BRIEF PROJECT SUMMARY
Vedanta Limited, formerly known as Sesa Sterlite Limited (SSL)/ Sesa Goa LTD, a Vedanta Group company is one of the world’s largest global diversified natural resource majors, with operations in zinc-lead-silver, oil & gas, iron ore, copper, aluminium and commercial power.
Vedanta Limited (Vedanta) is contemplating to establish a green field 0.5 MTPA hot metal plant (Pig Iron), 3 MTPA of pellet plant. The process for production of hot metal is based on blast furnace, sinter plant and coke oven plant. Vedanta is already having 0.832 MTPA pig iron manufacturing unit at Goa along with 1.0 MTPA sinter plant, 0.6 MTPA heat recovery coke plant & 60 MW waste heat recovery plant.
The proposed project area is located at Dimbuli Village, Circle Manoharpur, West Singhbhum District, Jharkhand State.
Process Details
1. Hot metal (Pig Iron) Plant:
The following has been considered for 0.5 MTPA blast furnace and related facilities:
A. 0.5 MTPA Blast Furnace:
It is proposed to install a blast furnace of 0.5 MTPA capacity in Manoharpur village Jharkhand.
This furnace will be a modern blast furnace equipped with hot blast stoves, bell less top, and pulverized coal injection including O2 enrichment.
B. Sinter Plant:
The availability of the calibrated iron ore lumps is becoming scarce; hence it is proposed to install sintering machines of adequate capacity along with the blast furnace.
The advantages with the use of sinter is that, it improves the productivity of the blast furnace, lowers the coke rate, allows usage of low iron bearing material and low value coke breeze in the production.
C. Waste Heat Recovery Coke plant and Power Plant (based on waste heat of Coke plant and Blast Furnace gas):
To cater to the coke requirement of blast furnace it is proposed to add coke making capacity of 250,000 TPA with Sesa’s technology of heat recovery, which conforms to the most stringent environment norms worldwide.
The proposed power plant will have capacity of 30 MW and will utilize the waste heat from coke ovens and the excess gas available from the proposed 0.5 MTPA blast furnace.
2. Pellet Plant:
The pellet plant will make the iron ore concentrate into a product of oxide pellet. The capacity of pellet plant will be 3.0 MTPA. The process of pelletization involves bulk handling and storage of raw materials - mainly iron ore fines, coal, limestone, dolomite, bentonite etc; preparation of raw materials by grinding and mixing with adequate moisture content; balling of the prepared mixture and hardening of the pellets in a specially designed furnace. The main plant facilities include additives grinding, mixing, balling, induration and product load out besides the auxiliary and service facilities.
Resource Requirement
Area: The proposed green field project requires 439.09 acres for installation of pellet plant, blast furnace, sinter plant, coke oven heat recovery and waste heat recovery power plant.
Water Requirement: Estimated make up water requirement for the project is 9000 m3/day which will be drawn from Koina river. Total water quantity is 3.3 MCM annually.
Power Requirement: Power will be taken from grid. 30 MW (approx.) waste heat recovery power plant is proposed. Required power for plant operation is approximately 28 MW.
Manpower Requirement: The proposed project will generate direct employment of approx. 1500 manpower including contract labour. It will provide new opportunities for local people also resulting in indirect employment of 5000 manpower. Training programs will be setup for the development of local community as per the work requirement.
The project cost for the proposed green field project is about Rs. 1700 Crores and EMP cost is about Rs. 100 Crores.
APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE
FORM-I
FOR THE PROPOSED 0.5 MTPA HOT METAL PLANT (PIG IRON) 3.0 MTPA PELLET PLANT AT MANOHARPUR TALUK, WEST SINGHBHUM DISTRICT, JHARKHAND STATE
Submitted to: Ministry of Environment, Forest & Climate Change New Delhi
Submitted by:
Vedanta Ltd. Jharkhand
Environmental Consultant:
Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally, Hyderabad–500 051, Telangana State [email protected], www.vimta.com (QCI/NABET Accredited and ISO 17025 Certified Laboratory, Recognized by MoEF, New Delhi)
July, 2018
TABLE OF CONTENTS
Contents
Annexure-I Study Area Map Annexure-II List of Khasra numbers Annexure-III Comparison of alternative sites Annexure-IV Directorate of Industries letter Annexure-V Process Flow Sheets Annexure-VI Proposed Terms of Reference
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FORM-1 (I) BASIC INFORMATION
Sr. No. Item Details 1 Name of the project/s: Vedanta Limited proposes to establish 0.5 MTPA hot metal plant (pig iron) and 3.0 MTPA pellet plant in Manoharpur Taluk, West Singhbhum district, Jharkhand state. 2 S. No. in the schedule 3(a) Metallurgical industries (ferrous & non ferrous) 3 Proposed capacity/ area/ length/ 0.5 MTPA Hot metal plant (pig iron) tonnage to be handled/ command 3.0 MTPA Pellet plant area/ lease area/ number of wells to be drilled 4 New/Expansion/Modernization New 5 Existing Capacity/ Area etc. Nil
6 Category of Project i.e. ‘A’ or ‘B’ Category ‘A’
7 Does it attract the general condition? No If yes, please specify. 8 Does it attract the specific condition? No If yes, please specify. 9 Location: Latitude: 22°21’41.9” to 22°22’32.56”N Longitude: 85°12’57.84” to 85°13’59.93”E
Study area map is enclosed as Annexure-I Plot/ Survey/Khasra No. Khasra No. list enclosed as Annexure-II Village Dimbuli village Tehsil Circle Manoharpur District West Singhbhum State Jharkhand 10 Nearest railway station/ airport Manoharpur Railway station (2.0 km, W) along with distance in kms Rourkela airport (42.0 km, WSW) 11 Nearest town, city, district West Singhbhum, Dipa village (0.4 km, S) headquarters along with distance Baradungri (0.2 km, N) and direction in kms 12 Village panchayats, Zilla parishad, Dimbuli Municipal corporation, local body (complete postal addresses with telephone nos. to be given) 13 Name of the applicant Vedanta Ltd 14 Registered Address 1st Floor, M-11,VIP Road, Harmu Housing Colony. Harmu PS- Argora, Ranchi-824002 Jharkhand 15 Address for correspondence Name Mr. Frank Morais Designation Head- Projects (Owner/Partner/CEO) Address 1st Floor, M-11,VIP Road, Harmu Housing Colony. Harmu PS- Argora, Ranchi-824002 3
Sr. No. Item Details Jharkhand Pin Code 824002 E-mail [email protected] Telephone No. 0651-2245661 Fax No. - 16 Details of Alternative Sites Three sites were examined for setting up examined, if any. Location of these the proposed plant. Comparisons of sites should be shown on a topo alternative sites are given in Annexure- sheet III.
