil Test Methodology” -1992 edited by B.S.Mathur, a Technical Bulletin 3/92 of Department of Soil Sciences and Agriculture Chemistry (SSAC), Birsa Agriculture University (BAU), Ranchi.
Results of Soil Analysis
The results of analysis of Colour, Texture, Bulk Density, Water Holding Capacity, pH and conductivity of the tested soils samples are presented in Table 3.19.
Table 3.19. Physical & Chemical properties of Soil Electrical Water Holding Bulk Density pH Sample No. Color Texture Conductivity Capacity (%) (gm/cc) (1: 5) (μs/cm) S1 (Behind slag dump area) Blackish Brown Loam 42 1.25 6.9 58 S2 (Near Shibutar village) Yellowish Brown Sandy Loam 35 1.05 6.2 42 S3 (Near Mahuar Village) Grey Loam 39 1.52 6.4 57 S4 (Near Balidih Village) Reddish Brown Sandy Loam 32 1.10 6.7 315 S5 (Near City Park, Sector-III) Blackish Grey Sandy Loam 40 1.39 6.1 610 S6 (Near electrical loco shed) Reddish Brown Sandy Loam 36 1.45 6.5 95
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Electrical conductivity (EC) is a measure of the concentration of soluble salts and ionic activity in the soil. Salt concentration is directly proportional to the osmotic pressure, which governs the process of osmosis in the soil–plant system. In the collected soil samples the electrical conductivity ranged from 42 to 610 μs/cm indicating normal nature of the soil with respect to severity of the salt content.
The availability of major nutrients are presented in Table 3.20. Organic carbon, Nitrogen and Phosphorus are limiting nutrients, especially Phosphorus. In the tested soil samples most of the nutrients are available in low to high concentration ranges. Organic carbon was found to be in high concentration range. Available Phosphorus levels are found to be in low to medium concentration range and available Nitrogen levels are found to be in low to medium concentration range, whereas availability of Potassium is found to be in low to high range. As the major nutrients are not showing any major deviation among the tested soil samples, it is indicating that there is no impact on nutrient contents of soil due to industrial activity.
Table 3.20. Available Major Nutrients in Soil Nutrients and Ratings S1 S2 S3 S4 S5 S6 Available Nitrogen (kg/ha) & 263 389 414 351 502 213 Rating L M M M M L Available Phosphorus (Kg/ha) 1.9 1.1 2.3 1.7 11.5 2.1 and Rating L L L L M L Available Potassium (Kg/ha) 123 90 123 370 549 146 and Rating M L M H H M Organic carbon (%) and 1.34 1.29 1.46 1.17 1.70 1.20 Ratings H H H H H H Organic matter % 2.75 2.67 2.97 2.46 3.04 2.51 Rating based on: Available Nitrogen : <280 - Low; 280- 560 Medium; >560 - High Available Phosphorus: <10 - Low; 10 - 25 Medium; >25 - High Available Potassium : <120 - Low; 120 - 280 Medium; >280 - High Organic carbon : <0.50 - Low; 0.5-0.75 Medium; > 0.75 - High
The results of determination of exchangeable cations are presented in Table 3.21.The results show that the Calcium and Magnesium constitutes the bulk of exchangeable cations in the tested soil samples whereas levels of exchangeable sodium and potassium are relatively low. This indicates that the collected soil samples are not showing any signs of increase in alkalinity (Sodium / Potassium) due to industrial activity.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 95 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.21. Exchangeable Cations Parameters S1 S2 S3 S4 S5 S6 Calcium (meq/100gm) 6.20 7.40 4.20 9.20 11.20 7.20 % contribution to the Base 88.19 86.65 58.91 60.41 65.69 77.25 Saturation Magnesium (meq/100gm) 0.40 0.80 2.60 5.00 4.60 1.80 % contribution to the Base 5.69 9.37 36.47 32.83 26.98 19.31 Saturation Sodium (meq/100gm) 0.24 0.20 0.12 0.61 0.37 0.16 % contribution to the Base 3.41 2.34 1.68 4.01 2.17 1.72 Saturation Potassium (meq/100gm) 0.19 0.14 0.21 0.42 0.88 0.16 % contribution to the Base 2.70 1.64 2.95 2.76 5.16 1.72 Saturation
Soil micro–nutrients also play an important role in plant growth and can act as limiting nutrients. Soil micro–nutrient analysis can be employed as a diagnostic tool for predicting the possibility of deficiency of a nutrient and the profitability of its application. For this, it is necessary to fix the critical limits. The critical limit of a micro–nutrient is that content of extractable nutrient at or below which plantation practised on it will produce a positive response to its application. Results of available micronutrient of soil samples collected from various locations of the study area are given in Table 3.22.
Table 3.22. Available Micronutrients Results (mg/kg) Micro Nutrients S1 S2 S3 S4 S5 S6 Copper 0.422 0.384 0.534 0.400 0.810 0.526 Zinc 1.240 0.680 0.546 0.770 2.780 1.108 Iron 9.302 5.008 7.160 1.140 6.428 2.592 Manganese 19.686 12.978 11.980 12.266 7.666 9.226 Critical Limits (mg/kg): Iron: 4.5 – 6.0; Copper:0.20 – 0.66; Zn: 0.50 – 0.65
From the above table it can be seen that Iron is in higher concentration in the entire tested soil sample except in S4 & S6 where it is in lower concentration in respect to critical ranges. The concentration of Copper is found to be within range in all five samples except S5where it is found to be slightly exceeding the range. In the study area, the level of some micro–nutrients is above the critical limits. Hence, it implies that no external application of micro-nutrients is required (fertilisers) for good plant growth.
3.6.7 Traffic Density
To quantify the impact of the proposed project and allied activities on traffic, it is necessary at first to evaluate the existing load of vehicular traffic near plant site. The major transport of finished products/ raw material passes through these roads. Traffic survey was done at four locations. The existing traffic density for different types of vehicles was counted at 06 locations during the study on a particular day for 24 hours. The survey locations were as follows:
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The monitored locations with the roads used for traffic movement by vehicles to-fro between Bokaro Steel plant is indicated in figures below:
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The traffic survey data monitored at these location is indicated in Tables 3.23(a) to 3.23(f) below.
Table 3.23(a): Traffic density at various gates leading to steel plant Location: T1 - Main Gate(Gate No.:01), Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0630 -0730 0 0 0 0 5 5 1050 787.5 1055 792.5 0730 -0830 0 0 0 0 152 152 1244 933 1396 1085 0830 - 0930 0 0 0 0 11 11 1932 1449 1943 1460 0930 – 1030 1 2.2 0 0 46 46 529 396.75 576 444.95 1030 – 1130 0 0 0 0 17 17 66 49.5 83 66.5 1130 – 1230 1 2.2 0 0 32 32 173 129.75 206 163.95 12.30 -1330 0 0 0 0 16 16 235 176.25 251 192.25 1330 – 1430 0 0 0 0 65 65 2575 1931.25 2640 1996.25 1430 – 1530 0 0 0 0 53 53 2260 1695 2313 1748 1530 – 1630 0 0 0 0 14 14 83 62.25 97 76.25 1630 – 1730 0 0 0 0 64 64 97 72.75 161 136.75 1730 – 1830 0 0 0 0 130 130 3908 2931 4038 3061 1830 – 1930 0 0 0 0 53 53 242 181.5 295 234.5 1930 – 2030 0 0 0 0 44 44 139 104.25 183 148.25 2030 – 2130 0 0 0 0 17 17 96 72 113 89 2130 – 2230 0 0 0 0 60 60 1126 844.5 1186 904.5 2230 – 2330 0 0 0 0 0 0 1575 1181.25 1575 1181.25 2330 – 0030 0 0 0 0 0 0 247 185.25 247 185.25 0030 – 0130 0 0 0 0 0 0 0 0 0 0 0130 – 0230 0 0 0 0 0 0 0 0 0 0 0230 – 0330 0 0 0 0 0 0 0 0 0 0 0330 – 0430 0 0 0 0 0 0 0 0 0 0 0430 – 0530 0 0 0 0 0 0 0 0 0 0 0530 – 0630 0 0 0 0 45 45 1502 1126.5 1547 1171.5 TOTAL 2 4.4 0 0 824 824 19079 14309.25 19905 15137.65 % in traffic 0.01% 0.00% 4.14% 95.85%
stream (<10%) (<10%) (<10%) (>10%) Worst case Baseline PCU/hr (i.e. maximum hourly PCU observed): 3061 Total width of the Road in meters (Arterial Roads): 21 Carrying capacity of the road (the road is 4 lane (divided)2 way arterial road) as per: IRC:106-1990 (PCU’s per hour) 3600
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 99 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.23(b): Traffic density at various gates leading to steel plant Location: T2 - Gate No.:03, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.08.2018) to 6:30 AM (29.08.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0630 -0730 0 0 0 0 0 0 0 0 0 0 0730 -0830 0 0 0 0 0 0 70 52.5 70 52.5 0830-0930 0 0 0 0 0 0 0 0 0 0 0930 – 1030 0 0 0 0 0 0 0 0 0 0 1030 – 1130 0 0 0 0 0 0 0 0 0 0 1130 – 1230 0 0 0 0 0 0 0 0 0 0 12.30 -1330 0 0 0 0 0 0 0 0 0 0 1330 – 1430 0 0 0 0 0 0 102 76.5 102 76.5 1430 – 1530 0 0 0 0 0 0 0 0 0 0 1530 – 1630 0 0 0 0 0 0 0 0 0 0 1630 – 1730 0 0 0 0 0 0 65 48.75 65 48.75 1730 – 1830 0 0 0 0 0 0 5 3.75 5 3.75 1830 – 1930 0 0 0 0 0 0 0 0 0 0 1930 – 2030 0 0 0 0 0 0 0 0 0 0 2030 – 2130 0 0 0 0 0 0 0 0 0 0 2130 – 2230 0 0 0 0 0 0 96 72 96 72 2230 – 2330 0 0 0 0 0 0 4 3 4 3 2330 – 0030 0 0 0 0 0 0 0 0 0 0 0030 – 0130 0 0 0 0 0 0 0 0 0 0 0130 – 0230 0 0 0 0 0 0 0 0 0 0 0230 – 0330 0 0 0 0 0 0 0 0 0 0 0330 – 0430 0 0 0 0 0 0 0 0 0 0 0430 – 0530 0 0 0 0 0 0 40 30 40 30 0530 – 0630 0 0 0 0 0 0 58 43.5 58 43.5 TOTAL 0 0 0 0 0 0 440 330 440 330 % in traffic 0.0% 0.0% 0.0% 100%
stream (<10%) (<10%) (<10%) (>10%) Worst case Baseline PCU/hr (i.e. maximum hourly PCU observed): 76.5 Total width of the Road in meters (Arterial Roads): 7.8 Carrying capacity of the road (the road is 2 lane 2 way arterial road) as per: IRC:106-1990 (PCU’s per hour) 1500
Table 3.23(C): Traffic density on various gate leading to steel plant Location: T3 - Gate No.: 05, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0630 -0730 0 0 1 1.4 0 0 0 0 1 1.4 0730 -0830 0 0 0 0 0 0 18 13.5 18 13.5 0830-0930 0 0 1 1.4 0 0 0 0 1 1.4 0930 – 1030 0 0 0 0 0 0 0 0 0 0 1030 – 1130 0 0 1 1.4 0 0 0 0 1 1.4 1130 – 1230 0 0 1 1.4 0 0 0 0 1 1.4 12.30 -1330 0 0 0 0 0 0 0 0 0 0 1330 – 1430 0 0 0 0 0 0 11 8.25 11 8.25 1430 – 1530 0 0 2 2.8 0 0 0 0 2 2.8 1530 – 1630 0 0 0 0 0 0 0 0 0 0 1630 – 1730 0 0 0 0 0 0 18 13.5 18 13.5
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 100 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Location: T3 - Gate No.: 05, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 1730 – 1830 0 0 0 0 0 0 0 0 0 0 1830 – 1930 0 0 0 0 0 0 0 0 0 0 1930 – 2030 0 0 0 0 0 0 0 0 0 0 2030 – 2130 0 0 0 0 0 0 0 0 0 0 2130 – 2230 0 0 0 0 0 0 14 10.5 14 10.5 2230 – 2330 0 0 0 0 0 0 0 0 0 0 2330 – 0030 0 0 0 0 0 0 0 0 0 0 0030 – 0130 0 0 0 0 0 0 0 0 0 0 0130 – 0230 0 0 0 0 0 0 0 0 0 0 0230 – 0330 0 0 0 0 0 0 0 0 0 0 0330 – 0430 0 0 0 0 0 0 0 0 0 0 0430 – 0530 0 0 0 0 0 0 0 0 0 0 0530 – 0630 0 0 0 0 0 0 13 9.75 13 9.75 TOTAL 0 0 6 8.4 0 0 74 55.5 80 63.9 % in traffic 0.0% 8% 0.0% 92%
stream (<10%) (<10%) (<10%) (>10%) Worst case Baseline PCU/hr (i.e. maximum hourly PCU observed): 13.5 Total width of the Road in meters (Arterial Roads): 8 Carrying capacity of the road (the road is 2 lane 2 way arterial road) as per: IRC:106-1990 (PCU’s per hour) 1500
Table 3.23(D): Traffic density on various gate leading to steel plant Location: T4 - Mansa Singh, Gate No.: 08, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0630 -0730 0 0 0 0 0 0 0 0 0 0 0730 -0830 0 0 0 0 0 0 16 12 16 12 0830-0930 0 0 0 0 0 0 0 0 0 0 0930 – 1030 0 0 0 0 0 0 0 0 0 0 1030 – 1130 0 0 0 0 0 0 0 0 0 0 1130 – 1230 0 0 0 0 0 0 0 0 0 0 12.30 -1330 0 0 0 0 0 0 0 0 0 0 1330 – 1430 0 0 0 0 0 0 19 14.25 19 14.25 1430 – 1530 0 0 0 0 0 0 0 0 0 0 1530 – 1630 0 0 0 0 0 0 0 0 0 0 1630 – 1730 0 0 0 0 0 0 16 12 16 12 1730 – 1830 0 0 0 0 0 0 0 0 0 0 1830 – 1930 0 0 0 0 0 0 0 0 0 0 1930 – 2030 0 0 0 0 0 0 0 0 0 0 2030 – 2130 0 0 0 0 0 0 0 0 0 0 2130 – 2230 0 0 0 0 0 0 18 13.5 18 13.5 2230 – 2330 0 0 0 0 0 0 0 0 0 0 2330 – 0030 0 0 0 0 0 0 0 0 0 0 0030 – 0130 0 0 0 0 0 0 0 0 0 0 0130 – 0230 0 0 0 0 0 0 0 0 0 0 0230 – 0330 0 0 0 0 0 0 0 0 0 0 0330 – 0430 0 0 0 0 0 0 0 0 0 0 0430 – 0530 0 0 0 0 0 0 0 0 0 0
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 101 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Location: T4 - Mansa Singh, Gate No.: 08, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0530 – 0630 0 0 0 0 0 0 17 12.75 17 12.75 TOTAL 0 0 0 0 0 0 86 64.5 86 64.5 % in traffic 0.0% 0.0% 0.0% 100%
stream (<10%) (<10%) (<10%) (>10%) Worst case Baseline PCU/hr (i.e. maximum hourly PCU observed): 14.25 Total width of the Road in meters (Arterial Roads): 8 Carrying capacity of the road (the road is 2 lane 2 way arterial road) as per: IRC:106-1990 (PCU’s per hour) 1500
Table 3.23(E): Traffic density on various gate leading to steel plant Location: T5 - Steel Gate,Gate No.: 09, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 3.7 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0630 -0730 7 25.9 0 0 0 0 0 0 7 25.9 0730 -0830 25 92.5 0 0 0 0 80 60 105 152.5 0830-0930 0 0 0 0 0 0 0 0 0 0 0930 – 1030 35 129.5 0 0 0 0 0 0 35 129.5 1030 – 1130 60 222 0 0 0 0 0 0 60 222 1130 – 1230 14 51.8 0 0 0 0 0 0 14 51.8 12.30 -1330 22 81.4 0 0 0 0 0 0 22 81.4 1330 – 1430 0 0 0 0 0 0 100 75 100 75 1430 – 1530 37 136.9 0 0 0 0 0 0 37 136.9 1530 – 1630 32 118.4 0 0 0 0 0 0 32 118.4 1630 – 1730 70 259 0 0 0 0 0 0 70 259 1730 – 1830 21 77.7 0 0 0 0 45 33.75 66 111.45 1830 – 1930 0 0 0 0 0 0 35 26.25 35 26.25 1930 – 2030 0 0 0 0 0 0 0 0 0 0 2030 – 2130 0 0 0 0 0 0 0 0 0 0 2130 – 2230 0 0 0 0 0 0 40 30 40 30 2230 – 2330 0 0 0 0 0 0 0 0 0 0 2330 – 0030 0 0 0 0 0 0 0 0 0 0 0030 – 0130 0 0 0 0 0 0 0 0 0 0 0130 – 0230 0 0 0 0 0 0 0 0 0 0 0230 – 0330 0 0 0 0 0 0 0 0 0 0 0330 – 0430 0 0 0 0 0 0 0 0 0 0 0430 – 0530 0 0 0 0 0 0 0 0 0 0 0530 – 0630 0 0 0 0 0 0 80 60 80 60 TOTAL 323 1195.1 0 0 0 0 380 285 703 1480.1 % in traffic 46.0% 0.0% 0.0% 54.0%
stream (>10%) (<10%) (<10%) (>10%) Worst case Baseline PCU/hr (i.e. maximum hourly PCU observed): 259 Total width of the Road in meters (Arterial Roads): 14 Carrying capacity of the road (the road is 4 lane (undivided) 2 way arterial road) as per: IRC:106-1990 (PCU’s per 3000 hour)
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 102 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.23(F): Traffic density on various gate leading to steel plant Location: T6 - CEZ Gate,Gate No.: 11, Bokaro Steel Plant Date: 28th July, 2018 Time: 6:30 AM (28.07.2018) to 6:30 AM (29.07.2018) Time (Clock Heavy vehicles LMV(except Cars) Cars Two wheelers TOTAL Hours) Nos. @ 2.2 PCU Nos. @ 1.4 PCU Nos. @ 1 PCU Nos. @ 0.75 PCU Nos. PCU 0630 -0730 0 0 0 0 0 0 0 0 0 0 0730 -0830 0 0 0 0 9 9 15 11.25 24 20.25 0830-0930 0 0 0 0 0 0 8 6 8 6 0930 – 1030 0 0 1 1.4 0 0 0 0 1 1.4 1030 – 1130 0 0 0 0 0 0 0 0 0 0 1130 – 1230 0 0 0 0 0 0 0 0 0 0 12.30 -1330 0 0 1 1.4 0 0 0 0 1 1.4 1330 – 1430 0 0 0 0 0 0 23 17.25 23 17.25 1430 – 1530 0 0 0 0 0 0 0 0 0 0 1530 – 1630 0 0 0 0 0 0 0 0 0 0 1630 – 1730 0 0 0 0 9 9 18 13.5 27 22.5 1730 – 1830 0 0 0 0 0 0 5 3.75 5 3.75 1830 – 1930 0 0 0 0 0 0 0 0 0 0 1930 – 2030 0 0 0 0 0 0 0 0 0 0 2030 – 2130 0 0 0 0 0 0 0 0 0 0 2130 – 2230 0 0 0 0 0 0 23 17.25 23 17.25 2230 – 2330 0 0 0 0 0 0 0 0 0 0 2330 – 0030 0 0 0 0 0 0 0 0 0 0 0030 – 0130 0 0 0 0 0 0 0 0 0 0 0130 – 0230 0 0 0 0 0 0 0 0 0 0 0230 – 0330 0 0 0 0 0 0 0 0 0 0 0330 – 0430 0 0 0 0 0 0 0 0 0 0 0430 – 0530 0 0 0 0 0 0 0 0 0 0 0530 – 0630 0 0 0 0 0 0 24 18 24 18 TOTAL 0 0 2 2.8 18 18 116 87 136 107.8 % in traffic 0.0% 1.0% 13% 86%
stream (<10%) (<10%) (>10%) (>10%) Worst case Baseline PCU/hr (i.e. maximum hourly PCU observed): 22.5 Total width of the Road in meters (Arterial Roads): 5 Carrying capacity of the road (the road is2 lane 2 way arterial road) as per: IRC:106-1990 (PCU’s per hour) 1500
The steel plant has a number of entry gates. Some of the gates are used regularly, while others are used only occasionally. Of the gates used regularly, some are used for entry of BSL employees and visitors, whereas some are used only by goods vehicles some by both. In case of gates meant for use by both employees and goods, to ensure smooth traffic flow and avoid accidents, no heavy vehicles are allowed to use gates meant for during shift change times.
x Gate No. 1 (T1) is used by BSL workers as well as visitors to the plant. No goods vehicles are allowed to use this gate. Consequently, the traffic at this gate comprises only of cars and two- wheelers. The traffic surges during shift changes. Since visitors are allowed entry during day- time there is heavy traffic throughout the day. However, after around 10 p.m. there is no traffic as all visitors and day shift workers would have left the plant and night shift workers would have entered the plant. It is to be noted that most BSL x Gate no. 3 (T2) is used only by BSL workers. No heavy vehicles are allowed to use this gate. As this gate is used only by BSL workers, there is some movement of light vehicles only during shift change-overs.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 103 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Gate Nos. 3 (T2) and 8 (T4) are very sparingly used by light vehicles only. x Gate No. 9 (T5) is used by light as well as heavy vehicles. Heavy vehicles are permitted to enter or leave the plant only during day time. During shift change-over times, large number of light vehicles (2-wheelers) use this gate. During this time, heavy vehicles’ movement is stopped. x Gate No. 11 (T6) is a sparingly used gate meant only for light vehicles. x The maximum incremental traffic due to the additional incoming & outgoing material is estimated to be 2242 trucks per annum (i.e. ~28 PCUs/day). This increased heavy vehicular movement will be through Steel Gate-9 (T5) and will be well within the carrying capacity of the road indicated as T5 in figure above on which maximum heavy vehicle movement occurs.
3.6.8 Biological Environment 3.6.8.1 Objectives of the study
The present study was undertaken with the following objectives: x To assess the nature and distribution of vegetation in and around the project site within the study area; x To assess the type of wild animals within the study area; x To assess the biodiversity of natural system present in the study area; x To ascertain migratory routes of fauna and possibility of breeding grounds within the study area;
3.6.8.2 Methodology of the Ecology Study
The study area taken for the study is 10 km radius with the Plant site as centre. The different methods adopted were as follows: x Inventorisation of flora / fauna: A preliminary list of flora and fauna found in the study area was prepared by conducting field survey and was finalized after discussions from Forest Offices of the Forest Division (falling within the study area). x Discussion with local people so as to elicit information about local plant and animals found within the study area. x The present study is based on field studies conducted during summer season March 2018.
The study area lies in the Climatic Zone – “Humid subtropical” (Koppen Classification) and under Agro-climatic Zone – “Eastern Plateau & Hill Region” and within Agro-climatic Zone (Eastern Plateau & Hill Region), the Agro-Ecological Zone is “Hot Sub-Humid Eco-Region” (Planning Commission). The area is plateau region interspersed with plain and small hillocks. Part of the study area is urban and industrial and the rest is rural and is covered with agricultural fields and small patches of forest along Damodar River towards North.
The biotic environment can be described under following heads.
1) Project Area a) Industrial setup b) Plantation
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 104 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 2) Study Area a) Agricultural land b) Forest area c) Waste land d) Vegetation in and around human settlement e) Wild life and avifauna f) Aquatic Life
There is no Biosphere Reserve, Ramsar Site, National Park, Wild Life Sanctuary, Tiger Reserve, Elephant Reserve or Wildlife Corridor in study area. 3.6.8.3 Ecology of Project area
The project site is the existing steel plant site, which basically comprises of the existing industrial set up and the green belt developed by the project.
a) Industrial Setup
The Integrated Steel Plant was established four to five decades back and since then under various expansion plans the present status of the plant exists. Each unit is well laid with associated facilities and green cover adding to aesthetic look of the unit.
b) Plantations
Horticulture Department of the project has covered all possible areas within the plant and township under green cover. Moreover further areas are being explored for further plantation. Also in certain areas of the plant and township naturally growing trees have been protected by the Department. The plants planted and naturally occurring tree species are given in Table 3.24.
Table 3.24. Plants planted within plant premises Sl.No. Vernacular Name Botanical Name Family Remarks 1 Aam Mangifera indica Anacardiaceae Economic 2 Agati Sesbania grandiflora Fabaceae 3 Amaltas Cassia fistula Fabaceae Ornamental 4 Amra Spondias pinnata Anacardiaceae Economic 5 Aonla Phyllanthus emblica Phyllanthaceae Medicinal 6 Arjun Terminalia arjuna Combretaceae Medicinal 7 Asan Terminalia tomentosa Combretaceae 8 Ashok Polyalthia longifolia Annonaceae Ornamental 9 Bahera Terminalia bellirica Combretaceae Medicinal 10 Bakain Melia azedarach Meliaceae Medicinal 11 Bargad Ficus benghalensis Moraceae 12 Basant rani Tabebuia rosea Bignoniaceae Ornamental 13 Bel Aegle marmelos Rutaceae Medicinal 14 Bhelwa Semecarpus anacardium Anacardiaceae Economic 15 Bottle Brush Callistemon citrinus Myrtaceae 16 Chakundi Cassia siamea Fabaceae Ornamental 17 Champa Plumeria rubra Apocynaceae Ornamental 18 Chhatian Alstonia scholaris Apocynaceae Medicinal
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 105 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl.No. Vernacular Name Botanical Name Family Remarks 19 Dumar / Gular Ficus glomerata Moraceae 20 Eucalyptus Eucalyptus citriodora Myrtaceae 21 Fountain tree Spathodea campanulata Bignoniaceae 22 Gamhar Gmelina arborea Verbenaceae Economic 23 Gulmohar Delonix regia Fabaceae Ornamental 24 Harsingar Nyctanthes arbor-tristis Oleaceae Medicinal 25 Imli Tamarindus indica Fabaceae Economic 26 Jamun Syzygium cumini Myrtaceae Medicinal 27 Kachnar Bauhinia varigeta Fabaceae 29 Kadamb Anthocephalus cadamba Rubiaceae Medicinal 30 Kala Siris Albizia lebbeck Fabaceae Ornamental 31 Karanj Pongamia glabra Fabaceae Economic 32 Kathal Artocarpus heterophyllus Moraceae Economic 33 Konar Bauhinia purpurea Fabaceae Ornamental 34 Mahogany Swietenia humilis Meliaceae 36 Mahua Madhuca Indica Sapotaceae Economic 37 Maulsree Mimusops elengi Sapotaceae 38 Neem Azadirachta indica Meliaceae Medicinal 39 Palas Butea monosperma Fabaceae Ornamental 40 Paradise Tree Simarouba glauca Simaroubaceae Ornamental 41 Peltophorum Peltophorum roxburghii Fabaceae 42 Pipal Ficus religiosa Moraceae 43 Pterospermum Pterospermum acerifolium Malvaceae 44 Putranjiva Putranjiva roxburghii Putranjivaceae 45 Rain Tree Albizia saman Fabaceae 46 Rubber fig Ficus elastica Moraceae 47 Sagwan Tectona grandis Verbenaceae Economic 48 Sajan Moringa oleifera Moringaceae Medicinal 49 Semal Bombax ceiba Malvaceae Economic 50 Sidha Lagerstroemia speciosa Lythraceae 51 Silver Oak Grevillea robusta Proteaceae 52 Sindur Vitex negundo Verbenaceae 53 Sisoo Dalbergia sissoo Fabaceae Economic 54 Sonajhuri Acacia auriculiformis Fabaceae 55 Sterculia Sterculia alata Malvaceae 56 Yellow Kaner Thevetia peruviana Apocynaceae Medicinal
3.6.8.4 Ecology of Study Area
The study area covers 10km radius around the project site center. The study area can roughly be divided in to, Hillocks and undulated plain areas. The undulated plains are best utilized for paddy cultivation during kharif season. The plant species inventoried in the study area is given in Table 3.25. Table 3.25. List of Plants found in study area Sl.No. Vernacular Name Botanical Name Family Remarks 1 Aam Mangifera indica Anacardiaceae Economic 2 Agati Sesbania grandiflora Fabaceae 3 Amaltas Cassia fistula Fabaceae Ornamental 4 Amra Spondias pinnata Anacardiaceae Economic 5 Aonla Phyllanthus emblica Phyllanthaceae Medicinal 6 Arjun Terminalia arjuna Combretaceae Medicinal
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 106 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl.No. Vernacular Name Botanical Name Family Remarks 7 Asan Terminalia tomentosa Combretaceae 8 Ashok Polyalthia longifolia Annonaceae Ornamental 9 Babul Acacia arabica Fabaceae 10 Bahera Terminalia bellirica Combretaceae Medicinal 11 Bakain Melia azedarach Meliaceae Medicinal 12 Bakul / Maulshree Mimusops elengi Sapotaceae 13 Bargad Ficus benghalensis Moraceae 14 Basant rani Tabebuia rosea Bignoniaceae Ornamental 15 Bel Aegle marmelos Rutaceae Medicinal 16 Bhelwa Semecarpus anacardium Anacardiaceae Economic 17 Bijasal Pterocarpus marsupium Fabaceae Economic 18 Bottle Brush Callistemon citrinus Myrtaceae 19 Chakundi Cassia siamea Fabaceae Ornamental 20 Champa Plumeria rubra Apocynaceae Ornamental 21 Chhatian Alstonia scholaris Apocynaceae Medicinal 22 Chilbil Holoptelea integrifolia Ulmaceae Medicinal 23 Dhautha Anogeissus latifolia Combretaceae 24 Dumar / Gular Ficus glomerata Moraceae 25 Eucalyptus Eucalyptus citriodora Myrtaceae 26 Fountain tree Spathodea campanulata Bignoniaceae 27 Gamhar Gmelina arborea Verbenaceae Economic 28 Gulmohar Delonix regia Fabaceae Ornamental 29 Gurukaram Mitragyna parviflora Rubiaceae 30 Harre Terminalia chebula Combretaceae Medicinal 31 Imli Tamarindus indica Fabaceae Economic 32 Jamun Syzygium cumini Myrtaceae Medicinal 33 Kachnar Bauhinia varigeta Fabaceae 34 Kadamb Anthocephalus cadamba Rubiaceae Medicinal 35 Kaitha Feronia limonia Rutaceae 36 Kala Siris Albizia lebbeck Fabaceae Ornamental 37 Karam Adina cordifolia Rubiaceae. Medicinal 38 Karanj Pongamia glabra Fabaceae Economic 39 Kathal Artocarpus heterophyllus Moraceae Economic 40 Kendu Diospyros melanoxylon Ebenaceae Economic 41 Keonjhi Sterculia urens Sterculiaceae 42 Khair Acacia catechu Fabaceae Economic 43 Khajur Phoenix acaulis Arecaceae Economic 44 Konar Bauhinia purpurea Fabaceae Ornamental 45 Koraiya Holarrhena antidysenterica Apocynaceae Medicinal 46 Kusum Schleichera oleosa Sapindaceae 47 Mahogany Swietenia humilis Meliaceae 48 Mahua Madhuca Indica Sapotaceae Economic 49 Maulsree Mimusops elengi Sapotaceae 50 Neem Azadirachta indica Meliaceae Medicinal 51 Palas Butea monosperma Fabaceae Ornamental 52 Panigambhar Trewia nudiflora Euphorbiaceae 53 Paradise Tree Simarouba glauca Simaroubaceae Ornamental 54 Peltophorum Peltophorum roxburghii Fabaceae 55 Pipal Ficus religiosa Moraceae 56 Pterospermum Pterospermum acerifolium Malvaceae 57 Putranjiva Putranjiva roxburghii Putranjivaceae 58 Rain Tree Albizia saman Fabaceae 59 Rubber fig Ficus elastica Moraceae
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 107 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl.No. Vernacular Name Botanical Name Family Remarks 60 Safed Siris Albizia procera Fabaceae Ornamental 61 Sagwan Tectona grandis Verbenaceae Economic 62 Sajan Moringa oleifera Moringaceae Medicinal 63 Sal Shorea robusta Dipterocarpaceae Economic 64 Salai Boswellia serrata Burseraceae 49 Semal Bombax ceiba Malvaceae Economic 66 Sidha Lagerstroemia speciosa Lythraceae 67 Silver Oak Grevillea robusta Proteaceae 68 Sindur Vitex negundo Verbenaceae 69 Sisoo Dalbergia sissoo Fabaceae Economic 70 Sonajhuri Acacia auriculiformis Fabaceae 71 Sterculia Sterculia alata Malvaceae 72 Tar Borassus flabellifer Arecaceae Economic 73 Yellow Kaner Thevetia peruviana Apocynaceae Medicinal B.BAMBOO 1 Bans Bambusa arundinacea Poaceae 2 Bans Dendrocalamus strictus Poaceae C. SHRUBS 1 Aintha Helectris isora Malvaceae 2 Akwain Calotropis gigantea Apocynaceae 3 Ber Ziziphus mauritiana Rhamnaceae 4 Bhuin Anala Phyllanthus niruri Phyllanthaceae Medicinal 5 Chakwad Cassia tora Fabaceae 6 Chuimui Mimosa pudica Fabaceae 7 Dhatura Datura metal Solanaceae Medicinal 8 Dhawal Woodfordia fruticosa Lythraceae 9 Dhela Alangium salviifolium Cornaceae 10 Harsingar Nyctanthes arbor-tristis Oleaceae Medicinal 11 Jirhul Indigofera pulchella Fabaceae 12 Kamini Murraya koenigii Rutaceae 13 Kanod Carissa opaca Apocynaceae 14 Kathber Ziziphus xylopyrus Rhamnaceae 15 Masondha Croton oblongifolius Euphorbiaceae 16 Murabba Agave americana Agavaceae 17 Nimbu Citrus medica Rutaceae Medicinal 18 Putus Lantana camara Verbenaceae 19 Rendi Ricinus communis Euphorbiaceae 20 Sharifa Annona squamosa Annonaceae 21 Sindur Vitex negundo Verbenaceae D.CLIMBERS 1 Amarbel Tinospora cordifolia Menispermaceae Medicinal 2 Ratend Combretum decandrum Combretaceae 3 Ratti Abrus precatorius Fabaceae Medicinal 4 Shatawar Asparagus racemosus Asparagaceae Medicinal E.GRASS 1 - Imperata cylindrica Poaceae 2 - Cymbopogon martini Poaceae 3 Choranth Heteropogon contortus Poaceae 4 Dub grass Cynodon dactylon Poaceae 5 Khus-khus Vetiveria zizanioides Poaceae 6 Munj Saccharum munja Poaceae
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 108 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Agricultural Land
The agriculture in the area is predominantly rain-fed with predominant Kharif crop as paddy followed by Maize and Pigeon Pea. During Rabi, Mustard is the main crop followed by Wheat Lentil and Chick Pea. The agricultural is poor due to lack of irrigation. The season wise major crops and productivity (kg/ha) in the area is given in Table 3.26.
Table 3.26. Agricultural pattern and productivity in the area SN Kharif Crop Productivity SN Rabi Crop Productivity (July - Sept) (kg/ha) (Dec. - April) (kg/ha) 1 Paddy 1542.3 1 Mustard 242.7 2 Maize 1644.4 2 Wheat 1025.2 3 Pigeon Pea 508.6 3 Lentil 779.8 4 Chick Pea 889.8 Source : Agriculture Contingency Plan - Bokaro
Forest Vegetation
There are some stretches of forest within the study area as marked in Drg. No. MEC/11/S2/E24P/02. These forests are classified as Moist Peninsular Valley Sal Forests, sub- group of Northern Tropical Moist Deciduous Forests. In some areas, Dry Deciduous Scrub Forests have developed due to biotic influences. The forests in general in the area are under high biotic influence and are under degraded state. There is stretch of Protected Forest along the southern bank of Damodar River about 2 km north of the steel plant.
The PF along the southern bank of Damodar River is mostly degraded with scanty tree and shrub growth due to extreme biotic pressure. The forest is growing on small hillocks. The ground vegetation is dominated by lantana. The tree height in good patches >7m and girth is > 60cm The phyto-sociological features of the forest areas are shown in Table 3.27. Butea monosperma (Palas) is the most dominant species followed by Bombax ceiba (Semal), Lagerstroemia parviflora (Sidha), Madhuca indica (Mahua) and Alangium salviifolium (Dhela). The species diversity of the forest is 1.01i.e. quite low.
Table 3.27. Frequency Density of Protected Forest (PF) Along Damodar River SN Plant species No. of Quadrat (10m x 10m); Tree Height > 10m; Girth > 75cm 1 2 3 4 5 6 7 8 9 10 Tot. RF RD IVI Sp. Div 1 Lagerstroemia parviflora 1 0 0 1 0 0 0 0 1 0 3 34.6 47.9 82.6 2 Madhuca Indica 0 0 0 1 1 0 0 0 0 0 2 13 6 19 3 Butea monosperma 4 6 4 6 1 4 2 5 1 3 36 9 4 13 1.01 4 Bombax ceiba 2 2 1 1 1 0 0 0 0 1 8 43 71 114 5 Alangium salviifolium 0 0 0 0 0 1 0 0 0 1 2 26 16 42 Total 7 8 5 9 3 5 2 5 2 5 51 9 4 13
Waste land
Wasteland has developed in the areas where the soil conditions are poor and under high biotic pressure. All such areas are either without any vegetation or are covered with species like
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 109 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Calotropis spp, Croton sp., Ziziphus sp., Leonotis sp., Xanthium straumarium, Parthenium hysterophorus, Lantana camara, Jatropha gossypiifolia, Argemone mexicana etc.
Vegetation in and around Settlements
Near the villages, the common species are those which are useful to the human beings. The species commonly found are given in Table 3.28.
Table 3.28. List of common trees/shrubs growing in and around Settlements Sl. Vernacular Name Botanical Name Family Remarks No. 1 Aam Mangifera indica Anacardiaceae Economic 2 Amada Spondias pinnata Anacardiaceae Economic 3 Amaltas Cassia fistula Fabaceae Ornamental 4 Aonla Phyllanthus emblica Phyllanthaceae Medicinal 5 Bans Bambusa arundinacea Poaceae 6 Bans Dendrocalamus strictus Poaceae 7 Bargad Ficus benghalensis Moraceae 8 Bel Aegle marmelos Rutaceae Medicinal 9 Ber Ziziphus jujuba Rhamnaceae Economic 10 Chakundi Cassia siamea Fabaceae Ornamental 11 Champa Plumeria rubra Apocynaceae Ornamental 12 Chhatian Alstonia scholaris Apocynaceae Medicinal 13 Druping Ashok Polyalthia longifolia Annonaceae Ornamental 14 Gambhar Gmelina arborea Verbenaceae Economic 15 Gular Ficus glomerata Moraceae 16 Gulmohar Delonix regia Fabaceae Ornamental 17 Harsingar Nyctanthes arbor-tristis Oleaceae Medicinal 18 Imli Tamarindus indica Fabaceae Economic 19 Jamun Syzygium cumini Myrtaceae Medicinal 20 Kala Siris Albizia lebbeck Fabaceae Ornamental 21 Kamani Murraya koenigii Rutaceae 22 Karanj Pongamia glabra Fabaceae Economic 23 Kathal Artocarpus heterophyllus Moraceae Economic 24 Khajur Phoenix acaulis Arecaceae Economic 25 Mahua Madhuca Indica Sapotaceae Economic 26 Neem Azadirachta indica Meliaceae Medicinal 27 Nimbu Citrus medica Rutaceae Medicinal 28 Pipal Ficus religiosa Moraceae 29 Sajan Moringa oleifera Moringaceae Medicinal 30 Semal Bombax ceiba Malvaceae Economic 31 Sharifa Annona squamosa Annonaceae 32 Tad Borassus flabellifer Arecaceae Economic 33 Teak Tectona grandis Verbenaceae Economic 34 Yellow Kaner Thevetia peruviana Apocynaceae Medicinal
Wild life and avifauna
There is only one small forest patch in the study area. Due to high biotic pressure the forests are under degraded stage. There is not much wildlife in the study area as there is very little forest cover in the study area. The common wild life found in the study area are given in Table 3.29 and Table 3.30
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 110 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.29. List of animal species in the study area Sl. Local Name English Name Scientific Name WPA Schedule No. Mammals 1 Lomdi Indian Fox Vulpes bengalensis II 2 Siyar Jackal Canis aureus II 4 Neula Common Mongoose Herpestes edwardsii II 5 Navela Indian Porcupine Hystrix indica IV 6 Badodi Shortnosed fruitbat Cynopterus sphinx V 7 Billi Jungle Cat Felis chaus II 8 Gilahari Squirrel Funambulus palmarum IV 9 Khargosh Indian hare Lepus nigricollis IV 10 Bandar Rhesus Macaque Macaca mulatta II 11 - Barking Deer Muntiacus muntjak III 12 - Indian Field Mouse Mus booduga V 13 Langur Common Langur Presbytis entellus II 14 Mus Common house Rat Rattus rattus V Reptiles 1 Dhaman Yellow Rat Snake / Ptyas mucosa II 2 Chandra-boda Russel’s Viper Vipera russelli II 3 Laudoga Oriental Whip Snake Ahaetulla prasina IV 4 Cobra Cobra Naja naja II 5 Dendu saap/ Jol Dhora Checkered Keelback Xenochrophis piscator IV 6 Babhani Common skink Mabuya carinata - 7 Endua Common garden lizard Calotes versicolor - 8 Chipkali House lizard Hemidactylus flaviviridis -
Table 3.30. List of common birds found in the region Sl.No. English Name Scientific Name WPA Schedule 1 Common Mynah Acridotheres tristis IV 2 White Breasted Water Hen Amaurornis phoenicurus IV 3 Pond Heron Ardeola grayii IV 4 Crow Pheasant Centropus sinensis IV 5 Pied Mynah Sturnus contra IV 6 Blue Rock Pegion Columba livia IV 7 Indian Roller Coracias benghalensis IV 8 Jungle Crow Corvus marorhynchos IV 9 Common Crow Corvus splendens V 10 Black drongo Dicrurus macrocercus IV 11 Koel Eudynamis scolopacea IV 12 Red Jungle Fowl Gallus gallus IV 13 Pariah Kite Milvus migrans IV 14 Black Headed Oriole Oriolus xanthornus IV 15 House Sparrow Passer domesticus - 16 Rose Ringed Parakeet Psittacula krameri IV 17 Spotted Dove Streptopelia chinensis IV 18 Common Babbler Common Turdoides caudatus IV 20 Jungle Babbler Turdoides striatus IV 21 Red Vent Bulbul Pycnonotus cafer IV 22 Cattle Egret Bubulcus ibis IV 23 Red Naped Ibis Pseudibis papillosa IV 24 Purple Sunbird Nectarinia asiatica IV 25 Crow Pheasant Centropus sinensis IV 26 Tree Pie Dendrocitta vagabunda IV
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Aquatic Life
Damodar River flows from West to East in the study area. Damodar is one of the major rivers of Jharkhand. The River water before and after the confluence of treated effluent discharge from the plant on visibly appears meso-trophic in condition.
Garga Reservoir is one of the major man made water reservoirs in the area (ES5), the reservoir water due to stagnation shows good plankton growth and appears to be Eutrophic. The common plankton found in the River Damodar and Garga reservoir are shown in Table 3.31. The fishes found in the area are given in Table 3.32. The common hydrophytes growing in the water bodies are given in Table 3.33.
Table 3.31. List of common planktons in study area SN. Group / Taxa / Family Genus / Species Phytoplankton 1 Bacillariophyceae Navicula sp Nitzschia sp. 2 Chlorophyceae Chlorella sp Cladophora Closterium sp Gonium sp Microspora sp Ulothrix sp Pediastrum Spirogyra Scenedesmus Volvox sp
3 Cyanophyceae
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5 Ostrachoda Cypris sp Gastrocypris sp
Table 3.32. List of Fishes found in the study area SN. Local Name English Name Scientific Name 1 Balia Wallago Wallago attu 2 Bhakura Catla Catla catla 3 Mangur Walking catfish Clarias batrachus 4 Rohu Rohu Labeo rohita 5 Garai Snakehead Channa punctata 6 Pothia Pothia Puntius ticto
Table 3.33. Common hydrophytes in the study area SN. Scientific Name Family 1. Typha sp Typhaceae 2. Trapa sp Onagraceae 3. Nelumbo nucifera Nymphaceae 4. Valisneria sp Hydrocharitaceae 5. Ipomea sp Convolvulaceae 6. Hydrilla sp Hydrochorideae 7. Eichhornea crassipus Pontederiaceae 8. Potamogeton sp Naiadaceae 9. Nymphea sp Nympheaceae 10. Lemna sp Lemnaceae
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Steel plays a very important role in the society in countless things, demand of steel is increasing in day to day life. The iron and steel industry is one of the most important industries in India. During 2014 through 2015, India was the third largest producer of raw steel and the largest producer of sponge iron in the world. National steel policy – 2005 has the long-term goal of having a modern and efficient steel industry of world standards in India. The focus is to achieve global competitiveness not only in terms of cost, quality, and product-mix but also in terms of global benchmarks of efficiency and productivity. In this perspective, BSL is going for modernization-cum-expansion of the steel plant located at Bokaro Steel city, Jharkhand.
The growth of industrial sectors and infrastructure developments in villages and towns are bound to create its impact on the socio-economic aspects of the local population. The impacts may be positive or negative depending upon the developmental activities. To assess the impacts on the local people, it is necessary to study the existing socio-economic status of the local population, which will be helpful for making efforts to further improve the quality of life in the study area. To study the socio-economic aspects of people in the study area around the BSL project site, the required data has been collected from various secondary sources and supplemented by the primary data.
The baseline socio economic data including demographics of the study area, economic situation of the area, and general perception of the people residing within 10 km of the project site has been conducted by an accredited team of experts and furnished by BSL.
Methodology adopted for the Desktop Study
The methodology adopted for the study is based on the review of secondary data, such as Census of India 2011, Jharkhand Administrative Atlas for the parameters of demography, occupational structure of people within the study area of 10-km radius around the project site.
Socio-economic environment includes description of demography, basic amenities housing, water facilities, health care services, transportation and education. Information on the above said factor has been collected to define the socio-economic profile of the study area (10 km radius), which is also a part of Environmental Impact Assessment study for the proposed activities.
Administrative Details
The 10 km radius study area is almost entirely within Bokaro district of Jharkhand. A very small portion of the study area’s southern side falls within Purulia District of West Bengal {the Jharkhand – West Bengal Border is ~9.5 km south of the plant’s southern boundary}. BSL is located on the site formerly a village by the name of Maraphari. In the study area, there were total 25 villages and 6 towns/ urban settlements in the study area. The list of villages and towns identified in the study area is listed in Table 3.34.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 114 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.34. List of Towns & Villages within Study Area Sn Village/town name Settlement Type Sn Village/town name Settlement Type 1. Mongo Rangamati Rural 17. Tanr Mohanpur Rural 2. Nawadih Rural 18. Jena (CT) Urban 3. Khunta Rural 19. Tanr Balidih (CT) Urban 4. Mungo Rural 20. Dharampura Rural 5. Karmatanr Rural 21. Narayanpur Rural 6. Sijhua (CT) Urban 22. Sijhua Rural 7. Dugda (CT) Urban 23. Chainpur Rural 8. Nawadih Rural 24. Satanpur Rural 9. Rangamati Rural 25. Ghatiali Rural 10. Gomi Karmatanr Rural 26. Sunta Rural 11. Birsa Rural 27. Sonabad Rural 12. Rohidih Rural 28. Sijhua Rural 13. Mungo Rural 29. Mohanpur Rural 14. Rangamati Rural 30. Bandhgora (CT) Urban 15. Tantri Rural 31. Chas Urban 16. Khutri Rural
Existing Socio-Economic Scenario
A brief profile of the Bokaro District as per Census 2011 is given in Table 3.35
Table 3.35. Brief profile of Bokaro district Item Year Unit Bokaro Population 2062330 Male 1072807 (52.02%) Female 989523 (47.98%)
Rural 2011 No. of people 1078686 (52.3%) Urban 983644 (47.7%)
Schedule Castes 299227 (14.51%) Schedule Tribes 255626 (12.4%) No. of people/sq. Population density 2011 715 km Literates 1,273,520 Male 2011 No. of people 759,088 Female 514,432 Average Literacy rate 72.01 Male 2011 % of population 82.51 Female 60.63 Sex Ratio 2011 Per 1000 people 922 Workers Total workers 685368 (33.23%) Main workers 380304 (18.44%) 2011 No. of people Marginal workers 305064 (14.79%)
Non-workers 1376962 (66.77%) Source:www.censusindia.gov.in
The information on socio-economic aspects of the study area has been compiled from secondary sources, which include various public offices as indicated in the above section. The sociological aspects of this study include human settlements, demography, social such as
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Population Distribution
Demographic pattern of the area is given in Table 3.36.
Table 3.36. Demographic Profile of Population in the Area (2011 Census) SN. Population Data Radial Distance from Plant Centre in km (Total 1-10 km) 1 Area sq km 314 2 Number of House Holds 107667 3 Total Population 544934 4 Total Males 287306 5 Total Females 257628 6 Female per 1000 Males 897 7 Rural Population 71155 8 Urban Population 473779 9 % Rural Population 13 10 Population Density (Nos/sq. km) 1735 11 Schedule Cast Total Population 63948 12 Schedule Cast Male Population 33571 13 Schedule Cast female Population 30377 14 Schedule Tribe Total 63198 15 Schedule Tribe Males 31945 16 Schedule Tribe Females 31253 17 Total Literates 382629 18 Literates Males 222232 19 Literate Females 160397 20 Literacy Percent (%) 70.21 21 Literacy Percent (%) Males 77.35 22 Literacy Percent (%) Females 62.25 23 Total Illiterates 162305 24 Male Illiterates 65074 25 Female Illiterates 97231
The above table indicates the following demographic features about the study area and up to 10 km of the project site.
x There are about 5,44,934 persons in the 10 km study area. There are about 897 females per 1000 males. x The population density up to 1-10 km is ~1735 person/sq km, x The study area of 10 km radius consists of both rural and urban population but urban population is much higher than rural. x Literacy rate is 70.21%. x Scheduled Tribes make up ~11.6% of the total population. Scheduled Castes make up ~11.7% of the total population CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 116 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Occupational Structure
The occupational structure of residents in the study area is studied with reference to main workers, marginal workers and non-workers. The main workers include 10 categories of workers defined by the Census Department consisting of cultivators, agricultural laborers, those engaged in live-stock, forestry, fishing, mining and quarrying; manufacturing, processing and repairs in household industry; and other than household industry, construction, trade and commerce, transport and communication and other services.
The marginal workers are those workers engaged in some work for a period of less than six months during the reference year prior to the census survey. The non-workers include those engaged in unpaid household duties, students, retired persons, dependents, beggars, vagrants etc.; institutional inmates or all other non-workers who do not fall under the above categories.
As per 2011 census altogether the main workers work out to be 28.47% within 10 km radius area. The marginal workers constitute only 1 % within 10 km radius of the total population. The non-workers constitute about 71.52% within 10 km radius. The occupational structure of the study area is shown in Table 3.37.The marginal workers can possibly be the pool for unskilled labour for the plant.