Site-1 is more appropriate for setting up proposed plant.
Government of Jharkhand vide letter no 05/U.Ni (MoU/Vedanta Ltd)-31/2015 dated 22 Nov 2017 has confirmed to MoEF&CC that the 439.09 acres of land is under process of acquisition/allotment/transfer to Vedanta Limited. This land is being transferred for industrial purpose. The letter copy is enclosed as Annexure-IV. 17 Interlinked Projects Yes 18 Whether separate application of Application for Terms of Reference for the interlined project has been “Proposed 5.0 MTPA iron ore mine in submitted Manoharpur taluk, West Singhbhum district, Jharkhand” has been submitted. 19 If yes, date of submission 29th September, 2017 20 If no, reason - 21 Whether the proposal involves No approval/clearance under:
(a) The Forest (Conservation) Act, 1980
(b) The Wildlife (Protection) Act, 1972
(c) The C.R.Z Notification, 1991 22 Whether there is any Government No Order/Policy relevant/relating to the site 23 Forest land involved (hectares) Nil 24 Whether there is any litigation No pending against the project and/ or land in which the project is propose to be set up (a) Name of the Court (b) Case No. (c) Orders/ directions of the Court, if any and its relevance with the proposed project. 4
(II) ACTIVITY
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr. No. Information/Checklist Yes/ Details thereof (with approximate Confirmation No quantities/ rates, wherever possible) with source of information data 1.1 Permanent or temporary Yes The total land requirement for the change in land use, land proposed project would be 439.09 acres. cover or topography including The area is fairly flat. The land is mostly increase in intensity of land unirrigated, wasteland and single crop. use (with respect to local land use plan) The break-up of the current land use for the proposed plant is given below:
Government land: 41.01 acres Private land: 398.08 acres Total area: 439.09 acres
Site modifications, wherever required, with respect to approved drawings will be carried out.
Thus, with set up of plant , land use will be changed to industrial category. 1.2 Clearance of existing land, Yes There will be clearance of existing vegetation and building? vegetation wherever required. 1.3 Creation of new land uses? Yes Industrial use 1.4 Pre-construction Yes Land survey is done. Soil testing and investigations e.g., bore other investigations will be soon carried houses, soil testing? out. 1.5 Construction works ? Yes 0.5 MTPA hot metal plant, 3.0 MTPA pellet plant and allied facilities. 1.6 Demolition Works ? No There will not be any demolition works during the construction of the plant. 1.7 Temporary sites used for Yes There will be temporary housing sites for construction works or the construction workers and housing of construction construction officers within the plant site workers? area only. 1.8 Above ground buildings, Yes The structures related to the plant will be structures or earthworks constructed. The project may require less including linear structures, cut and fill as the site is generally flat cut and fill or excavations and gradually sloping. 1.9 Underground works including No Not envisaged mining or tunneling? 1.10 Reclamation works? No Not Applicable
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Sr. No. Information/Checklist Yes/ Details thereof (with approximate Confirmation No quantities/ rates, wherever possible) with source of information data 1.11 Dredging? No Not Applicable 1.12 Offshore structures? No Not Applicable 1.13 Production and Yes The description of manufacturing process manufacturing Process? and process flow of plant is presented in Annexure-V. 1.14 Facilities for storage of goods Yes Storage facilities are planned for raw or materials? material and finished goods. 1.15 Facilities for treatment or Yes The wastewater generated from the disposal of solid waste or indirect cooling circuit would be routed liquid effluents? through the cooling tower and pressure filter for recycling purpose. The water treatment and recycling facilities shall be planned for Pellet Plant.
The solid waste to be generated in the proposed plant is slag, scrap, scale and dust. The dust from dust collection unit will be recycled in the sinter plant itself. 1.16 Facilities for long term No Operational workers will stay in nearby housing of operational villages. workers? 1.17 New road, rail or sea traffic Yes Existing road connecting the proposed during construction of plant site is adequate. operation? Dedicated rail line to nearest railway station Manoharpur located at 2 km distance from the plant site will be explored.
There will not be any sea traffic during construction or operation of the plant. 1.18 New road, rail, air Yes Existing road connecting the proposed waterborne or other transport plant site is adequate. infrastructure including new or altered routes and Dedicated rail line to nearest railway stations, ports, airports etc.? station Manoharpur located at 2 km distance from the plant site will be explored.
There will not be any sea traffic during construction or operation of the plant. 1.19 Closure or diversion of No Not envisaged existing transport routes or infrastructure leading to changes in traffic movements? 1.20 New or diverted transmission Yes New power transmission lines will be laid lines or pipelines? for the proposed project. Waterline will be laid. 6
Sr. No. Information/Checklist Yes/ Details thereof (with approximate Confirmation No quantities/ rates, wherever possible) with source of information data 1.21 Impoundment, damming, No No changes to the hydrology of culverting, realignment or watercourses or aquifers. other changes to the hydrology of watercourses or aquifers? 1.22 Stream crossings? No No stream crossings through the plant site 1.23 Abstraction or transfers of Yes Make up water requirement is estimated water from ground or surface to be 9,000 Cum/day. 3.3 MCM per waters? annum water is required for the proposed plant and shall be met from neighboring river Koina.
Required permissions will be obtained from State Water Resources Department/ Irrigation Department. 1.24 Changes in water bodies or No Not envisaged the land surface affecting drainage or run-off 1.25 Transport of personnel or Yes The transport of personnel during materials for construction, construction / operational will be by operation or public / company arranged conveyance decommissioning? mode.
Construction material will be transported by road and will be stored in storage material yard. 1.26 Long-term dismantling or No Not envisaged decommissioning or restoration works? 1.27 Ongoing activity during No No decommissioning which could have an impact on the environment? 1.28 Influx of people to an area in Yes During construction phase, temporary either temporarily or influx of people is envisaged and during permanently? operation phase there will be permanent influx of people 1.29 Introduction of alien species? No Not applicable 1.30 Loss of native species or No Not envisaged genetic diversity? 1.31 Any other actions? No Not envisaged
2. Use of Natural resources for construction or operation of Project (such as land, water, materials or energy, especially any resources which are non- renewable or in short supply).
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Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 2.1 Land specially undeveloped Yes The break-up of the current land use for the or agricultural land (ha) proposed plant is given below:
Government land: 41.01 acres Private land: 398.08 acres Total area: 439.09 acres
Land identified for the proposed project is mostly unirrigated , waste land and single crop. 2.2 Water (expected source & Yes Make up water requirement is estimated to be competing users) unit KLD 9,000 Cum/day. 3.3 MCM per annum water is required for the proposed plant and shall be met from neighboring river Koina.
Suitable impounding arrangements in the form of a pickup weir or intake well at the river source will be constructed to meet the plant water requirement, along with dedicated pipeline. 2.3 Minerals (MT) Yes Hot metal plant
Iron ore fines: 7,30,000 MT High grade lumps: 90,000 MT Limestone: 68,500 MT Dolomite: 69,000 MT Coking coal: 400,000 MT PCI coal: 60,000 MT Quartz: 5,000 MT
Pellet Plant
Iron ore: 30,00,000 MT Limestone: 45,000 MT Dolomite: 45,000 MT Bentonite: 24,000 MT Coal (Anthracite/Coke breeze): 52,500 MT 2.4 Construction material – Yes The construction material will be procured stone, aggregates, and/soil locally. (expected source - MT) 2.5 Forests and timber (source- No Not envisaged MT) 2.6 Energy including electricity Yes Required power for plant operation is approx. and fuels (source, 28 MW. competing users) Unit: fuel Power requirement will be met from grid (MT), energy (MW) power. A 30 MW Waste Heat Recovery Power plant is proposed,. The plant is expected to operate at a load factor of 70%. The Plant will use closed cycle water system. 8
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data It is proposed to utilize Blast Furnace and Coke Oven gases as a fuel for boiler.
Fossil fuels such as HFO/LDO/LPG/LNG will be used for the operations of plant.
2.7 Any other natural resources No Not envisaged (use appropriate standard units)
3.0 Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 3.1 Use of substances or No Not envisaged materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies) 3.2 Changes in occurrence of No Not envisaged disease or affect disease vectors (e.g. insect or water borne diseases) 3.3 Affect the welfare of Yes There would be positive change in welfare people, e.g., by changing amenities for the people due to CSR living conditions? interventions by company and also the socio economic condition will improve due to generation of jobs 3.4 Vulnerable groups of No Not envisaged people who could be affected by the project e.g. hospital patients, children, the elderly etc. 3.5 Any other causes No Not envisaged
4.0 Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 4.1 Spoil, overburden or mine No Not applicable wastes 9
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 4.2 Municipal waste (domestic Yes Domestic waste: Domestic waste is expected and or commercial from the temporary workforce. Suitable waste wastes) collection systems will be made for collection and disposal.
4.3 Hazardous wastes (as per Yes The oil sludge from the oil storage area and oil hazardous waste & grease removed from the waste water management rules) treatment plant will be handled by authorized users/recyclers approved by state pollution control board.
Used oil of the equipments in the plant will be collected & disposed to the authorized recycler as used oil, a Hazardous Waste under Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016. 4.4 Other industrial process Yes Process sludge generated from the plant will be wastes used as raw material in sinter plant.
The solid waste to be generated in the proposed plant is slag, scrap, scale and dust. All the solid waste described above would be recycled/ used in a proper manner/sinter plant and the rejects would be dumped in a designated area.