Table 3.37. Occupational Structure in the Area (2011 Census) Sl. Population Data Nos. or % of Total Population No. in Study Area 1 Total Population 544934 2 Total Worker (Main + Marginal) Population 155188 3 Total worker male (main +marginal ) population 127965 4 Total worker female (main +marginal ) population 27223 5 Total Working Population % to Total Population 28.47% 6 Total Working Male % to Male Population 44.53% 7 Total Working Female % to Female Population 10.57% 8 Main Workers Total 115925 9 Main Workers Male 100897 10 Main Workers female 15028 11 Total Cultivators 2597 12 Main Agricultural Labour 2026 13 Main Household Industry Labour Total 3277 14 Main Other Workers Total 108030 15 Marginal Worker Total 5189 16 Total Marginal Workers % to Population 1% 17 Non Working Population Total 389746 18 Non Working Population Male 159341 19 Non Working Population Female 230405 20 Total Non-workers % to Total Population 71.52% 21 Male Non-workers % to Male Population 55.46% 22 Female Non-workers % to Female Population 89.43%
From the above table it is to be noted that “Main Other Workers” constitute ~93.7% of “Main Workers”. This very high proportion of “Main Other Workers” indicates that most of the workers are employed in industry, commerce and allied activities.
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General:
The total study area (10 km) falls in Bokaro district (Jharkhand). The infrastructure and amenities available in the district denotes the economic well-being of the region. The area as a whole possesses moderate level of infrastructural facilities.
A review of infrastructure facilities available in the area has been done based on the information available at the websites of Directorate of Economics and Statistics, Department of Medical and Family Welfare, National Health Mission, Medical Health and Family welfare Department, Government of Jharkhand and field survey. The geographical area of Bokaro district is about 2883 km2. Total number of villages in the district is635.
Educational infrastructure
The educational infrastructure has been evaluated with respect to some key infrastructural issues such as number of schools of various grades and schools with basic amenities such as tap water supply, toilet facilities and electricity.
Official statistics show the presence of all levels of schools for elementary, secondary and higher secondary education. However, the numbers of schools for various levels vary. As per the District Education Officers Bokaro district the education facilities in the district in general and in particular in the blocks falling in study area is more or less adequate fulfilling the Government of India norms, i.e. availability of primary school within one kilometer of habitation, middle school within 3 km of habitation and high school and secondary education within 5 km of habitation. The above requirements are almost met in the area considering the fact that a middle school, high school and secondary school also have the lower level classes, i.e. from standard one onward standards.
Table 3.38. Presence of school in the study area (gradewise) Block name Pr. Pr.+U.P. Pr.+UP+ Pr.+ U.P.+ U.P U.P.+ U.P.+ Sec. H.S. Sec.+ Sec+H.S. Sec. Sec. Sec+ H.S H.S. Bermo 58 51 5 18 0 3 0 2 2 2 Chandrapura 89 56 3 07 0 2 2 7 2 0 Chandankiyari 176 86 1 11 0 4 1 3 2 1 Gomia 202 104 4 13 0 7 1 7 2 1 Nawadih 145 61 0 07 0 3 1 2 1 1 Petarwar 163 73 0 11 0 1 2 4 3 1 Chas 323 251 28 29 0 14 3 11 13 1 Jaridih 98 64 0 07 0 1 1 5 2 1 Kasmar 119 47 0 08 0 1 1 4 1 1 Total 1373 793 41 111 0 36 12 45 28 9 Source: The DISE Report, 2015-16
The data on these basic amenities shows that while toilets are present in most of the schools across the district, the access to tap water and the coverage of electricity is very limited
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 118 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.39. Schools with tap water, toilets and electricity facilities Block name Schools with Schools with Schools with tap water (%) toilets (%) electricity (%) Bermo 35 93 70 Chandrapura 16 93 28 Chandankiyari 1 98 9 Gomia 8 91 22 Nawadih 0 93 10 Petarwar 0 91 12 Chas 12 92 32 Jaridih 4 95 19 Kasmar 1 99 10 Source: The DISE Report, 2015-16
To develop the society through education, Steel Authority of India Limited is supporting over 145 schools in the steel townships to provide modern education to more than 55,000 children and is assisting over 636 Government schools in Bhilai and Rourkela with about 75,000 students by providing Mid-day meals in association with Akshya Patra Foundation. 21 Special Schools (Kalyan & Mukul Vidyalayas) are benefitting over 3600 BPL category students at Integrated Steel Plant locations with facilities of free education, mid-day meals, uniform including shoes, text books, stationary items, school bag, water bottles and transportation in some cases. 335 number of Tribal children are getting free Education, Accommodation, Meals & Uniforms, textbooks, etc. at Saranda Suvan Chhatravas, Kiriburu; RTC Residential Public School, Manoharpur; Gyanodaya Chhatravas, BSP School Rajhara, Bhilai; Kalinga Institute of Social Sciences, Bhubaneswar; Gyanjyoti Yojna, Bokaro. Over 2100 school students been awarded annual scholarship in plant peripheries.
Irrigation Facilities in the District
The details of irrigation source & facility are given in the following table:
Table 3.40. Irrigation source &facilities Percentage of farmers land having access to irrigation 20.68 Average irrigation coverage for farmers having access, acre/family 0.64 Source of Irrigation Well Lift Irrigation Pond Others %age of farmers 65.56 26.67 4.44 3.33 Source: District irrigation plan, Bokaro
The fluctuating trend in rainfall over the past few years coupled with less area under assured irrigation are primarily responsible for the large extent of mono-cropped area in the district. There are no perennial streams and drains in the district. Due to incidence of bed rock near the surface, the ground water resources are limited. The irrigation potential is mainly confined to:
x Dug wells tapping shallow groundwater. x Tanks and Check-dams for collecting surface run-off water. x Low land collecting tail-water from drains.
The coverage of irrigated area as per source of irrigation is depicted below:
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Health Care system in Bokaro
Given the severity of pollution and poor health conditions of people as reported to the researchers, the available health infrastructure, along with qualified health staff at the facilities is critical. Indian Public Health Standards (IPHS) stipulates the minimum requirements of these public health facilities. According to IPHS, in the rural areas with plain grounds, there should be at least one sub-centre for every 5,000 people, one PHC per 30,000 people, and one CHC per 1,20,000 people.
In Bokaro district, the number of CHCs when considered with regard to the corresponding rural or urban population, are more or less as per the IPHS standards. However, it is the HSCs and PHCs which are way short of requirement. Considering the rural population of the district, on an average, there is just one HSC per 14,000 people and one PHC per 98,000 people.
Table 3.41. Health Care systems Block name Total Total Total Subdivisional District HSCs PHCs CHCs hospitals hospital Rural areas Chandankiyari 12 2 1 Gomia 20 3 1 Nawadih 14 3 1 3 1 Petarwar 13 1 1 Jaridih 08 1 1 Kasmar 09 1 1 Urban areas Bermo 16 1 1 Chandrapura NIL NIL NIL Chas 24 4 1 Source: Indicative Plan District Mineral Foundation, Bokaro
The gaps or deficits in the health sector in the mining-affected areas shows deficits both in infrastructure as well as resources. The key deficits include:
a. Inadequate human resources – doctors, nurses and frontline health workers. b. Inadequate number of primary healthcare facilities.
Electrification
The following table gives the status of electrification of the villages (block-wise) of Bokaro district which are covered under Rajiv Gandhi Grameen Vidyutikaran Yojana (RGGVY) scheme.
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Further, a needs assessment study was also carried out in the study area. The details of the Need assessment study is attached as Annexure 3.3.
3.6.10 Baseline status of Existing plant
To establish the baseline scenario for different environmental components in the project site data generation has been done with respect to the followings: x Air emissions including stack emissions from the existing units, fugitive Emissions and Work zone air quality x Work zone noise levels x Effluent Quality x Solid waste and Hazardous waste BSL is submitting the EC compliance status of the steel plant periodically to JSPCB and MoEFCC reg. centre. The certified EC compliance status is enclosed as Annexure 2.1(e).
3.6.10.1 Air Emissions
Stack Emissions:
Stack emissions monitoring is being conducted regularly at regular intervals by BSL. The results of the stack monitoring for major stacks recently conducted are given in Table 3.43(a).The results of work zone (fugitive emissions) near all major units are given in Table 3.43(b).
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Table 3.43. (a): Stack emissions from Different Units of BSL Name of the Stack Height of Diameter of Pollution Date of the Production Flow rate of Parameters Plant connected to the stack the stack Control unit monitoring of the unit, the flue gas (whichever are applicable) (Name of the (m) (m) provided during the (NM3/Hr) unit) period of monitoring 1 2 3 4 5 6 7 8 9 Blast Furnace Particulate SO2 NOx HC CO (Space dedusting) matter (PM) (mg/Nm3) (mg/Nm3) Kg/TDCP & Stoves (mg/Nm3) (Vol./vol.) BF-1 Chimney-1 50 8.2m. Wet scrubber Under Capital Repair BF-2 Chimney-2 50 8.2m. Wet scrubber 19.05.18 6431 T 274660 85.75 - - - - BF-3 Chimney-2 50 8.m. Wet scrubber - - - BF-4 Chimney-3 50 8.2 m. Wet scrubber 09.05.18 6801 T 280709 80.26 - - - - BF-5 Chimney-3 50 8.2m. Wet scrubber - - BF Stoves-2 Chimney-2 70 3.5 m. - 24.05.18 3708 T 106364 24.97 80.20 36.12 - 0.48% BF Stoves-4 Chimney-4 70 3.5 m. - 30.05.18 2418 T 110352 27.06 74.82 30.96 - 0.32% 3 3 3 3 Standards : Charging side chimney- PM - 100 (Units: mg/Nm ) BF Stoves – PM- 50 mg/Nm , SO2- 250 mg/Nm , NOX- 150 mg/Nm CO- 1% v/v (Max) x BF#1 is connected to chimney no-1 , BF#2&BF#3 are connected to chimney no-2 and BF#4&BF#5 are connected to chimney no-3 Each BF stove is connected to corresponding chimney No. Refractory Material plant Kiln-1 Stack – 1 80 3.3 Electro Static 05.05.18 11.25 T/hr 147625 142.14 82.16 - - - Precipitator (ESP) Kiln-2 Stack – 1 80. 3.3 ESP 17.05.18 10.85 T/hr 148772 145.06 74.32 - - - Kiln -3 Stack - 2 80 3.3 ESP 01.05.18 11.05 T/hr 150062 146.69 76.30 - - - Kiln-4 Stack – 2 80 3.3 ESP 15.05.18 11.25 T/hr 149705 148.42 77.00 - - - Kiln-5 Stack – 3 80 3.3 ESP Shut down - - - Kiln-6 Stack – 3 80 3.3 ESP 22.05.18 11.25 T/hr 144826 26.16 66.30 Standards: PM - 150 , SO2 - , NOx - , CO - (Units: mg/Nm3) Monitoring values for corresponding Kiln duct. Two Kilns through individual Ducts are connected to a common stack. SMS – 1 Conv. – 1( NB) Stack – 1 100 4.3 Wet scrubber Under Shutdown - - Conv. – 1( BL) Stack – 1 100 4.3 Wet scrubber - -
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Name of the Stack Height of Diameter of Pollution Date of the Production Flow rate of Parameters Plant connected to the stack the stack Control unit monitoring of the unit, the flue gas (whichever are applicable) (Name of the (m) (m) provided during the (NM3/Hr) unit) period of monitoring Conv. – 2( NB) Stack – 1 100 4.3 Wet scrubber 10.05.18 - 108235 26.87 - - - - Conv. – 2 (BL) Stack – 1 100 4.3 Wet scrubber 10.05.18 - 240469 240.17 86.17 65.72 Conv. – 3(NB) Stack – 1 100 4.3 Wet scrubber 21.05.18 - 100352 30.46 - - - - Conv. – 3(BL) Stack – 1 100 4.3 Wet scrubber 21.05.18 - 252672 248.51 78.69 70.34 - - Conv. – 4(NL) Stack – 1 100 4.3 Wet scrubber 29.05.18 - 101802 29.13 - - - - Conv. – 4 (BL) Stack – 1 100 4.3 Wet scrubber 29.05.18 248360 250.44 90.38 58.85 - - Conv. – 5(BL) Stack – 1 100 4.3 Wet scrubber Under Modernization SMS-2/CCS LF- 2 80 1.25 Bag filter 31.05.18 - 108436 24.97 - - - - Standard : PM - 300, SO2 - , NOx - , CO - * Monitored in individual ducts(of dia 2.5 m each) from corresponding converters. SMS-2/CCS Stack -PM #50mg/Nm3 (Units: mg/Nm3) All ducts are connected to a common stack Coke Oven Batt. # 1 Stack – 1 100 3.5 - 22.05.18 - 142324 24.82 216.02 64.96 - 1.72 Batt. # 2 Stack – 2 100 3.5 - 07.05.18 - 143321 32.84 208.15 89.92 - 1.82 Batt # 3 Stack - 3 100 3.5 - 12.05.18 - 144071 24.81 240.53 90.66 - 1.82 Batt. # 4 Stack – 4 100 3.5 - 26.05.18 - 145337 29.06 230.15 105.1 - 1.99 Batt. # 5 Stack – 5 100 3.5 - 18.05.18 - 148308 32.62 210.35 108.6 - 2.05 Batt # 6 Stack - 6 100 3.5 Shut Down for Cold Repairs Batt. # 7 Stack – 7 100 3.5 - 22.05.18 - 142320 24.81 216.04 64.93 - 1.71 Batt. # 8 Stack – 8 100 3.5 Under Rebuilding Standard: PM - 50, SO2 - 800, NOx - 500, CO – 3.00 Kg/TDCP, HC - (Units: mg/Nm3) Sinter Plant Sinter Machine Duct-A 100 * 3.5 Batt. cyclone 03.05.18 - 395702 145.8 86.11 56.72 - - -1 Duct-B 3.5 Batt. cyclone 16.05.18 - 390625 143.6 - - - - Sinter Machine Duct-A 3.5 Batt. cyclone 08.05.18 - 382005 146.8 88.66 17.52 - - -2 Duct-B 3.5 Batt. cyclone 08.05.18 - 380660 147.5 - - - - Sinter Machine Duct-A 3.5 Batt. cyclone 23.05.18 - 398325 142.6 78.70 45.15 - - -3 Duct-B 3.5 ESP-6 14.05.18 - 325740 85.35 - - - - Standard: PM - 150 , SO2 - , NOx - (Units: mg/Nm3) * All three Sinter M/c Exhaust are connected to a common single stack of 100m height
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 123 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.43. (b): Fugitive Emissions Status (Work Zone) Name of Date & time Parameters (as applicable) Sn Loc. of Station Unit of monitoring PM10* SO2* NOx* CO* Pb* 1. Sinter Plant Hammer crusher 28.05.18 1452 38.44 30.68 - - 2. CCS Tandish area 05.05.18 1932 39.42 34.14 - - 3. Coke Oven Tar distillation plant 07.05.18 1707 39.14 41.32 - - 4. Coke Oven BRP-1 02.05.18 744 56.20 23.42 - - 5. BF # 2 Cast house no.3 05.05.18 1828 52.60 39.79 4824 0.516 6. SMS-2 Converter - 1 01.05.18 2818 54.18 27.16 4752 0.502 7. RMHP Tippler # 2 25.05.18 1675 39.65 40.32 - - 8. CRM HDGL 15.05.18 514 30.48 22.60 - - 9. HRCF Piler area 18.05.18 442 34.02 20.76 - - 10. S. Mill Soaking pit 19.05.18 564 47.61 27.43 - - 11. BF # 2 Charging side 23.05.18 1895 34.18 24.48 - - *all values in μg/m3 Fugitive emission Standards: Parameters PM10 SO2 NOx CO Pb Blast Furnace 4000 200 150 10000 2 (Converter floor) SMS(BOF) 4000 200 150 1000 (1 hrly) 2 (Cast house)
Fugitive Emissions from Coke Oven Batteries were monitored and the results are given in Table 3.43(c). The results indicate that all the parameters except few results are well within the MoEFCC norms for existing Coke Oven.
Table 3.43. (c): Fugitive Emissions from Coke Oven battery Charging PLD PLL PLO Battery area Other units in coke Battery No. emission (%) (%) (%) (top of the battery)* oven plant* (sec/charge) Battery 1 3.62-4.88 0.36-0.72 1.26-2.98 42-44 402 237 Battery 2 3.80-6.33 0.48-0.60 0.72-2.89 39-42 895 1374 Battery 3 6.81-9.46 0.50-0.88 1.32-3.21 67-71 982 502 Battery 4 3.98-5.61 0.48-0.72 1.26-2.17 48-49 522 302 Battery 5 7.98-9.05 0.60-0.96 1.60-2.71 46-48 1535 1045 Battery 6 Under Cold Repair - - Battery 7 3.62-4.88 0.36-0.72 1.26-2.98 42-44 402 237 Battery 8 Under Rebuilding - - Standards EP(Act) Norm for 5 1 4 16 Greenfield site 5000** 2000** Rebuilt Batteries 10 1 4 50 Existing Batteries 10 1 4 75 **values in ng/m3
3.6.10.2 Work Zone Noise Levels
Work zone noise levels were monitored and the monitoring details in different units ofBSL are given in Table 3.44. From the results it can be seen that the noise levels are below the norms as prescribed by OSHA norm for eight hours.
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 124 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.44. (a): Work Zone Noise levels Date of Plant Location Noise Level Monitoring Leq dB(A) Near Sinter M/C # 1 84.5 Near Sinter M/C # 2 84.2 14.04.18 Sinter Plant Near Exh. House gate 90.8 ESP# 6 (GF) 81.8 Near Battery Cyclone -1 & 2 86.8 & 88.6 Tuyer's area 84.8 17.04.18 BF # 3 Cast House no. 6 88.2 Near GCP 87.8 Mixer floor, Near Mixer – 1 83.4 Circulating pump – 3A&3C 82.1 & 85.9 SMS # 2 Near ID Fan # 1&2 86.2 & 89.6 10.04.18 Converter No- 1 (Non Blowing) 81.0 SRU (7.8 mtr.& GF) 88.5 & 82.7 TCM area - 3 & 4 87.1 & 89.0 CCS Near Caster # 1, Strand # 1 87.0 Near Caster # 1, Strand # 2 78.0 Mixer floor - 2 79.9 Converter # 2 & 3 83.7 & 81.9 30.04.18 SMS # 1 Pit side area 72.1 Feed pump area control room 79.2 Exhauster # 2 & 3 89.6 & 88.5 Near Exhauster # 2 92.3 Opposite Batt # 4, on Road 74.7 03.04.18 CO & BPP Hammer Crusher Bldg. 82.3-85.9 PGC area 81.3-88.1 19.04.18 HRCF, Line-2 Piler area cabin 83.5 Flying shear cabin 86.1 30.04.18 RMHP Near Stacker # 2 65.9 Lime Screening Plant 68.0-70.3 Tippler control room 80.8 Near reclaimer – 6 81.7 19.04.18 HSM Coiler # 1 86.3 Laminar cooling area 83.3 Near finishing stand # 8 &6 84.6 & 85.4 Near shearing stand 87.8 Near roughing stand 4 & 5 84.5 & 84.8 Near R. R. stand 87.4 Near reheating furnace # 2&1 86.4 & 85.2 27.04.18 CRM-1&2, TM - 2 Uncoiler area 87.6 Between stand 1&2 89.3 27.04.18 CRM 1&2, PL-2 Acid tank area 85.4 Coiler area 87.6 09.04.18 Slabbing Mill Shearing stand area 89.8 Slab yard area 79.2 26.04.18 CRM-3, ECL Uncoiler area 81.9 Cleaning section 79.7 Coiler area 81.2 CRM-3, PLTCM Uncoiler area 76.5 Welding area 89.7 Cleaning section ( Acid tank area) 83.7-88.6 Coiler area 89.6
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 125 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.44. (b): Noise level at the Boundary of the Plant Date of Monitoring: 06.04.18 Noise Level dB(A) Noise Level dB(A) Location (Day time) (Night time) Gate No - 1 62.1 44.9 Gate No – 3 (New) 54.6 42.9 Gate No – 4 65.0 40.8 Gate No – 5 57.7 39.2 Gate No – 6C 61.4 38.5 Gate No – 8 60.6 40.5 Gate No – 9 60.7 41.2 Gate No – 11 59.4 41.9 CPCB Stds. (Ind.) 75 70
3.6.10.3 Effluent Quality
The existing plant is generating effluents at the rate of 550 m3/hr and discharging through 2 no. of drains, called outfalls, into Damodar River after treatment. Damodar River carries the total treated wastewater coming from the plant and transports it back to cooling ponds of BSL to be reused into plant operations.
The effluent quality at the individual out falls, Sewage treatment plant, BOD plant and Effluent water Quality of Individual units are given in Table 3.45, Table 3.46, Table 3.47 and Table 3.48
respectively.
Table 3.45. Quality of various Outfalls at the Boundary line of the plant Parameters (mg/l, except pH and temp.) Monitoring Flow Stream Amm. Date m3/hr Temp. 0C pH TSS Phenol Cyanide BOD COD O&G Nitrogen OF- 1 300 28.3 7.25 42 0.039 0.032 11.32 72 4.58 1.27 23.05.18 OF- 2 250 28.0 7.82 36 0.032 0.020 8.06 68 3.02 0.36 OF- 3 Abandoned Standards: <400C 6.0-8.5 100 1.0 0.20 30 250 50 5.0 Note: Outfall-1: (COBPP, Sinter Plant, TPP, BF, RMP) Outfall-2:(SMS-1, SMS-2 &CCS, Rolling Mills) Outfall-3: (This outfall ceases to exist.)
Table 3.46. Quality of Treated Sewage at Oxidation Pond Outlets Name of STP Parameters (mg/l, except pH and temp.) Date (Oxidation Ponds) Temp. 0C pH TSS BOD COD BGH 28.1 7.15 13 12.5 80 Dhandabra 28.0 6.92 12 10.8 78 15.05.18 Sector -6 27.6 7.35 14 9.6 69 Camp-2 28.4 7.00 10 14.8 115 Sector-12 27.2 7.58 13 9.6 74 Standards: < 400C 6.0-8.5 30 20 250 (as notified in MoEFCC Notification G.S.R. 1265(E) dtd. 13.10.17)
Table 3.47. BOD Plant Effluent Analysis Sn. Location/Source Ammonia Range (mg/L) Phenol Range (mg/L) Cyanide as CN- (mg/L) 1 TST (BOD Plant Inlet) 383-595 159.3-229.2 17.90-36.40 2 CCT (BOD Plant Outlet) 41.1-47.2 0.228-0.441 0.142-0.189
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 126 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 3.48. Plant Outlets Parameters (mg/l, except pH and temp.) Monitoring Outlet Temp. Amm. Date pH TSS Phenol Cyanide BOD COD O&G 0C Nitrogen CO&BPP 27.3 7.68 34 0.282 0.076 14.6 125 5.15 1.23 SP 27.5 6.80 40 0.010 0.008 10.5 70 2.02 0.62 21.05.18 BF 28.5 7.36 44 0.022 0.006 10.5 80 1.69 0.48 Mills 27.8 7.34 42 0.024 0.012 9.8 68 1.80 0.43 SMS 27.9 7.54 36 0.008 0.004 10.9 65 1.35 0.38 6.0- <400C 100 1.0 0.20 30 250 50 5.0 Standards: 8.5
The analysis results of outfalls indicated that all pollutant concentrations are within the limits.
3.6.10.4 Solid Waste
The existing plant generates a number of Solid wastes which is of both Hazardous and non- Hazardous category. Major shops which generate solid wastes are BF, SMS, Coal and coke oven shops and Rolling mills. BSL is recycling most of the wastes generated in the plant. The solid wastes generated from the various shops during 2017-2018 and percentage of utilization is given
in Table 3.49. Table 3.49. Solid waste generation from existing plant (2017-18) Average Solid Waste Quantity (in Tons) Utilization Description Reused/ Mode of Generation Sold Source of use Dumped (%) Recycled transportation Granulated in Slag granulation BF Slag 1537464 530153 993185 plant and used in cement Rail 14126 99.08 making. Mostly utilized in Sinter plant & SMS as well as partly used to BOF slag 406294 352187 6633 Rail 47474 88.32 make bricks by combining with Fly ash BF Flue Dust 45325 45325 0 Utilized in Sinter plant Rail 0 100.00 Mill Scale 67683 67683 0 Utilized in Sinter plant Road 0 100.00 Sold to Refractory /mortar Waste Refractory 5678.47 0 5678.47 Road producers 0 100.00 Ferric Oxide 5995 0 5995 Sold as scrap in packaged bags Road 0 100.00 Utilized in Sinter plant & partly ESP (RMP) dust 13302.2 5040 8262.2 Road 0 100.00 sold Coke Breeze 320326 320326 0 Utilized in Sinter plant Conveyor 0 100.00 BF Sludge 20228.4 0 20228.4 Sold in secondary market Road 0 100.00 BOF Sludge 29548.7 0 29548.7 Sold in secondary market Road 0 100.00 1320714 1019754 61600 Total 2451845.1 (53.87%) (43.62 %) (2.51%) 97.5% Source: Monthly monitoring reports furnished by BSL
The existing solid waste generation is represented in Fig. 3.9(a) and its utilisation for the last three years is shown in Fig. 3.9(b).
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 127 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 3.9.(a): Existing Solid waste generation
BF Flue Dust Mill Waste Refractory 1.8% Scale 0.2% 2.8% BOF slag Ferric Oxide 16.6% 0.2% ESP (RMP) dust 0.5%
Coke Breeze 13.1% BF Sludge 0.8% BF Slag 62.7% BOF Sludge 1.2%
Source: Monthly monitoring reports furnished by BSL
Fig 3.9. (b): Existing Solid waste utilization for last three years Source: Monthly monitoring reports furnished by BSL
3.6.10.5 Hazardous Wastes
Hazardous Wastes generated from BSL, its re-cycling and existing disposal practices are given in the Table 3.50(a).
Table 3.50. (a): Hazardous waste generation from existing plant (2017-2018) HAZARDOUS ANNUAL SOURCE OF STORAGE CATEGORY OF SN TYPE OF DISPOSAL WASTE QTY (T) GENERATION DURATION WASTE 1. Acidic Tar Sludge 1106 Disposed in captive secured land fill on regular basis NIL 13.4 of Schedule – I Spent Vanadium Disposed in captive secured land fill on as & when 2. 0.1 7days 17.2 of Schedule - I Pentoxide generated By Product Disposed in captive secured land fill on as & when 3. Sulphur Sludge 214 plant of Coke 7days 17.1 of Schedule – I generated Ovens 4. Decanter Tar Sludge 933 Partly charged in Coke oven & partly disposed in SLF NIL 13.4 of Schedule – I 5. Tar Muck with Sand 215 Disposed in captive secured land fill on regular basis NIL 13.5 of Schedule – I
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 128 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT HAZARDOUS ANNUAL SOURCE OF STORAGE CATEGORY OF SN TYPE OF DISPOSAL WASTE QTY (T) GENERATION DURATION WASTE 4.1 of Schedule – I 6. Oil & Grease Muck 152 Mills area Disposed in captive secured land fill on regular basis 7days 4.4 of Schedule – I Disposed in captive secured land fill on as & when 7. Asbestos Rope 11 Coke oven area NIL 15.2 of Schedule – I generated 8. Transformer oil 30 KL DNW Sold to authorised buyer within one month of its generation 30days 5.1 of Schedule – I Oil Oil sludge from oil 9. 0.516 regeneration Disposed in captive secured landfill on monthly basis 30days 4.1 of Schedule – I regeneration unit unit 6.3 of Schedule – I, 10. Zinc dross 475 Sold to authorised buyer within one month of its generation 30days 11,12 of Schedule- IV HDGC/CRM 6.2 of Schedule – I, 11. Zinc ash 66.02 Sold to authorised buyer within one month of its generation 30days C-14 of Schedule – II C-12.3 of Schedule Mills/Iron – I 12. Used batteries 1057 Sold to authorised buyer within one month of its generation 30days zone/OG/Traffic C-14 of Schedule – II BOD plant of 35.3 of Schedule – I 13. ETP sludge 1100 Charged in Coke Oven batteries by mixing in coal NIL COBPP Note: HAZARDOUS WASTE AUTHORIZATION REF. No.: HW/D-2219 dtd. 11.11.2016 and is valid up to 31.03.2020 Source: ECD, SAIL-Bokaro Steel Plant
The typical chemical composition of some of the major hazardous wastes generated is presented in Table 3.50(b).
Table 3.50. (b): Typical composition of Hazardous waste generated Sn. Hazardous waste Composition/Information on Ingredients Unit Quantity 1. Tar Decanter General Composition Sludge* Coal Tar 40-81 Carbon <25 % by Ash <3 weight Water <36 Sulfur 1 Toxic Compounds found Anthracene <3 Benzene <0.1 Benz(a)anthracene 1.05 Benzo(k)fluoranthene 0.42 Benzo(g,h,i)perylene 0.54 Benzo(a)pyrene 0.98 Chrysene % by 0.82 Dibenz(a,h)anthracene weight 0.13 Ethylbenzene <0.1 Fluoranthene 3.42 Indeno(1,2,3-cd)pyrene 0.61 Naphthalene 11.75 Phenanthrene <7 Styrene <1.0 *As per United States Steel Corporation-Safety Data Sheet The above statistics show that BSL has a robust system for disposal of Hazardous wastes generated through existing facilities with almost all of the hazardous waste being internally reused or recycled, a small part being dumped in a Secured Land fill and rest being sold to authorised
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 129 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT parties. Presently BSL has developed a secured land fill site inside the plant boundary (length 125m x breadth 30m x depth 4m) with arrangements collection of leachates. The leachates collect in a solar evaporation pan. The pan has been provided with a system for pumping unevaporated leachates to the BOD plant of the COBPP. An additional Hazardous waste pit is also being contemplated for future requirements.
3.6.11 TRACE METAL / TOXIC METAL / TOXIC CONTENT FROM STEEL PLANT OPERATIONS
General: Special studies were conducted, to cover the below mentioned ToR points (Annexure-2 of ToR letter) as accorded by MoEFCC :
1. PM (PM10 and P2.5) present in the ambient air must be analysed for source analysis - natural dust / RSPM generated from plant operations (trace elements) to be carried over. 2. Trace metals, Mercury, arsenic and fluoride content in the raw material. 3. Trace metals in waste material especially slag. 4. Details on toxic metal content in the waste material and its composition and end use (particularly of slag). 5. Trace metals in water 6. Details on toxic content (TCLP), composition and end use of slag & sludge.
For covering the above ToR points additional studies conducted were as follows: 1. Trace metals Mercury, arsenic and fluoride content in the raw material 2. Source Analysis Study for Trace Metal (Elements) from plant Operations in Work Zone Air/ Fugitive emission, stack emission and Ambient Air. 3. Trace metal content in waste material (slag) and toxicity test by Toxicity Characteristic Leaching Procedure (TCLP) Studies
Methods of analysis followed for the above studies are described in Table 3.51:
Table 3.51. Method of analysis of Trace / Toxic Metal for Different Type of Samples SN. Pollutants Method of analysis I. Trace Metal, Mercury, Arsenic and Fluoride content in Raw Material Trace metals in Raw Material Ashing followed by acid digestion, extraction and analysis using Microwave Plasma Atomic Emission Spectrophotometer (MP-AES) instrument Mercury in Raw Material Digestion followed by analysis using Cold-vapour technique on Mercury Analyzer. Arsenic content in Raw Material Digestion followed by analysis on MP-AES instrument. Fluoride content in Raw Material Ashing/fusing with alkali followed by distillation and analysis on spectrophotometer II. Trace Metal (Elements) from Plant Operations in Stack Emissions, Fugitive Emission and Ambient Air Trace metals in Particulate Matter of Stack Collection of flue dust samples on glass fiber thimble, followed by acid emissions digestion of flue dust, extraction and analysis using MP-AES instrument Trace metals in PM10 of Work Zone Air/ Fugitive Collection of samples on EPM-2000 filter paper, followed by acid digestion, emission/Ambient Air extraction and analysis using MP-AES instrument III. Trace / Toxic Metal Content of Slag and TCLP Studies of Waste Material (Slag & Sludge) Trace metals in Slag & Sludge samples. Ashing followed by acid digestion, extraction and analysis using Microwave Plasma Atomic Emission Spectrophotometer (MP-AES) instrument Toxicity by testing the TCLP leachate for metal Leachate of samples as per Method-1311, US EPA, followed by analysis constituents in Slag samples using MP-AES instrument
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 130 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 3.6.11.1Trace Metal Mercury, Arsenic and Fluoride content in Raw Material
Studies were conducted to access the trace metal mercury, arsenic and fluoride contents in Raw materials used in steel production. Samples of various raw material mentioned below were collected and analysed for above parameters as per method described in Table 3.50. - Iron Ore - Limestone - Dolomite - Coal
Results of analysis of samples prepared as described in Table3.51 are presented in Table. 3.52.
Table 3.52. Results of Mercury, Arsenic and Fluoride content in Raw Material Sample ID Results in mg/Kg As Hg F Iron Ore <3.0 <0.05 151.4 Dolomite <3.0 <0.05 153.0 Coal <3.0 <0.05 150.8 Limestone <3.0 <0.05 149.7
3.6.11.2Trace metals in PM10 of Work Zone Air/ Fugitive emission
With a view to assess the trace metals getting emitted through fugitive dust from Raw material, work zone air samples were collected for PM10. Samples of eight hours duration were collected on EPM 2000 filter papers from the following locations: - Coke Oven 1 - Coke Oven 2 - Sinter Plant near Sinter Machine 1 - Sinter Plant near Sinter Machine 2 - Refractory Material Plant (RMP) 1 - Refractory Material Plant (RMP) 2
Samples collected were analysed for trace metal as per method described in Table 3.51.Results of analysis of samples are presented in Table 3.53.
Table 3.53. Results of Metal analysis in Work zone air/fugitive emission Sample ID Results are in μg/m3 Proportion Proportion
PM10 Cd Cu Ni Pb Cr Zn Fe Mn Total of metals of Fe & Mn Metals in PM10 (%) In total metals (%) WZ-CO-1-S1 478 <0.0018 0.049 <0.0018 0.136 0.023 0.506 27.29 0.420 28.427 5.95 97.49 WZ-CO-1-S2 620 <0.0018 0.048 0.0025 0.116 0.014 0.607 14.20 0.282 15.271 2.46 94.84 WZ-SP-2-S1 1680 <0.0018 0.049 0.0516 0.088 0.036 0.360 47.26 0.450 48.296 2.87 98.79 WZ-SP-2-S2 1240 0.0020 0.054 0.0044 0.137 0.035 0.401 60.24 0.434 61.307 4.94 98.97 WZ-RMP-1-S1 832 <0.0018 0.061 0.0407 0.096 0.022 0.511 16.94 0.222 17.894 2.15 95.92 WZ-RMP-1-S2 1495 <0.0018 0.177 <0.0018 0.262 0.144 1.090 26.60 1.729 30.005 2.01 94.41 OSHAS Permissible Exposure Limit 5 1000 1000 50 1000 - 5000 5000 (TWA)
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 131 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sample ID Results are in μg/m3 Proportion Proportion
PM10 Cd Cu Ni Pb Cr Zn Fe Mn Total of metals of Fe & Mn Metals in PM10 (%) In total metals (%) OSHAS Threshold Limit Value ((TLV(R)) / NIOSH 4000 - - 15 - 500 5000 1000 1000 Recommended Exposure Limit (REL) PEL is Time Weighted Average (TWA), some are Short Term Exposure Limits (STEL) or Ceiling Limits. A TWA is a TLV (R) based on a 8-hour work-day and 40 hour work- week. TLV(R) of a chemical substance establishes the reasonable level to which a worker may be repeatedly exposed, day after day, over a working lifetime without adverse health effects. The National Institute for Occupational Safety and Health (NIOSH) Source: http://conservation-us.org/docs/default-source/resource-guides/chart-of-heavy-metals-and-their-salts-and-other-compounds-nsbp-.pdf
Results indicate that iron and manganese are the major constituents in fugitive dust. At least in Bokaro Steel Plant, the concentrations of metals in fugitive dust are too low to affect the workers’ health.
3.6.11.3Trace metals in Particulate Matter of Stack emissions
With a view to assess the trace metals getting emitted through stacks, samples of stack particulate emissions were collected following isokinetic sampling methodology from the below mentioned process stacks: - Sinter Plant 1 - Sinter Plant 2 - Coke Oven 1 - Coke Oven 2 - Refractory Material Plant (RMP) 1 - Refractory Material Plant (RMP) 2 - Steel Melting Shop (SMS) 1 - Steel Melting Shop (SMS) 2
Samples of PM were analysed for presence of trace metal as per method described in Table 3.51. Results of analysis of samples are presented in Table 3.54.
Table 3.54. Results of trace metal analysis in Stack emission 3 Proportion Proportion of Sample ID Results are in mg/Nm of metals in Fe & Mn In total PM Cd Cu Ni Pb Cr Zn Fe Mn PM10 (%) metals (%) Sinter Plant 1 137 0.001 0.030 <0.001 0.105 0.023 0.048 15.034 0.134 11.22 98.65 Sinter Plant 2 128 <0.001 0.011 <0.001 0.025 0.006 0.027 4.845 0.055 3.88 98.59 Coke Oven 1 39 <0.001 0.008 0.019 0.019 0.013 0.664 0.985 0.055 4.52 58.96 Coke Oven 2 37 <0.001 0.025 0.014 0.056 0.063 0.693 0.796 0.049 4.52 50.49 Refractory Material 2.764 0.091 5.97 33.66 142 0.003 0.019 0.008 0.264 0.056 5.278 Plant (RMP) 1 Refractory Material 1.740 0.084 4.91 25.46 146 0.002 0.020 0.013 0.107 0.069 5.130 Plant (RMP) 2 Steel Melting Shop 18.169 0.172 38.47 75.68 63 0.001 0.030 <0.001 0.066 0.066 5.789 (SMS) 1 Steel Melting Shop 3.418 0.057 19.91 29.58 59 <0.001 0.021 0.008 0.066 0.063 8.115 (SMS) 2 Blast Furnace -3 35 <0.001 0.011 <0.001 0.017 0.017 6.730 3.381 0.038 29.13 33.54
CHAPTER-3 DESCRIPTION OF THE ENVIRONMENT Page 132 of 297 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 3.6.11.4Trace metals in PM10 of Ambient Air
Samples of PM10 of twenty hours duration were collected on EPM 2000 filter papers from the following eight (8) locations: x TA Building (A1) x Garga Dam Pump House (A2) x Sector – XII (A3) x Bokaro Niwas (A4) x Slag Granulation Plant, CISF Barrack (A5) x Bokaro Industrial Area, Baladih (A6) x Near Air Strip (A7) x Sector-IX (A8)
Samples were analysed following method described in Table 3.51. The Results of analysis are in Table 3.55. Table 3.55. Results of Metal Analysis in Ambient Air Sample ID Results are in μg/m3 % of Metal % of Fe + Mn PM10 Cd Cu Ni Pb Cr Zn Fe Mn in PM10 in Metals TA Building (A1) 91 <0.001 <0.001 0.0084 0.013 0.008 0.43 0.272 0.021 0.82 39.18 Garga Dam Pump House (A2) 69 <0.001 <0.001 0.0028 0.014 0.004 0.47 0.163 0.013 0.96 26.44 Sector – XII (A3) 97 <0.001 <0.001 0.0013 0.018 0.003 0.44 0.072 0.022 0.57 16.91 Bokaro Niwas (A4) 89 <0.001 <0.001 0.0055 0.01 0.003 0.38 0.298 0.013 0.46 75.71 Slag Granulation Plant, CISF Barrack (A5) 67 <0.001 <0.001 0.0049 0.014 0.002 0.43 0.115 0.011 0.86 21.84 Bokaro Industrial Area, Baladih (A6) 98 <0.001 <0.001 0.0019 0.017 0.001 0.42 0.049 0.012 0.51 12.20 Near Air Strip (A7) 86 <0.001 <0.001 0.0046 0.012 0.001 0.29 <0.003 0.008 0.37 3.12 Sector-IX (A8) 77 <0.001 <0.001 0.0076 0.015 0.003 0.45 0.118 0.10 0.92 30.80 Norms as per NAAQS 2009 100 - - 0.02 1 - - - - Ontario Ambient Air Quality Criteria April 2012 0.025 50 0.1 0.5 0.5 120 4 0.2 (24 Hour); (Values μg/m3)
The two most prominent downwind sectors relative to the steel plant are the South - South-southeast and North – North-northeast sectors {see Fig. 3.7(a)}. The AAQ Monitoring Stations located in these sectors are Sector XII (A3) and SGP-CISF Barracks (A5). Garga Dam PH (A2) and Bokaro Industrial Area, Baladih (A6) hardly receive any wind from the direction of the steel plant. The proportion metals in PM10, and the proportion of Iron & Manganese in PM10 at the AAQ Monitoring Stations is much less when compared to the corresponding values in dust emitted from the plant (both fugitive as well as from stacks). This indicates that only a small proportion of the PM10 at the AAQ Monitoring Stations is contributed by the steel plant.
3.6.11.5Trace / Toxic Metal Content of Slag & Sludge
With a view to assess the trace metal contents in waste material (slag & sludge) generated from steel making process, samples were collected and analysed for trace metal contents in the samples mentioned hereunder: - BF Slag - SMS Slag - BF Sludge - SMS Sludge
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Table 3.56. Results of Trace Metal Content of Slag & Sludge by acid digestion Sample ID Results are in mg/Kg Cd Cu Ni Pb Cr Zn As BF Slag <1.0 2.4 <1.0 <1.0 19.6 <10.0 <3.0 SMS Slag 20.9 4.5 <1.0 <1.0 337.7 <10.0 <3.0 BF Sludge 93.3 14.0 <1.0 2106.3 51.4 5167.0 <3.0 SMS Sludge 95.4 136.5 <1.0 <1.0 104.2 <10.0 <3.0
3.6.11.6TCLP Studies of Waste Material (Slag & Sludge)
Further, to assess the toxicity of the slag & sludge generated, leaching studies were carried out following "Toxicity Characteristic Leaching Procedure (TCLP)" as per EPA method 1311 and as recommended in Hazardous & Other Wastes (Management and Transboundary Movement) Rules, 2016 for the following samples: BF Slag SMS Slag BF Sludge SMS Sludge
Leaching of samples were carried out using appropriate extraction fluid and resulting leachates were analysed for different toxic metals using Micro Wave Plasma Atomic Emission Spectroscopy (MPAES). Results of analysis of TCLP studies as described in 3.6.11.6 are presented in Table 3.57
Table 3.57. Results of TCLP studies for Slag & Sludge samples Sample ID Results, mg/l Cd Cu Ni Pb Cr Zn As BF Slag <0.01 0.022 <0.01 <0.01 <0.01 <0.1 <0.03 SMS Slag <0.01 0.022 <0.01 <0.01 0.020 <0.1 <0.03 BF Sludge <0.01 0.022 <0.01 0.141 <0.01 33.40 <0.03 SMS Sludge <0.01 0.024 <0.01 <0.01 <0.01 <0.1 <0.03 Limit in mg/l, as per Hazardous and Other Wastes Rules 2016, Schedule II (Class A). 1 25 20 5 5 250 5
Results indicates that values of all the trace metals in TCLP extracts are well below the limits specified in Hazardous and Other Wastes Rules 2016, Schedule II (Class A) and hence both slag & sludge of Blast furnace and SMS are non-hazardous.
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4.1 INTRODUCTION
This chapter identifies the environmental attributes that may be affected due to the proposed project. The existing environmental conditions have been described in the previous chapter. The anticipated impacts due to the proposed expansion-cum-modernization project have been predicted and discussed in this Chapter. Mitigation measures planned to be implemented during the proposed project have also been discussed in this Chapter.
4.2 ANTICIPATED ENVIRONMENTAL IMPACTS
Previously BSL had proposed increasing production capacity from 4 MTPA to 7 MTPA. EC for the same was accorded by MoEFCC in 2008 and construction activities were started thereafter. However, due to prevailing market conditions and financial constraints, the project considered to be unviable. Therefore, BSL proposed augmentation of proposed capacity 4.606 MTPA instead of 7 MTPA. Amendment in EC for the same was accorded by MoEFCC in Jan 2014.
Subsequently keeping in pace with the project development, BSL further proposed for modernization of existing plant by installation of new a Coke Oven Battery and a Pellet Plant. Application for the same was submitted to MoEFCC for grant of EC. By this time, some of the units proposed during the expansion from 4.0 MTPA to 4.606 MTPA had already been installed.
Due to the complexity of present and proposed plant configuration, MoEFCC directed BSL to submit a combined proposal, including the units presently proposed and the units which were proposed during previous expansion but have been deleted.
Therefore, the present proposal involves installation of a new Sinter plant, a pellet plant, a new coke oven battery, a new vertical shaft kiln and debottlenecking of existing CRM Complex.
Most of the revamping activities proposed during previous EC have already been completed. The new Sinter Plant 2 is still in construction phase.
Impact prediction is a way of mapping the environmental consequences of the significant aspects of the proposed plant. The impact assessment will focus on the proposed plant and will broadly cover the following information and components: x Assessment of physical effects for all phases including location, design, construction, operation and possible accidents. x Estimation by type and quantity of expected contaminants, residues, and emissions (air, water, noise, solid wastes) resulting from the operation of the proposed plant.
The anticipated environmental impacts of the proposed plant are discussed below under the following categories: x Impacts and mitigation measures due to project location. x Impacts and mitigation measures due to project design. x Impacts and mitigation measures during construction.
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4.3 IMPACTS & MITIGATION MEASURES DUE TO PROJECT LOCATION
Impacts:
The proposed units will be located within the 6973.68 ha of existing land area under possession of BSL.L adjacent to existing similar units as some infrastructure of existing units can be used for the new units. The land of the existing plant is in industrial use. Location of new units shall involve little disturbance to the natural eco system as no additional area will be acquired. The land over which the new units shall be/ have been set up was a vacant area which had been earmarked for such expansion units since inception. Due to location of proposed units within the existing steel plant, there will be no impact on the land use of the study area.
Mitigation measures:
No negative impact is envisaged due to project location on the existing environment. Thus, no mitigation is required.
4.4 IMPACTS & MITIGATION MEASURES DUE TO PROJECT DESIGN
Impacts:
The proposed plant is being envisaged based on techno-economic feasibility of the state of art technology as presently available in the country and thus no adverse impacts are anticipated due to project design.
Mitigation measures:
A number of environmentally friendly features at the design stage of the proposed facilities, several available technologies have been considered to minimize or avoid emissions, increase recycling of waste & solid wastes recycling and energy savings. These features are described in brief below: x “Travelling Grate” process has been considered for making of Pellets in the Pellet plant. x Purified Mixed gas, which is generated in-house, will be used as fuel for heating purposes and fuel in Pellet Plant and Coke Oven battery to control the air emissions during combustion process as well as reduce dependency on external energy sources for the plant, thus leading to optimised energy consumption. x Sinter Cooler Sensible Heat Recovery in Sinter plant. x High-Efficiency Multi slit Burner in Ignition Furnace eliminates “NO FLAME” areas and supplies minimum heat input for ignition, therefore saving energy. x All units are designed based on “Zero discharge” concept. x Coke Dry Quenching Plant sensible heat recovery with steam generation. x Exhauster VVVF drive for better control of gas suction and energy conservation. x Stage Combustion / Recirculation of Flue Gas for Energy Conservation and NOx control
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x H2S Recovery from Coke Oven Gas to reduce SO2 emission during COG combustion in Steel Making Process x State-of-the-art pollution control technologies have been considered to have minimum impact on the environment.
4.5 IMPACTS & MITIGATION MEASURES DURING CONSTRUCTION PHASE
Construction phase impact may be on land use, ground water, water quality, air quality, noise etc. These aspects are discussed here under.
4.5.1 Land Use
Impacts:
As the new units will be set up within the premises of existing steel plant, most of the construction activity will also be limited to the plant boundaries and in the already built-up area. Thus, no large- scale excavation, soil erosion and loss of topsoil are expected. Moreover, Bokaro is already a fairly well developed area with all sorts of infrastructure available. It is therefore most unexpected that influx of construction labour is going to change present land use pattern. Further this land use change during construction is only temporary and will persist during construction phase only.
4.5.2 Ambient Air Quality
Impacts:
The construction phase involves civil activities primarily, which generates fugitive dust. Vehicular emission from trucks etc. is also another contributor to the emissions during construction phase to ambient air. However, as all activities are confined within the boundary of existing plant premises, the fugitive dust is not expected to spread beyond plant area and that too would be over a small extent. Gaseous pollutants like SO2, NOx and CO will also be added to the ambient air due to vehicular traffic movement associated with this construction phase. Gaseous emissions from construction machineries and vehicles will be attempted to be minimized by enforcing strict emission monitoring system. The impact will be confined within the specific plant area where the construction is taking place. Further, the impact of such activities will be temporary and will be restricted to the construction phase only.
During the construction period the impacts that are associated with the air quality are: x Deterioration of air quality due to fugitive dust emissions from construction activities (especially during dry season) like excavation, back filling and concreting, hauling and dumping of earth materials and from construction spoils. x Generation of pollutants due to operation of heavy vehicles and movement of machineries and equipment for material handling, earth moving, laying of sands, metal, stones, asphalt, etc.
Mitigation measures:
The following mitigation measures will be employed during construction period to reduce the pollution level to acceptable limits.
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4.5.3 Noise Levels
Impacts:
Major sources of noise during the construction phase are operation of construction equipment such as excavators, pile drivers, cranes, drills, concrete mixers, etc., metal fabrication and vehicular traffic. The operation of construction equipment will generate noise level ranging between 75 to 90 dB (A). However, this noise level will be near the source only and is not expected to raise noise levels outside the plant premises. The noise generated due to movement of trucks and machinery will be regulated to only during day time to reduce the impacts of increased noise. The noise generated during the construction phase from different equipment may have some adverse impact on the operators.
Mitigation measures:
x Personal Protective Equipment (PPE) such as earplugs, earmuffs etc. will be provided to construction personnel exposed to high noise levels as preventive measures by contractors and will be strictly adhered to minimize / eliminate any adverse impact. x It will be ensured that all the construction equipment and vehicles used are in good working condition, properly lubricated and maintained to keep noise within the permissible limits and engines turned off when not in use to reduce noise.
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Impacts:
The impacts on water quality during construction phase mainly arise due to site cleaning, levelling, excavation, storage of construction material etc. Levelling and excavation activity normally increases the level of suspended solids in the surface water runoff. However, for the proposed plant, no large scale levelling is required. Excavation will also be limited. During the monsoon season, storm water run-offs will contain large amounts of suspended solids. Efforts will be made to reduce the suspended solids content of storm water run-offs by routing the storm water drains through catch pits.
Mitigation measures:
x Quality of construction wastewater emanating from the construction site will be controlled through the existing drainage system with sediment traps (silting basin as water intercepting ditch) for arresting the silt / sediment load before its disposal. x All the washable construction material will be stored under sheds or enclosed space by fencing it with brick or earth in order to prevent spillage into the drainage network, so that the same does not find its way into the surface water runoff. x The sediment traps and storm water drainage network will be periodically cleaned and especially before monsoon season.
b) Ground Water
Impacts:
The water requirement during the construction phase will be low and will be met through the already existing water supply facilities. Thus, no ground water extraction is envisaged. Therefore, it is most unlikely that construction phase will bring any significant modification in the ground water regime of the area.
4.5.5 Socio-economics of the area
The construction activities will generate of a lot of employment, both direct and indirect, which will affect the economy of the study area. Most of the workers will come from nearby places. In addition, arrangements will be made with local traders / businesspersons to supply kerosene & fuel-wood to eliminate the possibilities of illegal felling of trees. But these impacts will be temporary and will revert back close to the original conditions once the construction work is over and the temporary labour force moves away.
4.5.6 Infrastructure facilities
BSL is an already operational steel plant and going for expansion to 4.606 MTPA Crude steel. It has all required infrastructural facilities for the workers already. Thus, no additional facilities shall be required and the existing facilities shall be used for this project too.
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During the operation phase, depending upon operating condition environmental releases may occur from raw material and product handling, processing, fuel burning etc. Environmental releases may be in the form of x Air emission x Waste water discharges x Solid waste disposal x Noise etc.
These emissions, discharges and disposal may release different pollutants, which may affect air, water land and ecological environment directly. However, all these are mainly primary impact. In addition to these primary impacts any industrial project or expansion of a project has some overall impact on its surrounding socio-economic environment through the existence of social and economic linkages between the project and society, which are actually secondary impact. Under this clause, all these primary and secondary impacts due to this proposed project are being discussed and wherever required, impacts have also been quantified. Accordingly impacts on air environment, water environment, soil, noise, land use, and socio-economic environment due to the proposed project are being elaborated under subsequent paragraphs.
4.6.1 Ambient Air Quality
A) Impacts on Ambient Air Quality
In the upcoming units, air pollutants are likely to be generated at different stages of production. Air pollutants may be particulate matter, sulphur dioxide, oxides of nitrogen, volatile organic carbons etc. The pollutants may be released as point source emissions or fugitive emissions. In Chapter 3, the existing air quality status has been reviewed. It was observed that the maximum of all mean pollutant concentrations in the study area of PM10, SO2 and NOx are 88, 21 and 45 μg/m3 respectively. These concentrations are due to the emissions emitted in to the atmosphere from the existing plant, other industries as well as other sources in the area.
a) Emissions from the proposed units
The anticipated emissions from different expansion units of BSL have been computed based on the present performance of different units, monitoring results and the emission factors as suggested and accepted by other countries. Emission estimates are important for developing emission control strategies.
For future projection of emissions from upcoming new units, the emissions have been computed based on emissions from similar plant elsewhere having same configuration and fuel consumptions. However the emission estimates for existing units which are proposed for augmentation are based on actual monitoring results. Major unit wise emission estimates are discussed below.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 140 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT i) Pellet Plant
During agglomeration process green pellets need to be hardened. Travelling grate carries the green pellets on a 30–50 cm thick bed through a furnace with updraft drying, downdraft drying, preheating, and firing, after-firing and cooling zones. These processes may generate carbon dioxide, sulphur compounds, chlorides, and fluorides, which are driven off during the pellet production process. Large amounts of dust, containing metals and other ore and additive constituents, may also be generated. These wastes are usually collected by electrostatic precipitators.
ii) Coke Oven Battery
BSL has proposed to install a new coke oven battery of 0.77 MTPA gross coke. The unit shall produce coke through carbonization of coking coal. This involves preparation of coking coal (crushing, sizing and sorting), charging of coal in coke ovens pre-heated by firing Coke Oven gas/Mixed Gas, discharge of hot coke from the ovens, quenching of hot coke in CDCP (Coke Dry Cooling Plant) and processing of produced cool coke (screening, sizing and sorting). Carbon dioxide, sulphur dioxide, NOx and particulate matter are the major emissions generated from the Coke Oven. Also, a lot of fugitive dust may be generated at material transfer points and handling areas, which are proposed to be controlled using dust suppression system such as dry foggers. These dusts containing coal fines and other fluxes shall be reused in sintering / pelletizing process.
The existing coke oven complex at Bokaro Steel Plant consists of 8 nos. of by-product recovery type coke oven batteries. However, due to rebuilding / repairing of batteries on a regular basis, only 6 out of 8 of the batteries are available for operation at any given time. So, the contribution from the existing coke oven complex is due to operation of only 6 coke oven batteries to the pollution load. The same is being reflected in monitored AAQ. In addition to above, due to the operation of new coke oven battery, additional emissions shall be generated in future.
iii) Sinter Plant
During the process of agglomeration by sintering, waste gases containing particulate matter, oxides of sulphur and nitrogen as major pollutants are generated during the process stage and cooling of sinter. The waste gasses after passing through an electrostatic precipitator are released to the atmosphere.
A new Sinter machine of 360 m2 area is being installed. There are two main stacks in Sinter plant, one is process stack and another is de-dusting stack for charging and discharging side of sinter machine.
The major pollutant emitted from these stacks is dust which will be cleaned in ESPs before discharging to the atmosphere. The PM levels shall be maintained in these stacks less than 50 mg/Nm3.
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Apart from the above given units, some other new unit/ augmentation of existing units are also proposed- x Up-gradation of Blast Furnace #2 (from 2000m3 to 2365 m3 useful volume). x Up-gradation of SMS-II from 2.7 MTPA to 3.35 MTPA capacity x Augmentation of HSM from 3.2 MTPA to 4.5 MTPA x Installation of New RMP Kiln 7.
The augmentation of BF and SMS has already been completed, but the units are being run at lower capacity. However, after the installation of all the proposed units in future, the same shall produce at maximum rated capacities.
Based on the process flow of the individual units, stack emissions are estimated and given in Table
4.1. Table 4.1 - Expected Stack Emissions from Proposed units Exit Anticipated Emissions Flow Rate Temp Height Sn Unit Dia (m) velocity (g/sec) (Nm3/h) (oC) (m) (m/s) PM SO2 NOx Existing Units at 4.5 MTPA Stage 1. BF1 Stove 112510 280 3.5 70 6.0 0.8 2.3 0.9 2. BF2 Stove 110795 271 3.5 70 5.8 0.8 2.5 1.1 3. BF3 Stove 114128 279 3.5 70 6.1 0.9 2.1 0.7 4. BF4 Stove 114949 275 3.5 70 6.1 0.9 2.4 1.0 5. BF5 Stove 110168 295 3.5 70 6.1 0.8 2.2 0.9 6. BF1 SH 289251 50 8.2 50 1.6 6.0 0.0 0.0 7. BF2 & BF3 SH 286101 50 8.2 50 1.6 6.0 0.0 0.0 8. BF4 & BF5 SH 292402 50 8.2 50 1.7 6.1 0.0 0.0 9. SMS1 1409861 53 4.3 100 29.5 70.6 24.5 16.6 10. SMS2 LF1 108436 50 1.25 80 26.6 0.8 0.0 0.0 11. SMS2 LF2 108436 50 1.25 80 26.6 0.8 0.0 0.0 12. HSM-RHF1&2 447532 375 7.2 120 6.6 3.1 28.0 9.3 13. HSM-RHF3&4 438031 400 7.2 120 6.7 3.4 27.3 9.1 Existing Units at 5.77 MTPA Stage 1. BF1 Stove 144262 280 3.5 70 7.7 1.1 2.9 1.2 2. BF2 Stove 142063 271 3.5 70 7.5 1.0 3.2 1.4 3. BF3 Stove 146337 279 3.5 70 7.8 1.1 2.7 0.8 4. BF4 Stove 147390 275 3.5 70 7.8 1.1 3.1 1.3 5. BF5 Stove 141259 295 3.5 70 7.8 1.0 2.8 1.2 6. BF1 SH 370885 50 8.2 50 2.1 7.7 0.0 0.0 7. BF2 & BF3 SH 366845 50 8.2 50 2.1 7.6 0.0 0.0 8. BF4 & BF5 SH 374924 50 8.2 50 2.1 7.8 0.0 0.0 9. SMS1 783600 53 4.3 100 4.7 10.9 13.6 9.2 10. SMS2 LF1 134541 50 1.25 80 33.0 0.9 0.0 0.0 11. SMS2 LF2 134541 50 1.25 80 33.0 1.0 0.0 0.0 12. HSM-RHF1&2 629342 375 7.2 120 9.3 4.4 39.3 13.1 13. HSM-RHF3&4 615981 400 7.2 120 9.5 4.8 38.4 12.8 ADDITIONAL UNITS 1. COB 9 260000 250 3 120 17.9 3.6 7.2 7.2 2. Pellet Process 280000 250 3 55 19.3 3.9 7.8 7.8 3. Pellet SDD 90000 75 1.5 35 16.5 1.3 0.0 0.0 4. SP2 Process 1800000 160 7 100 18.9 25.0 100 50 CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 142 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Exit Anticipated Emissions Flow Rate Temp Height Sn Unit Dia (m) velocity (g/sec) (Nm3/h) (oC) (m) (m/s) PM SO2 NOx 5. SP2 SDD 1200000 45 5 80 18.1 16.7 0.0 0.0 6. RMP7 46672 120 1.2 51 15.1 0.6 4.7 3.2
Based on the above data, the comparison of air pollution loads at difference stages of the plant is
shown in Table 4.2.
Table 4.2 - Comparative pollution loads before and after the present Proposal Sl. Pollution Load (Kg/hr) Scenario No PM SO2 NOx Emissions at 4.5 MTPA stage from existing plant units 1 363 328 143 which are proposed for augmentation Emissions at 5.77 MTPA stage from existing plant units 2 181 382 148 which are proposed for augmentation 3 Emissions from upcoming new Units 184 431 245 Net Increase (2+3-1) 2 485 250
From the above table, it can be seen that after revamping of old ESPs in SMS complex, there is a significant reduction in PM Loads. However, there is a marginal increase in SO2 and NOx loads after expansion. In addition to this, after addition of upcoming new units of Coke Oven, Pellet, & Sinter plant, PM, SO2 and NOx loads are expected to increase by 184 Kg/hr, 431 Kg/hr, & 245 Kg/hr respectively.
The above emissions are expected to be released from the stack at 5.77 MTPA stage. Once the pollutants are emitted into the atmosphere, the dilution and dispersion of the pollutants are controlled by various meteorological parameters like wind speed and direction, ambient temperature, mixing height, etc.
b) Area Source Emissions
Area source emissions are described as the emissions generated during the handling of raw material and other intermediate material in the plant.
In the proposed project, it is proposed to install a new wagon tippler along with conveyors for efficient unloading of raw materials from railway wagons.
From tippler area and the stockyard, major area source emissions will be fugitive dust. Fugitive emissions are generated during wagon tippling, transfer of material at junction boxes, during crushing and stocking the material. In order to minimize the fugitive emissions from the handling area, dust suppression systems have proposed at all the dust generating sources.
Since the fugitive emissions due to present raw material handling at 4.5 MTPA stage is being reflected in AAQ, only the proposed increase in raw material handed are considered for impact prediction. The impact due to material handling in stockyard is studied by estimating the emissions from all the dust emission sources. First step was the estimation of rate of emissions of pollutants from the sources. In the present case the emissions are mainly due to displacement of material
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 143 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT while loading and unloading. Hence, it is required to quantify the emissions emitted from each of these activities. The amount of dust generated is dependent on a number of variables like, x Nature of handling of material x The physical characteristics of the material handled (degree of compaction, content of silt, moisture content) x Meteorological conditions
The rate of fugitive dust (emission factor) emitted from the activities while handling the material is estimated from the empirical formulae given by EPA given in document AP-42 (13.2.4 Aggregate Handling and Storage Piles).
The quantity of dust was estimated using the emission factors and the quantity of material handled
Table 4.3 - Estimated fugitive emissions from proposed units Emission Factors Area Raw Materials Emissions Source Kg/t m2 t/sec g/sec/m2 Stock yard 3.78 X 10-5 439100 0.073 6.3 X 10-9
c) Line Source Emissions
BSL receives major raw materials by rail and empty wagons for product dispatches from inward Exchange Yard of Tupkadih railway Station. Only about 4% of the saleable steel is dispatched through road.
Almost all of the raw material is received by BSL through railways (99.86%). The same will be continued even after expansion of the project. No appreciable change in road traffic is anticipated even after the expansion.
d) Prediction of Impacts
In order to study the ground level concentrations in future scenario and to predict the impact on the ambient air quality due to the increase in pollution load during expansion and introduction of new units following methodology has been adopted.
For assessment of expected air emissions from the proposed expansion plan the basic assumption followed are: x The air pollution load emitted from the existing stacks of BSL is reflected in the air pollutants concentration in the ambient air quality as monitored during the three-month continuous monitoring done during summer season around BSL. x The units, which are going to be added/modified, will result increase in air pollutants concentration in the existing ambient air quality.
BSL is enhancing its production capacity from 4.5 to 5.77 MTPA of hot metal by adding some new units as well as by enhancing the efficiency by modifying some already existing units. Addition of the new units will result in some increase in quantity of emitted pollutants. The emissions from existing plant stacks of 4MTPA plant are only reflected in the monitored data.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 144 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT To assess the actual impacts due to proposed changes air quality impact prediction modelling has been conducted considering site specific meteorological data to estimate the incremental Ground level concentrations due to proposed changes.
In the present project revamping of existing units have already done. However, these units are not producing its rated capacity. Even total plant has not reached its rated capacity. To obtain ultimate contribution from the plant when plant reaches it capacity 5 MTPA on ambient air, few following assumptions/considerations were made:
(a) The contribution from existing plant with present production capacity is being reflected on the air quality. (b) The present contribution of all existing units proposed to be revamped is predicted at individual monitoring station using the monitored emission values. (c) GLCs have been predicted for existing units proposed to be revamped when they are operating at rated capacity (at 5.77 MTPA stage). (d) Modified AAQ values have been obtained for each monitoring location by subtracting the predicted additional contribution of existing units at 5.77 MTPA stage. (e) The GLCs have also been predicted considering emissions from all new units. (f) The cumulative maximum AAQ in future at 5.77 MTPA operational stages are obtained by adding Modified AAQ values at individual station with GLCs due to emissions from new units. (g) GLCs have been predicted for fugitive emissions due to handling and transportation of additional quantities of raw material for proposed expansion and added with Cumulative AAQ.
Following the above, the GLCs are predicted for contribution of BSL on ambient air quality. The US Environmental Protection Agency’s (EPA’s) AERMOD computer code is used to estimate atmospheric dispersion and concentrations of the released emissions in the immediate vicinity of the proposed sources. The modelling is conducted to be inclusive of the weather conditions that are possible and representative of the sources.
Both airborne and surface concentrations are modelled with AERMOD. Hourly derived air concentrations (DAC) are modelled for an array of receptors covering the sources and surrounding areas. Peak values of time-integrated air concentrations at these major receptors points are derived from these hourly values, with modelled results reported as total incremental air concentrations in DAC-hours occurring over the selected time period. Total pollutants concentration over the plain areas are evaluated with AERMOD using the same array of receptors, with results reported as microgram per m3.
The GLCs has been predicted over a 20 km X 20 km area with the location of the SMS1 as the center. GLCs have been calculated at every 500 m grid point.
Meteorological data plays an important role in computation of Ground Level Concentration using AERMOD model. Meteorological data of the project site is required for computation of the contribution by the proposed expansion. The actual monitored site meteorological data for one full season of summer has been considered. The meteorological data was generated near the plant site for three months period on hourly basis.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 145 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
The maximum GLCs for each grid point were predicted with respect to pollutants PM, SO2 and NOx. After expansion, the maximum GLCs derived from the proposed new units are 7.4, 8.9 and 5.8 μg/m3 for PM, SO2 and NOx respectively.
The maximum values are obtained within/very close to the plant. The maximum predicted value of fugitive emissions is obtained within the raw material yard itself.
The Isopleths of PM, SO2, NOx for the upcoming new units are presented in Fig 4.1(a), (b), (c) & (d). The Meteorological data of the day on which the maximum values have occurred has been given in Table 4.4.
Table 4.4: Meteorological data used as input for Air quality modelling Time Wind Direction (Deg.) Wind speed (m/s) Temp. (°C) Relative Humidity (%) (hours) 01 356 0.1 18.2 85 02 359 0.1 17 88.3 03 26 0.0 16 94.4 04 335 0.1 16.4 97.5 05 333 0.3 16.5 95.2 06 305 0.1 16.3 95.2 07 300 0.0 16.3 97.4 08 324 0.1 16.6 98.2 09 326 0.2 17.2 95.1 10 330 0.5 19.1 86.2 11 338 1.2 20.1 82 12 339 1.5 21.5 73.3 13 326 1.4 22.4 69.2 14 350 1.0 23.6 65.1 15 2 1.3 23.1 62.3 16 5 1.1 23.1 61.2 17 349 1.1 23.2 61.6 18 348 0.7 22 65 19 8 0.2 20.4 71.2 20 344 0.4 19.5 75.3 21 341 0.6 18.1 77.5 22 323 0.6 18.1 78.3 23 319 0.5 17.6 79.3 24 314 0.5 17.1 80.3
As indicated above, in order to obtain the impact due to expansion, Background mean values recorded in the study area are considered and the contribution due to existing plant and future are studied at that area. The predicted GLC values have been provided in Table 4.5 and Table 4.6.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 146 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 4.5 - Expected GLCs from various units of BSL *Concentrations are in μg/m3 and of 24 hours averaging time PM (μg/m3) Existing units at 4.5 Existing units at MTPA before 5.77 MTPA after Net Change in GLC Due to Net Change after Stn ID revamping revamping Existing units New Units Expansion A1 3.92 2.93 -0.99 1.39 0.40 A2 4.38 3.40 -0.98 1.90 0.92 A3 3.56 2.73 -0.83 1.28 0.45 A4 2.64 2.04 -0.60 1.04 0.44 A5 3.00 2.16 -0.84 1.81 0.96 A6 1.97 1.62 -0.35 1.16 0.81 A7 2.33 1.66 -0.67 1.02 0.35 A8 1.96 1.62 -0.34 0.67 0.32
SO2* (μg/m3) Existing units at 4.5 Existing units at MTPA before 5.77 MTPA after Net Change in GLC Due to Net Change after Stn ID revamping revamping Existing units New Units Expansion A1 2.81 3.09 0.28 2.62 2.90 A2 2.01 2.26 0.25 3.54 3.79 A3 2.47 2.78 0.31 2.48 2.79 A4 2.03 2.26 0.23 2.03 2.26 A5 1.73 1.93 0.20 2.96 3.16 A6 1.39 1.56 0.17 2.33 2.50 A7 1.96 2.18 0.22 1.97 2.19 A8 1.35 1.56 0.21 1.36 1.57
NOx* (μg/m3) Existing units at 4.5 Existing units at MTPA before 5.77 MTPA after Net Change in GLC Due to Net Change after Stn ID revamping revamping Existing units New Units Expansion A1 1.20 1.22 0.02 1.60 1.62 A2 0.89 0.93 0.03 2.19 2.22 A3 1.07 1.13 0.06 1.53 1.59 A4 0.87 0.90 0.03 1.27 1.30 A5 0.80 0.84 0.04 1.83 1.87 A6 0.63 0.65 0.02 1.36 1.38 A7 0.84 0.88 0.04 1.19 1.23 A8 0.58 0.61 0.03 0.80 0.83
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 147 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 4.6 –Cumulative AAQ Values at various receptor points after expansion PM10* (μg/m3) Loc. Background monitored Additional GLCs after GLCs due to Code Total Value (Mean) Expansion Fugitive Emissions A1 77 0.4 0.1 77.5 A2 68 0.9 0.3 69.2 A3 80 0.5 0.0 80.5 A4 78 0.5 0.0 78.5 A5 78 1.0 0.0 79 A6 88 0.8 0.0 88.8 A7 86 0.4 0.0 86.4 A8 87 0.3 0.0 87.3 NAAQS Standard 100
SO2* (μg/m3) Loc. Background monitored Additional GLCs after Code Total Value (Mean) Expansion A1 19 2.9 21.9 A2 15 3.8 18.8 A3 17 2.8 19.8 A4 19 2.3 21.3 A5 21 3.2 24.2 A6 21 2.5 23.5 A7 20 2.2 22.2 A8 19 1.6 20.6 NAAQS Standard 80
NOx* (μg/m3) Loc. Background monitored Additional GLCs after Code Total Value (Mean) Expansion A1 36 1.6 37.6 A2 31 2.2 33.2 A3 34 1.6 35.6 A4 39 1.3 40.3 A5 41 1.9 42.9 A6 42 1.4 43.4 A7 45 1.2 46.2 A8 42 0.8 42.8 NAAQS Standard 80 *Concentrations are in μg/m3 and of 24 hours averaging time
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 148 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand
PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 4.1 (a) - Isopleths of PM over 10km area around BSL
Plant Center at (10,10) Max Value – 7.4 μg/m3 at (8.5,11) Within Plant’s Boundary
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 149 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand
PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Fig 4.1 (b) - Isopleths of SO2 over 10km area around BSL
Plant Center at (10,10) Max Value – 8.9 μg/m3 at (9.5,9.5) Within Plant Boundary
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 150 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand
PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 4.1 (c) - Isopleths of NOx over 10km area aroundBSL
Plant Center at (10,10) Max Value – 5.8 μg/m3 at (9.5,9.5) Within Plant Boundary
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 151 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand
PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 4.1 (d) - Isopleths of Fugitive dust over 10km area around BSL
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 152 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The above tables and isopleths reveals that, after implementation of the proposed project it is expected that there will be a marginal increase in the background ambient concentrations. However, it is observed that even after adding net change in GLCs with the back ground concentrations, the cumulative values shall be within the norms.
e) Impact due to Transportation
All major external material movement, both incoming as well as outgoing, will be done by rail. Since the railway network serving BSL is electrified, hardly any diesel locomotive hauled trains will serve BSL. Only ~7 trucks/day will be required for additional material movement due to the proposed project. Thus, no significant impact of transportation of material is anticipated on the air environment due to the proposed project. Over and above, it will be ensured that all internal transport vehicles are in good working condition, properly tuned and maintained to keep emission within the permissible limits and engines turned off when not in use to reduce pollution. Vehicles would be regularly maintained so that emissions confirm to standards of Central Pollution Control Board (CPCB).
B) Mitigation measures for Air Pollution during Operation phase In order to mitigate air pollution, following measures are being implemented in the proposed units.
Table 4.7 - Air pollution control measures in the proposed units Area of Design Sn. Air Pollution Control measures Operations Limits 1. Pellet Plant
Induration process xIn order to reduce CO, SO2 emissions, purified mixed gas is xStack: 50 proposed as fuel for the Indurating Furnace of Pellet plant. mg/Nm3 xESP for collected Indurating furnace gas Raw material xStack: 50 preparation & mg/Nm3 xCentralised De-dusting system with ESP common for both areas handling xOverall xDust suppression consisting of water spraying facilities, mechanical Pellet screening Fugitive gas cleaning equipment, dust recycle arrangement and exhaust and transport Dust content stack in the work xExhaust gas from drying and grinding system will be cleaned using zone shall fans, ductings, suction hoods, cyclones, bag filters, ESPs etc. be limited to 3 mg/Nm3 2. Coke Oven Battery Coal & Coke xStack: 50 xDE systems with Bag Filters handling mg/Nm3 Coal charging xOn main charging with HPAL aspiration xScrew feeders and Zero-leak charging hole lids shall be provided in Charging cars for speedy coal charge to reduce charging time emissions xAs per Carbonization xUse of purified Mixed gas for under firing MOEF xLow NOx burners norms Coke pushing xLand based pushing emission control applicable xComputerized heating system shall be provided to reduce pushing for new coke time emissions ovens Coke quenching xPrimary coke quenching shall be done by Dry quenching xStandby Wet quenching tower shall also be provided with grit arrestors and vapour spray system to reduce quenching emissions.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 153 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Area of Design Sn. Air Pollution Control measures Operations Limits 3. Sinter Plant Sintering Process xHigh-Efficiency Multi slit Burner in Ignition Furnace eliminates “NO FLAME” areas and supplies minimum heat input for ignition, xStack: therefore saving energy and reducing emissions. PM<50 mg/Nm3 xProcess Waste Gas Cleaning ESP with higher treatment time for effective control ultra-fine dust emission xOverall Fugitive xCentralised ESP based Dedusting system to cater to all material Dust content transfer points. in the work xSinter Cooler Sensible Heat Recovery zone shall Low Specific coke breeze requirement thereby reducing SO2 x be limited to generation. 3 mg/Nm3 xOptimization of water addition in sinter Raw mix 4 Refractory Material Plant Shaft Kiln xCombustion control inside kiln to maintain desired air –fuel ratio and reduce stack loss and un-burn CO emission xWaste gas heat recovery system for combustion gases in the shaft xStack: kiln. PM<50 xBag filter based process waste Gas Cleaning Plant mg/Nm3 xBag filter based dedusting system to cater all material transfer points
Fugitive dust control: Plain water type dust suppression systems consisting of water sprinkling systems is provided all around the raw material stockpiles to suppress fugitive dust. In enclosed spaces, dust extraction & filtration systems and dust suppression systems are installed. The dust extraction and filtration systems consist of suction hoods, fans and bag filter units with all accessories.
Pollution control by means of conservation of Energy The following measures shall be adopted for gainful utilization of waste heat from the flue gases: x In pellet plant, the waste heat from the induration process shall be utilized for drying of green pellets. x In CDCP of Coke Oven battery, steam generated from Waste Heat Boiler (WHB) by cooling the hot inert circulating gases coming out of the coke cooling chamber will be used to generate power from a back pressure turbine. x Sinter Cooler Sensible Heat Recovery x Waste gas heat recovery system in RMP Kiln for Pre-heating.
4.6.2 Water Resources A) Impacts on Water Resources
a) Impact due to water usage No additional water withdrawal is envisaged for the proposed expansion-cum-modernization plan apart from the existing allocation of 227 cusecs (~23000 m3/hr) from Damodar River. The water drawl from Damodar River for meeting all requirements after proposed expansion-cum- modernization project shall be ~17000 m3/hr and the existing water allocation of ~23000 m3/hr is sufficient to cater this future water requirement. Also, extensive recycling & water reuse is envisaged in the present proposal, which will ensure no additional fresh drawl of water is required.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 154 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Also, no abstraction of groundwater is envisaged for the proposed activities. Thus, no negative impact on existing water regime (ground water as well as surface water) is envisaged.
b) Impact on Water quality
Coke Ovens Waste waters are generated from the coke oven & by-product plant as waste ammonia liquor from moisture contaminated in the charged coal, steam used in distilling ammonia from the waste liquor, light oil recovery and other processes. Wastewaters are contaminated with oil & grease, ammonia, cyanides, thio-cyanates, and phenols. Further whatever waste-water is generated from the Coke Oven &By Product Plant area is collected and transported through pipeline to a wastewater treatment plant (BOD Plant). The wastewater after treatment will be consumed for industrial purposes in the plant and as such no water pollution is anticipated.
Effluents will be generated from the proposed Coke Oven and By-product Plant (COBP), which are likely to be contaminated with ammonia, phenol, tar & oil, cyanide, etc. and needs treatment to remove pollutants to meet the statutory norms before use in coke quenching. A biological Effluent Treatment Plant (BOD Plant) of capacity 50 m3/hr has thus been envisaged, where all waste-water generated by the coke oven battery will be treated and subsequently reused in the plant.
Sinter Plant Wastewater may be generated in Sinter Plant if wet scrubbers are used for pollution control facilities. However in this project dry ESPs are used in the sinter plant for pollution control, which does not generate any effluent. Further the water requirement / consumption in sinter plant is very less and no water is required for process purposes and as such no wastewater is generated from the process.
Pellet Plant In pellet making process, all input materials shall be received either in form of fines or crushed to suitable size by dry grinding & crushing process. However, a limited amount of water (~60 m3/hr) shall be required for mixing and balling, equipment cooling circuit and dust suppression systems. No water shall be used in the process. Also, the water requirement shall be fulfilled by recycling of treated wastewater of existing BSL plant.
Thus, no additional effluent shall be discharged into the local surface water bodies due to the proposed units. Implementation of Zero liquid discharge will also reduce wastewater discharge from the plant.
c) Impact on Ground water
The proposed project does not envisage any ground water abstraction and hence no impact on ground water availability around the BSL plant is anticipated. The waste disposal area around any industry is one of the major factors for deteriorating ground water quality. However, all waste generated in the proposed project will be either reused in the plant itself as feed material to coke oven/pellet plant or will be sent to sinter plant as feed material.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 155 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT So, no large scale storage of wastes is required, eliminating the possibility of leaching of hazardous material into the ground.
B) Mitigation measures for Water Pollution
During the design phase, all efforts have been made to adopt latest state-of-the-art technology and to install adequate effluent treatment facilities for different units expected to generate water pollutants. The following mitigation measures will be employed during operation period to reduce the pollution level to acceptable limits:
New Coke Oven Plant x Re-circulating of water is envisaged in the process whereby discharged volume is minimum. x All waste waters and effluents of the COB-9 /BPP-2 complex will be managed by the provision of suitably designed waste water collection sewerage networks with suitable treatment and recycling facilities. All floor washings which are likely to be contaminated with chemical impurities, gas condensates, chemical equipment and vessel washings and excess Ammoniacal liquor will be brought to the new BOD plant for treatment and recycled appropriately for industrial use for wet quenching and make up for industrial cooling water circuits. x Removal of oil and grease from the contaminated water by means if oil traps, skimming devices will be done before treatment/recycling. x Effluent quality monitoring at inlet and outlets of the effluent treatment plant to ensure proper functioning of the treatment facility. x Use of treated wastewater in different shops and for plantation development as far as practicable.
An effluent treatment plant/BOD plant is also proposed for the new Coke oven, COB#9. All chemically contaminated waste waters from the various units and systems of the COB#9 complex contaminated with various organic and inorganic contaminants such as phenolic compounds, ammonium salts, coal tar and oils, etc., generally called phenolic effluents having a high Bio- chemical Oxygen Demand will be suitably handled in an exclusive phenolic effluent sewerage network of COB#9. This network will be designed to bring all such chemically contaminated waste waters arising out of excess flushing liquor, coke oven gas condensates, process vessel drains, contaminated overflows and washings, etc. will be suitably treated in a new Phenolic Effluent Treatment Plant[PETP), generally called BOD plant]. The new BOD plant will have a treatment capacity to treat all such waste waters and the capacity will be 50m3/hr (minimum). BOD plant will be located by the side of the existing BOD plant of CO-BPP. The BOD plant will be designed considering the input effluent quality as indicated: Parameter Unit Quantity Phenol mg/l 500 Total Ammonia mg/l 500 Tar & Oil mg/l 100 to 350 Cyanides mg/l 50 Thio-cynides mg/l 100 pH mg/l 7.5 to 9 Temperature mg/l 50°C to 60°C
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 156 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The treated effluent will generally conform to the following quality parameters: Parameter Unit Quantity pH mg/l 6 to 8 Suspended solids mg/l <100 Phenols mg/l <1 Cyanides mg/l <0.2 Ammonical nitrogen mg/l <50 Free ammonia mg/l <5 Oil & grease mg/l <5 Nitrate nitrogen mg/l <10 BOD (3 days, 27°C) mg/l <30 COD mg/l <250
The treated effluents from the BOD plant will be used as industrial make up water within the COB#9 complex to the extent practical in conformity to the zero-discharge principles. The treated effluents will be recycled to facilities within the plant.
All floor washings which are likely to be contaminated with chemical impurities, gas condensates, chemical equipment and vessel washings and excess ammonical liquor will be brought to the new BOD plant for treatment and recycled appropriately for industrial use for wet quenching and make up for industrial cooling water circuits.
Existing Coke Oven Plant complex
BSL has taken up steps to control and reduce Cyanide also in effluent coming into existing BOD Plant. The details are as follows.
¾ Cyanide Reduction Measures: Many Useful by-products such as Ammonium Sulphate, Naphthalene, Wash oil, extra hard pitch, Road tar, Pitch creosote mixer and Crude Benzol are recovered in By-product plant and sold in the market. During by-product recovery process, a lot of effluent containing Phenols, Cyanide, Thiocyanate & Ammoniacal Nitrogen is generated. This Toxic effluent is treated in BOD Plant i.e. Biological Oxidation and Dephenolization Plant. The effluent is treated by Bacteriological aerobic Oxidation method. The Flow diagram has been enclosed. The influent quality is maintained by regular operation of Ammonia Striping plant and other standard operating practices. In the influent Phenol, Ammonia and Cyanide are maintained in the range of 400mg/l, 400mg/l and 30mg/l respectively. By following standard operating practices of BOD plant and proper maintenance of pH and MLSS in Aeration tank-1 & Aeration tank-2, Phenol and Ammonia norms are continuously maintained in BOD plant outlet effluent. All the parameters are being maintained within norm.
¾ Treatment Scheme: ETP in proposed Coke Oven and By Product Plant of BSL consists of waste water collection tank, tar settling unit, dissolved air floatation unit equalization basin, flash mixer, clariflocculator, two stage activated sludge process with separate clarifiers and trickling filter system followed by final clarifier and chlorine contact tank. In addition, sludge thickener and sludge drying beds are also provided for dewatering of sludge generated. The treated effluent shall be used in coke quenching. The scheme of BOD plant at BSL is shown in Fig. 4.2.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 157 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
INLET EFFLUENT CHARACTERISTICS: Fig. 4.2: Scheme of BOD plant at BSL FLOW: 200m3/hr, PHENOL: 400mg/l, COMPRESSED AIR AERATORS NH3: 400mg/l, CN: 30mg/l NUTRIENT O&G: 20mg/l FLOCCULANT & COAGULANT ST (Orthophosphoric acid) 1 STAGE AERATION TANK INLET 1ST STAGE COMPRESSED AIR CLARIFLOCCULATOR CLARIFIE
DISTR DAF BOX
FLASH MIXER EXCESS TST SLUDGE RETURN SLUDGE
EQUALISATION TANKES NaOH/NaHCO3
NUTRIENT ORTHO- TAR & OIL SLUDGE LOADING PHOSPHORIC ACID TANK THICKENER INTO TANKER
2ND STAGE BIO SLUDGE DISPOSAL AERATION TANK
SLUDGE DRYING BEDS
RETURN
SLUDGE nd 2 STAGE TO TREATED WATER FOR COKE QUENCHING SODIUM HYPOCHLORITE SLUDGE CLARIFIER
TRICKLING 2ND STAGE OUTLET CHARACTERISTICS FILTER CLARIFIER PHENOL : < 1 mg/l NH3 : 50 mg/l TREATED CHLORINE RD CN : 0.2 mg/l 3 STAGE WATER SUMP CONTACT TANK CLARIFIER RETURN RECYCLE O&G: 5mg/l RECYCLED TREATED WATER NUTRIENT H3PO4, ALKALI NaOH/NaHCO3 CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 158 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT New Pellet Plant A recirculation cooling water system has been considered for equipment cooling in pellet plant. The recirculation water system will be based on the ‘Zero discharge concept’ and will consist of recirculation pumps, Cooling Tower, Duplex Filter, Emergency Overhead Water Tank, Chemical dosing unit, supply water pipelines and return water pipelines with valves, fittings etc. All the equipment will be installed in a new Pump House located near the proposed pellet plant.
New Sinter Plant The primary water requirements in sinter plant is for cooling purposes and process needs. Soft water/ industrial water based water recirculation system is envisaged for meeting the water requirements.
Extensive recycling shall be adopted in the design of plant water systems. Quality of circulating water will be maintained through dosing of conditioning chemicals for controlling corrosion, scale deposit and microbial growth. Effluent of soft water plant, after proper neutralization, shall be discharged in the existing uncontaminated water network of BSL and returned into the Return canal between Cooling Pond-1 and Cooling Pond-2.
The measures envisaged for water pollution are expected to contain the water pollution within tolerance limit as specified in CPCB and other related statutory norms. The following measures will be employed during operation phase to reduce the pollution level to acceptable limits: x Recirculating water in the process whereby the discharge volume is brought to minimum. x Clarifier and sludge pond for removal of suspended solids x Neutralization of acidic water by lime x Removal of oil and grease from the contaminated water by means of oil traps and skimming devices x Use of treated waste water in different shops and for plantation development as far as practicable. x Treatment of faecal sewage in a sewage treatment plant /septic Tanks & soak pits and removal of sludge after biological treatment.
Modernized CRM Complex: A new Effluent treatment plant (ETP) & Tertiary treatment plant (TTP) has also been envisaged for the CRM complex of BSL. The details of the scheme is elaborated in subsequent paragraphs.
¾ Effluent treatment plant (ETP): Effluents will be generated from the different process units of new CRM complex viz. Coupled Pickling Line and Tandem Cold Mill Plant, Hot Dip Galvanising Line and Electrolytic Cleaning Plant, Acid Regeneration Plant, Skin Pass Mill Plant and Roll Shop. The different streams of waste water effluents generated from above process units shall constitute oil contaminated effluents from pickling line, oil / emulsion contaminated liquid effluents along with iron fines and
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 159 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT other solids, etc. from TCM, alkaline effluents containing oil, iron fine, soap, detergent, etc. from HDGL and ECL, neutralized effluent containing suspended solids, TDS, etc. from Acid Regeneration Plant, liquid effluent containing oil emulsion, iron particles, scales, dust and hydraulic oil, detergent oil, etc. from Skin Pass Mill and oil / emulsion contaminated liquid effluents along with iron fines, detergent, grease, etc. from Roll Shop which needs treatment to remove contaminants / pollutants to meet the statutory norms before discharging into the storm drain. An Effluent Treatment Plant (ETP) has thus been envisaged for treatment of above effluents. The effluents anticipated to be generated shall be mainly; x Oil emulsion contaminated effluents x Chemical contaminated effluents x Alkaline & oily Alkaline effluents x Neutralized effluent
The different streams of effluents are expected to be discharged separately from individual process units of the CRM complex. Some of the effluents shall be discharged in batches while other effluents shall be discharged continuously.
¾ Oil contaminated Effluent Treatment System: Oil contaminated liquid effluents are mainly from the Pickling Line, TCM, Skin Pass Mill and Roll shop which contain rolling oil / emulsion, fine iron and solids, mineral oil, bearing lub oil, hydraulic oil, grease, etc.
The oil contaminated effluent shall be collected in separate collection tanks at the proposed ETP. Two numbers of collection tanks, one for collection of bulk rolling emulsion oil effluent from Roll Coolant Main Tank System Draining from TCM, which shall be drained twice in a year and the other tank for collection of rolling oil / emulsion contaminated effluent from the Pickling Line, TCM, Skin Pass Mill and Roll shop on regular basis.
Each of the collection tanks shall be provided with belt type motorized oil skimmer for removal of free floating oil.
Since the oily effluent due to Roll Coolant Main Tank System Draining shall be twice in a year, the drained quantity of emulsion oil effluent needs to be treated with in four to five months’ time period. From effluent collection tanks, effluent will be pumped to the Reaction Tank fitted with SS agitator and also provided with on line pH monitor. Chemicals like Ferrous Sulphate (Ferric alum), acid, alkali (NaOH) in required proportions shall be dosed to the reaction tank for breaking the emulsion (de-emulsification) at the required pH range. This de-emulsified effluent from the reaction tank shall be pumped through DAF feed pumps to the Dissolved Air Floatation (DAF) Unit for separation of the de-emulsified oil as floating oil and any suspended particles as sludge. Polyelectrolyte solution from the polyelectrolyte solution preparation and dosing tanks shall be dosed in the DAF unit to enhance the separation of oil and settling of the suspended particles / solids. The floating oil from the DAF Unit shall be skimmed off by the skimmer provided in the DAF unit and the skimmed oil shall be collected in the skimmed oil tank. The over flow effluent from the DAF unit shall flow by gravity to the two stage Aeration
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 160 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Tanks and followed by respective Secondary Settling Tanks (SST) for reduction of BOD/ COD and other pollutants.
¾ Oily Alkaline contaminated Effluent Treatment System: Oily and Alkaline contaminated liquid effluents are mainly from the Hot Dip Galvanising Line (HDGL) and Electrolytic Cleaning Line (ECL). These effluents are contaminated with alkali (NaOH) and along with oil, iron fines, soap, detergent, Zinc particles, etc. The effluent collection tank will be provided with motorized oil skimmer for removal of free floating oil.
Neutralized effluent generated from ARP which is in alkaline pH range is also envisaged to be collected in the same collection tank along with oily alkaline effluent. The free floating oil shall accumulate on the top layer of the effluent surface in the effluent collection tank. The effluent from the effluent collection tank shall be pumped by effluent transfer pumps to the neutralisation cum reaction tank. Required quantity of chemicals like acid solution and ferrous sulphate solution shall be dosed into the neutralisation cum reaction tank for neutralization of the alkali effluent and also for de-emulsification of the oil present in the effluent. The neutralized de- emulsified effluent from the neutralization cum reaction tank shall be pumped by DAF feed pumps to the independent DAF unit for separation of the de-emulsified oil and suspended solid particles present.
¾ Common Treatment to Oily Contaminated & Oily Alkaline contaminated Effluents: The Aeration Tanks will be provided with surface aerators. The Secondary Settling Tanks (SSTs) will be provided with bottom sludge scrapper arrangement and sludge removal arrangement along with sludge collection sump and sludge recirculation and excess sludge disposal pumps. Provision shall be provided to dose poly electrolyte / ferric alum in the SSTs to enhance settling of suspended particles.
The two stage aeration tanks treatment system followed by respective secondary settling tanks will be common for both the oil contaminated effluent treatment stream and the oily alkaline effluent treatment stream (for treatment of effluents from the HDGL & ECL and ARP). The clear clarified partially treated effluent overflowing from the second SST shall be collected in the clarified effluent collection tank. The combined clarified effluent thus collected in the clarified effluent tank shall be pumped by pressure sand filter feed pumps to the Pressure Sand Filters and Activated Carbon Filters in succession which will act as polishing units for removal of any suspended solids and remaining organic matter so as to meet the norms of BOD and COD and the treated effluent quality.
The filtered and treated effluent shall be collected in the filtered treated effluent tank. This treated effluent shall be partially used for backwashing of the pressure sand filters and the activated carbon filters. The back washed dirty waste water from the filters shall be collected and pumped back into the treatment system. The treated filtered water tank will be provided with a pH meter for monitoring the final pH of the treated effluent being reused. Provision is also to be kept by providing piping arrangement / system to partially reuse this treated effluent
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 161 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT for chemical solution preparation. The balance treated effluent from the treated filtered water tank shall be reused.
The underflow from the DAF unit and the SSTs shall be collected in the respective sludge collection sump and then shall be pumped through respective vertical sludge transfer pumps for sludge recirculation into aeration tanks and excess sludge to the common sludge drying beds provided with filter media and filtrate collection jointed pipes for dewatering and drying of the excess sludge. The dried sludge shall be later disposed to designated low lying areas or designated waste dump area. The filtrate from the sludge drying beds shall be collected in the filtrate collection tank and pumped by filtrate recirculation pumps back into the treatment system.
The indicative quality of influent to the ETP from various shops is as follows: Shop Section Parameter Unit Quantity 3 Pickling Section Average flow m /h 1 to 3 HCl g/L 20 to 40 Temperature °C 50°C Rinsing Section Average flow m3/h 4 to 6 FeCl2 g/L 20 HCl g/L 20 to 40 Temperature °C 70° C Fume Exhaust – Scrubber Average flow m3/h 1.2 FeCl2 g/L trace COUPLED PICKLING LINE COUPLED PICKLING HCl g/L 10 Condensate from Fume Average flow m3/h 3 exhaust Oil % 3% Fine iron mg/l 15 Roll Coolant Sump pit Average flow m3/day 1.0 Rolling emulsion % 1.50% Mineral oil & other solids % 0.50% Effluent from Sump pits 1 Average flow m3/day 1.0 to 4 Rolling emulsion % 1.5 to 2.5 Mineral oil & other solids % 0.5 Effluents from Roll Coolant Average volume m3 400 m3, two (2) times/year
TANDEM TANDEM COLD MILL (TCM) Main Tank System Draining Rolling oil % 3%-5% (max) Iron fines mg/l 5 (max) Cleaning section Average flow m3/h 1 to 2 NaOH g/L 20 to 30 Temperature °C 80°C Oil g/L 6 Overflow rinse Average flow m3/h 5.0 to 6.0 solution NaOH g/L 6.0
(HDGL) (HDGL) Temperature °C 60°C Fume exhaust system - Average flow m3/h 0.3 scrubber NaOH g/L 1.0 De-concentration Temperature °C 50°C HOT DIP GALVANISINGHOT DIP LINE Skin Pass Mill Average flow m3/h 0.8 Cleaning section Average flow m3/h 1 to 2 NaOH g/L 20to 30 Temperature °C 80°C (ECL) (ECL) ELECTROLYTIC ELECTROLYTIC CLEANING LINE Oil g/L 6
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 162 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Shop Section Parameter Unit Quantity Overflow rinse Average flow m3/h 5 solution NaOH g/L 6.0 Temperature °C 60°C Fume exhaust system - Average flow m3/h 0.3 scrubber NaOH g/L 1.0 De-concentration Temperature °C 50°C Average flow m3/h 30 ACID REGENERATION PLANT (ARP) pH - 7.5 to 9
The total treated effluent from the proposed ETP shall conform to the following quality (tentative): Parameter Unit Quantity pH mg/l 7.0 to 8.5 Suspended solids mg/l <100 Oil & grease mg/l <10 BOD (3 days, 27oC) mg/l <30 COD mg/l <250 Iron as Fe mg/l <3.0 Sulphide as S mg/l <2.0
A scheme for treatment in the ETP is shown in Fig. 4.3.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 163 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig. 4.3: Scheme of ETP of CRM complex in BSL
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 164 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT A Tertiary treatment is also envisaged for CRM complex of BSL. The proposal envisages addition of a new Tertiary Treatment Plant of capacity 110 m3/hr with necessary pre-treatment, zero liquid discharge treatment plant of capacity 11 m3/hr along with auxiliaries. The details of the TTP is elaborated hereunder.
¾ Tertiary Treatment Plant (TTP) RO based Tertiary treatment plant is proposed for the treatment of blow down water of various cooling towers, RO reject from water supply complex, underflow from HRSCC of water supply complex and advanced treatment of treated effluent from the existing Effluent Treatment Plant of CRM Ill for further reuse as make up to cooling tower of circulation system of CRM - Ill. The Tertiary treatment plant will consist of pre-treatment plant to treat the incoming effluent to the quality as acceptable for the RO plant.
The tertiary treatment plant will have following stages of treatment scheme for satisfying the norms of treated water quality. x Primary Treatment comprising of Equalization tank, Flash Mixer, x Solid Contact Clarifier Reactor, sludge dewatering plant x Tertiary Treatment comprising of Multi Grade Filter and x Advanced membrane technology comprising of Ultra, reverse x Osmosis. x Zero Liquid discharge Plant x Make-up clarified water, drinking water, fire fighting facilities
Combined waste water from RCC common collection sump will be collected into Equalization tank having retention time about 2 hours where Sodium Hypochlorite I suitable chemical will be dosed. One tank in MSRL construction and two dosing pumps will be provided for dosing Sodium Hypochlorite for pre-chlorination purposes i.e. to take care of BOD & COD present in effluent water. Effluent water from the tank will be pumped by means of two pumps (one working and one standby) to the pre-treatment units i.e. in HIGH RATE SOLID CONTACT CLARIFIER (HRSCC), from where it will be collected in CWST and will be pumped by means of two pumps (one working and one standby) to Multi-Grade pressure Sand filters to remove the suspended matter from effluent water. Backwashing of the filters will be done with the help of OHT. The waste back washed Waste water will be collected in waste collection pit and from where it will be pumped to flash mixer.
The raw effluent from equalization tank will be pumped to flash mixer unit, where Lime, Dolomite will be added to increase the pH of effluent for reduction in silica content of effluent and to enhance the settling of solid particles present in effluent.
ACTIVATED CARBON FILTER (ACF): Either Na2SO3 will be dosed in the filtered water or Activated Carbon Filter (ACF) will be provided for de-chlorination purpose and accordingly either one tank in FRP construction with agitator and two pumps will be provided for Na2SO3 dosing or one ACF along with all piping will be provided. Back washing of ACF will be done with the help of OHT and waste back washed water will be used for dilution of RO reject.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 165 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT After Chemical reaction with the lime and dolomite lime effluent will enter under gravity to Ultra High Rate Solid contact clarifier whereFeCI3 and Polyelectrolyte will be dosed in the effluent.
The sludge generated from HRSCC will be collected in sludge sump and will be sent to Centrifuge for dewatering. Polymer dosing system need to be provided with dosing tanks and pumps. Overflow from the clarifier will be passed through chlorine contact chamber after pH correction by acid in upstream channel before collecting into the Clarified water tank.
Tertiary Treatment: Clarified water will then pass through the MULTI GRADE FILTER (MGF) for removing suspended solids, turbidity etc. The arrested solids/ turbidity in the filter will be removed by back washing.
Sludge generated from clarifier will be dewatered by Centrifuge. The filtrate from Centrifuge will be routed back under gravity to the Filter Back wash collection tank from where it will be pump to Flash Mixer. The filtered and sterilized water will be dosed with hydrochloric acid for lowering pH so as to avoid the possibility of scale formation on membranes. The pH correction of feed water will be followed by chemical treatment with Sodium Bi-sulphite to remove any free residual chlorine if any and anti-scalant to avoid scaling of membrane.
Advanced membrane technology: The treatment system for effluent water will comprise of two train of Ultra Filtration (UF) Membrane of latest technology. The pre-treated filtered water will be passed through basket type strainer & then through the filtration skid.
For the removal of colloidal suspended solids, colloidal solids that maybe present in the water, a skid mounted, automatically operated. Filtration system will be provided. Removing of solids from the water will help in reducing the COD, BOD content in the water. The reject / Waste generated from the Ultra filtration will be taken back into the Filter back wash collection sump and from where it will be pumped in let of Flash mixer Tank
This Membrane filtration module will be used for the removal of colloidal matters, suspended solids & pre-treatment to reverse osmosis system. It also helps in removing COD, BOD to some extent due to separation of solids.
Reverse Osmosis System: Pre-treated water after adjustment of pH and chemical conditioning will be pumped by high pressure pumps (Two working pump and two standby pump) into Reverse Osmosis train. The permeate from pressure tubes of R.O. blocks will be combined and will flow to the Permeate water storage tank.
Provision will be made for flushing of the system automatically after each shutdown so as to prevent the precipitation of sparingly soluble materials on the membrane surface during periods of shutdown. pH of the permeate will be corrected by caustic soda. The alkali dosing system will consist of one alkali preparation tank, one alkali day tank and two alkali metering pump. Alkali preparation tank will be fitted with agitator for making solution using flakes.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 166 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The R.O system will be manually operated. Since cleaning to the membrane system requires intermittently, manual operation system provided for cleaning of both filtration as well as RO Systems.
The tentative scheme for the TTP is shown in Fig. 4.4.
Fig. 4.4: Scheme of TTP of CRM complex in BSL
¾ Zero Liquid Discharge Plant for CRM complex: The feed to the Zero Liquid discharge Plant will be the stream from RO reject from RO plant in TIP area.