4.5 Surplus product Yes Surplus product shall be stockpiled and evaluated with proper planning. All control measures to protect the environment on this account shall be inbuilt in system. 4.6 Sewage sludge or other Yes The sewage sludge from the STP will be used sludge from effluent within the plant premises as organic manure. treatment 4.7 Construction or No Not envisaged demolition wastes 4.8 Redundant machinery or No Not envisaged equipment 4.9 Contaminated soils or No Not envisaged other materials 4.10 Agricultural wastes No Not envisaged 4.11 Other solid wastes No Not envisaged
5.0 Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr)
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 5.1 Emissions from combustion Yes Fossil fuels such as HFO/LDO/LPG/LNG/BF gas 10
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data of fossil fuels from will be used in plant operations Emissions of stationary or mobile SO2 and NOx sources from stationary sources and Linear sources from movement of plant vehicles. 5.2 Emission from production Yes Emission from production processes will be processes controlled by installing air pollution control devices such as bag filter house with adequate stack height. 5.3 Emissions from material Yes There shall be fugitive emissions arising out of handling including storage the movement of vehicles used for or transport transporting material 5.4 Emissions from construction Yes During construction activity, particulate matter activities including plant is the main pollutant arising from vehicular and equipment movements, and earth moving machinery. 5.5 Dust or odours from Yes Dust will be generated from the construction handling of materials activity. However, no odour is expected from including construction proposed project. materials, sewage and waste 5.6 Emissions from incineration No Not applicable of waste 5.7 Emissions from burning of No Not envisaged waste in open air (e.g. slash materials, construction debris) 5.8 Emissions from any other No Not envisaged sources
6.0 Generation of Noise and Vibration, and emissions of Light and Heat
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data 6.1 From operation of Yes There will be generation of noise from the equipment e.g. engines, proposed plant machinery of pig iron plant, ventilation plant, crushers pellet plant and WHRB. Light and heat emissions are envisaged from blast furnace. 6.2 From industrial or similar Yes Noise will be generated during operation phase processes due to stationary equipments and will be restricted to plant boundary by providing acoustic enclosures and developing greenbelt all along the boundary 6.3 From construction or Yes Noise will be generated by earth moving demolition equipment during construction phase, loading and unloading of materials and vehicle movement 6.4 From blasting or piling No Not envisaged 6.5 From construction or Yes During construction: temporary During operational traffic operation: less to moderate, the noise levels are 11
Sr. Information/Checklist Yes/ Details thereof (with approximate No. Confirmation No quantities/ rates, wherever possible) with source of information data expected to be in the range of about 75-80 dB (A) 6.6 From lighting or cooling No Not envisaged systems 6.7 From any other sources No Not envisaged
7.0 Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea
Sr. Information/Checklist Yes/No Details thereof (with approximate No Confirmation quantities/ rates, wherever possible) with source of information data 7.1 From handling, storage, Yes Risk that may arise during handling, storage, use or spillage of use or spillage of hazardous material will be hazardous materials managed as per Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016. 7.2 From discharge of sewage No The proposed project will be designed with or other effluents to water appropriate collection, treatment and disposal or the land (expected facilities for all process effluents. mode and place of discharge) 7.3 By deposition of No Not envisaged pollutants emitted to air into the land or into water 7.4 From any other sources No Not envisaged 7.5 Is there a risk of long No Not envisaged term buildup of pollutants in the environment from these sources?
8.0 Risk of accidents during construction or operation of the project, which could affect human health or the environment
Sr. Information/Checklist Yes/ Details thereof (with approximate No Confirmation No quantities/ rates, wherever possible) with source of information data 8.1 From explosions, Yes In-built safety features of the plant and spillages, fires etc. from machinery would be made adequate in order to storage, handling, use or avoid hazardous events causing damage to the production of hazardous life and property. substances
8.2 From any other causes No Not envisaged 8.3 Could the project be No There is no record of occurrence of floods, affected by natural landslides, cloud bursts etc. The proposed disasters causing project site falls under Seismic Zone-II as per 12
Sr. Information/Checklist Yes/ Details thereof (with approximate No Confirmation No quantities/ rates, wherever possible) with source of information data environmental damage IS 1893 (Part-I):2002 classification. Hence, (e.g. floods, earthquakes, seismically it is a stable zone landslides, cloud burst etc)?
9.0 Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Sr. Information/Checklist Yes/ Details thereof (with approximate No Confirmation No quantities/ rates, wherever possible) with source of information data 9.1 Lead to development of Yes Supporting and ancillary development will take supporting facilities, place. These facilities will be ancillary development or developed/strengthened as per the development stimulated requirement. by the project which Ancillary developmental activities due to could have impact on the proposed project will be developed in the environment e.g region.
Housing development Nil Extractive industries Nil Supply industries Nil Others 9.2 Lead to after use of the No Not envisaged site, which could have an impact on the environment 9.3 Set a precedent for later Yes Will enhance social , economic, industrial and developments commercial development 9.4 Have cumulative effects No Nil in 10 km study area. due to proximity to other existing or planned projects with similar effects
(III) Environmental Sensitivity
Sr. Areas Name/ Aerial distance (with 15 No. Identity km) Project Location Boundary 1 Areas protected under Elephant Within the study area international conventions, national movement or local legislation for their reported in ecological, landscape, cultural or Saranda Forest 13
Sr. Areas Name/ Aerial distance (with 15 No. Identity km) Project Location Boundary other related value Division 2 Areas which are important or Water Bodies sensitive of ecological reasons – wetlands, water courses or other Koina river Adjacent to west water bodies, coastal zone, South Koel river 1.8 km, West biospheres, mountains, forests Karo river 10.9 km, E 3 Areas used by protected, Protected/ important or sensitive species of Reserve Forests flora or fauna for breeding, nesting, foraging, resting, over Boranga PF 5.6 km, W wintering, migration Kurna PF 6.9 km, NW Chiramatha PF 10.0 km, NW Ganmor PF 1.1 km, NNE Dimbuli PF 0.3 km, E Ambia PF 2.3 km, E Ankua RF 1.7 km, SSE Chuararara RF 7.8 km, NW Kurthabera PF 7.6 km, WNW Rabangda RF 3.5 km, SW Ranabara PF 10.7 km, NW North Sukra RF 13.5 km, W South Surkra RF 12.5 km, SW Dhanapali PF 12.4 km, WSW Mahipani RF 14.3 km, WSW Sagori PF 14.2 km, SW Samtha RF 10.7 km, SW Dhobil PF 12.4 km, SE Henu PF 11.5 km, ESE Ghatkuri RF 13.0 km, E Leda RF 13.6 km, NE Raibera PF 12.1 km, NE PF near Konaina 12.5 km, NNE village Rungikocha PF 13.6 km, NNW Semi PF 13.5 km, N 4 Inland, coastal, marine or Water Bodies underground waters Koina river Adjacent to west South Koel river 1.8 km, W Karo river 10.9 km, E 5 State, national boundaries Interstate 11.3 km, SW boundary of Odisha-Jharkhand 6 Routes or facilities used by the SH-4 Adjacent to site public for access to recreation or other tourist, pilgrim areas 7 Defense installations No - 8 Densely populated or built-up area Manoharpur 2.0 km, W 9 Areas occupied by sensitive man Nil `- made land uses (hospitals, schools, places of worship, 14
Sr. Areas Name/ Aerial distance (with 15 No. Identity km) Project Location Boundary community facilities) 10 Areas containing important, high Nil - quality or scarce resources (ground water resource, surface resources, forestry, agriculture, fisheries, tourism, minerals) 11 Areas already subjected to Nil No pollution or environmental damage. (those where existing legal environmental standards are exceeded) 12 Areas susceptible to natural Nil The area is not known for hazard which could cause the these natural hazards. project to present environmental Seismically, this area is problems categorized under zone-II (earthquakes, subsidence, as per IS-1893 (Part-1)- landslides, erosion, flooding or 2002, which is a stable extreme or adverse climatic zone. conditions)
(IV) Proposed Terms of Reference for EIA Studies
In order to assess the environmental impacts due to the mining project on the surrounding environment, Vedanta Limited proposes to carry out EIA studies covering various environmental attributes and to suggest an effective Environment Management Plan. Proposed Terms of Reference for EIA studies are given in Annexure-VI.
I hereby give an undertaking that the data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project be rejected and clearance given, if any, to the project will be revoked at our risk and cost:
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ANNEXURE-I
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ANNEXURE-II
PRIVATE LAND SCHEDULE APPLIED PRIVATE LAND PURCHASED FOR ACQUISITION Government Land Schedule EARLIER MOUZA: DIMBULI , THANA NO: 86; HALKA- 7 MOUZA : DIMBULI ; THANA NO: 86 ANCHAL: MANOHARPUR ; WEST ANCHAL: MANOHARPUR , WEST SINGHBHUM SINGHBHUM
KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 1 3 2 / A 1 3 2 1 125 854
2 3 2 / B 2 3 7 855
3 3 2 / C 3 3 10 868
4 3 2 / D 4 3 17 126 362
5 3 2 / E 5 3 20 365
6 3 2 / F 6 3 22 366
7 3 2 / G 7 3 24 2 244 1112
8 3 2 / H 8 3 40 1113
9 3 2 / I 9 3 50 3 146 802
10 3 2 / J 10 3 81 805
11 3 2 / K 11 3 118 807
12 3 13 12 3 121 810
13 3 16 13 3 131 813
Sl. No. Khata No. Plot No. 14 3 141 147 508
14 199 21 15 3 150 4 43 516
15 199 23 16 3 160 546
16 199 25 17 3 164 1096
17 199 26 18 3 170 5 37 1089
18 199 27 19 3 288 1091
19 199 28 20 3 292 6 288 503
20 74 29 21 397 325 504
21 74 30 22 3 371 505
22 199 31 23 3 381 291 502
23 199 32 24 3 387 506
24 198 33 25 3 391 509
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 25 198 37 26 3 400 510
26 199 38 27 3 415 544
Sl. No. Khata No. Plot No. 28 3 417 581
27 199 39 29 3 422 582
28 198 41 30 3 423 583
29 199 42 31 3 424 584
30 264 58 32 3 448 585
31 201 65 33 398 449 7 163 461
32 201 66 34 4 451 493
33 201 67 35 3 452 495
34 201 68 36 397 460 499
35 201 69 37 397 497 553
36 264 70 38 397 500 569
37 144 80 39 3 523 570
38 144 82 40 3 542 575
39 100 88 41 397 543 579
40 100 89 42 3 550 8 163 457
41 100 90 43 3 557 462
Sl. No. Khata No. Plot No. 44 3 564 494
42 100 91 45 3 577 501
43 3 92 46 3 580 552
44 104 93 47 3 597 574
45 104 94 48 3 601 9 185 1142
46 104 95 49 3 611 1146
47 104 96 50 3 613 10 185 531
48 104 97 51 397 628 1141
49 104 98 52 397 682 1147
50 104 99 53 398 701 1151
51 104 100 54 398 738 11 286 586
52 100 101 55 3 785 587
53 361 102 56 3 786 1068
54 3 103 57 3 793 12