The system will be based on Polymeric/Non-Polymeric Heat Exchanger Type Mechanical Vapor compression principle. The system will be fully integrated automated system incorporating a mechanical vapour compression unit with vibrating screen bowl centrifuge. The high purity distillate produced in the system will be used as process makeup water. The
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 167 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT evaporation system will be sized for concentrating RO rejects and will have the required normal water evaporation capacity.
The reject from the waste-streams will be collected in separate waste-water tanks. The wastewater will then be pumped at constant rate for preheating by exchanging heat with the outgoing distillate. The most cost-effective plate and frame exchanger for this service will be provided. The preheated reject will flow into the flash tank. The Slurry will discharge continuously from the flash tank to the centrifuge. This slurry is fed to the centrifuge which will separate out the salt crystals as a cake.
The evaporated vapor will flow through the mist eliminator in flash Tank to the suction of the Mechanical Vapor Compressor. The compressed vapor will flow to the heating side of the evaporator. As it condenses, it will transfer the latent heat of vaporization back to the liquid film on the tube side. Condensed water vapor will be pumped out of the system as distillate after transferring heat in the forced Circulation Heat Exchanger.
The following treatment steps are envisaged in the Evaporation Plant: x Preheating of the Feed x Evaporation of the water and concentrating the feed in Falling Film & Forced Circulation / MVR Evaporator using polymeric/Non-Polymeric heat exchanger. x Super saturation of the concentrate in MEE (Falling Film /Forced Circulation) x Separation of salt and mother liquor.
The reject from RO plant will be fed in to the Evaporator plant. Evaporation takes place under vacuum when it reaches its boiling point when heated with steam initially. The vapour generated flows into a fan, which adds energy by increasing the pressure and temperature of the vapour. After compression the vapour releases' its latent heat and condenses by transferring the heat through the polymeric heat exchangers causing the solution on the exterior surface to release more vapour. The concentration of the liquor increases as the evaporation progresses and concentrate is discharged to the MEE (Combination of falling Film and Forced Circulation).
The reject from MVRE process is preheated in pre-heaters. The preheated feed is then pumped through the calandria of the evaporation plant to be concentrated by vaporizing the water using dry saturated steam from the Boiler. The evaporation takes place under vacuum. The concentration of the liquor increases as the evaporation progresses and achieves a maximum possible saturation of major salt. The final concentrate is super-saturated in salt recovery system comprising evaporative crystallizer and centrifuged to separate the dry, salt from mother liquor. The evaporated water is then condensed using a condenser and pumped to the condensate tank for storage.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 168 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Zero Liquid Discharge Systems for Overall Bokaro Steel Plant: BSL receives raw water for industrial and domestic applications from Tenughat Dam through the Bokaro Canal. The raw water for industrial applications is received and stored in two interconnected Cooling Ponds with a gross storage volume of 50 million cum. The Bokaro Canal has a maximum carrying capacity of 20,000 m3/hr. Water for various consumer departments are pumped from the cooling ponds and most of the industrial waste water which are physically contaminated by heat or suspended impurities within acceptable norms are gravitated back to the cooling ponds.
However, a substantial quantity of water from the recirculation systems gets wasted to the storm water networks of the plant which ultimately drains to the Damodar River through various storm water outfalls.
In order to treat, recycle and reuse the water through the two Outfalls of BSL, Zero liquid discharge (ZLD) system has been contemplated by BSL. The details of system envisaged for recycling of waste water from CO & BPP, SP, RMP and Blast furnace area for reducing water consumption and achieving zero discharge is elaborated in paragraphs below.
¾ ZLD system for wastewater from CO&BPP, SP, RMP and BF (OF-1A) A substantial dry weather flow (DWF) of water has been observed in the outfall - 1 (discharge from CO & BPP, SP, RMP and BF areas) which drain to nallahs near ten hole culvert leading to River Damodar. These drains gravitate in RCC sewers within the plant periphery walls. It is proposed to Recycle about 1750 m3/hr of drainage water from outfall-1 and pump the same to the consumers by installation of two waste water treatment plants (WWTPs) of 1500 m3/hr and 250 m3/hr nominal capacity and having required facilities like settling, pH correction, oil skimming and pumping.
The proposed facility shall comprise of the two Waste water treatment plant (WWTP) for recycling the DWF water from the CO&BPP area (WWTP-1 of 250 m3/hr) & BF, SP, RMP area (WWTP-2 of 1500 m3/hr) to the CO & BPP area and Cooling Pond No-1/respectively through delivery pipe lines with all necessary design features for diversion of the outfall flows, primary settling, cyanide, phenol and oil removal using suitable belt oil skimmers etc.
Each WWTP shall consist of an arrangement to collect and divert water from the gravity RCC pipe/open channel to the recycling WWTP with suitable pumping and chemical dosing arrangement. WWTP 1 & 2 shall be properly designed to have the essential design features for diversion, settling, oil skimming and pumping of the waste waters from the respective outfalls which shall comprise of the following in general for each plant:
x WWTP-1:Waste water shall be collected from drain pipe with sluice gate arrangements to the underground RCC collection sump with screening arrangement for collection of waste water. (2w+2s) No. of horizontal centrifugal pumps, with electric motor each with a discharge capacity of 125 m3/hr of water having suitable discharge head and other accessories.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 169 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
The waste water collected will be pumped by pumps installed in RCC pump house to the above ground collection cum settling tank and dissolved air floatation (DAF) unit. There shall be arrangement for acid treatment in these units. After removal of BOD/COD, phenol and oil etc. the waste water shall be fed to the clarifier for TSS removal and pH correction. The treated water shall be pumped to inlet of BOD and partly to slag processing area nearby.
x WWTP-2: Waste water shall be diverted from open channel with sluice gate arrangements to the underground collection sump with screening arrangement for collection of waste water at ten hole culvert area. (2w+2s) Nos. vertical centrifugal pumps, with electric motor each with a discharge capacity of 750 m3/hr of water having suitable discharge head and other accessories.
The waste water collected will be pumped by pumps installed in RCC pumphouse to the above ground collection cum settling tank unit with aeration and skimmer arrangement.The treated water shall be pumped to the cooling pond-1.The collection and conveyance system in both the plants above shall be such that either during heavy and sudden downpour or during monsoon season the rain water shall automatically get diverted to Outfall nallah without any manual intervention.
The Input quality of waste water from the outlets observed are as follows: Parameters CO&BPP SP, RMP & Blast Furnaces pH 5.0-9.0 6.5-9.0 Oil/Grease (In mg/L) 2.0-12.0 1.0-3.0 Phenol (In mg/L) 0.5-8.0 Cyanide (In mg/L) 0.15-0.80 COD (In mg/L) 70.0-350.0 70.0-150.0 BOD (In mg/L) 10.0-50.0 7.0-17.0 Ammonical Nitrogen (In mg/L) 5.0-30.0 TSS (In mg/l) 55.0-150.0 80.0-160.0 TDS (In mg/l) 150-350 150-350
The indicative treated water quality for discharge to cooling pond/process water is as follows Parameters Unit Quantity pH 6.5 – 8.5 Oil/Grease mg/L <1 TDS mg/L <500 TSS mg/L <10 Phenol mg/L <0.01 Cyanide mg/L <0.05 COD mg/L <60 BOD mg/L <10 Turbidity NTU <5
An indicative scheme for treatment in the ZLD plant is shown in Fig. 4.5.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 170 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig. 4.5: Indicative Scheme of ZLD in BSL
In addition to the above measures, BSL’s storm water drainage systems are routed through engineered storm water drains to the plant’s Cooling Ponds, which also act as water reservoirs. Some of the minor effluents e.g. boiler blow-downs from the captive power plant are routed to the cooling ponds, where they get diluted.
¾ ZLD system for wastewater from TPP/TBS flows and excluding CO/SP (OF-1) & for wastewater from mils area excluding HSM, Slabbing mill (OF-2A) It is proposed to collect, treat and recycle the wastewater of outfall-1 by suitably setting up a facility at a convenient location having a nominal capacity of 1500 m3/h called the Waste Water Treatment Plant-1 (WWTP-1). The wastewater as reclaimed from WWTP-1 will be suitably discharged for industrial use to the existing cooling pond-1.
A similar facility for Outfall-2A suitably in another location called the WWTP-2 having a nominal capacity of 1500 m3/h is also envisaged. The wastewater as reclaimed through WWTP-2 will be suitably discharged for industrial use to the existing cooling pond-2.
The waste water in outfall-1 & outfall-2A of BSL are assessed as having more or less equal dry weather flows at around 1500 cu.m/hr each. It is proposed to have one Waste Water Treatment plant (WWTP) of 1500 cu.m/hr capacity, for each of these outfalls. The proposed WWTP 1 & 2 will be located at a place from where waste water of outfall-1 and 2A will be collected. This facility proposed will comprise of:
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 171 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Waste Water Treatment Plant-1 [WWTP-1] with wet well for collection of waste water, dry well pump house , above ground settling cum oil removal tank and gravity discharge pipelines having a capacity of 1500 m3/h near to the nallah at the mouth of outfall-1. The waste water will be diverted suitably from the nallah to the wet well using diversion pipe in such a way that flooding and siltation in the nalla and outfall sewer are avoided.
x Waste Water Treatment Plant-2 [WWTP-2] with wet well for collection of waste water, dry well pump above ground settling cum oil removal tank and gravity discharge pipelines having a capacity of 1500 m3/h for outfall-2. In this case, waste water is suitably diverted from the underground sewer pipe of approximately 2000 mm dia leading to outfall-2A and diverting it to the wet well of the pump house in such a way that flooding and siltation in the sewer line is avoided.
Both WWTP 1 and WWTP 2 will have similar design features. Both these plant will be built over an area of 50m x 50 m size approx. Both the WWTPs will have the following facilities:
x A collection sump (wet well) arrangement which shall be used to collect the waste water from the respective storm sewer and dry well for installing the pumps water will be pumped to the settling cum oil flotation sump of the respective WWTP.
x An RCC settling cum flotation tank with partition walls having a size approx. 30m x 25m x 4m depth. Major area of this tank will be open to atmosphere. The waste water intercepted will be admitted to this tank through pumps installed below ground level in dry well. Free oils and major part of suspended solids from the waste water will be removed in this. Floating oils from the oil separator chamber will be continuously removed by using belt-oil separator mechanisms of suitable design. Settled sludge will be periodically removed from the bottom of the tank using sludge underflow valves and piping.
x Oils skimmed out by the motorized oil skimmer will be collected in drums for periodical removals and disposal.
In general, the waste water which is of a chemical quality not exceeding that of the water in the Cooling Ponds (CP) or is not likely to adversely affect the CP water quality is deemed as suitable for recycling to the Cooling Ponds.
The proposed system will treat the effluent to the same quality before discharge into the cooling ponds, as typically noted below: Parameters Unit Quantity pH - 5.8 – 8.8 Oil/Grease ppm <2 TDS ppm <500 TSS ppm <150 COD ppm <100 BOD ppm <30
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 172 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Typical schematics of the WWTP(s) is shown below:
Fig. 4.6: Indicative Scheme of ZLD in BSL
Sewage Treatment Plant:
A Sewage treatment plant (on BOO basis) is also envisaged by BSL for treatment of sewage generated from Bokaro Steel Township and reused for industrial purposes.
At present Bokaro Steel Plant (BSL) is supplying about 30 million gallons per day (i.e. 1,35,000 m3/day) of potable water to plant and different sectors of its township for domestic and other purposes. Total sewage/ waste water generation from the township and plant is approximately 20 MGD (i.e. 90,000 m3/day). There are a total of five oxidation ponds in Bokaro Steel City Township which treat approx. 10 MGD (i.e. 45,000 m3/day) of sewage. BSL envisages to treat the discharge from the existing oxidation ponds as well as the untreated sewage (totalling to 20 MGD) and reuse the treated water for industrial purposes.
Basic approach envisaged for setting up the treatment facility shall be based on Moving Bed Bio Reactor (MBBR)/ Sequential Bio Reactor (SBR)/ Membrane Bio Reactor (MBR) or Activated Sludge process (ASP) technology, whichever is found most techno-economically feasible.
A tentative capacity of each component of the proposed STP is as follows:
Sl. No. Description Design Capacity (MGD) Treatment Process 1 Intake Works, Sewage 20 (avg)/ 45 (peak) Intake Works :Intake chamber, Pumping Station at Nallah Intake Channel,Mechanical & Manual and Transmission pipeline Screening from raw sewage pumping Nallah Sewage Pumping Station: station to proposed STP. Raw Sewage Sump + Pump House arrangement withSubmersible Pumps Transmission Pipeline 2 Sewage Treatment Plant 20 (avg)/ 45 (peak) Primary Treatment : Inlet Chamber, (STP) Fine Screening System Grit Removal system, Secondary Treatment: CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 173 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. No. Description Design Capacity (MGD) Treatment Process Aerobic Biological Treatment including phosphorous removal + pH correction system Sludge Handling: Sludge Thickening + Dewatering + Belt filter press 3 Tertiary Treatment Plant 20 (avg)/ 45 (peak) Tertiary Treatment Plant and (TTP) and Tertiary Treated Pumping Station: Sewage Water Pumping Rapid Sand Gravity filtration (dual station at Site media) and Disinfection through UV and Chlorine or any other suitable technology for tertiary treatment. 4 Transmission Pipeline from 20 (avg)/ 45 (peak) The length of the pipeline is about 5 STP Site to Cooling pond KM (from STP Site to Cooling pond no -2 no-2)
The desired quality parameters of the treated water have been arrived at to match with present industrial water quality of the plant, as mentioned below. Sl. No. Parameters Units Waste water characteristics Desired treated quality 1. Daily Average Flow M. G. D. 20.00 ---- 2. Peak Flow Factor ---- 2.25 ---- 3. pH ---- 6.0-8.0 7.5 – 8.5 4. D. O. mg/l 1.0-1.8 6.0-8.0 5. Total BOD(5) at20°C mg/l 30-90 <5 6. Total COD mg/l 250 <50 7. TSS mg/l 130 <5.0 8. Hardness mg/l 130 <75 9. TDS mg/l 800 Lower than the TDS of raw sewage to the extent of total hardness reduction to level mentioned above 10. Total Alkalinity mg/l 180 ---- 11. Phosphate (As PO4) mg/l 7-11 <1.0 12 Sulphate mg/l 30-40 ---- 13 TKN mg/l 10.0 <5 14 Ammonia Nitrogen mg/l 6.0 4 15 Chloride mg/l 44.0 ---- 16 Oil & Grease mg/l 1.0 <5.0 17 Fluoride mg/l 1.0 <1 18 Turbidity NTU - <5.0 19 E. Coli MPN/100 ml - NIL 20 Residual Chlorine mg/l - 1.0 (Min.) 21 Total Nitrogen mg/l - <5.0
The summarised list of water pollution control systems envisaged for the proposed expansion-cum- modernization programme is summarized below in Table 4.8:
Table 4.8: List of Water Pollution Control Systems Sn Source Major Pollutants Control System Coke Oven and Oils, Suspended Solids, ammonia, Oil, organics and ammonia removal, in BOD 1. by product plant phenols etc. Plant Recirculation system based on zero discharge 2. New Pellet Plant Temperature, Dissolved Solids concept with chemical dosing, settling tank etc.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 174 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sn Source Major Pollutants Control System Recirculation system based on zero discharge Oils, pH, dissolved solids, 3. New Sinter Plant concept with oil traps, neutralization pits, clarifier Suspended Solids and sludge pond xETP with Oil traps/skimmers, alum dosing, alkali dosing, acid dosing, Polyelectrolyte Oils, chemicals, dissolved solids, dosing, floatation, clarification and sludge 4. CRM complex suspended solids, acidic effluent, drying beds. alkaline effluent xTertiary treatment with advanced membrane technology Overall discharges from pH, Oils, Suspended Solids, ZLD System including Waste water treatment 5. existing COBP, ammonia, phenols, dissolved including primary settling, cyanide, phenol and oil SP, RMP and BF solids, etc. removal and chemical dosing. area Discharges from ZLD System including Waste water treatment pH, Oils, Suspended Solids, 6. TPP/TBS and including primary settling, oil removal and dissolved solids, etc. Mills area chemical dosing with clarification/floatation. Soft and DM 7. pH and dissolved solids Neutralizing Pit Water Plant Cooling Tower 8. and Boiler Blow- Temperature, Dissolved Solids For re use down 9. Canteens, Toilets BOD, Suspended Solids Sewage treatment plant
4.6.3 Noise Environment A) Impacts In any integrated steel plant the major sources of noise are:
1. Movement of railway wagons / trains and road trucks bringing raw materials to the plant and / or carrying away finished products. 2. Mechanised handling of raw materials 3. Crushers, grinders & screens 4. High speed blowers, fans, compressors, pumps 5. Operation of turbo-blowers and turbines 6. Operation of rotary kilns 7. Operation of foundries 8. Operation of rolling mills 9. Operation of other machinery
The noise levels of these equipment and machinery are in the range of 90-100 dB(A). As such acoustic enclosures, hoods, laggings and screens are provided in such areas to the extent possible so that the sound pressure level in working areas are restricted below 85 dB(A) for 8 hours duty.
The existing noise level in the study area, as measured is ~67 dB(A) to 40.5 dB(A) during day time and 45.2 to 35.2 dB(A) at night (Refer Table 3.13, in Chapter 3).At the boundary of the steel plant, noise level in the study area, as measured is ~74 dB(A) to ~59 dB(A) during day time and 51.6 to 45.5 dB(A) at night (Refer Table 3.36(b), in Chapter 3).
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 175 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Noise level is likely to increase in the project area as the project becomes fully operational. In the plant the personal exposure shall be less than 90 dB(A) over 8 hours.
For hemispherical sound wave propagation through homogeneous medium, one can estimate the noise levels at various locations due to different sources using a model based on the following principle- Lp2 = Lp1 – 20 Log10 (r2/r1),
where Lp1 and Lp2 are the sound levels at points located at distance r1 and r2 from the source.
This indicates that noise level decreases by 6 dB(A) for doubling of the distance. Combined effect of all the sources (A,B,C,…. Etc.) can be determined at various locations by the following equation:
Lptotal = 10 Log10 (10Lpa/10+ 10Lpb/10+ 10Lpc/10…………..),
Where Lpa, Lpb and Lpc are noise pressure levels at a point due to different sources.
Considering that the maximum noise level just outside the steel plant at a distance of ~25 m is73.8 dB(A) [the maximum noise level at Gate No. 4], the noise levels on account of the project only at different distances from the plant are illustrated in Fig. 4.7.
Fig. 4.7 Noise levels on account of the project only at different distances from the plant
The expected noise levels at nearby receptors due to the proposed expansion project are given in Table 4.9.
Table 4.9: Resultant Noise Levels at Nearby Villages due to proposed Project Location Distance from Max. Existing Noise Addl. Noise due to Resultant Max. Project site (km) Level [dB(A)] * Project[dB(A)] # Noise[dB(A)] Bokaro Niwas 6.3 km, E 54.4 37.5 54.5 Sector – XII, Community Centre 5.2 km, SE 53.6 39.2 53.75 TA Building 3.5 km, E 64.8 42.6 64.8 City Center, Sector IV 3.6 km, ESE 64.8 42.4 64.8 Sector-IV B 3.8 km, E 53.8 41.9 54.1 Air Strip 5.2 km, SE 64.7 39.2 64.7 * Refer Table 3.12 # Considering Noise Level of 85 dB(A) at 10 m distance from source/project site
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 176 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Thus from the above table it can be observed that the activities at the proposed expansion area of project may marginally affect the ambient noise levels at nearby receptors in the study area, even if attenuation by the plant’s existing structures / buildings and green belt is not considered. Those at a distance will not be affected.
Measures suggested below shall reduce the noise level.
B) Mitigation measures
Various measures proposed to reduce noise pollution include reduction of noise at source, provision of acoustic lagging for the equipment and suction side silencers, vibration isolators, selection of low noise equipment, isolation of noisy equipment from working personnel. In some areas, personnel working will be provided with noise reduction aid such as ear muffs/ ear plugs and also the duration of exposure of the personnel will be limited as per the norms. The following measures will be undertaken:
Technological Measures x Plugging leakages in high-pressure gas/air pipelines. x Reducing vibration of high speed rotating machines by regular monitoring of vibration and taking necessary steps. x Design of absorber system for the shift office and pulpit operator's cabin. x Noise absorber systems in pump houses. x Noise level at 1m from equipment will be limited to 85 dB (A). x The fans and ductwork will be designed for minimum vibration. x All the equipment in different new units and in units where capacity expansion is taking place will be designed/operated in such a way that the noise level shall not exceed 85 dB (A). x Periodical monitoring of work zone noise and outside plant premises.
Management Measures In a steel plant, with a variety of noise generating equipment and processes, it may not be practicable to take technological control measures at all the places. Nevertheless noise exposure level shall be maintained below 90 dB (A) in work zone (for 8 hours exposure). The following measures will be taken to reduce noise levels.
Certain very high noise areas will be marked as such (e.g. Compressor area of Oxygen Plant, Turbo-Blower Station) and entry of personnel in such area will be kept to a minimum. The crushers and screens shall have independent block foundation isolated from other supporting structures. Crusher internal elements shall be covered by casing to reduce transmission of impact noise. The fans and ductwork will be designed for minimum vibration. Maximum allowable vibration level shall be as per VDI – 2056 guidelines. To the maximum extent possible nosy machinery shall be placed inside acoustic enclosures. Casings of turbines, high speed compressors and pumps will be covered with sound absorbing lagging.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 177 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Plugging leakages in high-pressure gas/air pipelines. Reducing vibration of high speed rotating machines by regular monitoring of vibration and taking necessary steps. Proper balancing of fans shall be carried out to reduce vibrations. All rotary machinery shall be adequately lubricated as per manufacturers’ guidelines In a steel plant, with a variety of noise generating equipment / machinery / processes, it may not be practicable to take technological control measures at all the places. In such cases the following administrative measures shall be taken. Crusher operators, pump operators shall be issued earmuffs. Wearing personal protective equipment will be compulsory and the Safety Department shall carry out regular inspections to this effect. In shops where measures are not feasible, attempts shall be made to provide operators with soundproof enclosure to operate the system. Duty hours of operators of noisy machinery shall be regulated to keep their noise exposure levels within limits. All workers will be regularly checked up medically for any noise related health problem and if detected, they will be provided with alternative duty.
Over and above all these, trees and shrubs of substantial widths will be planted to achieve sound attenuating effect. The trees and shrubs already planted inside plant and in the township have already shown that noise level in the township is within norms.
4.6.4 Ecological Features A) Impacts The proposed expansion activities are taking place within existing plant complex. Hence, there is no forest area within the project site or nearby. Some of the impacts identified due to operation of the project are enlisted below: x The fauna of the project site and the impact zone is scanty comprises of common small species. The impacts of the project will be manifested over a few hundred metres radius area around the project sites where there is hardly any wildlife. Thus the expansion projects are expected to have significant impact on the overall ecology of the area. x Emissions from plant operation may affect the natural vegetation around the proposed plant.
x The threshold limit for continuous exposure of SO2 on plants is about 50 μg/m3 and that for NOx is 100 μg/m3 (Env. Engg., Chapter 7 by H. S. Peavy, D. R. Rowe, G.T. Chobanoglous. Mc.Graw-Hill Book Co.1986).The level of air pollutants due to operation of the present project will be much below the above said level, and as such it is expected that the natural vegetation in the area will not be affected. So, as far as agriculture crops are concerned, as they will remain in the field for three to six months only, the impact on the same is also not anticipated.
B) Mitigation Measures x The proposed expansion activities are taking place within existing premises of Bokaro Steel Plant premises and all care will be taken to avoid tree felling / clearance of vegetation until absolutely necessary.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 178 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x All technological measures to minimise air emissions, generation of effluents (including contaminated storm water) and noise generation have been incorporated in the design of the proposed units. x An elaborate green belt / cover is envisaged within and around the plant to ameliorate the fugitive emissions and noise from the operation of the plant. x The proposed units are designed for maximum re-circulation and no effluent will be allowed to be discharged out of plant premises. Effluents generated at the project water will be treated and treated effluents will be re-used and recycled within the steel plant itself. Thus, there will be no impact on the ecological components of surface water bodies in the area. x Overall the ecological features of the study area will hardly be affected due to the proposed expansion units.
4.6.5 Land Environment
As the proposed facilities are being setup within the existing steel plant premises, additional land acquisition is not required and thus no impact on land use is expected.
4.6.6 Solid & Hazardous Waste and disposal
Integrated steel plants generate solid wastes, some of which are hazardous while others are non- hazardous. Almost all of these wastes are reused / re-utilised, some within the facilities itself and some in other units. But there do remain some solid waste which are left un-utilised. BSL is also no exception to that. Wastes are also generated during operation / maintenance / annual maintenance of other units / shops etc., which mostly are: x Flue dust from Pollution control equipment x Waste Refractory materials x Waste lubricant / oil etc. x Waste Lead – Acid Batteries
The activities proposed in the expansion-cum-modernization programme will lead to an increase in the waste generation also. The generation quantity along with the reuse / recycle and Action plan for disposal of the solid waste is also presented in Table 4.10.
Table 4.10: Generation & Action plan for 100% Utilization / disposal of Solid Wastes from proposed expansion-cum-modernization of BSL Average Solid Waste Quantity (in Tons) Utilization envisaged** Description Existing Generation after expansion-cum- Increase (%) Generation modernization* Will be 100% utilized in SGP and in BF Slag 1537464 2192750 655286 cement making ~80% will be reused in sinter plant and BOF slag 406294 512159 105865 rest will be used to make bricks by combining with Fly ash BF Flue Dust 45325 64643 19318 100% will be reused in sinter plant Mill Scale 67683 85645 17962 100% will be reused in sinter plant Waste 5678.47 8151 2472 100% will be used for Refractory /
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 179 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Average Solid Waste Quantity (in Tons) Utilization envisaged** Description Existing Generation after expansion-cum- Increase (%) Generation modernization* Refractory mortar production Ferric Oxide 5995 7557 1562 100% sold as scrap ESP (RMP) 13302.2 18972 5670 100% will be reused in sinter plant dust BF Sludge 20228.4 28850 8621.6 Will be sold in secondary market BOF Sludge 29548.7 37248 7699.3 Coke Breeze 320326 459784 139458 100% will be reused in sinter plant *Calculated based on existing generation rates as sourced from Annual Statistics of Bokaro Steel Plant, 2017-18 **Based on existing utilization schemes and practice at Bokaro steel plant
The anticipated hazardous waste generation from the proposed expansion-cum-modernization of BSL is presented in Table 4.11.
Table 4.11: Hazardous waste generation & Action Plan for disposal from proposed expansion-cum-modernization of BSL Source of Hazardous waste Existing Generation after Mode of Disposal / Recycle / Category of waste generation generation expansion-cum- Reuse vis-a-vis Action Plan for modernization* Disposal ** By Product plant Will be disposed in captive Acidic Tar Sludge 1106 T 1588 T 13.4 of Schedule – I of Coke Ovens secured land fill Spent Vanadium Will be disposed in captive 0.1 T 0.14 T 17.2 of Schedule - I Pentoxide secured land fill (SLF) Sulphur Sludge 214 T 307 T Will be disposed in captive SLF 17.1 of Schedule – I
Decanter Tar Will be partly charged in Coke 933 T 1339 T 13.4 of Schedule – I Sludge oven & partly disposed in SLF Tar Muck with 215 T 309 T Will be disposed in captive SLF 13.5 of Schedule – I Sand etc. Mills area Will be Disposed in captive 4.1 of Schedule – I Oil & Grease Muck 152 T 192 T SLF 4.4 of Schedule – I Coke oven area Asbestos Rope 11 T 13 T Will be disposed in captive SLF 15.2 of Schedule – I DNW Transformer oil 30 KL 43 KL Will be sold to authorised buyer 5.1 of Schedule – I Oil regeneration Oil sludge from oil 0.516 T 1.2 T Will be disposed in captive SLF 4.1 of Schedule – I unit regeneration unit HDGC/CRM 6.3 of Schedule – I, Zinc dross 475 T 1548 T Will be sold to authorised buyer 11,12 of Schedule-IV 6.2 of Schedule – I, Zinc ash 66.02 T 215 T Will be sold to authorised buyer C-14 of Schedule – II Mills/Iron C-12.3 of Schedule – I Used batteries 1057 T 1508 T Will be sold to authorised buyer zone/OG/Traffic C-14 of Schedule – II BOD plant of Will be charged in Coke Oven ETP sludge 1100 T 1579 T 35.3 of Schedule – I COBPP batteries *Calculated based on existing generation rates as sourced from Annual Statistics of Bokaro Steel Plant, 2017-18 **Based on existing utilization schemes and practice at Bokaro steel plant
Additionally, Bokaro Steel plant is contemplating the installation of canteen waste processing plant. The processing facility is proposed to be Biogas plant with a capacity of generating biogas of 500 kg/day from heterogeneous organic waste like food waste, vegetable peels etc. The plant shall be of plug and play model, integrated as single unit (twin digester, enclosed within the canopy), manure by-product shall be dewatered, nutrient – rich & ready to use, fixed structure, close loop, zero leakage system, equipped with submersible agitator for higher capacity, preventing any
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 180 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT settlement of slurry or scum foaming formation with properly insulated & temperature controlled digester to ensure consistent biogas output throughout its life. A brief of the major components as part of the facility is listed in Table 4.12. Table 4.12: Major components of the Biogas plant facility Sl. No. Detail specifications 1 xTotal waste processing Capacity - 500 Kg/day 2 xPrimary Digester with aeration and secondary digester with Microbe holding technology (minimum 38 days reaction time) Volume of digester approx. 21 m3. 3 xDigestor Insulation 4 xSubmersible agitator or mixer for efficient performance 5 xSS Segregation table with organic waste crusher with a collection /mixing tank 6 xAir Circulation in Pre Digestor 7 xBiogas Storage of Minimum capacity – 30 m3 8 xDiaphragm type Biogas Flow Meter 9 xAutomatic Biogas Pressuring system for biogas burner supply 10 xSlurry Dewatering and water recycling with Filtration system for solid liquid separation, Filtration bag for manure collection and Treated water collection tank
The present status of actions towards management of solid waste (including Municipal solid waste, garbage and road sweepings) for implementation of Solid Waste Management Rules (SWM), 2016 at BSL is as follows:
Table 4.13: Action Plan for Management of Solid Waste at BSL ACTION PLAN FOR MANAGEMENT OF SOLID WASTE AT BSL Activity Action plan I. EVERY DAY DOOR TO DOOR GARBAGE COLLECTION, TRANSPORTATION & SEGREGATION (A) Collection, xEveryday door to door Garbage collection, garden refuse, any heap of garbage, littered plastic bags Supervision & and other waste from residential quarters, roadside un built areas, unauthorized road side shops, all Segregation schools, Hotels, Restaurants, office complexes, commercial areas and public buildings like Banks, Post office, LIC with the help of Safai Mitra & Tri-Cycle and by sweeping the roads & road berms manually & Primary segregation at source into Bio-degradable & Recyclable Separately.
xSufficient Supervisor to look after collection, Segregation, Transportation & maintenance of landfill Site.
From 47100 units / day - 47100 units X 548 days =25810800 units for 01 yr. 06 month. (18 Months) (B)Transportation (Tri- xFor Transportation of collected Garbage from Residential / commercial/ Public places units through Cycle) Tri-Cycles to Tractor-Trolley placed in the sector @ 01 Tractor-Trolley per 07 Tri-Cycles or to Steel Garbage Bins placed in the area
Total Tri-cycle required is 157 /days = 157 Tri-cycle x548 days = 86036 Tri-cycle for 01 yr. 06 months. (C) Transportation xFor Transportation of Garbage from placed Tractor-Trolly or Garbage Bins from different Sectors to (Tractor-Trolley) Landfill Site at Sector-XI ,the contractors has to deploy @ 01 Tractor-Trolley per 07 Tri-Cycles i.e altogether 21 Tractor-Trolley or compactor Loader for transportation of collected Garbage in Bins
21 Tractor-Trolley /compactor loader Trips / day X 548 day =11508 Trips for 01 Yr. 06 months. II. COMPACTOR-LOADER OPERATION FOR EVACUATION OF STEEL GARBAGE BUCKETS AND TRASPORTATION OF GARBAGE TO LAND FILL SITE FOR 03 YRS. (A) Evacuation and x05 trips / day evacuation and transportation of garbage from 10 steel garbage buckets per trip. transportation of x10 bucket x 05 trips = 50 buckets / day. garbage x 05 trip x 313 days = 1565 trips/ yrs. x1565 trips x 03 yrs. = 4695 trips. (B) Operation of JCB xSupply and operation of JCB machine with fuel and operator for one year for clearing the heaps of machine in Public garbage etc. and loading them in vehicle from various sectors of Bokaro Steel City township as well
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 181 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Health/ Town as cutting of trench and also levelling and dressing of dumped garbage at Municipal Solid Waste land Administration fill site as per direction of the officer in charge. Department for 03 year III. SWEEPING OF PAVED MAIN ROADS / V.I.P ROADS BY TRUCK MOUNTED VACCUM SUCTION SWEEPING MACHINE AND UNPAVED AREAS MANUALLY AT B.S.CITY FOR 03 YEARS (A) Manual Sweeping xManual Sweeping of berm of V.I.P / Main Roads and unpaved areas of public places and removal of swept or accumulated garbage including horticulture waste, plastic, paper ,cow dung etc. as directed by officer in- charge
65KM (Single lane) X 310 days =20150 Km X 03yrs.=60450 KM (B) Truck mounted xOperation of Truck Mounted Vacuum & Suction Sweeping Machine over paved roads 65 Km sweeping machines /day(Single lane road)
65Km X 310 days =20150 Km/ year 20150Km X 3 years = 60450 Km. Source: Environment Control Dept., BSL
Environmentally sound technologies for recycling of hazardous wastes: As detailed above, the major hazardous wastes generated at BSL which are recyclable are oils, Zinc bearing wastes, batteries as well as e-waste.
BSL is not involved in recycling of any of the identified hazardous recyclable waste and sells the recycled wastes to authorised recyclers, which employ environmentally sound technologies for recovery of valuable products from the wastes at their end. The authorised recyclers for different types of hazardous waste generated at BSL are mentioned as under: x BSL sells its e-waste to M/s E-waste Recyclers India, UPSIDC Industrial area, Mathura x BSL’s zinc bearing wastes are sold to zinc recyclers as mentioned is the list below: - Zinc dross lumps & chips: Suraj Udyog, Gurgaon, Haryana - Zinc ash with solid chips: (1) Shri Ram Chemical Industry, Dhuri, Punjab (2) Chakradhar Chemical Pvt. Ltd., Muzzafarnagar (Auth. No. 119/KCRR/HW/HSPCB/B/4Y) - Waste batteries: Samta Metal industries, Kolkata
The Hazardous waste authorization of BSL is attached as Annexure-4.1.
4.7 ADDITIONAL MANAGEMENT PRACTICES
The potential environmental consequences can be either avoided or minimized in terms of size, scope and duration. It is based on the recognition that minimizing the environmental impact of an activity primarily entails managing the environmental consequence(s) of those activities by either avoiding them in the first place or by mitigating them to as low as reasonably practical. That is, any event will have an impact of some sort on the natural, social or economic aspects of the environment within which it occurs. However, the severity of the impact(s) depends on the extent to which the consequences to the environment can be eliminated or minimised. Therefore, the environmental consequences of each event can be either avoided or mitigated with proper management.
To ameliorate the adverse impacts of the project and for scientific development of the local environment, a comprehensive Environmental Management Plan (EMP) is necessary. This has
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 182 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT been worked out based on present environmental conditions, environmental impact appraisal and environmental prediction. The EMP has been made for formulation, implementation and monitoring of environmental protection measures during and after commissioning of the project taking into consideration of the following:
4.7.1 Rainwater Harvesting
In BSL, the engineered storm water drainage system leads to the cooling ponds. The cooling ponds also serve as raw water reservoirs. Thus the surface run-offs are collected and used to augment the plant’s raw water supply, thus reducing the dependence on Damodar River. Since the cooling ponds’ bottoms are earthen they also serve to artificially recharge the ground water table. In addition BSL will provide the following additional rain water harvesting system for new units:
Table 4.14: Location and Area for Rainwater Harvesting System Area required for providing ‘Rain Sn. Building description Remarks Water harvesting system’ (m x m) 04 no. of recharging pits 1. CRM-II Building 540 x 165 have been proposed
The proposed rain water harvesting systems broadly covers following: i) Assessment of catchment surface i.e. the collection surface from which rain fall runs-off. ii) Gutters and downpours i.e. channelling water from the roof to the Recharge pit. iii) Storm water drainage system i.e. channelling water from the surface run-off to recharge pit. iv)Leaf screen flush diverter, roof washers and screening facilities to remove debris and dust from the captured rain water before it goes to the Pit.
System description: The Rainwater harvesting is the simple collection or storing of water through modern techniques from the areas where the rain falls. It is as far the best possible way to conserve water.
There are two methods in the field of rainwater harvesting, viz. rainwater recharging and rainwater collection & reuse.
Recharge may be defined as the process of augmenting the groundwater table by providing artificial infiltration techniques which will reduce the excess surface run off and increase the storitivity of the soil. Other is the process of utilizing the rainwater by means of its collection.
Collected water can be utilized for industrial and domestic purposes.
Recharge: Rainfall collected over the roof top of building will be taken through down-comers. Rainwater will be taken to the Recharge pits with filtration bed at bottom through pipes connected with two (02) down-comers, each of 250 mm diameter and spaced at 12m apart, terminating in vertical drop pipes of 350 mm each. Before taking the water to the recharge pit, a first flash valve will be connected with each down-comer so that first rain usually containing higher level of silt can be diverted from the filtration circuit. There will be 4 nos. recharge pit with filter bed including 2 m of filtration bed at the bottom. Collected water from roof top will be first taken to a screen chamber.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 183 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT This chamber will be fitted with screens. Water from the screen chamber will be taken to 1st recharge pits and 2nd recharge pit will be connected internally. Overflow from 1st recharge pit be entered to 2nd Recharge pit. Before Screen chamber drain will be diverted to main plant drain by means of 2 no’s of MS shutter plate. Filter bed at the bottom of the Recharge pit will consist of: 1st layer - 0.5 m of coarse sand (1.5-2 mm size), 2nd layer -0.5 m of gravel (5-10 mm size) and 3rd layer -1 m of loose boulders (10-30 cm size). 2 nos. of pits will be used as Injection well for recharging of rainwater into ground.
From conical bottom of the Recharge pits through which rainwater will be recharged 1no. of 150 mm dia. slotted UPVC pipe (Ultra Poly Vinyl Chloride) will be driven to 1m below the 1st aquifer level through 200mm dia. bore for recharging of ground water. For getting the 1st Aquifer level necessary hydro-geological study to be done. There will be an overflow line from 2nd recharge pit which will be connected to the main drain so that in case of heavy rain no water logging will be there.
Collection & Reuse: Plant storm water drainage system will be allowed to receive treated effluents conforming to statutory norms from individual premises. The storm water from the plant proper will be collected by open drain system and finally lead to a settling pond through storm water drainage network. Settled storm water will overflow from the pond to the nearest existing nallah once the pond is filled up. Necessary inlet outlet arrangement for this pond has been envisaged. However, the details of the size & levels of pond and drains will be worked out during detail engineering.
While developing the Plant General Layout, it will be ensured that rain water is harvested/recharged. Run-off water from the administrative building roofs will be collected and stored for future use. A preliminary scheme of proposed rainwater harvesting facility is indicated in Fig. 4.8: Fig. 4.8. Scheme for Rainwater harvesting structures in CRM-II
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 184 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 4.7.2 Housekeeping
Proper housekeeping is the key to proper environmental management. This creates proper working environment for the work force and safe working conditions. BSL has taken up a massive drive for improving the house keeping conditions. Initial results have been encouraging. However efforts are on to improve the condition further. The following are a few examples: x Regular cleaning of plant roads to avoid accumulation of dust/garbage x Regular cleaning of shop floors x Endeavouring to keep all dedusting systems in perfect conditions x Keeping plenum ventilation systems of premises in perfect working order to avoid accumulation of dust on equipment inside the pressurized room. The air filters must be regularly cleaned. x Keeping air conditioning plants in perfect running conditions for control/ instrumentation rooms. x Raw materials spilled from the conveyors at the junction houses will be recovered and put back on the conveyors / raw material handling system. x The Materials Management Department will undertake an exercise for identifying / inventorising all condemned equipment (including vehicles, wagons, machinery etc.) steel structurals, wire ropes etc. inside the plant. Of these, the ferrous material will be salvaged / recovered and utilized in the plant (as scrap in the Steel Melting Shop). The non-utilisable scrap will be auctioned off. x Encouraging gardening inside steel plant units and in township. x Maintaining adequate green belts inside and along the plant for not only suppression of noise and pollutant transportation but also aesthetics. x Proper functioning of pollution control systems to minimize dust fall on plant and outside areas. x Proper control of fugitive dust from sources inside plant including open stockyards. x Avoiding accumulation and dumping of wastes and damaged equipment and items anywhere inside the plant affecting aesthetics. x Developing a positive outlook in the employees for keeping the work place, both in factory, office or laboratory, clean and well maintained. x Maintaining hygienic conditions in areas like canteens, near drinking water sources and toilets.
4.7.3 Greenbelt Development
Green belt, is an important sink for air pollutants, it also absorbs noise. Enhancing green cover not only mitigates pollutants but also improves the ecological conditions / aesthetics and reduces the adversities of extreme weather conditions. Trees also have major long-term impacts on soil quality and the ground water table. By using suitable plant species, green belts can be developed in strategic zones to provide protection from emitted pollutants and noise.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 185 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Plant species suitable for green belts should not only be able to flourish in the area but must also have rapid growth rate, evergreen habit, large crown volume and small / pendulous leaves with smooth surfaces. All these traits are difficult to get in a single species. Therefore a combination of these is sought while selecting trees for green belt.
The green belt should be planted close to the source or to the area to be protected to optimize the attenuation within physical limitations.
The green belt / cover will serve the following purposes:
x Compensate the damage to vegetation due to setting up and operation of the proposed plant expansion. x Prevent the spread of fugitive dust generated due to project and allied activities. x Attenuate noise generated by the project. x Reduce soil erosion x Increases green cover and improve aesthetics. x Provide habitat to small reptiles (garden lizards, geckos, agamid lizards), mammals (squirrels, shrews) and birds
A) Existing Green Cover / plantation
As has been mentioned earlier (in Chapter 2), at present green belt and plantations cover 1923.99 ha (i.e. 33.32%).During 2019 – 20 another 141.64 ha of plantations are proposed to be added. Thus the total area of green belt and plantations shall increase to 2065.63 ha.
BSL has developed extensive plantations in its plant, township and in nearby villages. Since inception, BSL has planted about 45.73 lakh trees. During 2018-19, plantations were carried out over ~141 ha. The plantation made during last few years is given in Fig. 4.9:
Fig 4.9. Cumulative Plantation in last 6 years
Greenbelt plantation (in lakhs) 47 45.73 46 45 44.68 44 43 42.43 42.64 41.91 42 41.49 41 40 39 2013-14 2014-15 2015-16 2016-17 2017-18 2018-19
Greenbelt plantation (in lakhs)
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 186 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT The details of plantation carried out by BSL in 2018-2019 is given below:
Year Plantation details Nos. 2018-19 Plantation breakup: xPlantation through horticulture near Garga Basin 100000 xPlant & Township 5,150 Total Plantation = 1,05,150
The list of plantations carried out in 2018 in peripheral villages are listed in Table 4.15.In these villages, BSL had arranged for the plantation of over one lakh saplings in during the year through their CSR department.
Table 4.15: Tree Plantation by BSL in Nearby Villages During 2017 Sl. No. Village Distance & Direction Nos. Species from Plant Planted 1 Kashi Jharia 7070 - Acacia (Acacia auriculiformis) , 2 Chowatand ~17.7 km SW 3000 - Amla (Embelicaofficinalis), 3 Gopalpur 4900 - Amaltas (Cassia fistula), 4 Pokhanna ~20 km SE 7325 - Arjun (Terminaliaarjuna)), 5 Sardaha 1500 - Babool (Acacia nilotica), 6 Abhadih ~13.5 km SW 1500 - Bel (Aeglemarmelos), 7 Berani 1500 - Chhatwan (Alstoniascholaris), 8 Pindrajora 1500 - Gamhar (Gmelinaarborea), 9 Durgatand 1500 - Guava (Psidiumguyava), 10 Dumri 1500 - Gulmohar (Delonixregia), 11 Kura ~13 km SE 1500 - Jackfruit (Artocarpusheterophyllus), 12 Santhaldih ~12.5 km SE 1500 - Jamun (Syzigiumcuminii), 13 Choratand 1500 - Mahogany (Swieteniamacrophylla), 14 Toridih 1500 - Mango (Mangiferaindica), 15 Ramdih ~7 km ENE 1500 - Molshree (Mimusopselengii), 16 Khamarbendi 1500 - Mulberry (Morus alba), 17 Gomadih 1500 - Neem (Azadirachtaindica), 18 Bandhpokhar 1500 - Pappaya (Carca papaya), 19 Tupra ~20 km SW 1500 - Sharifa (Annonasquamosa), 20 Kushma 1500 - Shisham (Dalbergiasissoo), 21 Simitand 1500 - Teak (Tectonagrandia), 22 Pondro 1500 23 Timada 1500 24 Silphor 1400 25 Dumadih 1500 26 Shakhaground 50 27 Chapatand 1500 28 Mahuda 1500 29 Varpokhar 1500 30 Durgapur ~10 km SE 1500 31 Dabarbahal 1500 32 Dudhigazar 1500 33 Harlagora ~13 km SE 1600
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 187 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl. No. Village Distance & Direction Nos. Species from Plant Planted 34 Amhertelia 1600 35 Sabra 1550 36 Chandra 1500 37 Beldih ~15 km SW 1500 38 Kadma 1500 39 Daber 1500 40 Kandra ~9km SE 1500 41 Bendi ~10.3 km SE 1500 42 Alokdih 1500 43 Bandhadih ~8 km WSW 1500 44 Bahadurpur ~9.8 km SE 1500 45 Bhangabazar ~9.9 km SE 1500 46 Sonabad 1500 47 Chitami 1500 48 Jala 1500 49 Ghatiyali ~9 km S 3000 50 TandBalidih 1500 51 Tantri - North ~2.9 km NW 1800 52 Tantri - South ~2.5 km NW 1800 53 Khutri ~3 km W 3600 54 Bodro ~10 km E 1800
In addition to the above, BSL had planted another about one lakh saplings in Garga Dam basisn (~75,000) and in the steel plant& township (~28550).
The plantations created by BSL, both outside the plant as well as inside the plant, have become the habitat of several species of birds, squirrels and small reptiles. In addition, migratory water fowl have been observed at the plant’s cooling ponds during winter.
Plantation Development Plan
Additional green cover has been planned for the coming years. Planting of 2,15,000 saplings during 2018 – 19 has been envisaged. The plan for plantation by BSL is as follows: Year Plantation details Nos. Area (ha) 2019-20 Plantation breakup: Fund xPlantation through CSR in Villages 100000 60.71 allocation = xPlantation through horticulture near Garga Basin 100000 60.71 Rs. 186.75 xPlant & Township 15000 20.22 lakhs Total Plantation = 215000 141.64
Selection of Species: The species for plantation have been selected on the basis of soil quality, place of plantation, chances of survival, commercial value (timber value, ornamental value, etc.), etc. It is to be noted that in future only indigenous species {such as Semal (Bombax ceiba), Mahua (Madhuca indica), Baheda (Terminalia belirica), Peepal (Ficus religiosa), Banyan (Ficus bengalensis), Sal (Shorea robusta), Druping Ashok (Polyalthia longifolia) etc.} will be planted. These species provide nectar,
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 188 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT edible leaves & fruit for birds and animals and Non-Timber Forest Produce which can be harvested by villagers. The saplings for plantation will be procured from the nurseries of the State Forest Department. Mixed plantations will be done keeping optimum spacing between the saplings. The species selected for plantation will be locally growing varieties with fast growth rate and ability to flourish even in poor quality soils. In the plant, higher proportions of Druping Ashok will be planted as this species is highly resistant to pollution and because its branches do not spread out, it can be planted close to each other ( 2 – 2.5 m spacing)
Post Plantation Care: Immediately after planting the seedlings, watering will be done. The wastewater discharges from different outfalls will be used for watering the plants during non-monsoon period. Further watering will depend on the rainfall. In the dry seasons watering will be regularly done especially during February to June. Watering of younger saplings will be more frequent. Manuring will be done using organic manure (animal dung, agricultural waste, kitchen waste etc.). Younger saplings will be surrounded with tree guards. Diseased and dead plants will be uprooted and destroyed and replaced by fresh saplings. Growth / health and survival rate of saplings will be regularly monitored and remedial actions will be undertaken as required.
The trees will be watered using the effluent from the sewage treatment plant and treated discharges from plant. Plantation will be manured using sludge from the sewage treatment plant. In addition kitchen waste from the town-ship and plant canteen can be used as manure either after composting or by directly burrying the manure at the base of the plants.
4.7.4 Occupational Health & Safety
Anticipated impacts:
The work place is divided in terms of activities e.g. raw material handling, loading, handling of processed raw materials (e.g. calcined lime, coke, sinter), handling of hot metal and molten slag, processing of metal, handling of finished products and wastes etc. . The principal occupational risks in integrated steel plants are:
x Diseases due to dust inhalation x Exposure to very high temperatures x Exposure to very low temperatures (in oxygen plant) x Exposure to toxic and / or inflammable gases x Working in confined spaces where suffocating / toxic / inflammable gases may be present x Fire and explosion which may also lead to generation / release of toxic gases x Accidents during handling of liquid metal and slag x Accidents during handling of corrosive and / or toxic liquids x Hearing loss and other disorders due to exposure to very high noise x Accidents involving various machinery x Accidents involving electrical installations, including fire
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 189 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT x Accidents in raw material handling area x Accidents in finished product handling area. x Accidents involving fall from height x Accidents involving railway rolling stock and heavy vehicles. x Accidents during construction, repair and maintenance
The most common safety issues are given in Table 4.16.
Table 4.16: Most Common safety issues Sl.No. Nature of Hazard Sources 1 Fire Hazard Release/leakage of Oxygen, Hydrogen, Acetylene, CO gas, BF gas, LD gas, Mixed gas, Propane, Methane, Benzene vapours, Fuel Oil, Coal Tar Fuel and liquid metal. Fire in storages of inflammable and / or combustible chemicals and dry vegetation in vacant areas. 2 Explosion Hazard Release/leakage of Hydrogen, Acetylene, CO gas, BF gas, LD gas, Mixed gas, propane, methane. 3 Toxic Hazard Release of CO gas, BF gas, Mixed gas, LD Gas, Chlorine. 4 Burns Release / leakage of steam, hot flue gases. 5 Cold Burns Exposure to liquid oxygen, liquid nitrogen and liquid argon 6 Asphyxiation Release of Nitrogen, Argon, Oxygen, CO gas, BF gas, LD gas, Mixed gas 7 Exposure to corrosive chemicals Leakage spillage of acids and alkalies. 8 Fire/Explosions due to Spillage of Spillage/Transfer of liquid metal, liquid steel and hot slag Liquid Metal 9 Heat Radiations due to coke, hot Spillage of hot coke, hot sinter, liquid metal and hot slag metal / molten slag Handling 10 Accidents due to Material Connected with all Material Handling Equipment, railway locomotives & Handling wagons and vehicles
Management measures:
A. Safety Management & Practices in BSL
Safety is a prime concern for SAIL as well as BSL. The plant has a dedicated “Safety Engineering Department” headed by the General Manager (Safety). He is assisted by the Dy. General Manager (Safety).There are around 30 Safety officers under him to look after the safety activities in all the departments. This department regularly scrutinizes, supervises and ensures implementation of safe working practices in various departments of the company.
SAIL has dedicated safety department at the corporate level - SAIL Safety Organization (SSO), which, monitors and guides the safety Promotional, fire and Occupational Health Services activities undertaken at different steel Plants/Units/Mines/Stockyards. To accomplish the above mentioned functions, SSO formulates and prepares appropriate safety policies, procedures, systems, action plans, guidelines etc. and follows up for their implementation and thereby helps in providing accident free work environment. Consistent efforts are also being made by SSO for competence building in the area of safety management through HRD interventions covering heads of shops, line managers, safety personnel & trade union leaders. SAIL has Safety Policy which is shown below. Bokaro Steel Plant also has a dedicated Integrated policy for Quality, Environment, Occupational Health Safety and Social Accountability as shown in Fig 4.10.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 190 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Fig 4.10: BSL’s Policy for Quality, Environment, Occupational Health Safety and Social Accountability
INTEGRATED QUALITY, ENVIRONMENT, OCCUPATIONAL HEALTH SAFETY AND OVERALL SAFETY POLICY OF SAIL SOCIAL ACCOUNTABILITY OF SAIL-BOKARO
Safety aspects are considered in the design stage itself for all the equipment. In spite of that, during process of steel making, many hazards may be encountered. The following are some of the identified hazards:
x Heat, Dust and Noise Hazards x Chemical Hazards x Material Handling Hazards x Burns due to hot metal / Hot objects x Cold burns x Slips & Falls x Fall from Heights x Gas Hazards x Explosion Hazards x Electrical and Fire Hazards
For managing these hazards “Occupational Health and Safety Management System” becomes key function of the top management. BSL manages the above safety and health hazards by adopting appropriate control measures to reduce / eliminate hazards for maintaining a safe and healthy environment at work place.
Several safety management practices are being adopted aiming to achieve Zero Accidents and to
meet the safety requirements of the company. Important efforts in this direction include:
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 191 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT B. Safety Inspections:
All the identified Contractual Agency Jobs, Shop-Floors and Equipment in various departments are inspected as per the schedule. The unsafe points identified or the non-conformances noticed are communicated to the concerned HOD for liquidation. Compliance of the same is monitored by the Zonal Safety Officers. Safety during all the major repairs and capital repairs is monitored round the clock and safety officers are deployed exclusively for this purpose. All the height related jobs performed by the qualified workers are closely monitored to ensure safety. Usage of certified safety appliances like safety belt and safety net are ensured while executing such jobs.
C. Safety Training:
Safety Engineering Department conducts Safety Training Programmes for all regular employees / contractual workers of BSL at various levels to inculcated safety awareness. Periodically, regular/contractual employees undergo training on several subjects of safety every year. During 2016-17, 17555 contract workers were imparted Induction training and 1888 were imparted safety training by IISM, Jamshedpur & 58 ROKOTOKO safety campaigns were carried out.
Special Training Programmes by external safety experts on various topics are being conducted on different topics such as Material Handling, Legal awareness on Safety Implementation of The Factories Act, Electrical Safety, BBSM, Road Safety, First Aid etc.
Regular Employees Training
The safety programs include General safety, Safety in Material Handling, Gas Safety, Electrical Safety, Fire Safety, Crane Safety, OH&S Management, Conveyor Belt Safety, Safety during welding, safety with rotating equipment, etc.
Special Training Programmes by external safety experts on various topics are also being conducted in co-ordination with Management Development Centre and Technical Training Institute.
Contractor Workers
¾ Once in a year, refresher safety training (Induction training) is imparted to all the contractors’ workers and their safety passes are renewed only after such training. Training material/literature in local language is distributed to all the workers during safety training. ¾ Only those workers, who have undergone Job Specific and Site Specific Safety Training, are permitted to work at site only those. ¾ Special safety training programmes on Gas Cutting, Welding, and Conveyor Belt Safety are conducted regularly. ¾ Height test is conducted for workers to work at heights and safety precautions to be taken during painting and roof sheeting jobs etc. are also imparted from time to time.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 192 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT D. Safety audits:
OHSMS Internal Audits are conducted once in a quarter in all major departments to improve the safety performance. Surveillance Audits are being conducted once in six months by an external certifying agency M/s. BVCI to assess the functioning of the system of safety in various departments of the plant.
Safety Audit is being conducted once in six months by the respective Zonal Safety Officers in all the major departments and the Safety Audit is conducted by a third party external experts once in a year as a part of the legal requirements.
E. Emergency Preparedness:
On site emergency mock drills are conducted to test the emergency preparedness for fire, electric shock, gas leak, rescue from heights, burn injuries in departments as well as plant level. Departmental mock drills are conducted every year. Two plant level mock drills are being conducted in a year in the presence of the Factories Dept. Officials, to know the preparedness of the rescue operations. Overall, more than 25 mock drills are conducted every year to ensure emergency preparedness of the plant personnel. Besides, a safety talk is conducted in every department at the end of every day for discussion on Safety issues, suggestions and discussion regarding safety to carry out the job assigned.
F. Safety committees:
The steel plant has an Apex Safety Committee. This Committee is convened by GM (Safety & FS) which has significant number of members as workers’ representatives and the rest are representatives of the Management. The Apex Safety Committee’s responsibility is to assist and guide the management in implementing Health and Safety measures effectively throughout the organisation. The Committee meets once every quarter as per Rule 62 - C of The Bihar Factories Rules, 1950. The points raised by the members are addressed on priority basis.
In addition there are Departmental Safety Committees, headed by a Departmental Safety Officer in the plant to discuss on Safety issues pertaining to their respective departments. Departmental Safety Committee meetings are held once every month.
G. Equipment Safety:
Equipment safety was properly addressed and was given due attention during its design stage itself. Safety devices like inter-locks, limit switches, battery backup system, emergency push buttons, safety valves, route relay inter locking for rail traffic, pull cords, earth fault protections, flame proof electrical fittings etc. are provided in the plant and their functioning is tested periodically and necessary corrective actions are taken.
H. Fire Safety:
In BSL has a dedicated Fire Department manned by three (3) officers and 90 (ninety) trained fire fighters. The Head of the Fire Department reports to the General Manager (safety & Fire Services).
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 193 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT There are three fire stations (Central Fire Station, Coke Oven Fire Station & SMS Fire Station). There are four Fire Turnouts (fire fighting teams), each comprising of six trained fire-fighters. Two Fire-turnouts are stationed at the Central Fire Station and one each at the Coke Oven Fire Station and the SMS Fire Station. It has eight water tenders in working condition, two foam tenders, one Dry Chemical Powder (DCP) tender (cap.2 t of dry chemical powder), one Crash Fire Tender and one Emergency Tender. The fire department has about 30 closed circuit breathing apparatus sets. For fighting electrical fires, the Fire Department has Dry Chemical Powder type fire extinguishers and two nos. Ultra High Pressure Mist Systems. About 8500 portable fire extinguishers are provided throughout the plant and are inspected at regular intervals.
Extensive network of fire hydrant points (>2000 nos.), landing valves and Fire Fighting Pump Houses are in place. Fire Detection and Alarm (FDA) systems are installed in all major production departments and fire sensitive areas to inform the Fire Wing in the event of any fire mishap and request necessary assistance. There is a Central Fire Control Room at the Central Fire Station and two sub fire control stations – one each at the other two fire stations.
On receiving fire alarm, the nearest fire station responds immediately. If necessary, help of the other fire stations may be sought. Though there is no written agreement, help may also be sought from Jharkhand Fire Services and the Fire Departments of DVC’s Chandrapura Thermal Power Station, ONGC – Parbatpur, IOCL, HPCL, M/s Electro Steel Castings’ steel plant. The arrangement is reciprocal.
3-4 Mock drills are conducted by the Safety Department every month, in which the Fire Department is a participant. The Fire Department also conducts response time training exercises for its personnel.
I. Protocols:
Protocols have been prepared for all critical jobs like, jobs in confined spaces, jobs near gassy areas, underground drains, etc. where prior permission from other departments is required to undertake any work. The role/responsibility of each dept./officer is defined and indicated on these permits till safe completion of the job.
Special drives are conducted for monitoring the implementation of Permit-To-Work and Shut-Down systems and usage of PPEs etc.
J. Gas Safety
¾ Gas Safety is given top most priority at BSL. ¾ Periodic Inspections are carried out in the Gas equipment and pipe lines. ¾ Regular monitoring of gas leakages in the gas prone areas. ¾ Gas detectors are provided at vulnerable areas (e.g. In confined spaces in coke oven batteries, CO gas detectors linked to alarm systems have been installed). ¾ On-line CO gas analyzers installed at gas prone control rooms. ¾ U - Seals are provided in gas lines for better isolation.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 194 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT K. Road Safety:
Road safety indeed is a matter of concern for BSL. Company has been continuously creating awareness on safety among the employees and contract workers. To prevent road accidents, various initiatives are taken like Awareness Campaigns, Road safety week celebrations, Special Road Safety training programs, Speed barriers, Speed Breakers, Signals Lights, Speed Limit Boards etc.
L. Personnel Protective Equipment (PPE):
The PPE provided in the plant are
a) Protective helmets b) Safety boots. c) Dust masks, canisters etc. for respiratory protection d) Ear plugs , ear muffs etc. for noise protection e) Goggles, spectacles for protection of eyes. f) Safety belts, Safety harnesses for protection against falls. g) Canvas gloves, Leather gloves, PVC gloves, Rubber gloves etc. for Hand protection h) Aprons for Body protection. i) Heat resistant Coat-Kevlar aluminium suit. j) Molten metal resistant jackets and trousers k) Molten metal resistant gloves-Kevlar gloves; l) Face shields or vented goggles;
Appropriate safety PPEs such as Safety Helmet, Safety Shoes, Goggles, Hand gloves, Aprons, Safety belts, Nose Masks, Ear Muffs etc. are provided to all employees as per the requirement at work place. The usage and importance of these appliances are being communicated through workshops and classroom training. Safety personnel carry out regular inspections to enforce the use of appropriate PPE.
The Safety Engineering Department is responsible for the purchase and issue of all PPE. PPE are distributed to both company employees and contractors’ employees. If any PPEs are damaged before their scheduled replacement, fresh equipment is issued.
M. Accident Investigation:
All the incidents/accidents of the plant and near miss cases are discussed in all Departmental Safety Committee meetings and remedial measures are implemented wherever such situation exists. As a pro-active measure, all major accidents happening in other steel plants are discussed and remedial measures are implemented wherever similar situation exists in our plant.
¾ Root cause analysis is carried out to prevent the recurrence. ¾ All Near Miss Incidents & Reportable Accidents- Jointly analysed by central and shop floor Officers ¾ All Road Accidents - By a team of Safety, Personnel and Concerned dept.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 195 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT ¾ Fatal & Fire Accidents - By a Standing Committee ¾ Recommendations are ensured for compliance.
The Departmental safety committee (DSC) meetings are carried out every month in all the zones while Apex Safety Committee meetings are carried out quarterly in all the shops.
Procedure for Investigation of accidents and incidents:
The investigation of accidents and incidents for finding out causes of accidents/incidents and implementing remedial measures for different shops at BSL is carried out jointly by Safety Engg. Department, BSL along with different Line managers in various shops. The details of the activities and responsibility is indicated below:
SN ACTIVITY RESPONSIBILITY 1 Collection of information of accidents from OHS and co-workers of injured Shift safety inspectors 2 Logging information in shift log book and filling the format “daily accident report” Shift safety inspectors 3 Collecting IOW form from OHS. Shift safety inspectors 4 Sending IOW forms with daily accident report to SED office next morning Shift safety inspectors 5 If the accident is serious in nature inform HOD and concerned In-charges of SED Shift safety inspectors immediately 6 IOW forms and daily accident reports is sent to statistical cell/SED Shift safety inspectors 7 Grid I/c notes down the details from the IOW/daily accident report Grid I/c 8 Grid I/c/representative visits the site of accident/incident Grid I/c & DSO 9 Observes the site condition Grid I/c & DSO - Equipment - Procedures - Housekeeping 10 Interrogates Grid I/c & DSO -Injured person -Eye witness - Co-workers -Supervisor -Shift I/c 11 Grid I/c/representative discusses the matter with senior officials and other concerned Grid I/c & DSO 12 Gathers fact about Grid I/c & DSO - Violation of SOP - Violation of legal requirement - Failure/ defects of equipment - Unsafe condition - Unsafe practices 13 Fixes the responsibility Grid I/c & DSO 14 Suggest /recommend remedial measures Grid I/c & DSO 15 Fills up the accident investigation report form Grid I/c & DSO/Engg I/c 16 Documentation of records SED & DSO 17 Monitors implementation status of the recommendation Grid I/c(SED)
N. Budget for safety.
The annual budget for procurement of PPE, conducting safety trainings, safety audits and safety promotional activities is around Rs.3 Crores.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 196 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT 4.7.5 Occupational Health Services at BSL
BSL has a full-fledged Occupational Health Services Centre (OHC) inside the plant premises, with round the clock doctor facility. Medical check-ups are carried out for all the workers at regular intervals. Facilities for carrying out lung function test, sputum test, X-ray etc. are available. First aid boxes are provided at strategic locations at shop floor.
The unit is manned by qualified OHS specialists, toxicologist and trained paramedical staff. The In- Charge is an M.B.B.S doctor with M.D. degree and is an AFIH (Associate Fellow of Industrial Health), which is a statutory requirement as per Indian Factories Act.
The OHS Centre is a part of Bokaro Steel Plant’s main hospital - Bokaro General Hospital (BGH) located in the plant’s township. BGH is a910 bedded hospital BGH is a full-fledged, multi- disciplinary Hospital whose emergency Medicare services are available to the OHS Centre round the clock including various facilities such as OPD facility, pipeline oxygen supply system, Critical care ambulances, Computerised audiometry, lung function test & ECG, well equipped library, air conditioned training hall etc.
First-aid stations are located in the plant, functioning round the clock with qualified doctors, paramedical staff and ambulances. After first aid at the site of the accident, the injured worker may be evacuated to the OHS Centre at the plant for further treatment. If necessary, the injured worker may be transferred to Bokaro General Hospital. BGH may refer the case to specialist hospitals in Kolkata, Ranchi or even Delhi and other places.
All employees undergo a Pre-employment Medical Examination followed by a Periodical Medical Examination (PME). The periodicity of the PME as per the workers’ deployment is given in Table 4.17. Table 4.17: Periodicity of the PME Departments Planned periodicity All workers in Benzol plant section of CO&CCP Once in 3 months CO&CCP, BF, SMS, SP, TPP, RMHP, CRMP, Foundry unit of engineering shops, Once in 3 months RED, and EMD, departments of Works division All other departments of works division Once in 3 months All departments of non-works division Once in 6 months All canteen contract workers Once a year
Periodical health check-up covers lung function test, audiometry, vision test, pathological test and bio-chemical test is being done. Various health awareness and training programme are being organized.
A preliminary interaction with OHC members of BSL indicates that the probable occupational health issues in plant employees can be Pneumoconiosis, NIHL, Dermatitis due to Benzene primarily, Melonosis (due to heat) and Silicosis. However, so far there is no Occupational disease detected as per OHC BSL.
The OHS Centre performs Annual Check-up of all BSL personnel with a daily maximum target of check-up of 60 persons a day. Various new initiatives are taken by the OHS also such as mass
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 197 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT check-ups through setting up of in-plant Health check-up camps for every department on every Wednesday along with coverage by physician, ophthalmologist, health counselling to risk groups, heath awareness programme, conducting Yoga classes etc. Occupational Health Services Performance for the years 2011-2018 are given in Table 4.18.
Table 4.18: Occupational Health Services Performances (2011-2018) Number of check-up Sn. Activity 2011-12 2012-13 2013-14 2014 -15 2015 -16 2016 -17 2017 -18 1. Periodical health check up 8765 8949 9035 7085 7335 7812 8392 2. Audiometry -do- -do- -do- -do- -do- -do- -do- 3. Vision Test -do- -do- -do- -do- -do- -do- -do- 4. Lung Function test -do- -do- -do- -do- -do- -do- -do- 5. Chest X-Ray (as required) -do- -do- -do- -do- -do- -do- -do- 6. FBS -do- -do- -do- -do- -do- -do- -do- 7. Urea -do- -do- -do- -do- -do- -do- -do- 8. Uric acid -do- -do- -do- -do- -do- -do- -do- 9. Creatinine -do- -do- -do- -do- -do- -do- -do- 10. Cholesterol -do- -do- -do- -do- -do- -do- -do- 11. ECG (>45 yrs of age) -do- -do- -do- -do- -do- -do- -do- 12. PMT, MSD (as required) -do- -do- -do- -do- -do- -do- -do- 13. Yoga Classes -do- -do- -do- -do- -do- -do- -do-
Health records of employees are stored safely for periodic retrieval and analysis. A specific coding system has been developed and followed for efficient and systematic placement. The historical employee health data is also stored in soft form and is linked to online system.
4.7.6 Training Facilities
To achieve the objective of pollution control it is essential not only to provide latest pollution control and monitoring systems but also to provide trained man power resources to operate and maintain the same. So far, the practice with many plants is to utilize the plant operations and maintenance crew for operation of systems. This has shown adverse results due to lack of specialized knowledge in addition to priority selection. In BSL, specific training is provided in the field. In-plant training facilities are developed for environmental control and also specialized courses at various environmental institutes are organized. The training is being given to employees to cover the following fields: x Awareness of pollution control and environmental protection to all. x Operation and maintenance of specialized pollution control equipment. x Field monitoring, maintenance and calibration of pollution monitoring instruments. x Laboratory testing of pollutants. x Repair of pollution monitoring instruments. x Occupational health/safety. x Disaster management. x Environmental management.
The number of trainings imparted to BSL employees on Environment as part of Environmental Awareness programme for the year 2017-18 is summarized in Table 4.19.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 198 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 4.19: Training imparted on Environmental Awareness During 2017 - 18 No. of No. of participants Sn. Name of training imparted programmes held Executive Non-Executive Others 1. Pollution Control & Waste Management 02 30 10 2. World Environment Day 05 100 200 400 3. Work Shop On Water Conservation 02 50 40 120 4. Safety, Health And Environment 01 15 25 5. Work Shop On E-Waste 01 24 08 05 6. Zero Waste Through 4 R 01 30 10 7. ISO 9001 QMS, ISO 14001 EMS & OHSAS 18001 01 25 35
4.7.7 Corporate Social Responsibility
As a responsible corporate, Bokaro Steel Plant has taken extensive initiatives in the realm of Corporate Social Responsibility (CSR). Some of the highlights of activities undertaken in 2016- 17 are:
Uplifting Society through Education: The Steel city is hailed as the educational capital of Jharkhand. The Shiksha Prothsahan Yojana provides financial support to meritorious students from economically weaker backgrounds pursuing courses in premier institutions of technology and medicine. Bokaro Steel Plant runs total 11 schools.- 4 CBSE affiliated high Schools and 9 Sr. Secondary Schools (5 CBSE and 2 JAC affiliated) . Bokaro Steel Plant has set up two special schools under CSR for children hailing from weaker section of the society.
Bokaro Steel Kalyan Vidyalaya : Started in Sector IIID in April 2007, the CBSE affiliated BSKV-IIID offers primary and secondary education to over 375 children from poor families, providing free education, uniforms, books, stationery and Mid-Day Meal. 5 batches have passed out from the school with flying colors.
Bokaro Steel Balika Vidyalaya : Dedicated exclusively to girls, the CBSE affiliated, BSBV Sector- IX B is providing education to girl students with the same facilities being extended to their counterpart at Kalyan Vidyalaya.4 batches have passed out with excellent result from the school.
Supply of bench desks in govt. schools: During the first governing body meeting of Jharkhand CSR Council held under the chairmanship of Chief Minister of Jharkhand, Secretary Education, it was mentioned that there is huge shortage of bench desks in Govt. schools. Taking the cue and urgency of the matter in consideration, Bokaro Steel Plant under CSR took up the task of providing bench desks in govt. schools. 124 no of dual bench and desks have been provided in Jharkhand Govt. run schools during 2016-17.
Literate to Matriculate Drive for 1400 women dropouts: To facilitate 1400 non matriculate women from peripheral villages to attain matriculation certificate, Bokaro Steel Plant under CSR has started a project in collaboration with Zila Saksharta Samiti, Bokaro and NIOS, Ranchi. 1210 women have appeared in the examinations.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 199 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Enlightening Lives of Children from Primitive Birhor Tribe: Under its Gyan Jyoti Yojna conceived in April, 2001, Bokaro Steel Plant had adopted 15 children from Birhor community- a primitive tribe of Jharkhand whose numbers have dwindled alarmingly over the years. Second batch of 15 Birhor children have been adopted in June, 2012. In the year 2013-14, taking a step further for imparting quality education, they all have been admitted in Kalyan Vidyalaya, an English medium CBSE affiliated school run under CSR.
Construction of toilets under Swacchh Bharat: Swacchh Vidyalaya Abhiyan: Bokaro Steel Plant, under its CSR Activities launched Swachh Vidyalaya Abhiyan in line with Prime Minister's Swachh Bharat Abhiyan. Bokaro Steel Plant has constructed 108 toilets in 76 state run schools identified by Ministry of HRD, Govt of India. Construction of 6 more toilets were taken up during 2016-17. A reputed NGO, M/s Sulabh International Social Service organization (SISSO) was engaged for the job. Sanitation campaigns were undertaken on use of toilets in the schools where the toilets have been constructed
Creation of Drinking Water facilities: Hand Pumps are installed in the peripheral villages as per the need analysis and the defective hand pumps are repaired and maintained. 50 hand- pumps were installed in 2016-17.
Skill Development of unemployed youth of periphery ¾ Running of an ITI: Bokaro Pvt. ITI, under the aegis of CSR of the company, provides opportunity to unemployed youths to get quality technical education. The trainees are provided on-the job training in Bokaro Steel Plant. 20% of the seats are reserved for local displaced persons whose cost of the training is borne under CSR. A number of trainees have got employment in Govt. & reputed private organizations.
¾ Introducing Dual System of Training: Bokaro Steel Plant is the Industry Partner for implementation of DST (Gov. of India has launched a new Skill Development scheme named- Dual System of Training). Under the scheme the theory classes are taught in ITI and the practical training is imparted in Bokaro Steel Plant. After the implementation of the scheme, Gov. of India approved 288 seats under DST for the first time (2016- 17), out of which 100 seats are for Bokaro Pvt ITI. 300 youths have received training at Bokaro Pvt. ITI in 2016-17.
¾ Employable Training in field of Plastic Engineering & Technology: Bokaro Steel Plant has entered into a MoU with Central Institute of Plastic Engineering & Technology (CIPET), Bhubaneswar to provide Residential Employable/Skill Development Training program for youths of peripheral villages. In 2016-17, 71 youths selected from rehabilitation sites have been imparted training.
Transforming Peripheral villages: For the purpose of Integrated Development of peripheral villages, Bokaro Steel has adopted seven identified villages for developing them as Model Steel Villages (MSVs). An integrated approach for overall development of these villages have been undertaken by constructing/providing amenities like school building with boundary, chaupal, PCC road, drain along the village street, Panchayat Bhawan etc. Facilities provided to MSVs
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 200 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT include Approach road, Arch gate, Roadside Drainage, Installation of hand pumps, Creation of water sources, School buildings, Medical camps, Community halls, Promotion of rural sports.
Infrastructural Developments of Periphery: x Repair & Maintenance of Community Hall at Jaina More x Construction of 2 additional rooms at Chandankiyari Mahavidyalaya, Chandra x Installation of 50 new hand-pumps in peripheral areas. Repair & Maintenance of 265 Hand-pumps installed in peripheral areas x Miscellaneous civil work viz. repairing, painting, white- washing etc. carried in schools, community centres and other facilities created under CSR in peripheral villages.
Support for opening a Medical College: The state of Jharkhand with predominant tribal population lags behind the national average in health infrastructure as there are few Medical Colleges with limited capacity. For opening a Medical College at Bokaro Steel City, Bokaro Steel Plant is providing 25 acres of land to State Govt.
Women Empowerment: With the active support and patronage of Bokaro Steel Plant, the Mahila Samiti, a NGO has grown multi-dimensionally. The various projects being run by Mahila Samiti are: x Low cost sanitary napkin production unit at Bokaro: Sanitary Napkin Machines have been installed at the Swablamban Kendra, 4E School. A group of 10 women went to SRI Ranchi for attending the training program on making low cost sanitary napkin. Sanitary napkins are distributed free of cost among girls and women of reproductive age, through Mobile Medical Van, x Silk Yarn Reeling project: Bokaro Steel Plant has entered into an agreement with JHARCRAFT to initiate activities for development and upliftment of women of peripheral villages of Bokaro Steel City, x Swablamban: Poor women and widows receive training in skills such as soap making, tailoring, carpet making etc. Post training, the women are engaged in production of gloves, raincoats, aprons and dress materials purchased by Bokaro Steel Plant, x Surbhi Masala Kendra: Destitute women are engaged in spice-making, food processing and meals for patients at BGH etc., thereby earning their livelihood with dignity, x Saurabh Shishu Mandir and Bal Mandir: Mahila Samiti not only provides support to poor women, but also to their children by providing educational facilities. Poor children get education at the two schools. Bokaro Steel Plant has been instrumental in providing support for school uniforms, textbooks etc. for the children.
Support to Specially-abled: Bokaro Steel Plant has given patronage to Asha Lata, an NGO working for the development, welfare and rehabilitation of differently abled children .Apart from the provision of land, building, water, electricity and transport facility Bokaro Steel Plant has adopted 95 poor students and provides a financial support of6.94 lakhs every year.
Preservation of Art & Culture: Bokaro Steel Plant has been supporting Bokaro Sangeet Kala Academy.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 201 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Promoting Sports: Bokaro Steel Plant under CSR has been organizing sporting events which are held in the adjacent rural areas. Tournaments in the discipline of Football, Kabaddi, Volleyball & Archery have been organized in the peripheral villages. Various important competitions organized include National Football Championships for the “East Zone Santosh Trophy 2016-17.
Health Performance: ¾ Providing Quality Healthcare: The Bokaro Steel Plant run Bokaro General Hospital (BGH), a 910 bedded hospital equipped with state-of-the art facilities and supported by qualified medical practitioners, has fast emerged as one of the most trusted names in healthcare in eastern India. In addition to its routine activities of patients care, Bokaro General Hospital actively participates in various National Programmes: x National Immunization program, National AIDS Control Program, Reproductive & Child Health Program, National Blindness Control Program, National Tuberculosis Control Program, National Leprosy Control Program, National Polio Control Program.85522 no. of non-BSL patients were treated in BGH in 2016-17. ¾ Bokaro Steel Sarva Swasthya Kendra has been set up for free treatment of the poor and needy people of the peripheral region. ¾ Treatment of Club-foot Disease: As a Medical-CSR initiative, a weekly club-foot clinic was introduced in March, 2013 in association with Cure International India Trust (CIIT) for treatment of Club-foot, a congenital deformity of children. In the year 2016- 17, 161 patients were treated. ¾ Mobile Health Services: In collaboration with Piramal Swasthya, Hyderabad, BSL launched Mobile Medical Unit (MMU) on 26th January, 2016 which covers 40 villages every month. Salient features are: ¾ IT-enabled Health Services, Focus on identification, screening, diagnosis, monitoring, and treatment, follow-up, record keeping and referral of high risk cases, Staff: Doctor(MBBS)- 1,Nurse- 1,Pharmacist-1,DataEntryoperator-1,Driver-1,DiagnosticServices: Blood- Sugar, Haemoglobin Test, Urine and Malaria test, Biometric Registration and Electronic Health Record generation, focus on chronic diseases, maternal and child health and health education to villagers. 21,536 patients were treated during 2016-17.
Promoting Development of Ancillary Units: Bokaro Steel Plant is committed to the development of ancillary units around Bokaro.
BSL has partnership with local SME ancillary units with ancillary policy where price preference and order quantity distribution for regularly required consumables like packing materials, idlers and rollers, fasteners, insulators, fabrications, mechanical spares limit switches etc. and orders worth around Rs 65 to 70 Crores are placed annually. The ancillary units are also given refurbishing and conversion job, thus adding value at vendor's premises. They have successfully manufactured import substitutes through reverse engineering like Contact Block for SMS, Double Chamber Tuyeres for BF, which have enabled Foreign exchange savings. Bokaro Steel Plant treats ancillary units as extension of the plant.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 202 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Various technical training programmes are also conducted by BSL to improve the industrial awareness of people around and help coming up of smaller, secondary industries around the area such as: x Training program on Steel Fabrication in collaboration with INSDAG(with Institute of Steel Development and Growth) to develop Steel Entrepreneurs in rural villages x Skill Development programme of Matriculate Birhor Boys adopted by BSL under Gyan Jyoti Yojana x Bokaro Steel Plant has made an agreement with JHARCRAFT (Jharkhand Silk, Textile & Handicraft Development Corporation Limited) to initiate activities for development and upliftment of women of peripheral villages of Bokaro Steel City by setting up a Silk Yarn Reeling Centre at Mahila Udyog Kendra where, after the training, the local women are engaged in production where the required raw materials are supplied by Jharcraft and the finished products as well as the waste generated is purchased back by them thereby generating livelihood for the beneficiaries.
The training centre of Bokaro Mahila Samiti and Udyog Kendra with wings for making spices, flour, safety gloves, soap, shawls, apparel and embroidered clothes, provide livelihood to a number of rural women.
SAIL-BSL has already spent Rs. 273.37 Lakhs in 2017-18 on peripheral development and community development through its CSR activities. The details of the expenditure for FY 2016- 2017 is presented in Table 4.20.
Table 4.20: Details of CSR Expenditure for FY 2016-2017 Sl.No. CSR project or activity Amount Spent (in Rs Lakhs) EDUCATION 1 Education of Birhor Children adopted under Gyan Jyoti Yojana 6.00 Scholarship to students passed out from BSL schools and studying 2 6.00 in IITs/NITs under Shiksha Protsahan Yojana 3 Bokaro Ispat Kalyan Vidyalaya & Balika Vidyalaya. 52.61 4 Supplying of Books by New Vidya Mandir 8.88 5 VIP visits including visit of PM's Trophy 4.51 Subtotal 78.00 HEALTHCARE Organizing medical camps in peripheral villages and providing 6 1.88 primary healthcare at Sarva Swasthya Kendra 7 Arrangement of blankets during winters 2.92 8 Mobile Medical Unit in Peripheral Villages 24.00 Subtotal 28.80 LIVELIHOOD GENERATION 9 Payment to BPITI against training of displaced candidates 4.8 Providing short term employment linked training in Plastic Engg 10 24 and technology to displaced youth at CIPET Bhubaneshwar 11 Miscellaneous expenses of ITI Kasmar 3.8 Subtotal 32.60 WOMEN EMPOWERMENT 12 Expenditure against Silk Yarn reeling project (Jharcraft) 0.55 Payment to NIOS for Facilitating 1400 non-matric girls/women of 13 10.02 peripheral villages to attain matriculation through National Indian
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 203 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Sl.No. CSR project or activity Amount Spent (in Rs Lakhs) Open Schooling (NIOS) &Zila Saksharta Samiti, Bokaro (ZSS) 14 Expenditure against low cost sanitary napkin project 0.3 Expenditure incurred on schools run by Mahila Samiti including 15 13.13 transportation facilities etc. Subtotal 24.00 DRINKING WATER 16 Installation of new Hand Pumps in peripheral villages 21.00 Subtotal 21.00 SANITATION Construction of 108 toilets in govt. schools in peripheral villages 17 21.00 under Swacch Vidyalaya Abhiyan (SVA) Subtotal 21.00 RURAL DEVELOPMENT Repair & maintenance of BSL School Buildings having more than 18 3.87 80% Non BSL Students 19 Providing Solar Street Light in peripheral villages 0.36 Construction of two additional rooms at Chandankiyari 20 8.53 Mahavidyalaya Chandra 21 Road Repair 28.06 22 Miscellaneous Civil Work in Peripheral Villages 3.15 Subtotal 43.97 SOCIAL SECURITY 23 Transportation Facility to Sangeet Kala Academy 6.00 Providing Transportation facilities for ferrying differently abled 24 7.00 children at Asha Lata Viklnag Kendra Subtotal 13.00 SPORTS, ART & CULTURE 25 Procuring Bows & Arrows for SAIL Archery Academy 3.00 26 Bokaro Grameen Football Championship 8.00 Subtotal 11.00 Grand Total 273.37
A total of Rs. 195.79 Lakhs has been allocated by SAIL-Bokaro for expenditure towards CSR activities in the year 2017-2018. The activity wise allocation is presented in Table 4.21.
Table. 4.21. CSR Budget & Expenditure (2017-18) Sl. CSR Activities Budget allocated No (in lacs) 1 Education 90.58 2 Healthcare 22.65 3 Livelihood Generation 35.38 4 Women Empowerment 14.86 5 Drinking Water 7.66 6 Sports 1.34 7 Art & Culture 0.96 8 Rural Infrastructure Development 12.45 9 Social Security(Senior Citizens & PWDs) 9.91 Total 195.79
4.7.8 Corporate Environment Responsibility (CER) As per the statute, in every financial year, it is required to spend at least 2% of the average net profits during the preceding fiscals on CSR endeavours. However, although BSL has been making loss averaged over the last three fiscal years, it has spent significant amount towards community
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 204 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT development as indicated in Tables 4.20 & 4.21. These activities are mostly concentrated in peripheral areas of the plant.
The total project cost of the project is Rs. 5219.1 Crores. As per Ministry’s Office Memorandum vide F.No. 22-65/2017-IA.III dated 1st May 2018, an amount of Rs. 17.22 Crores has been earmarked for Corporate Environment Responsibility (CER) based on public hearing issues as well as need assessment based socio-economic study carried out for the project. The total CER budget for the project has been allocated at Rs. 17.22 Crores and the details of fund allocation and activities for CER are given below Table 4.22
Table. 4.22. Focus area wise CER Expenditure Plan Amount to be spent (in Rs. lakhs) Sl. No. Sector 1st yr. 2nd yr. 3rd yr. 4th yr. 5th yr. 6th yr. 7th yr. Total (A) Based on Need based Socio-economic assessment 1 For education: i Gyan Jyoti Yojana-Adoption of 15 of 8 8 8 8 8 8 8 56 Birhor Children ii Scholarships under CSR to support 1.5 1.5 1.5 1.5 1.5 1.5 1.5 10.5 technical education iii Repair & maintenance of BSL school 5 5 5 5 15 15 15 65 buildings where more than 80% non- BSL students are studying iv Support to two Schools run under Mahila 5 5 5 5 10 10 10 50 Samiti v Non-matriculate to Matriculation drive for 8 8 8 8 8 8 8 56 girls/ women 2 For Healthcare i Sarva Swasthya Kendra, Sector- V 2.5 2.5 2.5 2.5 2.5 2.5 2.5 17.5 ii Low- cost Sanitary Napkin project 2 2 2 2 2 2 2 14 3 For Livelihood Generation Providing infrastructure and financial 25 25 25 25 30 30 30 190 i support to Bokaro Pvt ITI established CSR Silk Yarn Reeling project to provide skill 3 3 3 3 3 3 3 21 ii development of women 4 For Sanitation i Maintenance of 105 toilets under SVA 18.5 18.5 18.5 18.5 25.5 25.5 25 150 5 Rural Infrastructure Development Miscellaneous civil work in peripheral 4 4 4 4 4 4 4 28 i villages and other sites SUB-TOTAL (A) 82.5 82.5 82.5 82.5 109.5 109.5 109 658 (B) Based on Public consultation issues Installation of hand-pumps in 10 10 10 10 10 10 5 65 6 peripheral villages through CSR Dept. Annual repair & maint. of hand- 4.32 5.34 5.34 5 15 15 15 65 pumps installed in peripheral 7 villages, construction of toilets through CSR Repair of roads within the Bokaro 50 50 50 50 50 50 50 350 8 Steel township by Town Administration dept.
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 205 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Amount to be spent (in Rs. lakhs) Sl. No. Sector 1st yr. 2nd yr. 3rd yr. 4th yr. 5th yr. 6th yr. 7th yr. Total Infrastructural development as well 76 76 76 76 76 76 76 532 as financial support to Bokaro Balika Kalyan Vidyalaya as well as Bokaro 9 Steel Kalyan Vidyalaya. Additionally funding and operation of 8 different schools in township as well as peripheral areas. Repair & maintenance of roads in 2 2 2 2 2 2 2 14 10 peripheral villages (both PCC & pre- mix types) Greenbelt development in outside 4 4 4 4 4 4 4 28 11 plant area (near Garga Basin) Greenbelt development in peripheral 1.75 1.75 1.75 1.75 1 1 1 10 12 villages (including Satanpura village) SUB-TOTAL (B) 148.07 149.09 149.09 148.75 158 158 153 1064 GRAND TOTAL (A+B) 1722 Lakhs (i.e. 17.22 Crores)
4.7.9 Use of renewable energy sources x Two of BSL’s railway locomotives are run on bio-diesel. Use of bio-diesel reduced emissions by ~29%. x LED based solar powered lighting system has been installed in the ED (Works) – Office building to reduce electricity consumption. x Solar panels are being installed on roofs of BSL’s buildings (cumulating to 2.0 MW) to reduce dependence on electricity supplied from the grid. A system on the roof of BGH has already been commissioned. x Arrangements are being made for setting up a ground mounted solar photo-voltaic plant of 20 MW.
4.7.10 Energy Conservation Measures
BSL is also committed to improving its energy utilization and has been adopting various measures for conservation of energy. The same is highlighted in the Table 4.23.
Table 4.23: Energy Conservation Measures at BSL Energy Conservation Measures taken at BSL FY 2015-16 FY 2016-17 FY 2017-18 1.Cold repair of CO Battery no # 3 1.Capital Repair of 1.Commissioning of Battery #7 which 2.Capital Repair of a.Sinter machine no-1 helps to improve in CO gas yield. a.3 nos. Sinter Machines b.3 nos. Soaking Pit Ceramic 2.Commissioning of Acid Plant with b.3 nos. Soaking Pit Ceramic Recuperators, Recuperators fully & 02 nos. waste heat steam generation and recuperators partially facilities. c.3 nos. Soaking Pit Metallic Recuperators c.3 nos. Soaking Pit Metallic 3.Revival of Cooling towers in BRP to 3.Increase Blast Temperature by repairing stove Recuperators cleaned increase the tar yield. no 3.1 of BF#3 2.Improvement of power factor by 4.Replacement of 200KW motor at 4.Total skin insulation in HSM Reheating reviving capacitor bank of LF-1 Quenching tower #4 with energy Furnaces to minimize heat loss through furnace sub-station of CCS. 5.Efficient motor. wall. 3.Commissioning of new ID fan no- 6.Full repair of 02 no of Pits along with 5.Providing heat shield at delay table during 2 with VFD in SMS-II. recuperators and partial repair of 04 modernization of Mills to minimize temperature 4.Change of heating mode in nos of Pits. drop during rolling. pickling media from direct heating 7.Replacement of Exhauster#1 with
CHAPTER-4 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES Page 206 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Energy Conservation Measures taken at BSL FY 2015-16 FY 2016-17 FY 2017-18 6.Modification of skid insulation of HSM to indirect through steam. one of high capacity in Sinter Plant. Reheating Furnace #4 to minimise heat loss 5.Av cycle time in Annealing -1 is 8.Capital repair of Band #2 & 3 of through skid cooling water reduced by using base fan in 50 Sinter Plant 7.Change of recuperator in reheating furnace #2 bases. 9.Commissioning of new ID fan no-1 in HSM 6.About 110 points of steam with VFD in SMS-II 8.Lining for 5 nos. Bell Annealing Furnaces with leakage rectified & 25 nos steam 10. Liquidation of 115 Nos of steam castables up to burner level and ceramic fiber traps replaced. leakages. lining above burner level 9.Supply of surplus BF gas to CPP boilers #7 & 8
The future plans for energy conservation are as follows: x New dry type LD gas holder of 80000 M3 capacity with export system x Partially phase out of Ingot route and LD gas recovery after completion of SMS-1 modernization. x Use of surplus BF gas to CPP Blr. # 9 through new ND2600 dia. pipe x New Alternate Gas Network for efficient distribution of fuel gas. x Modernization of Gas Mixing & Boosting Stations along with Up-gradation of existing Computerized Fuel Gas Monitoring System. x Modernizations of stoves of Blast Furnace-1
4.7.11 Fly Ash Management
SAIL-Bokaro is not involved in coal-based power generation and hence no fly ash is being generated by BSL. Power generation is done by M/s BPSCL (Bokaro Power Supply Company Limited), a separate entity which has got separate CTO from JSPCB and separate EC from MoEF&CC. During the 20th R-EAC(Ind-1) meeting held on 26th June, 2020, SAIL-BSL submitted a Joint Action Plan for management of Fly Ash (as approved by Boards of both SAIL-Bokaro & BPSCL) with a revised time-schedule of implementation by August 2024 as suggested by the Hon’ble committee. The progress report in this regard shall be submitted to the Regional Office, MoEFCC along with the six-monthly compliance report. The EAC recommended action plan with budget provisions is attached as Annexure 4.3.
4.7.12 Stockpile Management
Coking coal and CDI coal are stored in covered silos only. Thus there is no chance of surface or ground water contamination due to leachates / surface run-offs from coal stock-piles. In case of iron ore and fluxes, the stockpiles have been built over very thoroughly compacted soil which minimises percolation of leachates. The stock-pile areas are also sloped towards engineered storm water drainage systems routed through settling pits. All the surface run-offs are collected by the drains and the suspended solids are settled out. The clarified storm water is routed to the plant’s cooling ponds, which also function as raw water reservoirs.
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CHAPTER-5: ANALYSIS OF ALTERNATIVES (TECHNOLOGY AND SITE)
5.1 INTRODUCTION
Analysis of project site alternatives and project technology alternatives and their assessment for selection of the most suitable location / technology in terms of environmental affability, energy efficient and optimised land utilising with maximum productivity is a good practice in EIA as a project of any nature consists of activities involving large number of human resource, material as well as financial investment. Discounting the financial aspect in assessment of impact of the project on the environment, the other activities consume various natural resources and generate wastes, which are likely to have effects on the environment. However, a number of alternative options may be available for conducting many of these activities. So, it is required to study these alternatives and select an option with the least or nil adverse impact on the environment. This chapter lays emphasis on the same and the Alternates analysis has been done for the proposed project of BSL.
Bokaro Steel Plant (BSL) is undergoing expansion to increase hot metal production from 4.5 MTPA to 5.77 MTPA. The expansion programme includes setting up of some facilitating units viz. a Coke oven battery, new Sinter plant, new Pellet plant, new Oxygen plant as well as up- gradation/modernization/debottlenecking of existing SMS-1, SMS-2 and CRM complex. These units have been contemplated for full capacity utilization of Bokaro steel plant and enable in production of 5.77 MTPA hot metal.
The proposed units are to be setup within the premises of the existing steel plant of SAIL-Bokaro at Bokaro Steel City, Bokaro, Jharkhand. No additional land is required as all land of existing steel plant is already under possession of BSL. Hence, no alternative sites are considered.
The following alternative technologies and methods are selected and tested to get the best results from the present capacity expansion by modernization/ debottlenecking of existing facilities.
5.2 ANALYSIS OF ALTERNATIVE TECHNOLOGY
5.2.1 New Coke Oven Battery
The existing coke oven complex at Bokaro Steel Plant (BSL) consists of eight by-product recovery type coke oven batteries (No.1 to 8) with associated coal, coke and gas handling facilities. Each battery has 69 ovens in single block, compound, regenerative with partial recirculation of waste gases, twin-flue, under jet type. However, out of eight (08) batteries at BSL, only six (06) coke oven batteries are available for operation as most of the batteries are very old and at a time, two (02) of the batteries are always under rebuilding and repair.
BSL initially proposed a 7m tall top charged Coke oven battery with 0.768 MTPA gross coke production capacity to meet its gross coke deficit. However, owing to limitations of Top-charged Coke oven battery to utilize inferior coal in the coal blend and to decrease dependence on imported high grade coal (Prime coal), BSL is contemplating to choose Stamp-Charged Coke Oven Battery over Top-Charged Coke Oven Battery. CHAPTER-5 ANALYSIS OF ALTERNATIVES Page 208 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Further, use of cheaper coal (Soft coal) in the coal blend of Stamp-charged Coke oven battery as compared to the more expensive, imported high grade coal also ensures better techno-economics for the Coke oven battery.
Comparison of options:
A comparative analysis of the two (2) technologies i.e. stamp charged and top-charged by-product recovery type coke ovens is mentioned below: OPTION-1 OPTION-2 Subject Stamp Charged Top Charged
Coal quality requirement Low rank, weakly caking and high volatile coals can be used Prime coking coal to the extent of around 20 % of the total charge required Coke yield Increased by 7% - 15% due to higher bulk density Relatively lower Higher density, improved strength (micum and CSR value) Coke quality due to closer packing of the individual coal particles during Relatively lower carbonization. Capital cost Lower due to reduced oven compartments Relatively higher Operating cost Lower due to ability to use lower grade coal Relatively higher xReduced spluttering during charging owing to lesser coal fine generation because of increased coal charge density. xLower charging time emissions due to lower charging Pollution potential Relatively higher frequency and higher coking time. xLower diffuse emissions due increased compactness of feed. Specific Thermal efficiency Higher Relatively lower
Both the processes are well established world over and have their own set of pros and cons of coke making.
Reason for selection:
Based on the available alternatives with respect to the various pre-carbonisation technologies, stamp charging is one of the most preferred technologies. Use of inferior coal in the coal blend is the major advantage of this technology. In view of benefits illustrated above, BSL has envisaged installation of a new Stamp-charged Coke Oven Battery over conventional top charge coke oven battery.
5.2.2 New Pellet Plant
Comparison of options:
There are two major processes for iron ore Pelletisation, namely Travelling Grate and Grate Kiln. Both the processes are well established world over. Comparison between these two technologies is as under: OPTION-1 OPTION-2 Item Travelling Grate Grate Kiln Heat hardening Drying, preheating induration and cooling Drying and preheating on a grate, induration cycle are done on a single grate in rotary kiln and cooling in annular cooler Grate bars are subjected to high No side and hearth layer is necessary. Bed Grate bars temperature, so side and hearth layers depth is nearly half CHAPTER-5 ANALYSIS OF ALTERNATIVES Page 209 of 298 © 2020 MECON Limited. All rights reserved
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OPTION-1 OPTION-2 Item Travelling Grate Grate Kiln necessary Pellets remain stationery throughout Pellet Movement Pellets tumble continuously in rotary kiln the process. Large number of burners along the length Burners Single burner is used for the kiln. of induration furnace. Several fans operating in series with Less number of fans with Single fan Fans multiple fan controls. control
Reason for selection:
Option-1 i.e. “Travelling Grate” process has been considered for the proposed pellet plant due to the following major reasons: x Rotary kiln of Grate Kiln Process will have more maintenance requirement as well as stricter operational discipline (to avoid clinker formation etc.) x Beneficiated ore for this Pellet Plant, as tested by RDCIS, will be having about 3-5% Loss on Ignition (LOI) which can be better handled in “Travelling Grate Process”. x This is more suitable for hematite rich iron ore fines, which are greatly available in India. x Major Pellet Plants in India are based on Travelling Grate Technology
5.2.3 New Sinter Plant
BSL is contemplating a new Sinter Plant of 3.7 MTPA production capacity (1 x360 m2) to meet its sinter requirements for achievement of 5.77 MTPA hot metal production.
Latest sintering technology and improved design features have been considered in this report while selecting the main plant and equipment. Some of the important features of the proposed Sinter Plant are: x Base blending facilities of raw materials x Automated proportioning of raw materials x High Intensive Mixer & Granulator for better mixing and micro-pellet formation with provision of magnetized & hot water x Lime addition facilities x Segregated sinter mix feeding to sinter machine x Deep-bed sintering x Energy efficient and compact ignition system with post heat hood x Economic, compact, energy efficient and pollution free deep-bed-dip rail circular cooler x Emergency sinter storage x Elaborate and centralised dedusting system x Waste heat utilisation system (heat from cooler) x Instrumentation, process control & automation x Centralised control room
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5.2.4 Up-gradation of Steel Melting Shop (SMS)
Bokaro Steel Plant (BSL) has two Steel Melting Shops (SMS) viz., SMS-I and SMS-II. SMS-I produces steel through BOF converter – Ingot Casting route. There are five (5) BOF converters of 100/130 t capacity in SMS-I out of which three (3) converters are in operation. To improve overall productivity, BSL has envisaged modernization of SMS-I in two stages and eventually phasing out existing ingot-casting route (after stabilization of Stage-1 modernization) and moving to Continuous-casting route of steel making.
SMS-II produces steel via BOF converter – Continuous casting route. There are 2 x 300t BOF converters at present. However, for further increasing the production rate from present level, various debottlenecking/augmentation schemes have been envisaged for SMS-II.
Comparison of options: The available technologies of steel making which were analysed are as follows: x BOF converter – Ingot Casting route x BOF converter – Continuous casting route
A comparison of the two methods of steel making is briefed hereunder: OPTION-1 OPTION-2 Item Continuous Casting Ingot casting Yield High Low Inferior because of cracks and butt Quality of finished steel Better deformations in finished yield Energy consumption Low High Process automation Highly automated process Low possibility possibility Waste generation Minimal Relatively higher Material logistics Con
Reason for selection:
SMS-l follows ingot casting technology for production of crude steel (Ingot steel) from the liquid steel produced at BOF converters. Ingot casting is an obsolete and uneconomical technology suffering from several drawbacks including low yield, high energy consumption, inferior quality of finished steel and offering hardly any possibility of process automation. Accordingly, steel makers all over the world have been phasing out ingot casting and changing over to continuous casting. Introduction of continuous casting technology in SMS-I of BSL will give a number of benefits which include: x Improvement in yield, x Improvement in quality of the finished steel by use of Ladle refining, x Reduction in energy consumption. x Phasing out of mould & stripper yard, soaking pits x Reduction in man power requirement as a result of phasing out of a number of operating units (e.g., Mould Yard, Stripper Yard. Soaking Pits, Slabbing Mill etc.) and introduction of process automation.
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Apart from the issues of technological obsolescence, poor logistics can also be improved upon in SMS-I after modernization to Continuous casting route from existing Ingot casting route.
SMS-II debottlenecking/augmentation primarily envisages improvement in production rate of the existing BOF converter-Continuous casting route by improving material movement in the shop. No technological change is envisaged.
5.3 ANALYSIS OF SITE ALTERNATIVES
It is proposed to set up all new units including the Pellet plant, Coke Oven Battery #9 and Sinter plant with a new shaft kiln within the existing plant premises. No additional land is required by BSL. Also, the modernization activities are envisaged in the existing units, so no additional land is envisaged for those activities also.