55 3 104 58 3 795 37 492
56 361 105 59 4 796 13 313 487
57 3 106 60 3 797 14 313 487
58 3 107 61 3 806 15 380 458
59 121 108 62 3 808 459
60 11 109 63 3 809 469
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO Sl. No. Khata No. Plot No. 64 3 815 470
61 11 110 65 3 816 571
62 12 111 66 3 826 16 94 471
63 23 112 67 3 835 1001
64 69 113 68 3 839 1100
65 3 114/A 69 3 845 1110
66 3 114/B 70 3 846 1115
67 69 115 71 3 850 221 1138
68 375 116 72 3 989 17 43 517
69 69 117 73 4 991 518
70 91 119 74 3 997 545
71 374 120 75 3 1011 18 295 433
72 69 122 76 3 1048 435
73 374 123 77 3 1065 439
74 374 124 78 3 1078 519
75 201 125 79 3 1120 19 37 472
76 200 126 80 397 1139 20 37 472
77 201 127 81 3 1156 21 37 472
Sl. No. Khata No. Plot No. 83 3 1160 22 37 472
78 201 128 84 3 50/3122 23 301 467
79 3 129 473
80 201 130 474
81 3 131 24 92 477
82 18 132 478
83 268 133 25 313 487
84 3 134 26 141 388
85 3 135 402
86 268 142 652
87 18 143 142 641
88 3 144 163 361
89 8 145 375
Sl. No. Khata No. Plot No. 385
90 8 146 386
91 8 147 395
92 8 148 409
93 3 149 631
94 120 151 632
95 120 152 635
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 96 120 153 640
97 168 154 643
98 197 155 655
99 278 156 668
100 277 157 672
Sl. No. Khata No. Plot No. 675
101 132 158 676
102 132 159 708
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 131 11 213 1000
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 166 222 248 703
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 200 277 282 1054
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 270 103 354
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 304 3 417
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 338 27 482
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 373 232 541
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 510 3 829
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 579 215 1007
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 611 295 1098
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KHATA PLOTS Sl. No. Khata No. Plot No. Sl. No. Khata No. Plot No. SL.NO. NO NO 644 185 1153
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ANNEXURE-III
Parameters Site–I Site -II Site -III Manoharpur Kharsawan Dipa Latitude 22°21’41.9” to 22⁰46'48"N 22⁰26'50.8"N 22°22’32.56”N Longitude 85°12’57.84” to 85⁰50'18"E 85⁰11'49.2"E 85°13’59.93”E Village in the Vicinity Dimbuli village (0.7 Kharsawan (0.2 Dipa village km, ENE) km, NNW) (0.4 km,S) Bandiram Baradungri Village(0.5 km, S) (0.2 km, N) Didhsah Village Adjacent to plant Distance from nearest city/town Rourkela (40 km, City: Chaibasa Rourkela WSW) Chaibasa (23.0km, S) (41.0 km, (61.0km, NE) Town: Saraikela SW) (12.6 km, SE) Elevation of the site, above MSL 220 MSL 200MSL 240 MSL Land availability (in acres) 439.09 700.0 612.3 Private/ Government Private and Government Private Private Agriculture land within 1km Yes Yes Yes Barren Single crop Double crop Barren Single crop Single Crop Forest land Single Crop Water body /Transmission line Koina River adjacent to Sanjoy River(6.0 Koel West boundary km, S) Sona Nala River(0.1 km, Koel River(1.8 km, W) (0.2 km, N) Khar NW) Koina Karo River (10.4 km, Khai River (11.6 River (5.6 E) km, SE) km, S) Karo River (4.4 km, NNE) Sapunala (0.9 km, NW) Road connectivity SH-4 Adjacent to site NH-149 (12.6km, SH-4 (1.4 SE) km, W) Rail connectivity Manoharpur(2.0 km, W) Mahali Posotia (5.1 Murup(5.0 km, km, E) SSW) Manoharapur (5.5km, S) Forests within 15 km There are 15 PF and 10 Chandil-Gamharia There are 16 RF Forest PF and 8 RF National parks & Wildlife Nil Nil Elephant sanctuaries Corridor exists
37
Location-1: Manoharpur
N
10KM
Plant Boundary
38
Location-2: Kharsawan
39
Location-3: Dipa
40
ANNEXURE-IV
41
ANNEXURE-V 42
Process Flow Diagram- Hot Metal Plant
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PROCESS FLOW DIAGRAM- PELLET PLANT
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ANNEXURE-VI PROPOSED TERMS OF REFERNCE
1.0 INTRODUCTION
The EIA study includes determination of baseline conditions within 10 km radius study area from the boundary of the plant site, assessment of the impacts on the environment due to the construction and operation of the proposed project and making recommendations on the preventive measures to be taken, to minimize the impact on the environment to acceptable levels. A suitable post-study monitoring programme will also be outlined. Preparation of Environment Management Plan will also be done.
2.0 METHODOLOGY FOR DATA GENERATION
2.1 Land Use
The existing land use pattern in the study area of 10 km radius around the project site will be established through the literature review of published census records. Based on this review, the land use pattern will be categorized into the following five categories:
1. Forest; 2. Irrigated and agricultural land; 3. Un-irrigated agricultural land; 4. Culturable wasteland; and 5. Land not available for cultivation, which includes built-up areas.
Further, land use pattern of the study area will be assessed by interpreting the recent IRS satellite imagery within 10 km radius study area.
2.2 Demography and Socio-Economic Aspects
The existing status of demography and socio-economic factors will be established covering 10 km radial distance around the project site based on the literature review and secondary sources such as the District Census Statistics. The demographic and socio-economic characteristics such as distribution and density of population, age-sex structure, sex ratio, social structure, literacy rates and occupational structure of people etc. will be established. There will not be any primary studies under this aspect.