A number of factors related to economical operations, land availability, power availability and environmental aspects were looked upon in site selection. The primary factors which influenced the project site selection are given below: x Techno-economic considerations including availability of suitable land, facility for receipt of raw material, adequate water source, power, construction manpower etc. x The new units are facilitating units for the existing hot metal and steel producing shops, so they have been located taking in consideration the easy logistics to & fro between the consumers units and the new units. x The new units are also located taking into consideration that they shall share existing fuel and water network of existing complexes. x Available infrastructure such as State/National Highway road access for ease of transportation for workforce, fuel and other smaller goods, interconnection with transmission and distribution systems for evacuation of power, logistics support for finished product from plant to markets, civic facilities such as medical, education facilities, railway station etc. x Environmental considerations such as avoiding use of forest land, minimum use of cultivable land, distant location from thickly populated towns, minimum requirement of cutting of trees, no / minimum displacement of people, at a long distance from national park and wildlife sanctuaries, Elephant reserve etc. x The existing plant is already an operational plant and all power and water requirement for the proposed project shall be met by the existing facilities. x The existing plant site is already well connected to steel consumers and raw material sources via Railway line of South-Eastern Railway Zone. Also, Bokaro Steel City is a fairly well developed city with all civic, construction and manpower infrastructure readily available within a small distance.
The above implies that the existing plant site as a location for the proposed project is the best available site option for the proposed units/activities.
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CHAPTER-6: ENVIRONMENTAL MONITORING PLAN
6.1 INTRODUCTION
The monitoring and evaluation of the management measures envisaged are critical activities in implementation of the Project. Monitoring involves periodic checking to ascertain whether activities are going according to the plan. It provides the necessary feedback for project management to keep the program on schedule. The purpose of the environmental monitoring plan is to ensure that the envisaged purpose of the project is achieved and results in desired benefits.
To ensure effective implementation of proposed mitigation measures, the following broad objectives of monitoring plan have been outlined: x To evaluate the performance of mitigation measures proposed in the EMP. x To evaluate the adequacy of Environmental Impact Assessment x To suggest improvements in environmental management plan, if required x To enhance environmental quality. x To implement and manage the mitigation measures defined in EMP. x To undertake compliance monitoring of proposed project operation and evaluation of mitigation measures.
6.2 ENVIRONMENTAL ASPECTS TO BE MONITORED
6.2.1 General
Several measures have been proposed in the environmental mitigation measures for mitigation of adverse environmental impacts. These shall be implemented as per proposal and monitored regularly to ensure compliance to environmental regulation and also to maintain a healthy environmental conditions around the steel works.
A major part of the sampling and measurement activity shall be concerned with long term monitoring aimed at providing an early warning of any undesirable changes or trends in the natural environment that could be associated with the plant activity. This is essential to determine whether the changes are in response to a cycle of climatic conditions or are due to impact of the plant activities. In particular, a monitoring strategy shall be ensured that all environmental resources, which may be subject to contamination, are kept under review and hence monitoring of the individual elements of the environment shall be done. During the operation phase Environment Control Department (ECD) shall undertake all the monitoring work to ensure the effectiveness of environmental mitigation measures. The suggestions given in the Environmental Monitoring Programme shall be implemented by BSL by following an implementation schedule.
In case of any alarming variation in, ground level concentration in ambient air, stack emission, work zone air and noise monitoring results, performance of effluent treatment facilities, wastewater discharge from outfalls, etc. shall be discussed in the ECD and any variance from norms shall be reported for immediate rectification action at higher management level.
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The environmental aspects to be monitored to ensure proper implementation and effectiveness of various mitigation measures envisaged / adopted during the design and commissioning stage of the proposed units are described here under.
6.2.2 Micro-Meteorology
It is necessary to monitor the meteorological parameters regularly for assessment and interpretation of air quality data. The continuous monitoring will also help in emergency planning and disaster management. BSL has two Continuous Ambient Air Quality stations, one installed at BSL Plant Main Gate and the other in BSL Township. The meteorological stations has been set up at the same locations to monitor wind speed & direction, air temperature, humidity, rainfall and solar insolation on a continuous basis.
6.2.3 Emissions and Air Quality
Ambient air quality will be monitored regularly in accordance with CPCB/State Pollution Control Board, Jharkhand (JSPCB). Work zone air quality will be monitored as per directives of JSPCB to assess the levels of particulate matter, NOx and SO2.
Ambient air quality shall be monitored to assess the levels of particulate matter, NOx and SO2 at minimum along with other 9 NAAQS parameters. At present, there are 7 AAQ locations around the plant and monitoring is conducted once in a month. To the extent possible, online monitoring for PM, SO2, NOx, CO and CO2 for each flue will be provided. Currently, all Coke Ovens batteries in operation and RMP kilns are equipped with Online Continuous Monitoring systems. Work-zone air quality shall also be monitored once a month, to assess the levels of particulate matter inside the plant.
After the implementation of project, the stacks will be monitored as per plan given in Table 6.1.
Table 6.1: Additional Stacks to be monitored after the Implementation of the proposed project Shop / Unit Nos. of Stacks (Working) Monitoring Frequency New Coke Oven 01 Once per month New Pellet plant 02 (Process + de-dusting) Once per month New Sinter Plant 02 (Process + de-dusting) Once per month New RMP Kiln 01 Once per month
6.2.4 Noise Levels (Ambient and Work Zone)
At present, Noise levels are being monitored inside the plant once in a month as well as at 7 ambient locations. The ECD are keeping a record of noise levels and take necessary organisational actions like rotation of workmen, availability and use of personal protective devices, damage to enclosures or insulation layers over enclosures and piping.
6.2.5 Drainage System
The effectiveness of the drainage system depends on proper cleaning of all drainage pipes/channels. Regular checking will be done to see that none of the drains are clogged due to accumulation of sludge/sediments. The catch-pits linked to the storm water drainage system from the raw material
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handling areas will be regularly checked and cleaned to ensure their effectiveness. This checking and cleaning will be rigorous during the monsoon season, especially if heavy rains are forecast.
6.2.6 Water and Waste-Water Quality
Effluents from two outfalls (previously existing third outfall has been abandoned) and Sewage treatment plant (Township and Plant effluent together) are monitored and tested in ECD laboratory at once a week and once in a fortnight respectively as per JSPCB guidelines / directives. However the frequency of monitoring may be increased if required in accordance with the stipulations of JSPCB, Jharkhand or other statutory authorities. In addition to above BSL is also carrying out monitoring of certain parameter in some of the plant equipment/area as a quality measure for measurement of pollutants going to outfalls.
BSL has initiated recycling the waste water and reducing water consumption by achieving zero discharge. Treatment schemes for achieving Zero Liquid Discharge (ZLD) have been envisaged comprising of waste water treatment plants of suitable capacities for recycling of the waste water through common channel leading to outfall-1A for wastewaters from CO & BPP area and other for BF, SP and RMP area as well as outfall-1B for wastewaters from TPP/TBS/part BF and outfall-2A from mills area.
6.2.7 Solid /Hazardous Waste Generation and Utilization
Maximum re-cycling and utilization of generated waste as per CREP guidelines shall be done. Hazardous waste shall be disposed off as per applicable statutory conditions.
6.2.8 Green Belt Development
At present Horticulture department of BSL is looking after all plantation programs within the township area and the CSR department looks after all plantations done within the plant area as well as in nearby villages. BSL shall continue to improve the green cover in the area by planting trees in the open area. As discussed in Chapter-4, BSL has planted trees in almost all possible locations and continuously encourages others to plant trees in their gardens, locality etc. During FY 2018-19, 1,05,150 saplings have been planted. The future green belt development details is given in Table 6.2
Table 6.2 Green Belt Development by BSL Total Plantation Plan for 2019-20 Total area under Acquired No. of Area Total area under Plant area (ha) plantation 2018-19 saplings covered plantation 2019-20 Land of Fund allocation for (ha) (ha) (ha) BSL(ha) additional greenbelt
6973.68 5773.69 1923.99 215000 141.64 1923.99 + 141.64 = development = 2065.63 Rs. 186.75 lakhs
Greenbelt (%) 33.32% 33.67%
The following plan shall also be implemented for future plantation program:
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x Annual plans for tree plantation with specific number of trees to be planted shall be made. The fulfilment of the plan shall be monitored by the ECD every six months. x A plan for post plantation care will be reviewed in every monthly meeting. Any abnormal death rate of planted trees shall be investigated. x Watering of the plants, manuring, weeding, hoeing will be carried out for minimum 3 years.
6.2.9 Rain Water Harvesting Facilities
An appreciable quantity of rainwater finds its way to drains and nullahs as runoff. If rainwater is stored and used afterward, then this could contribute to water conservation. Considering the aspect of water conservation, BSL has envisaged rain water harvesting of CRM-II (AB Bay to EF Bay) water management for the plant.
Water Management:
Rain water harvesting of CRM-II (AB Bay to EF Bay) water management have already floated tender specification (TS) for construction of recharge pits for harvesting rain water from roof top of CRM-II vide DB/12/35/TS/CE/01R=0 May 2014.
The storm water drainage will take into the following aspects: x Dismantling of existing drain. x Modification in slope to convey water to recharge pits and for construction of proposed drain as per drawing. x Area levelling and surface dressing of the ground near the proposed new buildings involving earth- work in cutting and filling in all types of soil as per requirement. x Necessary geodetic survey work including transferring & fixing of reference lines, levels & bench marks for set up of layout & construction works as part of the scope of work given in TS. x Construction of proposed drain including pre-casted removable RCC slab of required length along with provision of lifting hooks in the slab for cover the proposed storm water drain. x Repair the PCC apron all along the Row-A of AB Bay CRM-II.
6.2.10 House Keeping
The Safety Department keeps a very close monitoring of housekeeping activities and organising regular meetings of joint forum at the shop level (monthly), zonal level – (once in two months) and apex level (quarterly). The individual shop concern is taken care for the house keeping of shops. The same system shall be followed for the upcoming facilities too.
6.2.11 Occupational Health and Safety
Presently at BSL routine medical examination of personnel is being carried out in a systematic programme at plant medical unit, also called as the Occupational Health Service (OHS) Centre. The same procedure will be followed for personnel working for proposed project. A systematic programme for medical check-up at regular intervals shall be followed for all workers to ascertain any changes in health condition due to the working conditions.
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6.2.12 Laboratory Facilities
The existing steel plant’s chemical laboratory will be further equipped to take care of environmental monitoring. The chemical laboratory will be equipped and manned to carry out the necessary environmental monitoring work. The following equipment shown in Table 6.3 is available with the laboratory to take care of the environmental monitoring work of the proposed units:
Table 6.3: Equipment available with the Laboratory Sl. No. Instrument / Equipment Nos. 1 Noise level meter 02 2 Distillation set 04 3 Weighing balance 02 4 Desiccator 02 5 Incubator 01 6 Oven 01 7 Orion Ion selective electrode 02 8 Stack monitoring kit with acessories 03 9 Stack Monitoring System Model PEM – SMS 4 02 10 Fine Dust sampler 06 11 Spectrophotometer (DR-2008 & DR-5000) 01+01 12 Multimeter Water analyser (HACH) 01 13 Vacuum Pump 02 14 BOD Incubator 01 15 pH meter 01 16 Hot Plate 01 17 Steam Bath 01 18 COD Reactor 01 19 Flue gas analyser 02 20 Distilled water preparation set 02
6.2.13 Socio-Economic Development
The proposed project of BSL will facilitate development in infrastructural scenario and growth in economy, which, in turn, will facilitate the socio economic development. The communities, which are benefited by the steel plant, are thus one of the key stakeholders for the steel plant. It is suggested that the plant management should have structured interactions with the community to disseminate the measures taken by the steel plant and also to elicit suggestions for overall improvement for the development of the area.
6.2.14 Interaction With Jharkhand State Pollution Control Board
ECD is in regular interaction with JSPCB, Jharkhand and sends them half yearly progress report on EMP. Any new regulations considered by State/Central Pollution Control Board for the Industry are being taken care of.
6.3 MONITORING PLAN 6.3.1 General
The target of the Environment Control Department implementing the Environmental monitoring plan on a short-term basis would be to:
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x Interpret requirements of the EIA documentation into an environmental education plan; x Assist engineering team with the incorporation of EMP requirements in contract specifications and contract terms and conditions; x Undertake and/or co-ordinate all internal compliance monitoring and evaluation and secure external monitoring through suitable state level NGOs or any other consulting firm; x Provide all necessary specialized environmental expertise as needed during the project period. x Create awareness among employees on environmental issues through HRD.
The long-term objective of ECD would be to build environmental awareness and support, both within and outside the BSL management. The other long-term tasks would be to develop environmental training programme for the target groups of different units of BSL. The environmental monitoring plan contains: x Performance indicators x Environmental monitoring programme x Progress Monitoring and Reporting Arrangements x Budgetary provisions x Procurement Schedules
6.3.2 Performance Indicators
The physical, biological and social components identified to be particularly significant in affecting the environment at critical locations have been suggested as Performance Indicators (PIs). The performance indicators will be evaluated under three heads: x Environmental condition indicators to determine efficiency of environmental management measures in control of air, noise and water pollution and solid waste disposal. x Environmental management indicators to determine compliance with the suggested environmental management measures. x Operational performance indicators that have been devised to determine efficiency and utility of the proposed mitigation measures.
The Performance Indicators and monitoring plans will be prepared for the project for effective monitoring.
6.3.3 Environmental Monitoring Plan
The Environmental Monitoring Plan during construction and operation stages envisaged for the proposed project, for each of the environmental condition indicator is given in Tables 6.4(A) and 6.4(B). The monitoring plan specifies: x Parameters to be monitored x Location of the monitoring sites x Frequency and duration of monitoring x Special guidance x Applicable standard x Institutional responsibilities for implementation and supervision CHAPTER-6 ENVIRONMENTAL MONITORING PLAN Page 218 of 298 © 2020 MECON Limited. All rights reserved
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Table 6.4 (A): Environmental Monitoring Plan Environmental Issue/ Ref. to Contract Approximate Time Mitigation Institutional Responsibility Sn Mitigation Measure Impacts Documents Location Frame Cost Implementation Supervision Construction Stage All possible measures will be done to During Project Construction site 1. Dust Generation minimize dust generation during Project Req. construction preparation Contractor Projects within plant construction, like water spraying, etc. stage cost Solid waste generated during Construction site 2. Solid Waste disposal construction will be disposed in pre- -Do- within plant and -Do- -Do- -Do- -Do- identified dumping area. dumping area. Air Quality at Air Quality with respect to various 3. -Do- At construction site -Do- -Do- -Do- -Do- construction site pollutants shall be monitored. Implementation/Installation of all Environmental Environmental Protection Measures as Different units 4. -Do- -Do- -Do- -Do- -Do- Protection Measures envisaged in Chapter 4 for under expansion controlling/abating pollution. Operation Stage Proper functioning of all Environmental Environmental Protection Measures as envisaged in Project/Statutory Different units of Concerned Plant Top 5. Continuously Production cost Protection Measures Chapter 4 for controlling/abating requirement the operating plant Units/ECD, BSL Management pollution. Beginning Maintenance of Storm The drains will be periodically cleared to Entire drainage and end of Civil Maint. 6. Water Drainage maintain storm water flow within the -Do- network of the Production cost Contractor each Department System Plant. plant. monsoon. Suitable location Meteorological parameters through a Environmental ECD, BSL /Pollution Top 7. Meteorology -Do- within plant Continuously continuously monitoring system. monitoring cost Monitoring Agency, Management premises Stack emissions / All existing and Throughout Performance of stack Outlet of all process & de-dusting (major) new units of the 8. -Do- operation -Do- -Do- -Do- emissions pollution stacks in different units. proposed stage control facilities expansion plan Ambient Air Quality Regular AAQ monitoring is being Southern & South 9. -Do- Continuously -Do- -Do- -Do- Monitoring near & conducted at stations installed at 7 Eastern
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Environmental Issue/ Ref. to Contract Approximate Time Mitigation Institutional Responsibility Sn Mitigation Measure Impacts Documents Location Frame Cost Implementation Supervision within Plant Boundary Monitoring locations near &at plant Boundaries boundary. (downwind of the annual predominant winds) of the steel plant. Also a few stations are installed along North Western & Western boundary of the plant to account for upwind direction. All units of the Solid waste/Hazardous proposed plant Maximum re-cycling and utilization of Concerned Plant 10. Waste generation and -Do- generating & -Do- -Do- -Do- generated solid waste as per EMP Units/ECD utilization utilization solid wastes Horticulture Already good green cover exists, efforts Planting trees in 11. Green Belt -Do- -Do- -Do- Department/ECD, -Do- to further strengthen the green cover the open area BSL/CSR Dept. All responsible Corporate All units of the 12. House Keeping Cleanliness of work place -Do- -Do- units/safety -Do- responsibility plant Dept./ECD, BSL 13. Occupational Health Health of workers / Staff -Do- -Do- -Do- -Do- Plant Medical Unit -Do- Structured interactions with the community to disseminate the measures Socio-economic Personnel Dept. / 14. taken by the steel plant and also to elicit -Do- Stake Holders -Do- -Do- -Do- Development ECD, BSL suggestions for overall improvement for the development of the area Performance of Effluent Treatment facilities installed at Statutory All units of the Environmental Concerned plant units/ 15. Effluent Treatment -Do- -Do- different units requirement proposed plant Cost ECD, BSL Facilities CHAPTER-6 ENVIRONMENTAL MONITORING PLAN Page 220 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Environmental Issue/ Ref. to Contract Approximate Time Mitigation Institutional Responsibility Sn Mitigation Measure Impacts Documents Location Frame Cost Implementation Supervision 16. Work zone Air Quality At all units of the plant -Do- -Do- -Do- -Do- Safety Dept. -Do- Work zone Noise 17. At all units of the plant -Do- -Do- -Do- -Do- Safety Dept. -Do- levels Ambient Air Quality with respect to Atmospheric As per specified various pollutants shall be monitored as 18. Pollution(AAQ) -Do- AAQ monitoring -Do- -Do- ECD, BSL -Do- envisaged in the pollution-monitoring programme plan. As per specified Water quality at all the 2 outfalls of BSL wastewater Water Quality at BSL 19. as per the wastewater discharge (in -Do- discharge -Do- -Do- -Do- -Do- outfalls surface water) criteria of CPCB. monitoring programme As per noise pollution 20. Ambient Noise Noise pollution will be monitored. -Do- -Do- -Do- -Do- -Do- monitoring programme Changes in ground water quality will be As per ground monitored in the up-gradient and down 21. Ground Water Quality -Do- water monitoring -Do- -Do- -Do- -Do- gradient of the plant including slag dump programme will be monitored As per the soil 22. Soil quality Changes in soil quality will be monitored -Do- quality monitoring -Do- -Do- -Do- -Do- programme Note: EMP = Environmental management plan, ECD, = Environment Control Department, CSR= Corporate Social Responsibility, PM = Particulate matter, SO2 = sulphur dioxide, NOx = nitrogen oxides, CO = carbon monoxide, HC = hydrocarbons, Pb = lead
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Table 6.4 (B): Environmental Monitoring Plan for the Performance Indicators Environmental Project Stage Parameters Location Frequency Standards Tentative Cost (in Rs.) Implementation Supervision component Effluent Quality Operation stage All the parameters as At inlet and outlet of different Once in each month per year. Statutory 7 x 12 x 3500 = ECD and / or through ECD / BSL specified by statutory effluent treatment plants standards as Rs. 2,94,000 approved monitoring agencies applicable agency Work zone Air Operation stage As per applicable All units of BSL (05 space 8 hr. per shift continuous (to cover Statutory (28(existing)+6(proposed)) -Do- -Do- Quality (Stack statutory standards dedusting stacks of BFs & 01 all shifts of operation in a year for standards as x 3 x 12 x 6000 = emission) stack of BF stove, 06 stacks in each unit) per year during the applicable Rs. 73,44,000 Refractory Material plant, 07 operation at all plant units. stacks of SMS-1 & 01 stack of SMS-2, 08 stacks of Coke Oven plant and 06 ducts of common stack of Sinter plant).
Same applicable for proposed new units (Pellet plant, Coke Oven battery, Sinter plant, Modernized SMS-1) Work zone Operation stage As per OSHA work- All units of BSL. Same 8 hr. per shift continuous (to cover -Do- 21 x 3 x 12 x 1500 = -Do- -Do- Noise levels zone Noise norms. applicable for proposed new all shifts of operation in a year Rs. 11,34,000 units during the operation at 15 plant units. Ambient Air Operation stage PM10, SO2, NO2, Pb, Two (02) nos. of Continuous Hourly on continuous basis for -Do- 7 x 12 x 7500 = ECD and / or through ECD / BSL Quality CO Ambient Air Quality Monitoring CAAQM stations. Rs. 6,30,000 approved monitoring Stations (CAAQMS) installed agency & commissioned. Seven (07) Once for 24 hr. continuous, over ambient air quality monitoring the project period (once in a year stations located in all four except in monsoon) per year for directions of the Plant. other monitoring stations. Waste water Operation stage All the parameters for Two BSL plant outfalls (one Once in each month per year -Do- 2 x 12 x 3500 = -Do- -Do- discharge waste water discharge outfall abandoned) during operation. Rs. 84,000 quality in surface water as specified by CPCB Ambient Noise Operation stage As per National All along the boundary at 7 Once in a month during the -Do- 7 x 12 x 1500 = -Do- -Do- CHAPTER-6 ENVIRONMENTAL MONITORING PLAN Page 222 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Environmental Project Stage Parameters Location Frequency Standards Tentative Cost (in Rs.) Implementation Supervision component levels Ambient Noise locations. operation period. Rs. 1,26,000 Standard as per Environmental Protection Act, 1986 amended2002 Sewage Operation stage As per applicable At outlet of 5 STPs Once in each month per year -Do- 5 x 12 x 3500 = -Do- -Do- treatment statutory standards during operation. Rs. 2,10,000 quality Total Rs. 98,22,000 Note: Cd -Cadmium; CO - Carbon Monoxide; Cr - Chromium; HC - Hydrocarbon; IS - Indian Standards; NOx - Nitrogen Oxide; Pb - Plumbum(lead); RPM - Respirable Particulate Matter; SO2 - Sulphur Dioxide; SPM - Suspended Particulate Matter Total Estimated budget for Environmental Monitoring Costs = Rs 98.22 Lakhs per year
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6.3.4 Progress Monitoring and Reporting Arrangements
The rational for a reporting system is based on accountability to ensure that the measures proposed as part of the Environmental Monitoring Plan get implemented in the project. The monitoring and evaluation of the management measures are critical activities in implementation of the project. Monitoring involves periodic checking to ascertain whether activities are going according to the plans. It provides the necessary feedback for the project management to keep the programme on schedule. The rational for a reporting system is based on accountability to ensure that the measures proposed as part of Environmental Management Plan get implemented in the project.
A reporting system for environmental monitoring plan is given in Table 6.5.
Table 6.5: Reporting System for Environmental Monitoring Plan SN Details Indicators Stage Responsibility A Pre-Construction Stage: Environmental Management Indicators & Monitoring Plan 1 Suitable location for dumping of wastes has Dumping locations Pre-construction Projects / to be identified. Contractor 2 Suitable location for construction worker Construction camps Pre-construction Projects / camps have to be identified (if applicable) Contractor and parameters indicative of environment in the area has to be reported B Construction Stage: Environmental Condition Indicators and Monitoring Plan 1. Dust suppression at construction site Construction site Construction Projects / Contractor 2 The parameters to be monitored as per Air quality Construction Projects through frequency, duration & locations of monitoring approved specified in the Environmental Monitoring monitoring Programme agency C Operation Stage: Management & Operational Performance Indicators 1 Solid waste generation, utilization and As per CREP for Operation Concerned Plant dumping Integrated Steel Plant Units / ECD 2 Hazardous waste re-utilisation and dumping As per the notifications / Operation -Do- in designated pits as specified by statutory guidelines specified by authorities. statutory authorities. 3 Stack Emissions from Process & de-dusting All parameters as specified Operation Concerned Plant stacks for stacks of different units Units / ECD by Statutory Authorities 4 Meteorology, Ambient air quality, Waste All parameters as specified Operation -Do- water discharge through plant outfalls and by Statutory Authorities Noise levels.
6.3.5 Emergency Procedures
Suitable emergency procedures will be formulated and implemented at design stage itself for tackling of emergency situations arising out of the proposed operations. x Emergency situations arising out of non-functioning of the air pollution control systems and inter- locking of the systems. x Emergency situations arising out of non-functioning of effluent treatment plant and suitable storage facilities for effluent generation.
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x To contain oil spillage, proper system will be provided around the storage facilities to collect & use them later. x Fire and /or explosion due to handling of Coke Oven gas x Accidents during regular operations x Natural disasters x War and bomb threats
6.3.6 Interaction With Jharkhand State Pollution Control Board
BSL will maintain regular interaction with JSPCB, Jharkhand and send them progress report on EMP. Any new regulations considered by State/Central Pollution Control Board for the Industry will be taken care of.
6.4 BUDGETARY PROVISIONS FOR ENVIRONMENTAL PROTECTION MEASURES
Total capital cost of the proposed units including the new Coke Oven Battery and Pellet plant of BSL is estimated to be around Rs. 5219.1 Crores. The capital costs of environmental protection and enhancement measures (as mentioned in Chapter 4.0) included in the project cost have been estimated to be Rs. 365 Crores. The annual recurring costs of environmental conservation, pollution control and monitoring facilities for the proposed units have been estimated to be Rs 91.4 Crores per annum. Since BSL will be getting necessary assistance for monitoring of occupational health of their personnel, additional budget for the same is not required. The details of the capital costs and recurring costs per annum for Environmental Protection measures are mentioned in Table 6.6.
Table 6.6: Cost of Environmental Protection Measures (Rs. Crores) Capital Cost Recur. Cost/ annum Sn. Description (Rs. in Crores) (Rs. In Crores) 1. Air & Noise Pollution Control Systems 185 42.7 2. Water Conservation & Pollution Control 38 12.8 Solid/ Waste Management System/Noise control/rainwater 3. 140 35.8 harvesting 4. Green belt development 2 0.1 Total Cost for Environmental Protection Measures 365 91.4
6.5 UPDATING OF EMP
The directives from MOEF&CC and the regulations in force at any time shall govern the periodicity of monitoring. However it is suggested that the implementation of various measures recommended in the Environmental Monitoring Programme be taken as EMPs in the ISO–14001 system to effectively implement the measures for continual improvement in environmental performance. OHSAS and SA- 8000 shall also be implemented for the total plant.
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CHAPTER-7: ADDITIONAL STUDIES
7.1 RISK ASSESSMENT 7.1.1 General
Industrial activities, which produce, treat, store and handle hazardous substances, have a high hazard potential endangering the safety of man and environment at work place and outside. Recognizing the need to control and minimize the risks posed by such activities, the Ministry of Environment, Forests and Climate control have notified the “Manufacture Storage & Import of Hazardous Chemicals Rules” (MSIHC) in the year 1989 and subsequently modified, inserted and added different clauses in the said rule to make it more stringent. For effective implementation of the rule, Ministry of Environment, Forests and Climate Control (MoEFCC) has provided a set of guidelines. The guidelines, in addition to other aspects, set out the duties required to be performed by the occupier along with the procedure. The rule also lists out the industrial activities and chemicals, which are required to be considered as hazardous.
BSL is engaged the production of Steel from iron ore and other required raw materials. During the process of manufacture of steel and other associated materials hazardous gases are generated which are stored and used in the plant. In addition to this, some other hazardous substances, which are required as feed/fuel in the process or produced as a by-product, will also be stored/handled by BSL. The major substances handled / stored by BSL includes Coke Oven gas (primarily H2& CH4), Blast furnace gas (primarily CO), LD Gas (primarily CO, N2& CO2), Liquefied Petroleum Gas (LPG)/Propane, etc.
In view of this, BSL’s existing and proposed activities are scrutinized in line of the above referred “Manufacture, storage and import of hazardous chemicals rules” and observations / findings are presented in this chapter. An elaborate and well-documented Disaster Management Plan covering all substances/gases handled by BSL for their existing plant covering all the chemicals / gases handled by BSL is already in place. The same shall be upgraded and extended to the units under the expansion programme of BSL.
The assessment has been made in a systematic manner covering the requirements of the above- mentioned rules. Accordingly subsequent sections have been divided as follows: x Brief Process description x Applicability of the rule x Description of hazardous substances x Hazard Identification x Hazard Assessment (& hazard scenarios) x Consequence analysis x Brief description of the measures taken and x On site emergency plan
Accordingly next sections are elaborated.
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7.1.2 Brief Process Description
BSL is producing steel products via BF- BOF Route of steel making. Iron ore lumps, sinters and coke (made from coking coal) and fluxes such as limestone, dolomite are the major raw materials. The major steps in the manufacturing process are as follows: x Coke making - coal carbonisation x Sintering x Hot metal production (blast furnace) x Steel production (basic oxygen furnace) x Continuous casting
The detailed process of each of the aforementioned major activities is elaborated in Chapter-2 of this report.
The detailed analysis of the plant processes at BSL indicates that the process of Iron & Steel manufacturing via BF-BOF route requires considerable thermal energy. This thermal energy is supplied through fuel gasses generated in the plant e.g. Coke oven gas (COG), Blast Furnace gas (BFG), BOF gas as well as LPG/Propane gas. If there is any shortfall of these generated gasses then fuel gas is also supplied from outside source also.
The present proposal of BSL for expansion will create additional energy requirements, which will be catered to by in-plant COG, BFG, BOFG and/or Mixed Gas. In addition, use of LPG/Propane has also been considered for catering to the cutting requirements of SMS, Caster and auxiliary shops. In addition to these fuel gasses, a number of chemicals are being produced in the by-product plant of Coke Oven. Further Oxygen is also required as mentioned above. Therefore to run the plant, it is required to store and/or handle all these chemicals along with their distribution arrangement.
The expansion-cum modernization programme of BSL primarily envisages replacement as well as installation of new storage facilities such as replacement of existing BOF gas holder (50,000 m3) in modernized SMS-1, new BOF Gas holder in SMS-II (80,000 m3),and revamped existing Propane storages of 2 x 100 tonnes within the SMS complex to meet its requirements.
The major hazardous materials to be stored, transported, handled and utilized within the facility have been summarized in Table 7.1:
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TABLE 7.1: List of Major Hazardous Substances to be Stored /Handled Sn. Hazardous Quantity handled/ Type of vessel used for handling / storage Nature of hazard substance stored associated handled/stored 1. Coke Oven gas1 2.5 tonnes handled via In-plant Steel pipelines to new Gas Mixing Flammable gas (major in-plant piping network Station (GMS) components being CH4, H2 and CO) 2. Blast Furnace 86 tonnes handled via In-plant Steel pipelines to new GMS. Flammable gas Gas2 in-plant piping network 3. Mixed Gas3 81 tonnes handled via In-plant Steel pipelines from new GMS. Flammable gas plant piping network 4. BOF gas1 102.1 T + 63.8 T = 165.9 Stored in steel Cylindrical shaped gas holder (Wiggin’s Flammable gas Tonnes stored in 02 type) with Dry Rubber seal and handled via In-plant BOF Gas holders Steel pipelines 5. Propane 2 x 100 T = 200 Tonnes Horizontally placed steel Bullet with hemispherical Flammable stored in 02 bullets ends. pressurized liquid Note:1Coke Oven Gas density as 0.499 kg/m3 calculated at 25°C, 1 atm pressure conditions considering tentative gas mixture composition 2Blast Furnace Gas density 1.145 kg/m3 as calculated at 25°C, 1 atm pressure conditions considering tentative gas mixture composition 3Mixed Gas density as 1.08 kg/m3 calculated at 25°C, 1 atm pressure conditions 4BOF Gas quantity computed considering density as 1.37 kg/Nm3
7.1.3 Applicability of the Rule
As per MSIHC Rules, 1989 with subsequent amendments, the galvanization process is classified as an “industrial activity” storing/handling hazardous substances.
To decide whether the above mentioned industrial activities/substances are likely to come within the scope of the above mentioned “Manufacture Storage and Import of Hazardous Chemicals Rules, 1989 & subsequent amendments”, the threshold quantities mentioned in the rules are used for comparison, as given in Table 7.2.
TABLE 7.2: Threshold Quantity &Identified Hazardous Substances to be Handled as per MSIHC Rules, 1989& Subsequent Amendments Sn Hazardous Maximum Whether Included Type of vessel used Lower Upper Remarks substance Quantity in The List of for handling / storage Threshold Threshold handled/ handled/ Hazardous & Qty. (In Qty. (In stored stored Toxic Chemicals Tonne) [For Tonne) [For rules 5,7 to 9 & rules 10 to 12] 13 to 15] 1. Coke Oven 2.5tonnes Yes, In-plant Steel pipelines 15 200 Below the lower threshold gas handled As per Sch. 3(i) to new Gas Mixing limit. Does not require additional However, station (GMS) consequence analysis carried out due to COG’s high flammability potential 2. Blast Furnace 86 tonnes Yes, In-plant Steel pipelines 15 200 Exceeds lower threshold Gas handled As per Sch. 3(i) to new GMS limit but below upper threshold limit. Consequence analysis required to be carried out. 3. Mixed Gas 81 tonnes Yes, In-plant Steel pipelines 15 200 Exceeds lower threshold handled As per Sch. 3(i) from new GMS limit but below upper threshold limit. Consequence analysis required to be carried out.
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Sn Hazardous Maximum Whether Included Type of vessel used Lower Upper Remarks substance Quantity in The List of for handling / storage Threshold Threshold handled/ handled/ Hazardous & Qty. (In Qty. (In stored stored Toxic Chemicals Tonne) [For Tonne) [For rules 5,7 to 9 & rules 10 to 12] 13 to 15] 4. BOF gas 102.1 T + 63.8 Yes, Steel Cylindrical shaped 15 200 Exceeds lower threshold T = 165.9 As per Sch. 3(i) gas holder (Wiggin’s type) limit but below upper threshold limit. Consequence Tonnes stored with Dry Rubber seal and handled via In-plant Steel analysis required to be carried in 02 BOF Gas out. pipelines holders 5. Propane 2 x 100 T = 200 Yes, Horizontally placed steel 15 200 Equal to upper threshold Tonnes stored As per Sch. 3(i) Bullets with hemispherical limit. Consequence analysis required to be carried out. in 03 bullets ends.
After comparison of the stored / handled and threshold quantities, it can be noticed that BOF gas and propane exceed the lower threshold limits and come under the purview of MSIHC Rules, 1989 amended in 2000. Accordingly, Rule-7 i.e. notification of site requires submission of a written report containing among other information the followings: x Identification of major accident hazards x The conditions or events which could be significant in bringing one about x Brief descriptions of the measures taken x Area likely to be affected by the major accident etc.
Further, rule 17 i.e. preparation and maintenance of material safety data sheets are required for both the substances.
Owing to the hazardous nature of BOF gas, Mixed gas and propane, consequence analysis of the facility has been done, taking in consideration all hazardous substances identified at Table 7.2 above. MCAA (maximum credible accident analysis) approach ash been used to identify plausible worst case scenarios for hazard identification and risk assessment. As per Rule-17 of the MSIHC Rules-1989 amended in 2000, the material safety data sheets for identified hazardous substances are provided at Annexure 7.1.
7.1.4 Description of Hazardous Substances
The hazardous substances which are expected to be handled, are presented in Table 7.2 above. The Material Safety data sheets of different hazardous substances identified in the table are presented in Annexure 7.1. The brief nature of identified hazardous substances is described in the following paragraphs.
Coke Oven Gas: It is a flammable gas which is proposed to be used as fuel in the plant and is primarily a mixture of Hydrogen (55-56%), Methane (27.3-27.8%) and Carbon monoxide (7.3-7.6%). Coke Oven gas will be generated from existing Coke Oven batteries as well as proposed new coke oven battery, which will be transported via the gas network using pipelines, directly to the consumer units of BSL. Since, the gas is not proposed to be stored within the BSL complex, the risks associated with gas leakage and explosion are very low. A regular inspection of pipelines and maintenance operations along with installation of pressure detection systems in the pipelines will ensure no occurrence of pipeline failure. The physical & chemical properties of Coke Oven gas are given below:
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PHYSICAL PROPERTIES* Form : Gas Colour : Colourless Odour : Characteristic phenolic with a trace of hydrogen sulphide Density : 0.42 kg/m3 at NTP Molecular weight : ~170 g/mol Lower explosion limit (LEL) : 4.0 % Upper explosion limit (UEL) : 30.0 % Flash point : <60°C Solubility in water : Slightly soluble in water Toxicity : Acutely toxic if inhaled Flammable nature : Extremely flammable *Based on tentative data sourced from Material Safety Data Sheet of Clean Coke Oven Gas
CHEMICAL COMPOSITION* (mol %) Carbon Dioxide (CO2) : 2.6 – 2.8 Carbon Monoxide (CO) : 7.3 - 7.6 Hydrogen (H2) : 55 - 56 Methane (CH4) : 27.3 - 27.6 Nitrogen (N2) : 4.4 – 4.8 Oxygen (O2) : 0.4 Other higher hydrocarbons (CnHm) : 2.1 – 2.2 *Based on typical data for Clean Coke Oven Gas
The toxic component of the Coke Oven gas is listed below: Sn. Chemical Component Max quantity Quantity in % by wt. 1. Carbon Monoxide (CO) 7.8 % by mole ~1.20 2. Ammonia (NH3) 0.05 g/Nm3 ~0.012 3. Hydrogen sulphide (H2S) 0.85 g/Nm3 ~0.20 4. Naphthalene 0.1 g/Nm3 ~0.024
The high concentration of hydrogen and methane in COG suggests that the gas can be ignited by a low ignition energy (e.g., static). Therefore, the probability of ignition of COG leaks is likely to be high relative to other flammable gases. COG is a corrosive gas due to the presence of hydrogen and sulphides. This has significant implications for the maintainability of COG systems, because COG pipework frequently develops small corrosion holes.
Blast Furnace Gas (BFG): BFG is a by-product of the iron making process and is used as a fuel gas. It is an odourless, colourless and toxic gas. Its toxicity is mainly due to the presence of carbon monoxide (CO) (typically 21-25% v/v) in the gas. In confined space, it can form an explosive mixture.
BFG is a low heating value fuel (CV=800-900 Kcal/Nm3), containing approximately 56-58% nitrogen, 17-26% carbon monoxide and 18-20% carbon dioxide. Therefore, the gas is only likely to support stable combustion at elevated temperature, or with a permanent pilot flame. BFG may be ignited by a high ignition source such as a welding torch. However, the resulting combustion is slow.
BFG is not typically considered an explosion hazard for the following reasons: x Very high ignition energies are required to initiate BFG combustion;
x High concentration of inerts (N2 & CO2) in the gas; and x Very low combustion energy (3.2 MJ/m3).
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BOF Gas (BOFG): Convertor gas or BOF gas, typically has a high carbon monoxide content, low combustion speed and is very harmful. It has got a calorific value which varies in the range of 1600 to 2400 kcal/Nm3 of the gas. It is the function of the air ratio. Lower is the air ratio higher is the calorific value, since nitrogen percentage of the gas reduces. Lower air ratio also means lower specific yield of the gas. Density of Convertor gas is 0.865 kg/m3.
Convertor gas is highly poisonous and explosive and requires high degree of disciplined operation at the time of recovery .The gas is invisible and colourless. It cannot be detected by odor. It can readily form explosive mixtures with air, which are easily ignited by a static charge. Therefore, any leakage from flanges, valves and joints, may lead to severe explosion in the area resulting in fatal accident. Any ingress of external air or oxygen can also cause explosion in the system. So, supreme care is needed to avoid any kinds of leakage in the recovery, transportation as well as the utilization of the Convertor gas.
The physical & chemical properties of BOF gas is given below:
PHYSICAL PROPERTIES* Form : Gas Colour : Colourless Odour : Not distinctive Density : 1.37 kg/Nm3 Toxicity : Acutely toxic if inhaled Flammable nature : Flammable gas
CHEMICAL COMPOSITION* (mol %) Carbon Dioxide (CO2) : 16.7 Carbon Monoxide (CO) : 54.3 Hydrogen (H2) : 0.7 Nitrogen (N2) : 27.3 Oxygen (O2) : 1.0 *Based on typical data for BOF gas
BSL’s expansion-cum-expansion plan envisages a new BOF gas holder in SMS-II of 80,000 m3capacity and replacement of existing BOF gas holder in modernized SMS-I of 50,000 m3 capacity. Both of these are situated within the existing SMS complex of BSL.
Mixed gas: Mixed gas is a homogenous mixture of Coke Oven Gas, Blast furnace gas and sometimes, BOF gas. Its chemical and physical properties are similar to BF gas. The Mixed gas to be used by BSL for the proposed facility will be a mixture of BFG and COG.
A new Gas mixing station is proposed to be installed for the new Coke Oven Battery 9 of BSL, which is designed to handle a total capacity of 75,000 m3/hr of mixed gas. Proposed new pipelines carrying Coke Oven gas as well as Blast furnace gas will be proportioned using control valves and mixed via conventional gas mixing (in-pipe mixing) method to generate Mixed gas of desired calorific value.
Propane: It is a primarily handled in liquefied form under pressurised conditions. It is a flammable hydrocarbon gas used as fuel for heating purposes as well as for cutting etc. in manufacturing processes. In liquefied form, it is a colourless and odourless liquid.
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The physical properties of Propane (C3H8) are given below:
PHYSICAL PROPERTIES* Form : Gas, liquefied under pressure Colour : Colourless Odour : Odourless Liquid density : 0.54 kg/m3 Molecular weight : 44 g/mol Lower explosion limit (LEL) : 2.2 % Upper explosion limit (UEL) : 9.5 % Flash point : -104°C Solubility in water : Slightly soluble in water Flammable nature : Highly flammable *Based on tentative data sourced from Material Safety Data Sheet of Propane
Propane is envisaged to be stored at BSL in existing (2 x 100T) bullets with inlet, outlet and vapour balancing lines and associated pumps, compressors etc. The mounded bullet, as per design considerations mentioned in OISD-150(The Oil Industry Safety Directorate), eliminates chances of a BLEVE (Boiling Liquid Expanding Vapor Explosion) and reduces chances of fatal hazards at design stage itself. As for the pipes which form the part of inlet, outlet and vapour balancing lines, regular inspection of the pipelines and maintenance operations along with installation of pressure detection systems in the pipelines will ensure no occurrence of pipeline failure.
7.1.5 Hazard Identification
Hazards associated with the identified hazardous chemicals based on NFPA (National Fire Protection Association) ratings as well as other parameters are presented in Table 7.3.
Table 7.3: Type of Hazards Associated With Identified Hazardous Chemicals NFPA Hazard Rating Flash Remarks Type of IDLH Flammability range Name of Chemical point Hazard Health Flammability Reactivity Value (for gases) (°C) Hydrogen 1,6,9 0 4 0 - - LEL = 4% (<13%)
Methane 1,6,9 2 4 0 - - LEL = 4.4% (<13%) All gases transported Carbon 1200 1,3,9 2 4 0 - LEL = 12% (<13%) directly through monoxide ppm pipelines. COG/ BFG/ Release: Leak/rupture 300 LEL = 16% Ammonia (NH3) 4,8 3 1 0 - ppm UEL = 25% LD gas stored in Steel Hydrogen 100 LEL = 4.3% Gas holders. 1,4,8 4 4 0 - Release: Leak/ ppm UEL = 46% BOFG/ Mixed Gas sulphide (H2S) Rupture 250 LEL = 0.9%
Constituents of Naphthalene 1,7,8 2 2 0 79° ppm UEL = 5.9% 2100 LEL = 2.2% Stored in mounded Propane (C3H8) 1,3,9 2 4 0 -104° bullets. Release: ppm UEL = 9.5% Leak/rupture Note: IDLH: Immediately Dangerous to Life or Health Type of Hazard : 1 Flammable substance 6 Gas or vapour not dangerous other than displacing air 2 Oxidising substance, reacts with reducing agents 7 Causes skin irritation or burns 3 Emits a toxic gas or vapour 8 Toxic substance 4 Emits an irritating gas or vapour 9 Explosive material under certain conditions 5 Emits a narcotic gas or vapour NFPA HAZARD Rating a) HEALTH 1 - None 2 - Minor 3 - Moderate, could 4 - Severe, short 5 - Extreme, short exposure cause temporary exposure may cause may cause death incapacitation or injury serious injury
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b) FLAMMABILITY 1-None, Material does 2- Minor, material must 3- Moderate, moderate 4- Severe, material 5- Extreme, very flammable not burn be preheated to ignite heating is required for ignites at normal substance that readily forms ignition and volatile temperature explosive mixtures vapours are released c) REACTIVITY 1-None, stable when 2-Minor, unstable at high 3-Moderate, unstable but 4-Severe, Explodes if 5-Extreme, readily explosives exposed to fire temp. or press and may does not explode, may heated or water added under normal condition react with water form explosive mixture with water
From the above table it can be observed that Coke Oven gas, BF gas, BOF gas, mixed gas and propane are the hazardous materials of concern for the proposed project. Propane is proposed to be stored in mounded bullets, as per the design guidelines of OISD-150, which also confirms high levels of safety of mounded bullets, diminishing possibilities of BLEVE from the bullets.
The catastrophic potential of a hazardous substance depends on its flammability, toxicity and volatility. The ambient temperature vapour pressure of a substance is used as a measure of the ability to become air borne. Although COG, BFG and Mixed gas are not proposed to be stored in the plant and also, as per applicability of MSIHC Rules, 1989, there is no specific requirement for carrying out its consequence analysis, the fire hazards associated have been quantified owing to its toxic as well as high flammable nature. BOF gas and propane being highly flammable and stored in significant quantities in the plant require consequence analysis to be carried out for them.
7.1.6 Hazard Assessment
In the earlier section, type of hazard associated with different type of substances and the event of release of these substances is being identified. It has also been identified the category of hazard associated with different chemicals.
In any plan hazardous situation arises due to: x Failure in the monitoring of crucial process parameters e.g. pressure, temperature, flow quantity etc. x Failure in the utilities e.g. cooling water x Failure control elements e.g. pressure, temperature level, flow controllers etc. x Failure of components such as pumps, compressor etc. x Failure of safety systems, safety valves / relief valves, sprinkler systems, alarm etc. x Mechanical failure of vessels or pipe work due to excessive stress, over pressure, corrosion etc. x Wrong operation, failing to adhere to the safety norms etc.
Such a situation is possible during the storage as well as handling of aforementioned hydrocarbon gases. It is unlikely that small leakage through pipes, gaskets, glands or any other means (user points) will create a hazardous situation unless allowed to be released for a long time as will be established in the subsequent sections. It is expected that during such small leakage preventive steps will be taken within a specified time span. Therefore a Preliminary Hazard Analysis (PHA) is carried out first for assessment of hazard. It is to note that the storage of Propane involves mounded storage bullets, which are designed to be intrinsically safe from the occurrence of a BLEVE condition. It is also to be noted that the storage of BOF gas involves vertical storage tanks called Gas holders located at separate locations nearer to the existing SMS complex of BSL, considering the nature of risks involved
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in storage of BOF gas. All the above gases shall be transported through steel pipelines constructed as per applicable safety standards.
Effects of the above Hazards: The effect of accidents in these areas will be confined to the facilities only and can be controlled within the areas by the operating personnel themselves. At the extreme, it may require the resources of the whole facility to control the effects but these are not at all expected to spill over to the community. Primary Hazard Analysis is given in Table 7.4.
Table 7.4: Preliminary Hazard Analysis Sn. Project Incident type Failure Scenario Causes of failure Proposed preventive measures component 1. Mounded Release of Failure in inlet, outlet or xOverfilling xDesign of storage structures / tanks to Storage bullets pressurized gas vapour balancing line or xPressure increase in relevant standards and legislations. into the associated fittings, pump bullet xDesign of pipelines (i.e. wall thickness atmosphere, or pipe-work or operator xRupture of hose and stress relief), well sites, Central Formation of error leading to impacts xGasket Failure Processing Facility and related vapour cloud, including chemical or fuel xLeak at flanges infrastructure to relevant standards and fire, explosion contamination xWrong line-up legislation. xNon adherence to SOP xInstallation of pressure monitoring for sampling systems. xInstrumentation failure xRegular inspections and maintenance. xOperator error xHousekeeping activities – site would be xExternal fire kept clean and tidy and fire hazards xCorrosion removed where practicable. xAvailability of firefighting equipment. xMaintenance of fire breaks to slow the progress of bushfires. xRoutine hazard reduction burns. xFire-fighting equipment located in on-site vehicles and infrastructure (wherever appropriate). xRegular inspections and maintenance of firefighting equipment and storage areas, where required. xOperator induction and ongoing training. xOperational procedures. xMaterial safety data sheet (MSDS) register and MSDSs kept on-site at different locations in form of signage etc. xHazard Signage. xLocation of explosive storage shall be such that it has minimum interaction with people and property. Sabotage Malicious act/sabotage xInadequate protection of xRestriction of access to storage areas, resulting in off-site facilities. including securing storage facilities. impacts. xLapse in safety xProvision of adequate lighting around procedures due to storage facilities. Human error. xSignage (i.e. unauthorized entry warning and information signs). xPolice would be notified as soon as possible in case of a suspected breach. 2. 1Vertical Release from Failed tank or associated xRupture of hose xDesign of storage structures / tanks to .Storage tanks Leak / rupture fittings, pump or pipework xGasket Failure relevant standards and legislations.
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Sn. Project Incident type Failure Scenario Causes of failure Proposed preventive measures component (gas holders) or operator error. xLeak at flanges xRegular inspections and maintenance. xNon adherence to SOP xOperator induction and ongoing training. for sampling xOperational procedures. xInstrumentation failure xMaterial safety data sheet (MSDS) xOperator error register and MSDSs kept on-site at xExternal fire different locations in form of signage etc. xCorrosion xHazard Signage. Failed vessel due to xCorrosion mechanical impact or xMechanical impact corrosion Fire or Explosion Poor maintenance, poor Human/ Operator error in xDesign of storage structures / tanks to design, collision or human design and construction relevant standards and legislations. error leading to fire / xAppropriate storage of all chemicals, fuel explosion / fume related and dangerous substances in accordance impacts. with relevant Hazardous Chemical Rules, 2000 with subsequent amendments and associated legislations. xHousekeeping activities – site would be kept clean and tidy and fire hazards removed where practicable. xAvailability of firefighting equipment, such as overhead water spray system, mounted on top of gas holders. xRegular inspections and maintenance of firefighting equipment and storage areas, where required. xSite policies, management plans and procedures. xProtection of storage facilities (e.g. bollards). xOperator induction and ongoing training. xLocation of explosive storage should be such that it has minimum interaction with people and property. Sabotage Malicious act/sabotage xInadequate protection of xRestriction of access to storage areas, resulting in off-site facilities. including securing storage facilities. impacts. xLapse in safety xProvision of adequate lighting around procedures due to storage facilities. Human error. xSignage (i.e. unauthorized entry warning and information signs). xPolice would be notified as soon as possible in case of a suspected breach. 2. Gas Pipelines Release of Failure of pipeline, xPressure increase xDesign of pipelines (i.e. wall thickness flammable gas, bursting of pipeline due to xRupture of pipe and stress relief), well sites, Central Formation of -Corrosion xLeak in pipework Processing Facility and related vapour cloud, -Vibration xInstrumentation failure infrastructure to relevant standards and fire, explosion -External loading xOperator error legislation. -Operation error xExternal fire xInstallation of pressure monitoring -Over pressure xCorrosion systems. -Maintenance failure xConduct regular inspections, -Communication failure maintenance and testing of equipment. -Sabotage xSite policies, management plans and procedures. xOperator induction and ongoing training.
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Sn. Project Incident type Failure Scenario Causes of failure Proposed preventive measures component xMaintenance of fire breaks to slow the progress of bushfires. xRoutine hazard reduction burns. xFire-fighting equipment and spill kits located in on-site vehicles and infrastructure (where appropriate). Sabotage Malicious act/sabotage xInadequate protection of xRestriction of access to storage areas, resulting in off-site facilities. including securing storage facilities. impacts. xLapse in safety xProvision of adequate lighting around procedures due to storage facilities. Human error. xSignage (i.e. unauthorized entry warning and information signs). xPolice would be notified as soon as possible in case of a suspected breach.
The details of comprehensive HIRA (Hazard Identification & Risk Assessment) for the proposed projects and existing facilities of Bokaro Steel Plant along with the onsite-emergency plan is enclosed as Annexure 7.2. The Disaster Management Plan is also attached with Annexure-7.2.
7.1.7 Maximum Credible Accident Analysis (MCAA)
A Maximum Credible Accident (MCA) can be characterized, as an accident with a maximum damage potential, this is still believed to be probable. The selection of accident scenarios representative for a MCA-Analysis has been done on the basis of engineering judgement and expertise in the field of risk analysis studies, especially accident analysis.
In the proposed expansion programme of BSL, which is also identified as an “Industrial activity” handling hazardous substances as per MSIHC Rules, 1989 and subsequent amendments, hazardous substances may be released as a result of failures or catastrophes, causing possible damage to the surrounding area.
As mentioned above, the hazardous substances identified of posing major threats to the facility and people working at the facility are listed at Table 7.3 above.
MCA Analysis assists in identifying the potential major accidents arising due to flammable and/or toxic storages or handling facilities and estimate the maximum consequent effects on the surrounding environment in terms of damage distances of heat, radiation, toxic release, vapor cloud explosion etc. depending upon the effective hazardous attributes and the impact of the event, in the worst possible hazard situations.
The visualization of MCA scenarios has been done considering the chemical inventory being handled at the proposed plant, various loss of containment scenarios and subsequent accident scenarios and analysis of incident history of similar nature to establish credibility of the identified accident scenarios. Based on the above, the identified credible accident scenarios having maximum damage effects (worst case) were as follows: i. For BOF gas Holders: a. Release of BOF gas due to rupture resulting in - Fireball CHAPTER-7 ADDITIONAL STUDIES Page 236 of 298 © 2020 MECON Limited. All rights reserved
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- Flash fire - Vapour Cloud explosion - Toxic cloud dispersion
ii. For Gas Mixing Station/facility: a. Release of COG from COG inlet pipeline due to x leak from hole (eq. size 100mm) of piping resulting in - Jet fire - Flash fire
Note: No Vapour Cloud explosion and Toxic cloud dispersion effects observed due to hole releases due to very low release rates of gas quantity from the holes. Thus, they have been excluded from the analysis.
x rupture of pipeline resulting in - Fireball - Flash fire - Vapour Cloud explosion - Toxic cloud dispersion
b. Release of BF gas from BF gas inlet pipeline due to rupture resulting in - Fireball - Flash fire - Vapour Cloud explosion - Toxic cloud dispersion Note: Due to low mass release rates of the gas, no significant hazard distances were observed due to release from holes of all sizes upto 20% of pipe dia. Thus, only full bore rupture considered for the analysis.
c. Release of Mixed gas from Mixed gas outlet pipeline due to rupture resulting in - Fireball - Flash fire - Vapour Cloud explosion - Toxic cloud dispersion Note: Due to low mass release rates of the gas, no significant hazard distances were observed due to release from holes of all sizes upto 20% of pipe dia. Thus, only full bore rupture considered for the analysis.
iii. For Mounded bullet storage of Propane: a. Release of Propane from Bullet’s Liquid Inlet, Outlet Lines and/or Vapour Balancing Line connection points resulting in - Jetfire - Flash fire - Vapour Cloud explosion
7.1.8 Consequence Analysis
Subsequent to the accidental release of hazardous chemicals, the consequence depends on various factors e.g. type and inventory of released hazardous materials, presence and location of an ignition source, meteorological conditions, etc. Consequence analysis for the selected accident scenarios has been carried to estimate the vulnerable zones.
7.1.8.1 Consequence Model / Software Used
DNV’s PHAST (Version 6.4) software, which is a consequence and risk assessment software for calculation of physical effects (fire, explosion, atmospheric dispersion) of the escape of hazardous
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materials has been used to perform the consequence calculations. The software allows detailed modeling and quantitative assessment of release of pure chemicals as well as mixtures from different scenarios. 7.1.8.2 Hazardous Scenarios Modeled
Consequence analysis quantifies vulnerable zone for a conceived incident and once the vulnerable zone is identified for an incident, measures can be proposed to eliminate damage to plant and potential injury to personnel. Consequence analysis for existing BOF gas stored in gas holders, additional COG, BFG and Mixed Gas proposed to be handled via pipelines of new Gas mixing station and Propane envisaged to be stored in Mounded bullets at BSL has been carried out. The release scenarios selected and associated hazards based on MCA Analysis are listed below in Table 7.5.
Table 7.5: Probable Release&Accident Scenarios Identified as per MCAA Sl. No. Hazardous Credible Release scenario Credible identified accidents substance 1. BOF gas Complete failure of Gas holder leading to Fireball, Flash fire, Vapour Cloud catastrophic release of BOF gas explosion, Toxic Cloud dispersion 2. Propane Complete failure of inlet-outlet and other lines Fireball, Flash fire, Vapour Cloud connected to the bullets leading to release from explosion connecting points. 3. Coke Oven Gas, BF Leak from hole (100mm dia. hole) [for COG only] Jet fire, Flash fire Gas, Mixed gas Full bore rupture of piping [for all gases] Fireball, Flash fire, Vapour Cloud explosion, Toxic Cloud dispersion
7.1.8.3 Meteorological Conditions Considered
Minimum wind speed of 1.0 m/s and stable as well as neutral atmospheric stability conditions have been assumed to model fire effects in a worst case scenario having low chance of dilution of flammable substance concentration in the atmosphere and a higher damage effect. An average Wind speed of 3.0 m/s based on annual climatological trend of wind speeds at Bokaro as collected from IMD Atlas at Bokaro with neutral atmospheric stability conditions has been assumed to predict maximum extent of dispersion of toxic components of the identified hazardous substances during a release.
7.1.8.4 Damage Criteria Considered in the Model
In order to apprehend the damage produced by various scenarios, it is appropriate to discuss the physiological/physical effects of thermal radiation intensities due to fire accidents and overpressure effects of explosions. The thermal radiation due to pool fire or jet fires usually results in burn on the human body. Furthermore, inanimate objects like equipment, piping, cable, etc. may also be affected and also need to be evaluated for damages. The effect of overpressure due to blast effect and the effect of thermal radiation due to fire on unprotected skin, as per Indian Standard IS 15656 : 2006 HAZARD IDENTIFICATION AND RISK ANALYSIS — CODE OF PRACTICE is presented below in Tables 7.6(a) and 7.6(b), respectively.
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Table 7.6(a): Effect of Different Over-Pressures on Human Life& Property Overpressure (bar) Type of Damage on structure Type of Damage on Human life 0.02 Typical window glass breakage - 0.14 Partial collapse of buildings Personnel knocked down 0.21 Steel framed buildings get distorted and Ear drum rupture (beginning of serious injury to uprooted from their foundations human life)
Table 7.6(b): Relation Between Heat Radiation Intensity, Time &Effect on Man Heat Radiation Duration (Secs) Effect on Humans Effect on property Level (Kw/m2) 4 -6 20 Sufficient to cause pain to Impairment of escape routes personnel 12.5 5-20 Extreme pain within 20s Provides minimum energy required for piloted ignition of wood and melting of plastic 37.5 10 Immediate fatality (100% Sufficient to cause severe damage to lethality) process equipment
The results of consequence analysis are summarised in the succeeding Table 7.7 below.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Table 7.7: Results of Consequence Analysis Hazard extent(m) Hazardous Substance Plant Unit Failure size (mm) Hazard effects End Point Criteria Atmospheric Conditions Handled/ Stored 1.5F 1.5D 3D GAS MIXING STATION 4.0 kW/m2 9 - 11 Jet fire 12.5 kW/m2 - - - Flame length:12.27 m Hole (100mm) 37.5 kW/m2 - - - Flash Fire LFL 5 5 4 [½ LFL conc:23698.9 ppm ] ½ LFL 8 8 7 4.0 kW/m2 115 115 115 Fire Ball 12.5 kW/m2 66 66 66 [Max Fireball radius= 13.79m] COG Inlet Pipeline COG 37.5 kW/m2 38 38 38 Flash Fire LFL 14 12 13 [½ LFL conc: 23698.9] ½ LFL 34 31 35 Rupture (FBR) 0.21 bar 36 36 37 Vapour Cloud Explosion 0.14 bar 44 43 44 [Distance of ignition: 10m] 0.02 bar 142 140 143 Toxic Dispersion [Probability of fatality at 0 m 0.83 0.63 0.04 distance of ] 25 m 0 0 0 4.0 kW/m2 111 111 111 Fire Ball 12.5 kW/m2 51 51 51 [Max Fireball radius= 52.3m] 37.5 kW/m2 - - - Flash Fire LFL 65 14 23 [½ LFL conc: 162338 ppm] ½ LFL 210 34 51 BFG Inlet Pipeline BFG Rupture (FBR) 0.21 bar 48 47 47 Vapour Cloud Explosion 0.14 bar 59 58 58 [Distance of ignition: 10m] 0.02 bar 198 197 197 Toxic Dispersion [Probability of fatality at 0 m 0.83 0.93 0.34 distance of ] 25 m 0 0 0 4.0 kW/m2 99 99 99 Fire Ball 12.5 kW/m2 49 49 49 [Max Fireball radius= 38.25m] 37.5 kW/m2 9 9 9 Mixed gas Outlet Pipeline Mix. G Rupture (FBR) Flash Fire LFL 12 10 15 [½ LFL conc:104424 ppm ] ½ LFL 43 26 51 Vapour Cloud Explosion 0.21 bar 44 43 43
CHAPTER-7 ADDITIONAL STUDIES Page 240 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT Hazard extent(m) Hazardous Substance Plant Unit Failure size (mm) Hazard effects End Point Criteria Atmospheric Conditions Handled/ Stored 1.5F 1.5D 3D [Distance of ignition: 10m] 0.14 bar 54 53 53 0.02 bar 178 177 177 Toxic Dispersion [Probability of fatality at 0 m 0.87 0.93 0.31 distance of ] 25 m 0 0 0 4.0 kW/m2 410 410 410 Fire Ball 12.5 kW/m2 219 219 219 [Max Fireball radius= 135m] 37.5 kW/m2 84 84 84 Flash Fire LFL 127 76 120 [½ LFL conc: 110644 ppm] ½ LFL 262 126 192 BOF GAS HOLDERS BOF Gas Rupture (FBR) 0.21 bar 136 136 136 Vapour Cloud Explosion 0.14 bar 173 173 173 [Distance of ignition: 10m] 0.02 bar 640 640 640 0 m 0.52 0.90 0.37 Toxic Dispersion [Probability of fatality at 25 m 0 0.01 0 distance of ] 50 m 0 0 0 PROPANE BULLET 4.0 kW/m2 131 131 154 Jet fire 12.5 kW/m2 - - 45 Flame length:132 m] 37.5 kW/m2 - - - Connection point of Inlet/ Flash Fire LFL 6 6 8 outlet pipelines (80mm Propane Vessel hole (80mm) [½ LFL conc: 10000 ppm] ½ LFL 23 21 22 Ø) 0.21 bar 44 45 42 Vapour Cloud Explosion 0.14 bar 54 55 51 [Distance of ignition: 10m] 0.02 bar 179 184 169 4.0 kW/m2 81 9 98 Jet fire 12.5 kW/m2 - - 22 Flame length: 88.25 m] 37.5 kW/m2 - - - Connection point of LFL Not observed due to low mass flow Vapour Balancing lines/ Propane Vessel hole (50mm) Flash Fire ½ LFL release rate from hole other pipelines (80mm Ø) 0.21 bar 33 33 30 Vapour Cloud Explosion 0.14 bar 39 39 35 [Distance of ignition: 10m] 0.02 bar 123 123 108
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The above table makes evident that the majority of the hazardous consequence have highest hazard extents in the atmospheric stability class D. The worst case results for the different releases enumerated above have been observed in the atmospheric scenario similar to 3D. As observed from the table above, the worst case results are summarized in Table 7.8. For assessing maximum damage from most credible scenarios, results have been shown for end point criteria corresponding to maximum observed damage due to a particular hazard effect.
Table 7.8: Worst Case Hazard Extents for Identified Hazardous Facilities Plant Unit Failure size Nature of hazard Hazard effects Worst case Hazard extent (m) GAS MIXING Hole Fire & Explosion Jet fire 11m @ 4.0 kW/m2 STATION Flash Fire 8m @ LFL Rupture Fire & Explosion Fireball 38m @37.5 kW/m2 Flash Fire 65m @LFL Vapour Cloud Explosion 48m @0.21 bar(g) Toxic effect Toxic effect safe distance > 25m @ no probability of fatality BOF GAS Rupture Fire & Explosion Fireball 84m @37.5 kW/m2 HOLDERS Flash Fire 127m @LFL Vapour Cloud Explosion 136m @0.21 bar(g) Toxic effect Toxic effect safe distance > 50m @ no probability of fatality MOUNDED Vessel failure at Fire & Explosion Jetfire 45m at 12.5 kW/m2 PROPANE pipe junctions Flash Fire 8m @ LFL BULLET Vapour Cloud Explosion 45m @0.21 bar(g)
The worst case Hazard extents of all identified major hazardous units is shown in Figures. 7.1(a) to 7.1(f).
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BOF GAS HOLDERS GAS MIXING STATION WITH ASSOCIATED PIPEWORK
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MOUNDED PROPANE BULLET
CHAPTER-7 ADDITIONAL STUDIES Page 244 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT FIG 7.1:(b) Hazard Extents For Flash Fires In Identified Hazardous Facilities
BOF GAS HOLDERS GAS MIXING STATION WITH ASSOCIATED PIPEWORK
CHAPTER-7 ADDITIONAL STUDIES Page 245 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT FIG 7.1: (c) Hazard Extents For Flash Fires In Identified Hazardous Facilities
MOUNDED PROPANE BULLET
CHAPTER-7 ADDITIONAL STUDIES Page 246 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT FIG 7.1: (d) Hazard Extents For Vapour Cloud Explosion Effects In Identified Hazardous Facilities
GAS MIXING STATION WITH ASSOCIATED PIPEWORK BOF GAS HOLDERS
CHAPTER-7 ADDITIONAL STUDIES Page 247 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT FIG 7.1: (e) Hazard Extents For Vapour Cloud Explosion Effects In Identified Hazardous Facilities
MOUNDED PROPANE BULLET
CHAPTER-7 ADDITIONAL STUDIES Page 248 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT FIG 7.1: (f) Hazard Extents For Toxic Cloud Dispersion Effects In Identified Hazardous Facilities
GAS MIXING STATION WITH ASSOCIATED PIPEWORK BOF GAS HOLDERS
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The proximity of nearest habitations to Identified Hazardous facilities is shown in Figure 7.2 below:
FIG 7.2: Safe Distances From Hazardous Installations Of BSL To Nearest Habitations
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7.1.9 Conclusion on MCA Analysis
7.1.9.1 Gas Mixing Station
A maximum total of 75,000 m3/hr of mixed gas is proposed to be handled by a new Gas mixing station envisaged at BSL’s Coke Oven complex, wherein BF Gas and Coke Oven gas will be tapped from existing as well as future producing units and will be mixed in suitable proportions to produce Mixed gas of desired calorific value for use at the existing and new coke oven batteries. The results of MCA analysis indicates a maximum fire hazard distance for causing significant damage (@37.5 Kw/m2 thermal radiation) extending up to 38 m in the case of complete failure of the holder and catastrophic release of BOF gas, subsequently being ignited during worst meteorological conditions resulting in a fireball. The hazard extent for flash fire extends till 65 m (@ LFL concentration). Explosion effects having significant potential for damage (@0.21 bar(g) overpressure) is observed to be upto a distance of 48m.
The toxic effect of BFG, COG as well as Mixed gas (attributed to presence of Carbon Monoxide in the gases) will be limited to 25m from the gas holder, beyond which there will be no probability of fatality due to toxic effect in case of a release.
Overall, a minimum safe distance of 65 m from the Gas mixing station will ensure no damage to personnel as well as property, outside the plant premises. As observed from the overall analysis, the hazard extents will be contained within the plant premises and will not extend beyond plant boundary into any nearby settlement in the area. 7.1.9.2 BOF Gas Holders
There are two (2) BOF gas holders, i.e. a replaced BOF gas holder of SMS-1 of 50,000 m3 capacity and a new gas holder of 80,000 m3 capacity, both located within the SMS complex of BSL’s Bokaro Steel Plant. The results of MCA analysis indicates a maximum fire hazard distance for causing significant damage (@37.5 Kw/m2 thermal radiation) extending up to 84 m in the case of complete failure of the holder and catastrophic release of BOF gas, subsequently being ignited during worst meteorological conditions resulting in a fireball. Explosion effects having significant potential for damage (@0.21 bar(g) overpressure) is observed to be upto a distance of 136m.
The toxic effect of BOF Gas (attributed to Carbon Monoxide in BOFG) will be limited to 50m from the gas holder, beyond which there will be no probability of fatality due to toxic effect in case of a release.
Overall, a minimum safe distance of 136 m from the BOF Gas holders will ensure no damage to personnel as well as property, outside the plant premises. As observed from the overall analysis, the hazard extents will be contained within the plant premises and will not extend beyond plant boundary into any nearby settlement in the area.
7.1.9.3 Mounded Propane Bullet
BSL has envisaged two (2) propane bullets, each of 100Tonne capacity, located within the BSL’s Bokaro Steel Plant for heating and cutting purposes. The results of MCA analysis indicates a
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maximum fire hazard distance for causing significant damage (@12.5 Kw/m2 thermal radiation) extending up to 45 m in the case of complete failure of the pipeline connections on the bullets and release of propane, subsequently being ignited during worst meteorological conditions resulting in a jetfire. Explosion effects having significant potential for damage (@0.21 bar(g) overpressure) is also observed to be upto a distance of 45 m.
Overall, a minimum safe distance of 45 m from the Propane bullets will ensure no damage to personnel as well as property, outside the plant premises. As observed from the overall analysis, the hazard extents will be contained within the plant premises and will not extend beyond plant boundary into any nearby settlement in the area. Also, pressure-monitoring systems shall be installed to detect leaks or cracks in the pipeline. Fire-fighting facilities will also be installed to check any fire incident that may occur.
7.1.10 Hazardous Events with Greatest Contribution to Fatality Risk
The hazardous event scenarios likely to make the significant contribution to the risk of potential fatalities are enlisted in Table 7.9. The risks to people at plant site are categorized as “On-site” risks while the risks to communities outside the plant premises is categorized as “Off-site” risks.
Table 7.9: Hazardous Events Contributing to Risk and their Risk Ranking (A) (B) C = A*B Sn. Hazardous event Consequence of Consequence Likelihood* RISK significant damage severity* (1=least likely; RANK (1=least severe; 5=most likely) 5=most severe) Onsite vehicle impact on Potential for single fatalities, 1. 3 3 9 personnel onsite impact only Entrapment/struck by Potential for single fatalities, 2. 3 2 6 Machinery onsite impact only Potential for single fatalities, 3. Fall from heights 1 3 3 onsite impact only Potential for single fatalities, 4. Electrocution 2 3 6 onsite impact only Gas Mixing Station fire & Potential for multiple 5. explosion as well as toxic 4 1 4 fatalities, onsite impact only dispersion BOF gas holder failure and Potential for multiple 6. fire & explosion as well as 5 1 5 fatalities, onsite impact only toxic dispersion Propane Bullet’s fire & Potential for multiple 7. 3 1 3 explosion fatalities, onsite impact only *based on Historical survey of similar facilities
The above risk ranking indicates that although the most severe consequences will be due to rupture of BOF Gas holders followed by Gas Mixing station and Mounded propane bullets, their chances of occurrences are low due to implementation of better safety features in the installations and constant monitoring of vessel/pipework integrity for regular repair and maintenance, and hence these facilities have low levels of risk in the facility.
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7.1.11 Summary & Conclusions of Risk Assessment The risk assessment and analysis for BSL’s steel plant for most severe hazardous events is broadly summarized below:
x The nearest habitations in the vicinity of the BSL Plant are Tupkadih village at distance >4000min NW, Balidih village at distance >3000m in SW, LakdaKhanda village in SEat distance >2500mand Agardih village at distance >2300m in the NE, which are far away from the hazard distances observed for thermal effects (maximum at 127m) as well as toxic effects (maximum at 50m) due to failure of above identified hazardous facilities of BSL. Also, these facilities are located in the central part of the Bokaro steel plant away from each other to prevent multiple hazards, initiated due to fire in one facility and leading to a hazard in another facility, also known as domino effect. So, there will be no significant impact on the local community or damage to property / environment.
x The most severe damage effects due to the identified hazardous facilities will be limited to the plant premises and adequate safety controls as well as implementation of recommended control strategies in the design as well as operation stage will ensure effective management of the associated risks.
7.1.12 Recommended Risk Reduction and Mitigation Measures
The following opportunities shall be considered as a potential means of reducing identified risks during the detailed design phase: x The zones identified from consequence modelling as affected areas due to thermal radiations greater than 12.5 kW/m2 shall be marked as “Heat Zones” and provisions for fire fighting will be made available close to these zones. x It is also recommended to provide portable gas detectors within the site in order to facilitate manual gas leak monitoring and regular leakage checks. Constant monitoring of gas leak shall be ensured for immediate identification of leaks and subsequent implementation of action plan to prevent development of any hazardous situation. x Further, all major units / equipment shall be provided with the following safety facilities: - Smoke / fire detection and alarm system - Water supply - Fire hydrant and nozzle installation - Foam system - Water fog and sprinkler system - Mobile fire-fighting equipment - First-aid appliances x Personal Protective Equipment (PPE) shall be provided for additional protection to workers exposed to workplace hazards in conjunction with other facility controls and safety systems. x Restricted access to these areas to have minimum casualties in an event of exposure. x The onsite Emergency Plan will be integrated with the Bokaro district’s Offsite Emergency Plan for comprehensive management of emergencies in minimum response time and maximum rescue
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results in an event of a disaster /emergency. Co-ordination with nearby industries will also be maintained for creating unified Disaster management resource pool to be utilised in case of any disaster occurrence. x The plant structures shall be designed for cyclone floods and seismic events to prevent structural collapse and integrity of weather (water) proofing for storage of dangerous goods. x Isolate people from load carrying/mechanical handling systems, vehicle traffic and storage and stacking locations. x Security of facility to prevent unauthorized access to plant, introduction of prohibited items and control of onsite traffic; and x Development of emergency response management systems commensurate with site specific hazards and risks (fire, explosion, rescue and first aid). x Regular safety audits shall be undertaken to ensure that hazards are clearly identified and risk-control measures are maintained within tolerable limits.
7.1.13 On Site Emergency Plan
The on-site emergency plan relates to the laid-down and well-practiced procedure after taking care of all design based precautionary measures for risk control. This plan is aimed for tackling any emergency situation, if arises. The onsite emergency plan for the existing plant has been already prepared by BSL. The same will be extended to the proposed units also. The contents of the onsite emergency plan are briefed here under.
a) Identification & Assessment of Hazards Three major hazards of the steel plants are: 1. Fire 2. Explosion 3. Toxic release
b) Elements of assessment: 1. Potential sources – Storage, tanker loading points, plant equipment, pipe lines. 2. Vulnerable points – Flanges, valves etc. 3. High risk points to be mapped 4. Emission rate and dispersion behaviour were estimated
In each emergency preparedness plan (EPP), the above have been identified and assessed for development of emergency plan for each unit.
c) Development of Emergency 1. Raising of alarms 2. Declaration of emergency 3. implementation of emergency procedure
d) Work Emergency Plan Each emergency preparedness plan (EPP) has the following elements.
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Elements for plan: 1. Communication and control system 2. Personnel with specified responsibilities 3. Communication of the emergency 4. Works emergency procedure
(i) Communication and control system
A. Emergency control centre 1. Located in position of minimum risk zone with good access to both works and outside road system. 2. Accessible for controller to reach 3. Should be linked by telephones 4. Radio provisions 5. Contain a copy of the emergency plan 6. All the appropriate equipment required to deal emergency 7. Manned by Chief controller Senior officer Messengers
B. Alarm system 1. Raising alarms Easily accessible points Receivable by all part of workers Audio, visual alarms 2. Declaration of emergency long period alarm
(ii) Personnel with specified responsibilities
Essential Functions and Nominated Personnel are as follows: 1. Chief controller Responsibilities: a. Relieve the Dy. Chief controller to perform his duty. b. Ensure outside emergency services have been called in c. Ensure key personnel called in d. Exercise direct operation controlled of those parts of the works outside the affected area e. Maintain a speculative review of possible developments f. Direct the shutting down of plant and evacuation of plant personnel g. Ensure casualties receive adequate attention h. Liaisoning with chief officers of various agencies i. Control traffic movement within the works j. Ensure authorized elements to news media. 2. Dy. Chief controller Responsibilities: a. Assess the scale of emergency CHAPTER-7 ADDITIONAL STUDIES Page 255 of 298 © 2020 MECON Limited. All rights reserved
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b. Direct all the operations to minimize loss c. Direct rescue and fire fighting operation d. Ensure that the affected area is searched for casualties e. Ensure all non-essential workers, evacuated f. Setting up proper communication points g. Ensure other agencies, called in h. Report significant development to chief controller
3. Other functions and personnel a. Plant control / shut down b. Leakage control c. Hazard reduction (removal of tanker etc.) d. Movement of equipment (fire fighting first aid etc.) e. Engineering activities (repair of plant, utilities etc.) f. Traffic control g. Evacuation h. Rescue i. First aid and causality clearance j. Communication inside / outside works
(iii) Communication of emergency 1. Raising the alarm after assessing the situation quickly Authorization, training of personnel
2. Declaration of emergency After raising alarm, work emergency procedure is activated Dy. Chief Controller will declare the emergency
3. Communication Chief controller communicates to x Personnel of the plant concerned x Personnel of other threatened plants x Personnel throughout the works x Key works personnel x Police x Fire services x Medical services x Press x Head office etc.
Elements for plan: a. Communication and control system’ b. Personnel with specified responsibilities
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c. Communication of the emergency d. Works emergency procedure e. Co-operation with outside services f. Public relation
(iv) Work emergency procedure Action on declaration of emergency: Personnel should be trained
After alarm is raised following procedure to be followed: a. All members of the work force come to assembly point; key persons rush to man key areas/ positions. b. Personnel, in-charges, return to their office & wait for instructions c. Senior personnel go to emergency control center/ assembly point and act upon the instructions of the Dy. Chief controller. Evacuation of personnel: x Non-essential workers to assembly points x Shelter at assembly point with breathing apparatus etc. x Manned to note the name of persons x List of contractors, visitors should be available
Co-operate planning, training and exercise: a. Planned co-operation with other agencies: Area of responsibilities, chain of command and system of communication defined. b. Training for emergency: All personnel, contractors, visitors, outside agencies to be trained c. Exercise for emergencies: Mock drill, Fire fighting exercise
Transport Emergency Emergency planning includes: a. Chemical data b. Information and labelling (placards) & TRAM-CARD with the driver c. Incident control network d. Emergency procedure e. Emergency team f. External services g. Public relation
Emergency procedure: a. Keep people away, inform them about the hazards of chemical b. Inform incident control c. Try to Contain chemical spill & Avoid ignition d. Obtain chemical data
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Communication to incident control center a. Place and time of incident b. Chemical involve c. Condition of the container d. Injuries or death e. Area surrounding f. Weather conditions g. Assistance available h. Means of maintaining contracts
Emergency team: Team should have a. Chemical data b. Protective clothing c. Breathing apparatus d. Safety harness and lines e. General tools and flash lights f. Leak plugging equipment g. Analytical equipment h. Flood light with generator i. First aid kit
(v) Co-Operation with outside services 1. BSL has Fire Brigade – well equipped having 14 fire tenders distributed at 4 posts inside plant with well-trained manpower (249). It caters the needs of the plant as well as Jharkhand State and helps the Government agencies. 2. BSL is having a well-equipped 910 bedded hospital to take care of health conditions of employees as well as outsiders. Its casualty department is open 24 hrs. 3. District administration - District Magistrate and District Collector, Bokaro is Chairman of “District Crisis Management Group” Bokaro steel city. The committee meets in case of any disaster in the district. He is informed whenever BSL carries a full scale Mock-drill and he participates on one or two important Mock- drills. 4. Police department: Superintendent of Police Bokaro District is informed of all the Mock-drills where evacuation and general public is involved. His services are available whenever some disaster affecting general public living in nearby areas get affected and need for mass evacuation arises. (vi) Public relation Bokaro Steel Plant is having a well-established Public Relations department who are always in constant touch with the media. Any information and in case of any disaster, Chief of Communications who is heading the P.R. Department is responsible for press release etc. and takes care of all the information flowing out to media persons in case of disaster.
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Hazard Identification and Risk Assessment of existing Bokaro Steel plant: Bokaro Steel plant has an established Hazard Identification and Risk Assessment, developed for all critical shops of the plant. The same is integrated in the unit-wise emergency plans. Engineering measures have been taken for ensuring safety in plant operation and maintenance activities. As previously referred, the Onsite Emergency Plan for each critical unit along with Hazard Identification and Risk Assessment (HIRA) addressing all possible hazards / risks is attached as Annexure 7.2. The Annexure also includes the Disaster Management/Contingency plan for Bokaro Steel plant.
The safety procedures to be adhered to while handling hazardous gases as well as liquid metal at BSL is also elaborated in various Inter Plant Standard – Steel Industry (IPSS) attached as Annexure 7.3.
The safety management practices at BSL is detailed in Chapter-4 of this report.
7.2 SOCIO-ECONOMIC STUDY
All industrial projects have social and economic linkages. Therefore, putting up a new project and/or modernization/ expansion of existing projects have impact on the socio–economic environment of the locality around it. This impact may be marginal or non–marginal. The intensity of impact may depend upon the various social and environmental factors associated with it and the extent of change caused by the project to alter the existing equilibrium of the socio – economic system. Influx of people from outside during various stages of the project may also alter the existing cultural identity of the local people. Further, there is a cash flow associated with the project which may affects the existing socio– economic activities and introduces many more new activities associated with the project to which the local people have strong adherence.
BSL is proposing to modernize and expand its existing Bokaro Steel plant from 4.5 MTPA to 5.77 MTPA Hot metal production capacity at Bokaro Steel City, Bokaro, Jharkhand. The various activities of the projects are likely to stimulate the existing socio–economic environment in the surrounding area. The influx of money and various construction activities may not only change the economic status of the area but also influence the existing cultural scenario. This impact is expected to be more in the area closer to the site, which decreases with increase of distance from the site. The present project is likely to bring benefits for the local people. However, possibility of certain obvious hardships having substantial social cost cannot also be ruled out. Therefore, it is justified to carry out a thorough socio- economic impact assessment of the project.
7.2.1 Objectives of the Study
BSL already has made a widespread impact on the social and economic conditions of the people of the region in terms of direct and indirect employment, skill diversification, infrastructure development, business development etc. Over the years BSL has carried out excellent community development activities and now approaching towards implementation of sustainable development programmes. Nevertheless, the possibility of some adverse effects cannot be ruled out. Therefore, it is essential to carry out a through socio-economic impact assessment of the present project. On this backdrop, the present study is directed towards the following objectives:
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x To assess the impact of the project on agricultural situation; x To assess the impact of the project on pattern of demand; x To examine the impact of the project on consumption pattern; x To examine the employment and income effects of the project; x To assess the impact of the project on education; x To ascertain the impact of the project on industrialization in the study area; x To examine the impact of the project on community development activities; x To judge peoples' perception regarding the project;
7.2.2 Existing Socio-Economic Scenario
A 10km radius buffer around the existing plant area of BSL is considered as the study area for this project. The entire study area falls under Bokaro district of Jharkhand. A village by the name Bokaro lies on north bank of Konar where Bokaro Thermal Power Station of DVC is located. BSL is located on the site formerly a village by the name of Maraphari.
The details of the existing demographic and socio-economic status of the study area is discussed in Chapter-3 of this EIA-EMP report.
7.2.3 Methodology Adopted for the Study
The methodology adopted for the study is based on the following process:
Review of Secondary Data
Data from the secondary sources, viz. the latest available District Statistical Handbook, 2011 Census data and various census updates based on the 2011 census, were explored / reviewed for getting the demographic profile, occupational structure, etc. of the population within the study area (10 km radius) of the project site. The secondary data supplemented the primary data collected through direct field survey.
Field Survey
Baseline data on socio-economic parameters such as demography, infrastructure, economic resource base, health status, cultural aspects and aesthetic attribute were generated using information available with Govt. agencies, census data, and statistical abstract and health agencies. Socio-economic survey was carried out covering all the villages of the study area to record awareness, opinion, apprehensions, quality of life and expectations of the local people about the proposed project. The opinion of local people about the proposed plan was obtained through socio-economy survey of the villages in the study area.
A brief about the sampling design adopted for the field survey is described below. The survey has been conducted through specially designed questionnaire covering every aspect of the present study. In addition to the field data, secondary data / information collected, compiled and published by different Governmental agencies / departments were also collected and utilized appropriately.
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Sampling
For selection of respondents from the study area, Two Stage Random Sampling has been adopted. In the first stage, villages are selected and in the second stage, households/ respondents are selected. From each selected village, the respondents are selected randomly to account intra-village variability among the respondents for the character under study. As the variability of the characters in each study strata does not vary widely among the households, a smaller sample size is expected to represent the population.
Samples of 75 respondents from 15 villages (10 villages from 0-5 km, 5 villages from 5-10 km of project site) were drawn from the study area. The sample covers an estimated 298 persons.
Composition of the Questionnaire
Households/respondents were interviewed with the structured questionnaire specifically designed for this study keeping in view the objectives of the study. The questionnaire consists of following major sections: x Demographic profile of the households x Information on agricultural situation x Educational status x Employment (sources of employment) x Income of the family (income from various sources) x Information on family budget x Consumption and saving x Energy consumption x Respondents’ perception about the project
Analytical Framework / Methodology for Compilation & Analysis
The present study is carried out using different quantitative techniques suitable for explaining various objectives of the study. Major methods used as tools of analysis in this study are as given below:
Regression Analysis 1. Simple linear regression of the following type in considered and fitted to cross section data collected in course of field survey:
Yi = a + b Xi + Ui Where, Y = Dependent variable X = Explanatory variable U is the stochastic error term having its usual properties.
The above model is fitted to data applying Ordinary Least Square (OLS) technique to obtain estimated demand and consumption functions.
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2. Fitted regression models are used to work out i) Elasticity of demand (e), for food and non-food items with respect to disposable income (e) in case of demand functions:
e = (dY / dX).(X / Y)
ii) Marginal Propensity to Consume (MPC) from consumption function:
MPC = dC / dY 3. In case of aspects like demographic parameters, peoples’ perception, educational status, agricultural status, methods of descriptive statistics are used.
7.2.4 Demographic Structure of the Surveyed Area
Demographic data such as number of households, population, social composition, literacy and employment status in the identified villages of the people of the study area as per 2011 census is furnished in Chapter-3 of the EIA-EMP report.
The basic socio-economic conditions in the area as assessed by interactions with the respondents and filled questionnaire during field survey is briefly discussed in the ensuing section.
7.2.5 Basic Socio-Economic Conditions in the Study Area
The observations on basic socio-economic conditions of the people of the study areas of the respondents during survey work are as under: x The social structure of the study area is dominated by semi-urban culture with few villages scattered over the 10 km study area having traditional tribal culture on one hand, and urbanized consumerism on the other. Social changes are observed in rural communities which are the impact of influence of BSL. x Literacy level among the respondent is satisfactory. x Educational facilities, however, are not job-oriented which is required to improve skill-diversification among people, specifically, local youth so that they get jobs in the industries in the vicinity of BSL. x Private vehicles are the main mode of transportation in the study area. Bus service is available only through the NH-23 & NH-32. The villages where transportation facility is not available have to walk down 5-10 km from their place of residence and board buses from NayaMore bus stand or trains from Bokaro Steel city Railway Station. x The villages are connected by Kutcha roads. Many of the villages, however, get connected to the main trunk road of BSL township within a distance of 5-10km through these Kutcha roads. x The employment rate is moderate. Agriculture is not a major profession in the rural economy and people are mainly dependent on services and other activities. x People are having very small plot of land holding. The land is not enough to meet their needs & therefore, rural people of the area prefer to work in small scale industries, various construction related activities. Many of them are self-employed. x Houses in the rural portion of study area are predominantly semi-pucca. In the urban portion majority of the houses are pucca or permanent structure. CHAPTER-7 ADDITIONAL STUDIES Page 262 of 298 © 2020 MECON Limited. All rights reserved
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x Drinking water facility covers mainly in the form of wells. A few hand pump are also there. During summer season serious water scarcity is observed in some areas. x All the respondents are aware of activities of BSL and have mixed opinion for proposed activities. The respondents, however, are happy about the developmental activities carried out by BSL, especially by the “Bokaro MahilaSamiti” which has helped many a number of rural women in generating livelihood for themselves and support their families. This satisfaction in the people of the villages surveyed is due to the facilities provided by BSL.
7.2.6 Prediction of Socio-Economic Impacts
Educational status
The educational status of the respondents is shown in Figure 7.3 from which it is clear that out of 298 respondents 23 are illiterate. Among 298 persons, total number of people who havecompleted primary school, middle school and high school are 31, 55 and 81 respectively. 42 people have achieved technical education.
Fig.7.3 Educational status among the respondents
81
55 52 42 40 31 23 15
Sanitation and water supply facility
However the information based on the primary survey reveals that in the study area the problem of open defecation doesn’t exist. But as per the water supply is concerned most of the villages are dependent on traditional source of water resources. Very few villages have public or private supply of water to their home. So, the scarcity of clean drinking water facility exists in the study area.
Agriculture
Table 7.10 shows the landholding size distribution in the sampled population in the study area. From the table it can be seen that the marginal farmers constitute 61.1%, small farmers and semi-medium constitute 33.3% and 54.6% respectively. However there is absence of medium and large farmers.
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Table 7.10: Distribution of Landholding in the Study Area Sl.No. Land Holding Size Percent 1 Marginal (< 1 Ha.) 61.1% 2 Small (1 – 2 Ha.) 33.3% 3 Semi- Medium (2 – 4 ha.) 5.6% 4 Medium (4-10 ha.) NIL 5 Large (>10 ha.) NIL Total 100%
Table 7.11 depicts the cropping intensity in Bokaro district. Cropping intensity in the district is average (116 %), whereas, in the study area it is 144%.
Table 7.11: Cropping Intensity Bokaro, District SN. Agriculture Land-use Area (in 000'ha) Cropping Intensity (%) 1 Net sown area 46.6 2 Area sown more than once 6.7 116 3 Gross Cropped Area (GCA) 53.9 Source: agricultural contingency plan for district Bokaro
Table 7.12 depicts the cropping pattern and production in the study area. The cropping pattern in the general study area reveals that Paddy, Jawar, Ragi and sugarcane are the most predominant crop followed by Maize and Bazra etc.
Table 7.12: Cropping Pattern of the Study Area SN. Cropping Pattern Production in ‘000 t Yield kg/ha 1. Paddy 46.6 1542.3 2. Wheat 1.9 1025.2 3. Groundnut 0.10 608.4 4. Pigeonpea 1.6 508.6 5. Maize 11.8 3418.5 6. Black Gram 0.2 374.8 7. Green Gram 0.15 344.1 8. Mustard 0.3 242.7 9. Chickpea 2.5 889.8 Source: Agricultural contingency plan for district Bokaro
Cropping intensity in the study area is 144%. Average investment in agriculture is Rs.3405 per acre. Cropping intensity indicates multi-crop culture. Agriculture is profitable as net return is Rs.11465 per acre (Table 7.13).
Table 7.13: Cropping intensity, Net Return & investment Item Value Cropping intensity (%) 144 % Net return (Rs/acre) 11465 Average investment (Rs/acre) 3405
Agricultural situation of the study area indicates that agriculture in this area is moderate. The project is not going to cause any damage to agricultural situation of the study area. Instead, it is likely to help agriculture by way of providing income from non-farm sources
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Pattern of Demand
The survey reveals that the respondents spend major portion of their disposable income on food items. However, there has been a growing tendency among the respondents of allocating higher expenditure on non-food items although their basket of consumption have only few items other than food. To go to the details of their pattern of demand, income elasticity of demand is calculated by fitting demand functions. Table 7.14 presents the results of the regression analysis conducted for fitting the demand functions. It is observed that all the demand functions give uniformly good fits to the data because R2 in all the cases are found to be quite high. Two respective hypotheses are to be set for testing that the relationship is significant or not between net income and demand for food and non- food. Ho: b1=0 (null hypothesis) – no significant relationship between demand for food items and net income.
H1: b1≠0 (alternative hypothesis) - significant relationship between demand for food items and net income.
Similarly, hypothesis is built up for non-food items,
Ho: b2=0 (null hypothesis) – no significant relationship between demand for non- food items and net income.
H1: b2≠0 (alternative hypothesis) - significant relationship between demand for non-food items and net income.
Here, b1 and b2 are the parameters of food and non-food item respectively.
Moreover, as indicated by t-test (tcal>ttab), in both demand for food and non-food, the relevant parameter of the demand functions is found to be statistically highly significant at 5% level. The income elasticity of demand as measured from the fitted functions is 0.84 and 1.34 for food and non-food items, respectively.
Table 7.14:Demand Functions for Food and Non-food Items Demand Function Item Regression parameters log a log b R2 Dij = a * Ybj * U Where, Food 0.34 0.84 0.96 Demand for the ith item by jth respondent. (48.95) Disposable income of the jth respondent Non-Food 0.52 1.34 0.89 (32.04) Figures in ( ) indicate t - values *Significant at 5% level.
With the establishment of BSL since its inception, development of the locality has undergone and created a type of demand pattern has emerge which has placed more importance on consumer goods and quality products.
Employment and Income Effect Occupational pattern of the study area reveals that about 74 % of the income is generated from services, 23 % from business and 3% of the income is generated from agriculture and (Fig. 7.4).
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Fig. 7.4: Occupational Structure of the Study Area
Direct Employment Agriculture, business, and service are major sources of income in the study area. However, unemployment is quite common in the study area. The project has employment generation potential by way of recruiting local people directly for different activities of the project, specifically at the construction phase. It is expected that substantial portion of the investment in this project will trickle down to the local people in the form of employment and income.
Indirect Employment Indirect employment and income effects of a steel plant is widespread. Income and employment opportunities generated in the ancillaries, which are likely to come in the vicinity of the steel plant, along with growth of employment in services activities are likely to be much stronger due to its multiplier effect. Besides this, increase of population in the study area as a result of the project will lead to higher demand for food. As consequence, price of food is expected to increase. It is expected that the project may bring infrastructure development in the study area which may multiply in employment generation many fold. Hence, the project is expected to generate substantial indirect employment in other sectors.
BSL has created growth in indirect employment and the same will continue to grow in coming years in other sectors such as ancillary, transport and related manufacturing sectors, service units etc.
Further, increase of population in the study area due to BSL, will lead to higher demand for food. As a consequence, price of food is expected to increase. BSL has already brought infrastructure development in the study area which has multiplied in employment generation many fold. Hence, BSL is likely to generate substantial indirect employment in other sectors.
Overall assessment of the employment and income effects indicates that the BSL has strong positive direct as well as indirect impact on employment and income generation.
Consumption Behaviour Table 7.15 presents the source wise distribution of average family consumption. It is observed that the major portion of total consumption expenditure goes to meet the need for food (48.56%). The consumption expenditure on clothing is second highest (19.42%). Average expenditure on medical
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purposes is 9.14%. About 10.57 % of total consumption expenditure goes to meet the other social requirements. Expenditure on education in the study area is observed to be low at 12.31%.
Table 7.15: Source-wise Distribution of Family Consumption Item Food Education Clothing Medical Others Total Consumption(Rs\year) 87939 22289 35163 16549 19138 181066 Distribution of average 48.56% 12.31 % 19.42% 9.14% 10.57% 100.00 family Consumption (%)
Fig. 7.5: Consumption Pattern in the Study Area Others 11% Medicals 9%
Food 49%
Clothing 19%
Education 12%
To investigate the consumption behaviour of the respondents in detail, Marginal Propensity to Consume (MPC) is calculated by fitting the consumption function. The results of the regression analysis performed for fitting the consumption function are presented in Table 7.3f. By using the statistical tool of hypotheses testing, we will set following hypothesis,
H0: b*=0 (null hypothesis) – no significant relationship between consumption demand and net income.
H1: b*≠0 (alternative hypothesis) - significant relationship between consumption demand and net income.
Here b* represents marginal propensity to consume.
It is observed that the function gave uniformly good fit to data because R2 is high and parameters are also found to be statistically significant (tcal>ttab) at 5% level of significance.
Thus the null hypothesis will be rejected which leads to the conclusion that there is significant relationship between consumption demand and income. The MPC worked out on the basis of the fitted consumption function is 0.77.
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Table 7.16: Fitted Consumption Function Demand Function Regression parameters a b* R2 Cj = a + b Yj + Uj 11389.65 0.77 0.97 Where, (61.38) Cj = Consumption of the jth respondent Yj = Gross income of the jth respondent Figures in ( ) indicate t - values *Significant at 5% level.
The multiplier effect of investment on the people of the study area has been worked out by using the following model:
Consider the consumption behaviour of the respondents closely follow the following type of consumption function:
C = a + bY (1)
We know that, in equilibrium Y = C + I (2) Where, Y = Gross income, C = Consumption & I = Investment
Putting (1) in (2) one gets,
Y = a + bY + I =>Y=(1/(1-b)*[a+I] (3) Where, 1 / (1-b) is the multiplier.
Assuming that consumption behaviour of the people in the study area closely follows this fitted consumption function. One can easily see that existing size of the multiplier is 3.3. Hence, investment on this project and the consequent generation of additional income will have multiplier effect in raising average consumption.
BSL is going to have positive income effect and consequently, the multiplier effect is expected to lead to an overall increase in average consumption of the people of the study area. Therefore, one can conclude that the impact of BSL on consumption behaviour of the local people is likely to be satisfactory and positive.
Educational Status
Bokaro Steel plant, has increased people’s thrust towards education (since its inception) by bringing opportunities of some direct & indirect employment for the local people. The general awareness towards the importance of education has increased as a result of BSL since its inception, hence it can be said that BSL will continue to have positive impact on the level of education of the people of the study area.
7.2.7 People’s Perception
The results of the opinion poll are analysed and furnished in Table 7.17. The major advantages and disadvantages shown by the people are given in Table 7.17. It is observed that 78% of them have identified creation of employment opportunity as the main advantage. People are hopeful of getting employment in the small-scale units likely to come up in the vicinity of the plant. About 76 % of the
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respondents are expecting improvement in business. About 77 % of respondents are expecting that the educational facility will improve around the study area. Around 81% of the respondents feel improvement in peripheral development activities. The major disadvantage is that about 85 % of the respondents are showing concern to health due to environmental pollution.
Table 7.17: Peoples’ Perception on the Project Perception No. of Respondents Distribution (%) ADVANTAGES Employment opportunity 59 78% Improvement in educational facilities 58 77% Development of the area 61 81% Business development 57 76% Improvement in Health Care facilities 55 74% DIS-ADVANTAGES Pollution 54 72% Damage to health 40 53% Total Respondents 75
Perceptions on Major Advantage:
i. Present project may generate more employment, directly and indirectly, and major portion of it may be provided to the local people. ii. Improvement in the educational infrastructure around the study area. iii.Development of business opportunity in the area. iv.Development of infrastructure facilities including roads may take place due to the project which may help in improving the whole area. v. Improvement in living standard.
Perceptions on Major Disadvantage:
i. Pollution in the study area is expected to rise due to the project. People perceive that the increase in pollution may cause damage to agriculture and damage to health of people due to pollution.
Needs of the Villagers and their Expectations
It appears that the expectations and needs of the villagers are quite moderate. The people in the study require basic minimum amenities wherever they are not available and improving these facilities wherever these are inadequate. They appealed to the Government through this survey, for provision and improving of the following facilities: x More Higher secondary schools x Adult education centers x Dispensaries / Health Centers and availability of doctors and other para-medical staff x safe drinking water supply schemes x Loan facility for self-employment to open petty shops, purchase of cycle rickshaws, agricultural tools and implements, bullock carts, fertilizers, improved seeds and digging of well for irrigation.
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7.2.8 Conclusions
On the basis of the overall results of the present impact assessment the following conclusions are drawn: Bokaro Steel Plant is not going to cause any damage to the existing agricultural situation. Instead, it is likely to provide the farmers with supplementary income. x Bokaro Steel Plant has positive impact on pattern of demand x Bokaro Steel Plant has very strong positive employment and income effects. x There is a possibility of increase in industrialization in the vicinity of the plant. This is likely to bring more skill diversification among local people. x Bokaro Steel Plant has strong positive impact on raising average consumption and also income through multiplier effect. x The CSR activities of Bokaro Steel Plant will have very strong positive impact on the social and economic condition of the people of the study area x Bokaro Steel Plant, SAIL has positive impact on health situation of the local people through development of the area. x Bokaro Steel Plant, SAIL has significant positive impact on community development activities of the project which are likely to bring handful of benefits to the people of the study area.
7.2.9 Corporate Social Responsibility
Corporate Social Responsibility (CSR) is a form of corporate self-regulation integrated into a business model. CSR refers to strategies of corporations or firms to conduct their business in a way that is ethical, society friendly and beneficial to community in terms of development. CSR is the deliberate inclusion of public interest into corporate decision-making and the honoring of a triple bottom line: People, Planet & Profit.
Community Development(CD) refers to initiatives undertaken by community with partnership with external organizations or corporation to empower individuals and groups of people by providing these groups with the skills they need to effect change in their own communities. These skills are often concentrated around making use of local resources and building political power through the formation of large social groups working for a common agenda.
The role of CSR in CD is any direct and indirect benefits received by the community as results of social commitment of corporations to the overall community and social system. The common roles of CSR in CD are as follows: x To share the negative consequences as a result of industrialization. x Closer ties between corporations and community. x Helping to get local talents as an attractive employer for potential candidates.