2.3 Soil Characteristics
Soil samples at eight locations were collected in the project study area from a depth of 0-90 cm from the ground. The locations are selected to represent various land use conditions including proposed project site. The parameters will be analyzed with respect to agricultural importance and plantation purposes.
2.4 Water Quality
For assessing the water quality in the study area, water samples from eight locations were collected once during the study period. The locations cover important water bodies in 10 km radius area based on the reconnaissance survey 45
of the area. Both surface and ground water sources are covered under water quality assessment. Methods specified in "Standard Methods for Examination of Water and Wastewater" published by American Public Health Association (APHA) are adopted.
Meteorology
Meteorological observations are carried out at the proposed project site for 3- months covering one full non-monsoon season for developing the Environment Impact Assessment (EIA) report. The monitoring is carried out on regular basis for the following parameters on hourly basis:
Wind speed and direction; Temperature (dry and wet bulb); Relative humidity; Atmospheric pressure; Cloud cover; and Rainfall.
Micro-meteorological data generation will be carried out considering the IS-8829 (1978)-"Guidelines for Micro-Meteorological Techniques in Air Pollution Studies" and as per CPCB guidelines for modeling. For establishing the historical trend, past 5-10 year meteorological data will be collected from the nearest observatory of India Meteorological Department (IMD) located at Ranchi will be analyzed for probable wind directions, wind speeds, temperature, humidity, etc. Accordingly, the wind roses will be prepared. A critical comparison between long-term meteorological data collected from IMD and the data measured at the project site will be done to finalize the input for mathematical modeling.
2.6 Ambient Air Quality Monitoring (AAQ)
Ambient Air Quality monitoring was carried out at eight locations covering the proposed project site and its surrounding including sensitive locations. The frequency of AAQ monitoring is twice in a week for 13-weeks during the EIA study period. Samples were collected for PM10, PM2.5, NOx, SO2, CO for 24- hours. Carbon Monoxide monitored for every eight hours continuously for 24-hour AAQ monitoring. The frequency will allow comparison of the baseline concentrations with those specified by CPCB through their Notification of 16th November, 2009. The locations of the AAQ monitoring stations were fixed by reviewing the meteorological data of Ranchi IMD station. This will ensure collection of data upwind and downwind of each project sites for establishing the baseline air quality at critical locations. The samples will be collected and analyzed as per IS-5182 guidelines.
2.7 Terrestrial and Aquatic Ecology
a) Terrestrial Ecology
Field surveys were conducted at appropriate locations covering important vegetative areas for which vegetation analysis was carried out. The vegetation density, diversity, frequency, relative abundance, cover etc. were studied. In addition, wildlife including avifauna of the study area was also determined. The vegetation was sampled by using list-count-quadrant method.
46
A checklist of flora, wild animals and avifauna will be prepared. Abundance of wild animals and birds will also be estimated. A list of endangered species, both for flora and fauna of the study area will be prepared based upon the Red Book of BSI and Wildlife (Protection) Act 1972. Presence of wetlands and other ecologically sensitive areas like national parks/sanctuaries were identified. The woody vegetation i.e. tree and shrubs were sampled by random sampling and by taking quadrates of 10-m2 or 100-m2. For trees, basal area estimations will be done by taking Girth at Breast Height (GBH i.e. 132-cm from ground) or above buttresses. Herbaceous flora will be studied by taking quadrates of 1-m2.
b) Aquatic Ecology
Reconnaissance survey of the study area address identification of water bodies like rivers/nallahs/ponds etc. The existing status of major water bodies were thoroughly investigated for the flora and fauna including phytoplankton, zooplankton, fish and macrophytes.
Aquatic ecology of the study area was studied based on the literature survey and also investigated through limited primary surveys, if required.
The water bodies were studied during field studies for phyto and zooplankton density and diversity. Based on the primary and secondary surveys, a list of flora and fauna will be prepared. The water bodies will be studied for characterization for tropic status, areas of chemical and thermal pollution, primary productivity, density and diversity of phytoplankton, zooplankton, benthic micro invertebrates, fish and micro- phyto. Diversity indices of ecological groups will also be calculated.
For the estimation of plankton, 5 liters of composite water samples was collected from various depths. Water samples from mid-depth and bottom will be collected, by using Nansen reversible water sampler. Samples were concentrated to 100-ml and fixed with 4% formaldehyde and Lugol's Iodine. The samples were analyzed in the laboratory by simple drop method.
The available literature and collect data from government agencies like the Botanical / Zoological Survey of India etc. will be reviewed for listing the species and verifying if there are any rare or endangered species in this area.
2.8 Noise Levels
Noise Level Monitoring was conducted at about 8 locations of project area covering various categories such as industrial, residential, commercial and sensitive mentioned in the Environment Protection Rules and as per the specifications of the MoEF/CPCB. The survey was carried out once during EIA study period. Readings were taken over 24 hour period at each location depending on the level of activity. The equivalent continuous noise levels (Leq) were monitored using an integrating sound level meter manufactured by Hi-Tech Instruments Limited. Attenuation model will be used to predict noise level during operation of project in the surrounding areas.
3.0 IDENTIFICATION OF SOURCES OF POLLUTION
3.1 Data Generation This includes the following: 47
Identifying the sources of pollution of air, water, land, noise and solid wastes; Quantifying the emissions from the pollution generating sources; and Quantification of solid wastes and likely disposal methods will be suggested.