Community development activities (including that for its employees) are very important aspects for any organization / project, because people of the villages surrounding the plant and its employees are the stakeholders. The project proponents have always treated its periphery as a key stakeholder. The main objective of the Community Development Programme has been to create synergy and synthesis CHAPTER-7 ADDITIONAL STUDIES Page 270 of 298 © 2020 MECON Limited. All rights reserved
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with the environment. Guided and inspired by the objective of enhancing the living standards of the people.
The policy of BSL towards social welfare & community development aims at strengthening the bond between the project / station authorities and the local population in the vicinity of Bokaro Steel Plant. In line with this policy, BSL at the existing steel plant has been carrying out number of community welfare activities in the following areas: x Education x Health x Infrastructure x Community Welfare including skill development and woman empowerment & Miscellaneous
Accordingly, BSL plans to implement above social and community welfare measures in area around SAIL Project with the following major initiatives: x BSP would continue contribute in implementing social welfare activities in collaboration with local Gram Panchayat, Block Development Office etc. for better development of area around the Project. x To minimize strain on existing infrastructure, adequate provision for supporting basic amenities, viz. education, health, etc. would be made. x Regular environmental awareness programs would continue be organized by BSP to impress upon the surrounding population about the beneficial impacts of the project and also about the measures being undertaken for environmental safety.
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7.3 PUBLIC CONSULTATION
The Jharkhand State Pollution Control Board (JSPCB) notified in the Hindi daily newspaper Dainik Bhaskar on 03.11.2018 (copy of newspaper advertisement along with the Original PH proceedings as well as the authenticated English translation are enclosed at Annexure 7.4), the date and venue of the Public Hearing as 08.12.2018 at Bokaro Club Limited, Sector-V in Bokaro Steel City, District Bokaro. The Public Hearing was conducted by JSPCB on 08th December, 2018 as per the guidelines outlined in the EIA Notification 2006 and its subsequent amendments. The proceedings of the Public hearing conducted are shown in Fig. 7.6 below: Fig. 7.6 Proceedings of Public hearing conducted for the project on 08.12.2018
The views of the public and comments along with the budgetary action plan for the issues raised during the public consultation is given in Table 7.18 subsequently. CHAPTER-7 ADDITIONAL STUDIES Page 272 of 298 © 2020 MECON Limited. All rights reserved
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Table 7.18: Public Hearing Action Plan Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation 1. Md. Intkhab Ansari Few of the hand pumps Contract for maintenance of hand pumps Rs. 4.32 Lakh Contract awarded for repair Vill :Aagardih provided by BSL are working in villages already awarded by BSL’s CSR and maintenance of hand- Sector 9 and rest are unserviceable. dept. All hand pumps will be repaired pumps, Most of the hand- Bokaro Steel City shortly. pumps will be repaired. Work expected to be completed by Sept., 2019. 2. Shri Satyajeet Ojha of Areas near Bokaro do not It may be known that BSL has already Rs. 81.70 lakhs. Approx. 75000 saplings Asansol Mauja. Displaced. have well developed planted 44, 68,000 trees in Bokaro Steel planted during year 2017 - 18 Presently living at Jodhadih greenery. Further, a children’s City with view to maintain its greenery. A Rs. 1.22 Cores Approx. 1 lakh saplings will be More park may be developed in plan is being prepared for plantation in planted by December, 2019 of Chas, Dist. Bokaro Sector area. peripheral area during coming monsoon. which, approx. 45000 Bokaro township is already having park in saplings had already been all sector for playing their children which is planted by Jan., 2019. being maintained by Town Services Dept. Existing Children’s parks will further be developed by Dec., 2019. 3. Shri Ranjan Kumar It was mentioned in BSL’s The mission is on to control plastic - JNB Park has been declared Vill : Tand Mohanpur presentation that BSL is pollution by BSL. Occupants, shop as “No Plastic Zone” with Jaina More working on control of plastic keepers and general public are being effect from 5th June, 2018. Dist. Bokaro pollution, however, plastic made aware continually on pollution BSL is consistently putting waste is still seen in Bokaro caused due to single use plastic usage. efforts to control “single use Steel City. Use of plastic has Also all canteens of BSL, JNB Park and plastic bags” in areas under also been observed in BGH BGH have already been restricted of its control. hospital single use plastic bag. As the whole city can be get rid of plastic use only by the order of District Administration, We look forward to assistance from them, and the general residents of the city. BSL is consistently putting efforts to control single CHAPTER-7 ADDITIONAL STUDIES Page 273 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation use plastic bag and recently the “Surya Sarovar”in Sector 4 has been made plastic free. 4. Smt. Madhuri Devi To restrict degradation of BSL is putting efforts to preserve the Rs. 0.25 Lakhs. Horticulture section has Vill : Cizua, Bokaro fertile soil and to reduce environment and the suggestion of Asha sufficient nos. of earthen pots Presently working at Asha Lata plastic waste certain pots may Lata Nursery is welcomed and will be as of now. Nursery Sector 5 B S City be replaced by pots recycled implemented by the Horticulture dept. of In line of suggestion, BSL will out by waste plastic bags. BSL. considered in future use This is being practiced (2020-21) presently by Asha Lata Nursery. 5. Shri KK Rastogi How much specific water BSL is using state of art technology during Rs. 10.95 crores Treatment plant at Outfall 1B Senior Citizen reduction will be achieved its modernization hence there will be commissioned in Jan., 2018. Sector 5 A -2011 after modernization? reduction in consumption of water and Treatment plant at Outfall 2A Bokaro Steel City energy. Techno economics parameter will expected to be commissioned improve due to the modernisation of the by May, 2019. plant. There has been 11.4% reduction in Rs.16.97 crores Works on Outfall 2A expected water consumption in last 4 years. BSL is to be completed by June, putting ongoing effort for further reduction 2021. in its specific water use. 6. Shri Shailesh Kr. Sinha Disposal of dry fly ash of The appropriate disposal of fly ash is being City Centre, Sector boiler No. 9 is on the sport. looked after by M/s BPSCL Fly Ash is also Bokaro Steel City Rest of the boilers have no being used to make roads. A small unit of such disposal facilities and fly Ash bricks manufacturing has also been the same should be set up in BPSCL. An abandoned quarry in discharged in Ash Pond in Maheshpur has also been identified for slurry form. The fly ash is back filling where about 6 lakh tonnes of used in Cement Industry, so fly ash will be disposed and the work for the sale of Fly ash may be establishing a road to the back filling site is implemented from within the on way. CHAPTER-7 ADDITIONAL STUDIES Page 274 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation plant itself. Also the quality of Fly Ash may be improved. 7. Shri Khekha Manjhi Quality of Water of Tenughat BSL does not own and control water in Vill. Jhiglappa remains good should be Tenu canal. Jharkhand Water Resource Kanari Panchayat ensured. dept. is responsible for maintain water Displace quality of Tenu canal. Bokaro 8. Shri Shyam Turi What is being done for To maintain the greenery of township, Rs. 10 Lakhs By Sep'19 Vill Post Satanpur developing greenery in already 44, 68,000 trees have been (proposed) Bokaro Satanpur Village planted. In forthcoming monsoon (2019- 20) 10,000 trees will be planted in /around Satanpur Village. 9. Shri Shiv Dayal What is BSL doing for Water Management Department has Expenditure already Treatment plant at Outfall 1B Gumla Colony treatment and cleaning of established State of Art Water treatment included in budget of commissioned in Jan., 2018. Sector 4 water. facility. The water quality is being tested Rs. 10.95 Crores as Treatment plant at Outfall 2A Bokaro every day in laboratory and is found within indicated at Sl. No. 5 expected to be commissioned applicable standards. by May, 2019. 10. Shri Basudeo Mahto What is being done for school BSL’s CSR Department runs two schools. Rs 76 Lakhs allotted Already working Displaced. in different sector which are One is Balika Kalyan Vidyalaya in Sector 9 for FY 2018 – 19. Chaufan padlocked? and another is Kalyan Vidyalaya in Sector. The scheme shall Sector 11 Both the schools provide study materials continue with fresh Bokaro school dress and lunch free of cost to funding every year. students. Additionally The Education Department of BSL runs 8 schools in township and peripheral areas. 11. Md. Siraj Sah The water of Garga river is To retain aquatic standard of the river 20 MGD plant which will be Village : Bharra, Chas, Bokaro not clean. It used to be various oxidation ponds have been set up on BOO basis, has cleaned every year but this established. Before discharge it is being been proposed. year, no cleaning has been analysed. BSL is also committed to zero done discharge. The whole sewage water will be CHAPTER-7 ADDITIONAL STUDIES Page 275 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation accumulated and treated for reuse. The DPR of this project is ready and in process of tendering. 12. Shri Salik Sahu There are no road way as to BSL would construct new roads repair Rs. 2.0 lakhs Expected to be completed by Sector 4D, Gumla Colony the Gumla Colony. existing roads in nearby areas of Bokaro budgeted in 2018-19 February, 2020. Bokaro City for easy commute. 13. Shri JaleswarMahto Where from the land is being It may be known that the proposed - - Vill : Barum, Jaina More, acquired for the proposed expansion cum modernisation project will Bokaro modernization project. be executed within the Plant premises itself. 14. Shri Sarvesh Kumar There is no facility of drinking The hand pump will be repaired at Munda Expenditure already Contract awarded for repair Munda Tola, Shivpuri Colony, water. Schools have been Tola, Shivpuri Colony by CSR Deptt. included in budget of and maintenance of hand- Sector 6 , Bokaro padlocked. We drink the water CSR runs 2 schools. One is in Sector 9 Rs. 4.32 lakhs pumps, Most of the hand- of Garga river. Balika Kalyan Vidyalaya and another is in indicated at Sl. No. 1 pumps will be repaired. Work Sector 3 Kalyan Vidyalaya both of which expected to be completed by provide study material, school dress, lunch Sept., 2019. free of cost to students. 15. Shri Shambhu Kumar The hand pumps of The hand pumps repair work at length is Expenditure already 4 nos. Hand pumps already Kamdhenu Khatal Kamdhenu Khatal area and on. Also roadways repair in Kaamdhenu included in budget of repaired in Kamdhenu Khatal. Sector 6 school are unserviceable. The Khatal is under way which will improve the Rs. 4.32 lakhs Others repair works to be Bokaro roadways should also be road way. For the deprived students of indicated at Sl. No. 1 completed by Mar'19. repaired. Bokaro Niwasi there is a school at Sector 9 B Balika Kalyan Vidyalaya run by dept. of CSR. There is a school at sector 3 Kalyan Vidyalaya. There are 2 schools run by the dept. of CSR where study material school dress and lunch is free of cost.
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Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation 16. Smt. Kamla Das There is no school in Bagicha BSL through its CSR dept. runs Balika Expenditure for Repair works/new Bagicha Colony Colony. There is no facility of Kalyan Vidyalaya in Sector-9B for deprived schools already installations of hand pumps to Sector 5 D water. Garga river is full of children residing in Bokaro city. BSL also included in budget of be completed by Mar'19. Bokaro harmful germs and bugs. runs a school for deprived children in Rs. 76 lakhs Nothing is being done for the Sector-3 and provides school uniforms, indicated at Sl. No. deprived ones. books and mid-day meals through its CSR 10. dept. Hand pumps will also be provided in the Expenditure already area through BSL’s CSR Dept. included in budget of Rs. 4.32 lakhs indicated at Sl. No. 1 17. Smt. NaimiLakra The road is damaged has The maintenance and repair work of roads Rs. 2.0 lakhs Expected to be completed by Azad Basti many potholes. What is being in nearby village is in progress. budgeted in 2018-19 February, 2020. Siwandih, Bokaro done for repair of the roads. 18. Bhuneshwar Hazam Since production of electricity Solar lamps has already been installed in Rs. 9.1 Crores Expected to be ready by Displaced of Village Kundauri requires large quantity coal surrounding of ED works building. December, 2019 presently residing at and water, I appeal in this Additionally 2 MW solar energy based Rehabilitation site Tupkadih, Public Hearing to promote lights have been arranged in surrounding Bokaro development and use of Solar of Administrative Building and ED Works Energy. building. A complete solar energy based lighting system in BGH has also set up. Site for a 20 MW Solar Energy (land based) has been identified near Surya Sarovar, Sector 4. 19. Shri Vishwanath Dey There is no facility of drinking Adequate numbers of hand pumps were Proposed Budget for Proposal to be initiated in FY Vill. Machaura, Bokaro water in my village. There is a set in villages of displaced for adequate Installation of 100 19-20 after budget allocation single hand pump which is drinking water in view of social Nos. hand pumps in from Corp Office. unserviceable. responsibility. The CSR is being worked peripheral areas - Rs. on the unserviceable hand pumps. All the 65 Lakhs hand pump will be repaired shortly. CHAPTER-7 ADDITIONAL STUDIES Page 277 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation 20. Shri Kishori Singh There is so much dust (fly Adequate numbers of hand pumps will be Expenditure already Proposal to be initiated in FY Displaced from Mahuar village ash) flying in Mahuar village. installed for providing required quantity of included in budget of 19-20 after budget allocation Bokaro We are drinking water from drinking water through CSR dept. Rs. 65 lakhs from Corp Office and wells in which fly ash dust is Essential corrective action for hand pump indicated at Sl. No. implemented by 2020 found. There are no hand maintenance is likely to be taken soon by 19. pumps CSR dept. in coming days. All unserviceable hand pumps will be repaired and adequate supply of drinking water will be ensured soon. Plantation is being planned over ash mount to prevent generation of dust from fly ash in nearby areas. 21. Shri YN Singh Many suggestions were given BSL has been using Eco-friendly glasses Retired Officer BSL in a workshop “Beat Plastic and plates in all functions and this Institute of Engineers India Pollution” organised by BSL. environment friendly practice will be Bokaro Chapter My appeal suggestion to the continued. Public is to use organically made containers when organising occasions or public functions. 22. Shri DP JHA Entry of sand loaded vehicles The district administration cooperation and 2069 Sector 4 C to be banned in the township. assistance is looked for in this matter. Bokaro Steel City Fly ash may be used in place of sand for construction of buildings. 23. Shri Anand Kumar Sewage system may be BSL has no authority to administer inlet Adarsh Cooperative Colony improved. Newly developed discharges to Garga river. The Bokaro Steel City colony such as of Malti surrounding colonies of Garga river do not Complex, Bari Cooperative have proper drainage and sewage system Coloney, Chas area’s sewage for which assistance from the District CHAPTER-7 ADDITIONAL STUDIES Page 278 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. Name and Address Public/Member question Answer Budget Time schedule for No. implementation is discharged in Garga river Administration is sought. Cooperation of continually. Manufacturers of District Administration is also sought for plastic products to be banned. implementing ban in plastic producers. 24. Shri S. Kumar The roadways of township Repair of roads is being carried out by the Rs. 3.5 Crores Expected to be completed by BSL employee, Retired may be repaired immediately. Town Administration Department. Law and June, 2019 Sector 8 D The public should be provided order situation in the city is being looked B.S. CITY relief from snatching and after the district administration. thefts happening in the city. The padlocked schools may be re-opened. Total budget for addressing Public Hearing issues Rs. 44.15 Crores
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CHAPTER – 8: BENEFITS OF THE PROJECT
8.1 INTRODUCTION
The development of industrial projects plays a key role in the economic growth of any country. The growth of the steel industry significantly contributes to economic growth as it generates employment both directly and also due to development of downstream industries. Peripheral development takes place and due to more influx of money through the area, overall importance of the area increases and overall the infrastructure improves.
8.2 FINANCIAL BENEFITS
8.2.1 Increase In Steel Production
The proposed expansion will increase steel production which will contribute to achieving National Steel Production of 300 MTPA by the year 2030. This will also improve the revenue generation for the Central and State exchequer, besides reducing the Nation’s dependence on imports.
The proposed modernisation includes increase in sintering capacity, which will increase utilisation of iron ore fines (generated both at the plant and at SAIL’s captive iron ore mines), coke fines, lime fines and mill scales. The new pelletisation plant will enable utilisation iron rich tailings from SAIL’s captive mines. Utilisation of tailings will also free up space in the tailings ponds of SAIL’s mines which are mostly located in Forest Land.
8.3 ENVIRONMENTAL BENEFITS
The new units will have more modern / technologically better pollution control systems. Existing ESPs will be revamped and the new facilities will be installed with high efficiency ESPs, which will reduce the specific PM load from 0.76 kg/tcs (at 4.5 MTPA HM) to 0.69 kg/tcs (at 5.77 MTPA HM), a reduction of 9%. Implementation of Zero liquid discharge schemes will minimise wastewater discharge. Further, the specific water consumption will also decrease from 3.55 m3/tcs to 3.48 m3/tcs. The debottlenecking and modernization schemes will also improve productivity with improvement in energy efficiency. Also, use of renewable energy schemes will also lead to reduced dependence on fossil-based energy sources. Consequently, the overall energy consumption will improve from 6.67 Gcal/tcs (at 4.5 MTPA HM) to 6.5 Gcal/tcs (at 5.77 MTPA HM).
8.4 SOCIAL BENEFITS
8.4.1 Improvements In Physical Infrastructure
From the very inception Bokaro Steel Plant has been aware of and concerned about the health and safety of not only its own employees and their families but also about the ecology and issues affecting society around BSL and its stakeholders. As a corporate citizen it has always been the endeavour of BSL to take effective steps to tackle all these issues. The proposed project is expected to yield a positive impact on the socioeconomic environment. It shall help in sustainable
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development of this area including further development of physical Infrastructural facilities. The following physical infrastructure facilities will improve due to proposed project: x Road Transport facilities x Educational facilities x Water supply and sanitation x Medical & Health Services x Housing & Township facilities x Social security measures
8.4.2 Employment Potential
The Governments always give major emphasis on the employment generation and social upliftment while sanctioning any project in their state. The Integrated Steel plant at Bokaro is also a result of such phenomenon. Employment is generated directly in the project while others are related with its associated activities. The employment in both these areas involve employment of two kinds of people viz. skilled and semi-skilled as well as unskilled labour force. These two types of employment are discussed below:
Skilled and Semi-skilled: Skilled and Semi-skilled employment potential in terms of indirect employment of BSL will be non- marginal and will usually remain widespread across a long region. Over the years BSL has caused generation of income and employment opportunities the ancillaries and service units which came in the vicinity of the steel plant, specifically, in mining, ancillary, transport and manufacturing sectors. As also indicated in Table 8.1, the decadal growth in main workers and marginal workers from 2001 to 2011 is 13.14% and 76.6%, respectively. A part of this increase in employment potential may be attributed to the previous expansion / modernisation programme of BSL. Due to expansion of BSL, direct and indirect employment is likely to grow further. The project is expected to generate substantial indirect employment in other sectors such as metal based industries, chemical-based industries, small rolling units, scrap dealing units, service units etc. Overall assessment of the employment and income effects indicates that the project has strong positive direct as well as indirect impact on employment and income generation of the area.
Un-Skilled: Unemployment for un-skilled workers is quite common in the study area. However, BSL has taken a major drive as CSR initiative to impart training for developing technical skills of the villagers for enhancing economic strength. The present expansion project has employment generation potential by way of recruiting local people directly for different activities of the project, specifically at the construction phase. It is expected that substantial portion of the investment in this project will trickle down to the local people in the form of employment and income. As indicated in Table 8.1, the decadal growth in marginal workers from 2001 to 2011 is 76.6%, which was the phase of previous expansion programme. Though the sequential data for un-skilled workers were not available for 1991 and 2001, but major portions of the marginal workers are from unskilled labour force. A
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growth of 77% in ten years is enormous and a part of the same may be attributed to BSL and it is expected the trend will further grow with the new projects of BSL.
The result of decadal growth analysis with respect to major demographic pattern are summarized in Table 8.1.
Table 8.1: Decadal Growth in Demographic Pattern in Study Area Sn. Demographic Pattern 2011 2001 % Growth 1 No of household 3,94,918 3,17,378 24.43% 2 Population 20,62,330 17,77,662 16.01% 3 SC 2,99,227 2,36,472 26.54% 4 ST 2,55,626 2,18,600 16.94% 5 Literates 12,73,520 9,23,150 37.95% 6 Total Main workers 3,80,304 3,36,131 13.14% 7 Total Marginal workers 3,05,064 1,73,179 76.16%
Fig. 8.1: Decadal Growth in Demographic Pattern in Study Area
25,00,000
20,00,000
15,00,000
10,00,000
5,00,000
0 2001 2011
No of household Population SC
ST Literates Total Main workers
#REF! Total Marginal workers
The above graph shows a rise in population of Bokaro District by about 16% over the last decade from 2001 to 2011. However, the rise in total number of literates has risen by almost twice the rate of population growth. This shows that the efforts of BSL in developing educational facilities has had a significant impact over the area’s literacy rate. Also, the total number of workers (both marginal and main workers) has risen by around 35% which indicates a rise in employment opportunities in and around the area of both temporary as well as permanent nature.
The proposed expansion-cum-modernization of BSL shall generate permanent employment opportunities of 785 people, which will mostly be fulfilled by redeployment of existing power and some contractual employments. However, a total of 2500 temporary construction workers will also be required, which will be sourced locally.
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8.4.3 Industrialization around Bokaro Steel Plant
Steel plants by nature serve as the nuclei for development of small-scale industries in the areas around them. These small-scale units usually have input-output linkages with the steel plants. The demand for spares, assemblies and sub-assemblies by steel plants are generally met through the supply (of these items) from small-scale units located nearly. The small-scale units, in turn, get necessary steel products from the steel plants. Over the years, similar type of small-scale industrialization has already taken place in the vicinity of BSL. This brought mutual advantages with one acting as complementary to another. The advantages to steel plants as well as small- scale units are listed below:
Advantages to BSL x Assurance of a reliable source of supply of spares and consumables; x Supply on short-delivery schedules enabling maintenance of lower inventory; x Saving foreign exchange through import substitution; x Lower freight element in comparison to materials supplied by firm located far away; x Better service facilities etc.
Advantages to Small Scale Units x Availability of ready market; x Availability of raw material source for steel/by-product consuming industries; x Getting price preference over distant suppliers; x Availability of facilities from government; x Availability of infrastructure support from the steel plant etc.
In close collaboration with Bokaro Industrial Area Development Authority (BIADA), BSL has been encouraging the development of small scale industries since 1970-71. Price matching facility, purchase preference, exemptions like deposit of tender cost, earnest money and security are extended to the ancillary units. BSL offers facilities of its testing labs and R&D to support the ancillaries. These are efforts of BSL to convert the region as a thriving business district.
Proper utilisation of these mutual advantages played a catalytic role in the development of the region around BSL.
The small scale industries that came in the vicinity of BSL can be grouped into major three categories -- spares, metal based and chemical based, besides the service units. These are complemented by the service units. The present project is likely to accelerate such industrialization through “Bubble Effects” in the study area. It is important to note that the small scale units are usually labour-intensive and high-priority industries from social point of view.
The proposed project is coming as a part of the existing Steel plant and is similarly expected to serve as a significant generator of small-scale industrial economy around it complemented by the services sector. This is expected to play a major role in the future economic and social development of this area.
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8.4.4 Improvements In Social Infrastructure
Bokaro Steel Plant is committed to improvement of the social structure of the area. The proposed project is expected to generate employment opportunities, both direct and indirect, during construction as well operation stage of the project. Apart from employment opportunities, BSL has played a major role in development of various social amenities in and around the area including medical facilities, water supply and sanitation facilities, Schools etc.
Community Development Efforts of BSL: Steel plants by nature serve as the nuclei for development of small-scale industries in the areas around them. These small-scale units usually have input-output linkages with the steel plants. The demand for spares, assemblies and sub-assemblies by steel plants are generally met through the supply (of these items) from small-scale units located nearly. The small-scale units, in turn, get necessary steel products from the steel plant.
Several measures have been proposed in the environmental mitigation measures for mitigation of adverse environmental impacts. These shall be implemented as per proposal and monitored regularly to ensure compliance to environmental regulation and also to maintain a healthy environmental conditions around the steel works.
From the very inception Bokaro Steel Plant has been aware of and concerned about the health and safety of not only its own employees and their families but also about the ecology and issues affecting society around BSL.
The major areas where Bokaro Steel Plant has been taken up social responsibilities are x Medical & Health Services x Housing & Township facilities x Social security measures x Promotion Sports & Cultural activities x Concern for society and Environment Protection x Community development & cultural events in villages x Health camps in surrounding areas.
BSL has allocated Rs. 17.22 Crores as part of its Corporate Environmental Responsibility in addition to its expenditure on CSR activities, for improving the physical infrastructure of the peripheral areas. Further, all issues raised during public consultation by the local people have been addressed by BSL with a suitable time-bound budgetary action plan.
8.5 OTHER TANGIBLE BENEFITS
The other tangible benefits will be in the form of hospital and schooling facilities as well as Community Development plan of BSL which will also help local population to enjoy the development of better facilities in nearby area.
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As per EIA Notification 2006 & its subsequent amendments, this Chapter on the ‘Environmental Cost Benefit Analysis’ is applicable only if it is recommended at the Scoping stage.
As per the ToR points issued by MoEFCC, Delhi vide No.J-11011/99/2007-IA-II(I) dated 10th April, 2018, Environmental Cost Benefit analysis is not desired for the proposed project.
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CHAPTER-10: EMP-ORGANISATIONAL SET UP & IMPLEMENTATION ARRANGEMENT
10.1 ORGANISATIONAL POLICY
The importance of environmental control has been recognized by BSL and it has taken necessary steps to identify and control pollution in the plant, respond to impacts on its own captive population and also in the peripheral areas. The Corporate Environmental Policy of SAIL and Integrated Policy of SAIL-Bokaro is attached as Annexure 10.1.
BSL declared “Environment Management” as one of its thrust areas of operation. BSL management adopted a three-pronged strategy to abate pollution, as follows: x By developing a very strong monitoring/analysis and inspection setup. x Augmentation existing pollution control systems through retrofitting jobs. x Installation of new state of art pollution control equipment.
The above objective has been intended to be achieved through the following: x Improvement in the quality of raw materials. x Modernisation of manufacturing operations in steel plant. x Using automation & Computer control to have improvement on technology and on working condition. x Pollution Monitoring and Control. x Modernisation of occupational health set up including regular medical monitoring of employees. x A well-developed safety management organisation. x Preparation of emergency/disaster control plan and a properly trained group to meet the emergency situations. x Green belt development inside the plant and township. x Development of awareness in employees and public including student population towards environmental preservation. x R & D activities in regard to specific pollution problems.
BSL lays high importance to adoption of latest technologies for keeping the pollution to minimum levels. A separate Environment Control Department is set up with an Environmental Laboratory with latest monitoring instruments for the same purpose.
10.2 ORGANISATIONAL SETUP
Environmental monitoring and reporting has been designed to provide a close watch on the surrounding natural environment and provide early warnings of any adverse changes that may be related to some dimension of the plant’s operations.
10.2.1 Administrative Set Up
Presently the ECD is been looked by GM (Electrical) and the day-to-day work, is assisted by a Deputy General Manager (DGM) as the head of ECD. The work in the ECD is been divided among
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the employees who are under the DGM. There are two divisions under the DGM, the Manager and Deputy Manager (DM) which is further divided into four sub divisions of Deputy Manager (DM) and Assistant Manager (AM), under the Manager and one in DM. The DGM (ECD) reports to the General Manager (Electrical), who in turn reports the Executive Director (Works) and who reports to CEO of BSL. The organizational chart of ECD (existing setup) at BSL is given in Fig. 10.1. For development and maintenance of jobs like drainage, settling tanks etc. assistance from the projects civil engineering department are taken. The resources of the plant’s chemical laboratory have been augmented to carry out the regular environmental surveillance programme.
Fig. 10.1: Organizational Chart of Environmental Control Department
10.2.2 System of reporting environmental non-compliances/infringements
Bokaro Steel Plant (BSL) has a well laid-out procedure for reporting of non-compliance / infringements with respect to environment management to the Board of Directors at periodical interval including in cases of emergency / accident.
The safety related issues are addressed by Safety Engg. Department of BSL and environmental non- compliances/ infringements are handled through ECD. The Standard Operating Procedures (SOP) for reporting environmental non-compliance / infringements to the Board of Directors at periodical interval including in cases of an emergency / accident is as shown in Fig. 10.2 below:
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Fig. 10.2: Standard Operating procedure for reporting environmental non-compliances to higher management at Bokaro Steel Plant
Environmental control SOP for reporting of non compliances to higher management department Resolved – Resolved – Resolved – No No No
CEO Unit Env. Unit Head GM ED works Unit Nodal officer
Resolved Resolved Resolved Yes Yes Yes Compliance status Monthly reviews Core group -Plant head -Section incharge Compliance status - ECD weekly reviews
The Environmental non-compliances are reported to Environment Management Department (EMD) Kolkata on quarterly basis which are deliberated for overall SAIL plants at the Board level. The action plan for addressing the issues are communicated to individual plant units for implementation and corrective action of the reported non-compliances.
The safety procedures to be followed for safe handling of hazardous gases and other related issues/accidents are elaborated in Chapter-7 of this report.
10.2.3 Action plan for performance monitoring of pollution control equipment. Regular inspection is carried out by ECD representative and shop representatives of BSL. ISO 14001:2015 has been implemented in BSL. Regular audit is done by internal and external auditors. All shops have designated officers for monitoring the environmental parameters and taking corrective actions. CAPA meeting is also carried out regularly as per EMS system by In-charge, ECD. BSP also carries out performance monitoring of pollution control equipment through a CPCB/MoEFCC certified agency at least once in 3 years. The typical action plan with responsibility matrix followed at BSL for performance monitoring of pollution control equipment is as shown in Figure 10.3 below:
Fig. 10.3: Action plan for performance monitoring of pollution control equipment
Pollution control & Monitoring System
Unit Env. Nodal officer
Process irregularities Instrument Breakdown
Unit head Unit head
x Instrument Monthly Calibration, Periodical GM Env. Control. Deptt x Periodical Manual Monitoring, Env. Control. . x Efficiency Checks of Pollution Control Deptt. Systems
Repair by service Instrument engineers Calibration The ambient air quality, effluent quality of outfalls as well as stack emission data are continuously monitored by continuous online monitoring systems. The data from these systems are constantly CHAPTER-10 EMP-ORGANISATIONAL SET UP & IMPLEMENTATION ARRANGEMENT Page 288 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
monitored through a MIS (Monitoring Information system) by individual Unit Environmental Nodal officers and any irregularity noted is communicated to the respective unit heads for investigation and corrective action. The snapshot of the MIS displaying data from continuous emission, effluent and ambient air quality monitoring systems installed at BSL is shown in Fig. 10.4 below: Fig. 10.4 Continuous emission, effluent & ambient air quality monitoring systems at BSL
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
10.2.4 Laboratory Set Up
BSL has a well-equipped environmental laboratory in ECD inside the plant premises. The Environmental laboratory is recognised laboratory as per EP Act 1986 and notified in Government of India Gazette. It has 11 numbers of skilled and trained personnel for conducting monitoring and analysis.
All the personnel deployed presently in the laboratory have been given training to carry out necessary environmental monitoring as well analysis also. The newly recruited officers shall also be adequately trained to undertake the environmental requirements of the proposed expansion. The equipment available with BSL is given in Chapter-6 of this EIA-EMP report.
10.3 FUNCTIONING
Environmental monitoring programme and its reporting has been designed to provide a close watch on the surrounding natural environment and provide early warnings of any adverse changes that may be related to some dimension of the plant’s operations.
A separate department "Environmental Control Department" (ECD) already exists for environmental monitoring of the existing plant and for development and maintenance jobs like drainage, settling tanks etc. assistance from the projects civil engineering department are taken.
ECD is already functioning in the existing plant to look after all environmental aspects, carry out day to day environmental monitoring / inspection requirements and maintain records. Part of the environmental monitoring programme is carried out through external agencies on a part time basis. However, casual labourers etc. is employed for plantation, drain cleaning etc. as and when required.
The ECD carries out complete Air Monitoring, Noise Level Monitoring, Special monitoring on water and air, effluent, special surveys and Impact Assessment, solid waste management, occupational health, safety management, green belt development, community welfare and peripheral development, etc. The same setup with enhanced manpower will work for the environmental monitoring programme of the proposed projects. The officers of ECD shall frequently analyse the data and periodically assess the progress of the EMP.
Simultaneously, the BSL has taken into cognizance the importance of noise pollution at work sites, solid waste management, occupational health, safety management, green belt development, community welfare and peripheral development which are described in detail.
The ECD is also taking all necessary steps to implement the measures suggested by Central Pollution Control Board (CPCB) in the Charter on Corporate Responsibility for Environmental Protection (CREP) for Integrated Iron and Steel Industry.
All compliance reports are being submitted to SPCB, RO of MOEF&CC and also upload in the SAIL web site periodically.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
10.3.1 Micro-Meteorology
Two automatic continuous weather micro-meteorological station have already been set up on the terrace of Bokaro Niwas within the township as well as Main plant gate of Steel plant. The following parameters are being recorded regularly: x Wind speed and direction x Rainfall x Temperature and humidity
10.3.2 Emissions and Air Quality
Ambient air quality is being monitored regularly in accordance with CPCB / Jharkhand State Pollution Control Board (JSPCB). Work zone air quality is being monitored as per directives of JSPCB to assess the levels of particulate matter, NOx and SO2.
Continuous Ambient Air Quality monitoring stations have been installed as per advice of JSPCB within 5 to 7 km of the project. All major process stacks will be provided with on-line monitoring system. The emissions from all the stacks are being monitored once a month using the manually operated stack emissions monitoring equipment. However the frequency of monitoring may be increased if required in accordance with the stipulations of SPCB, Jharkhand or other statutory authorities.
10.4 IMPLEMENTATION ARRANGEMENT
10.4.1 Institutional Implementation Arrangements
Bokaro Steel Plant is responsible for implementation of all the mitigation and management measures suggested in Environmental Monitoring Programme. A separate department "Environmental Control Department" (ECD) already exists in BSL to look after all environmental related matters of the plant.
For successful implementation of the environmental management plan other agencies of the State may also be involved by BSL if required (for regulatory requirement or technical support). The coordinating agencies, which may be involved for specific environmental related activities, are State Forest Department, Jharkhand State Pollution control Board & Inspector of factories at state level, and the Divisional Forest Officer and Regional Officer, State Pollution Control Board at District level.
Local NGOs will also be identified at the district and block level to provide help and advice for implementation of EMP especially on matters related to community development programme.
10.4.2 Co-ordination With Other Departments
The Environment Control Department (ECD) also co-ordinates with other departments like Occupational Health, Safety Management, Project Engineering, Horticulture and Community Development ,Chief Town Administrator, Water Supply Department etc. and also do the liaison work with external agencies like State & Central Pollution Control Boards and Environment Management Division (EMD) SAIL Corporate Office.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
10.4.3 Interaction With Jharkhand State Pollution Control Board (JSPCB)
ECD shall be in regular touch with JSPCB and shall send them quarterly progress report on EMP in the prescribed format, as per the prevailing practice. Any new regulations considered by State/Central Pollution Control Board for the Industry shall be taken care of by ECD of BSL.
10.5 TRAINING
The ECD, who would be responsible for the implementation of the EMP, needs to be trained on the effective implementation of the environmental issues. To ensure the success of the implementation set up proposed, there is a high requirement of training and skill up-gradation. For the proposed expansion project, additional training facilities will be developed for environmental control. For proper implementation of the EMP, the officials responsible for EMP implementation will be trained accordingly.
To achieve the overall objective of pollution control it is essential not only to provide latest pollution control and monitoring systems but also to provide trained man power resources to operate and maintain the same. So far, the practice with many plants is to utilize the plant operations and maintenance crew for operation of systems. This has shown adverse results due to lack of specialized knowledge in addition to priority selection. Therefore apart from the ECD, specific training will be provided to personnel handling the operation and maintenance of different pollution control equipment. In-plant training facilities will be developed for environmental control. The training will be given to employees to cover the following fields: x Awareness of pollution control and environmental protection to all. x Operation and maintenance of specialised pollution control equipment. x Field monitoring, maintenance and calibration of pollution monitoring instruments. x Laboratory testing of pollutants. x Repair of pollution monitoring instruments. x Occupational health and safety. x Disaster management. x Environmental management. x Afforestation / plantation and post plantation care of plants. x Knowledge of norms, regulations and procedures. x Risk assessment and Disaster Management.
10.6 CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION (CREP)
The proposed expansion-cum-expansion programme is a brownfield project and the provisions defined under CREP for steel plants are being followed at the present plant. The recent quarterly compliance of CREP by BSL is attached as Annexure-10.2. The existing plan for implementation of CREP guidelines for the proposed expansion-cum-modernization programme will be extended to the new facilities to comply with all provisions of CREP for BSL after completion of proposed expansion- cum-modernization programme also.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT CHAPTER-11: SUMMARY AND CONCLUSION
Executive summary of the entire EIA study is enclosed as a separate report. This chapter briefly summarises the EIA study and highlights the findings of the study.
In the design phase of the Project, Environmental Impact Assessment (EIA) was done to assess the possible impacts of the proposed Expansion-cum-modernization plan of BSL from 4.5 MTPA to 5.77 MTPA hot metal. In the plant design itself, latest state-of-art technology has been envisaged so as to achieve the desired air emissions and noise levels from plant operation levels. Discharge of effluents beyond plant boundary will be reduced to as low as possible as all new proposed facilities have been designed for “Zero Water Discharge”. Also, Zero Liquid discharge facilities are being proposed for recycling the waste water being discharged from outfalls. Further, all generated solid waste will be either recycled back into the respective plant operations or sent to sinter plant for sintering.
Primary and secondary data were used to assess the environmental impacts of the proposed project. All the potential environmental impacts associated with different phases (i.e. during design or pre-construction, construction and operation) of the Project were assessed in the EIA study in a comprehensive manner. The environmental impacts identified by the study were found to be manageable. The implementation of environmental mitigation measures recommended in the report will bring the anticipated impacts to minimum. Site specific and practically suitable mitigation measures are recommended to mitigate the impacts. Further, a suitable monitoring plan has been designed to monitor the effectiveness of envisaged mitigation measures during the operation phase.
The introduction of state-of-art technology (including the technological mitigation measures) during the design has limited the associated environmental impacts of the Project. The implementation and monitoring of effectiveness of the environmental mitigation measures during the operation phase will be done by the Environmental Control Department of BSL. A senior management level officer will periodically assess and monitor the implementation of mitigation measures, and will tackle the management bottle necks of implementation of mitigation measures and environmental monitoring programme.
Thus, BSL’s proposal for Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal serves its need for achieving its rated production capacity of 5.77 MTPA hot metal and 4.656 MTPA steel and this EIA study highlights that the judicious implementation of proposed Environmental Management Plan will ensure negligible negative impacts on the environment with direct and indirect positive development to the society due to the proposed project.
CHAPTER-11 SUMMARY AND CONCLUSION Page 293 of 298 © 2020 MECON Limited. All rights reserved STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
CHAPTER-12: DISCLOSURE OF CONSULTANT
12.1 INTRODUCTION
The EIA/EMP report for the proposed Expansion-cum-Modernisation of Bokaro Steel Plant, located at Bokaro Steel City, Jharkhand, from 4.5 MTPA Hot Metal to 5.77 MTPA Hot Metal (BSL) has been prepared by MECON Limited, a Public Sector undertaking under the Ministry of Steel, Government of India.
12.2 PROFILE OF EIA/EMP CONSULTANT
MECON Limited - a Government of India Enterprise Mini Ratna company under Ministry of Steel (established in 1959), is a premier multi-disciplinary consultancy organisation in the country. MECON's corporate Office is at Ranchi and has branches at Bengaluru, New Delhi, Bhubaneshwar, Kolkata, Burnpur, Vishakhapatnam, Bhilai, Durgapur, Rourkela, Bokaro, Mumbai etc. and also has its establishment at Lagos, Nigeria etc. MECON has till date completed ~5000 consultancy and EPC assignments covering wide range of field and services. The company is registered with International financial Institutions like World Bank (WB), Asian Development Bank (ADB), EBRD, ADB, UNIDO etc. MECON is the first engineering and consulting organization in the country to be accredited with ISO 9001 (now ISO 9001: 2000) by RWTUV of Germany.
There are about 36 specialized disciplines to cater to the various technical needs of the industries and infrastructural development. MECON's services include the whole range of work relating to setting up of industrial projects in the field of Environment, power, metallurgy and mining, ferrous and non-ferrous, chemicals/petrochemical and allied engineering complexes including specialized fields, such as, Defence Projects, mints/currency note presses. Services for Environmental engineering are provided to industries through MECON’s Environmental Engineering Division.
MECON entered the business of Environmental Consultancy during the mid-1980s i.e. at the inception of this field in India. MECON also set up its own environmental engineering laboratory to undertake micro-meteorological, air quality, water quality, noise levels, soil quality and soil quality monitoring. By the time the EIA Notification came into force, MECON had already prepared a number of Environmental Impact Assessment and Environmental Management Plan (EIA/EMP) reports for various industries covering Integrated Steel Plants, Thermal Power Plants, Mineral Beneficiation Plants, nuclear fuel processing complexes, Ship Recycling projects, open-cast / underground Mines (Iron ore, Manganese ore, copper ore, chromite, limestone, dolomite, coal, uranium ore), POL Pipelines & Terminals, Cement Plants etc. MECON is also called upon to perform the task of being a consultant-adviser to the Government of India and foreign governments on the technical front.
With this unique back up from independent specialized sections, MECON’s consultancy services in the field of Environmental Engineering & Management includes but not limited to Project Specific EIA/EMP study, Regional EIA Study, ISO:14000 Consultancy, Environmental Audit, Ground water contamination study, Preparation of industry specific norms for CPCB, ETP/STP/Tailing disposal (FR/DPR/DE/Turnkey execution), Socio-Economic study, Rehabilitation & Resettlement study, CHAPTER-12 DISCLOSURE OF CONSULTANT Page 294 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Environmental Baseline data generation, Environmentally compatible land use zoning, Air Pollution (Dust Suppression & Dust Extraction Systems) /Water Management, Ecological study (Terrestrial & Aquatic/Marine), Effluent Treatment Plant, Sewage Treatment Plant and Rainwater Harvesting. The Environmental Engineering section of MECON has provided services for more than 350 numbers of projects.
Total manpower strength of MECON is about 1460. MECON’s Environmental Engineering Section is a multi-disciplinary group of about 25 engineers, specialists and scientists whose services are backed up by a sophisticated Environmental Engineering Laboratory.
MECON’s Environmental Engineering Section is well equipped with various computerized predictive tools required for carrying out environmental studies and participates regularly in inter laboratory quality assessment exercise conducted by CPCB.
Environmental division has a sophisticated environmental engineering laboratory equipped with modern state of the art apparatus/instruments for carrying out physico-chemical and biological analysis of environmental parameters. The equipment list is shown as Table 12.1.
Environmental Engineering laboratory of MECON is certified with BS OSHAS: 18001: 2007 with Occupational Health and safety management.
Table 12.1: List of Major Equipment at Environmental Laboratory Sl. Name of instrument Make & Model Qty. No. 1 Automatic absorption spectrophotometer (AAS) ECIL AAS-4141 1 2 MPAES Agilent Technologies, USA 1 3 Gas Chromatograph (GC) with TCD, FID, ECD & NPD detectors Thermo, Trace GC Ultra Thermo 1 4 High Performance Liquid Chromatograph (HPLC) Youglin-Koreas, YL 9100 1 Spectrophotometers a) UV-Visible - Spectrometer ECIL, UV5704SS 1 5 b) UV-Visible - Spectrometer Thermofisher 1 c) Photometer Systronic 5 d) Spectrophotometer Hach DR-2000 1 Auto chemistry system with Ion selective electro for CN-, NH3, 6 Orion 960 1 NO3-& F- TKN analyser with digester, scrubber, distiller and filtrator with Pellican make, models KJL08LR, 7 1 auto titrator Kjelovac-VA Kjelodist&Titroline 7000 8 Low volume/ Benzene sampler Ecotech, AAS 172 2 9 Mercury Analyser ECIL-MA5840 1 10 BOD analyser Oxi Top, WTW, Germany 2 11 COD Reactor Hach 1 12 Oil Analyser InfracalWilks 1 13 Weighing Balance : a) Micro balance Radwag, Poland, MYA 5.3Y 1 b) Semi-micro balance Wenser, MAB120 2 c) Macro-balance Mettler, AE-240 1 14 Flame Photometer AIML 1 15 Turbidity Meter Hach 1 16 Conductivity meter Hach 1 17 pH Meter Desk top type Lab India 2 18 Trinocular Research Microscope Wild LEITZ (Germany) 1 CHAPTER-12 DISCLOSURE OF CONSULTANT Page 295 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Sl. Name of instrument Make & Model Qty. No. 19 B.O.D. Incubator SICO/Yorco/Fikarm Sc. 4 20 Laminar flow system YORCO 1 21 High Speed Refrigerated Centrifuge Sorvall Instrument RC5C 1 22 Refrigerated Centrifuge Eltech 4100D 1 23 Gyratory shaker (Incubator cum shaker Vikaram Instruments 1 24 S.S. Water Distillation Unit - 1 25 Water double distillation unit (quartz) - 1 26 Autoclave SICO 2 27 a) Mechanical hot air oven (Air convention Type) ADCO 1 b) Drying oven SICO 2 28 Muffle furnace Lab Equip 1 29 Hot Plates Tempo 1 30 Magnetic Stirrer with hot plate SICO 3 31 Mechanical Shaker - 1 32 Heating mantle Hot Point (ACME Inst.) 6 33 S.S. water bath SENCO 1 34 Vacuum Pump PRECIVAC/ Axiva 2 40 Fume-chamber Modern Lab interio 1 41 Isokinetic stack sampler Vayubodhan 2 42 Respirable Dist Sampler (RDS) Envirotech/Ecotech 70 43 High Volume Air Sampler (HVS) Envirotech 8 44 Sound Level Meter a) Sound Level Meter B & K Type 2221/Quest/ Casella 5 b) Sound Level Meter with frequency analyser B & K Type 2231 1 c) Sound Level Calibrator B & K/ Quest/ Casella 3 45 CO Analyser Ecotech, USA 1 46 Portable Generator sets Yamaha 9 47 PM 2.5 Fine Dist Sampler Polltech/Envirotech 22 48 Automatic weather station Envirotech 5 49 Solid Phase Extration (SPL) Agilent Technologies, USA 1 50 Micro Wave Digestion System Milestone SYI, Italy 1 51 Multi Parameter Analyser (Electrode) pH,EC,DO Thermo Scientific 3 52 Turbidity Meter Thermo Scientific 1 53 Ultra Pure Water Purification System Merck 1 53 Deep Freezer Scien Tempo 1 54 Aquarium Local make 2
Table 12.2: List of Computer models for Environmental Studies Developed in-house x Multisource Dispersion Model based on Gaussian Model x Screening Model to determine Max. GLC at most unfavorable meteorological condition x Determination of Atmospheric stability x Noise Propagation Model x Subsidence Model (Coal) x Coastal Zone Dispersion Model x Model for preparation of Wind Rose Procured x USEPA approved models x Industrial Source Complex Short Term (ISCST) x AEROMOD for Air Quality prediction x Industrial Point Source Complex Long Term (ISCLT) x Multiple Point Source Model With Terrain Adjustments (MPTER) CHAPTER-12 DISCLOSURE OF CONSULTANT Page 296 of 298 © 2020 MECON Limited. All rights reserved
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
x Fugitive Dust Model (FDM) x Qual 2E River Model x CALINE – 3 (Highway Model) x Complex Terrain Dispersion Model (CTDM PLUS) x Groundwater Modeling System (GMS) x Surface Water Modeling System (SMS) x Watershed Modeling System (WMS) x Green Belt Model x Phast Model for Risk Assessment
12.3 STATUS OF ACCREDITATION
MECON Limited is accredited by QCI/NABET for preparing EIA/EMP reports in 17 sectors, including “Metallurgical industries (ferrous & non ferrous) – both primary and secondary ”vide their certificate no. NABET/EIA/1619/RA 0068. This certificate is valid up to 22nd September, 2020. A copy of this NABET certificate is attached as part of this report. MECON has been accredited for 17 sectors(listed in Table 12.3).
Table 12.3: Details of sectors accorded to MECON under the QCI-NABET scheme for accreditation of EIA consultant organization Sl. No. Sector Number Name of the Sector Category As per As per MoEFCC NABET Notification Scheme 1 1 (a) (i) 1 Mining of minerals including Opencast / Underground mining A 2 1 (b) 2 Offshore and onshore oil and gas exploration, development & production A 3 1 (c) 3 River valley, hydel, drainage and Irrigation projects A 4 1 (d) 4 Thermal Power Plants A 5 1 (e) 5 Nuclear power projects & processing of nuclear fuel A 6 2 (a) 6 Coal washeries A 7 2 (b) 7 Mineral beneficiation including pelletization A 8 3 (a) 8 Metallurgical industries (ferrous & non ferrous) – both primary and secondary A 9 3 (b) 9 Cement plants B 10 4 (b) 11 Coke oven plants B 11 6 (a) 27 Oil & gas transportation pipeline (crude and refinery / petrochemical products), A passing through national parks / sanctuaries / coral reefs / ecologically sensitive areas including LNG terminal 12 6 (b) 28 Isolated storage & handling of hazardous chemicals (as per threshold planning B quantity indicated in column 3 of schedule 2 & 3 of MSHIHC Rules 1998 amended 2000 13 7 (b) 30 All ship breaking yards including ship breaking units A 14 7 (c) 31 Industrial estates / parks / complexes / areas export processing Zones (EPZs), A Special Economic Zones (SEZs), Biotech Parks, Leather Complexes 15 7 (e) 33 Ports, harbours, jetties, marine terminals, break waters and dredging A 16 7 (f) 34 Highways, railways, transport terminals, mass rapid transport systems A 17 8 (b) 39 Township and Area development projects B
MECON has also been accredited for functional areas. Details of the Functional Area Experts of MECON working in Environmental area are given in Table 12.4.
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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT (BSL) Expansion-cum-modernization of Bokaro Steel Plant from 4.5 MTPA hot metal to 5.77 MTPA hot metal at Bokaro Steel City, Jharkhand PROJECT PROPONENT ENVIRONMENTAL CONSULTANT
Table 12.4: Brief description of the Functional Area Experts of MECON Sr. No. Functional area code Functional Area Approved 1. AP Air Pollution Prevention, Monitoring & Control 2. WP Water Pollution Prevention, Control & Prediction of Impacts 3. SHW Solid Waste and Hazardous Waste Management 4. SE Socio-Economics 5. EB Ecology and Biodiversity 6. HG Hydrology, Ground Water & Water Conservation 7. GEO Geology 8. SC Soil Conservation 9. AQ Meteorology, Air Quality Modeling& prediction 10. NV Noise & Vibration 11. LU Land Use 12. RH Risk Assessment & hazard Management
All EIA coordinators and Functional area experts are in-house experts of MECON.
Baseline environmental data generation covering micro-meteorology, air quality, water quality, soil quality and noise levels were carried out by the Environmental Engineering laboratory of MECON Ltd., which is recognized by MoEFCC under the Environment (Protection) Act, 1986. Copy of CPCB’s letter renewing recognition of Environmental Engineering Laboratory of MECON under Environment (Protection) Act is enclosed as Annexure 12.1.
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ANNEXURES
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