3.2 Sources of Pollution in the Project Area
The likely sources of air and water pollution will be identified and quantified; The proposed pollution control measures envisaged in project area for fugitive dust, noise pollution and other environmental effects of each project activities will be assessed for their adequacy; The present and proposed changes in land use pattern will be identified; and Suitable green belt development plan will be prepared.
Based on various project activities, the likely impact on the environment attributes in project area will be identified by:
Estimating the air pollution levels for PM, SO2 and NOx in the study area during construction and operational activities; Estimating the source emissions for each project specific pollutants; Monitoring the source noise levels for all the noise generating sources; Predicting the impact of wastewater discharges; Determining the impact of construction activities (movement of construction material); and Studying the short-term and long-term affects on sensitive targets like endangered species, crops and historically/archaeologically important sites (if any).
4.0 ENVIRONMENTAL IMPACT ASSESSMENT
The proposed project may have some impacts on the environment. The parameters likely to be affected are air quality, water quality, soil quality; noise levels, etc. on account of gaseous emissions, liquid effluent discharges, resultant particulates, generation of solid wastes, etc will be discussed. The baseline data generated from the above studies will be analyzed and will be compared with applicable standards prescribed by the CPCB. By this means, the impact whether positive or negative will be assessed and the environmental attributes requiring special attention for mitigating the negative impact, if any, will be identified. Also the areas, which fulfill the prescribed environmental norms and not requiring further improvements, will be specified. Both short-term and long term impacts particularly on sensitive targets such as habitat of endangered species of wildlife or mines, crops, historically / culturally important sites / monuments, centers with concentrated population in the study area will be established. Impact of the stack emissions on terrestrial flora will be scientifically documented based upon species composition of the area and their air pollution tolerance levels. The impacts of project on various components of environment and the possible mitigation measures for mitigating the negative impacts were described in the following sections.
4.1 Impact on Land Use
Impact Assessment The land use impacts due to proposed project will be identified in terms of local land use planning efforts. The change in land use pattern of project site will also be identified. This includes visual impact, impact on forest, impact due to industrial growth and growth due to socio-economic factors. 48
Mitigation Measures
The mitigation measures will be addressed towards restoration of land disturbed by the proposed project activities to the extent possible.
4.2 Impact on Water Use
Impact Assessment
The impacts of the proposed project due to water usage and wastewater discharges will be addressed covering the following: Ground water quality degradation due to likely solid waste disposal and sewage disposal; Agricultural productivity; Habitat conditions; and Recreation resources and aesthetics.
Mitigation Measures
The mitigation measures will be addressed ensuring the present and anticipated future water requirements for various purposes. The measures also address the need to maintain or improve the existing Class of Water (as per IS: 10500) to ensure that the current/proposed uses are not impaired due to deterioration of the water quality.
4.3 Impact on Demography and Socio-Economics
Impact Assessment
On the basis of the compiled information and the proposed employment and other benefits to the people of the study area as well as others, the likely socio- economic impacts of proposed project in post-project scenarios for demography, facilities and services, agricultural sector, civic infrastructure and basic amenities, industrial sector, economic status and health status of people, etc will be assessed. Mitigation Measures
Strategies to mitigate the negative impacts of the project will be developed for areas where negative impacts are projected to occur. The potential actions considered will include both policy and planning actions. The roles of different bodies in mitigation measures will be identified.
4.4 Impact on Soil
Impact Assessment
Impacts on soil characteristics include destruction of soil profile, changes in soil productivity, increased erosion and subsequent loss of agricultural soils and land use changes. The impact assessment includes an analysis of susceptibility of the area to loss of agricultural production, change in crop pattern etc. Details on solid wastes from the proposed activity will be estimated. Impact assessment of disposal of solid waste will be addressed to the effect on human settlement, vegetation, ground water contamination etc. 49
Mitigation Measures
Based on analysis of soil data, mitigation measures will be proposed which will avoid, minimize or compensate for significant adverse impact on soil characteristics.
4.5 Impact on Water Quality
Impact Assessment
The assessment of potential impacts of the project will be carried out with respect to: o Ground water quality degradation; o Surface and river water quality degradation; o Agricultural productivity; o Habitat conditions; and o Recreation resources and aesthetics.
Mitigation Measures
Considering the dependence of the people in the area on surface or ground water as sources for drinking purposes, the prevailing quality and extent of contamination due to the proposed project activities, the mitigation measures will include and the treatment required for meeting the effluent discharge standards specified under the Environment Protection Rules and JSPCB will be addressed. The disposal arrangements will be conceptually indicated.
4.6 Impact on Meteorology
Impact Assessment
The climatological factors, which play an important role in the environmental analysis of the process of transportation, dilution and dispersion of pollutants, will be analyzed. Meteorological data will be collected to ascertain wind roses, atmospheric stability conditions and prevalence of inversion levels around the project site. This will enable to define the atmospheric conditions likely to prevail in the study area and use it as a basis for air quality modeling studies.
4.7 Impact on Ambient Air Quality
Impact Assessment
Emission inventory will be carried in the study area. A computer based internationally recognized mathematical air quality model (AERMOD) suitable for the region will be used to predict the concentration of SO2, NOx & PM due to the operation of the proposed plant. The results will be presented for short-term (24- hourly) concentrations in and around the project site. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area. The predicted air quality results will be compared with existing regulations.
Mitigation Measures 50
Potential mitigation measures include the control measures at the source level and providing adequate stack heights. The measures to control the fugitive dust emissions such green belt development and sprinkling will be suggested.
4.8 Impact on Noise
Impact Assessment
Sources of noise and its impact on the environment will be addressed. The noise level at varying distances for multi-sources will be predicted using noise model. A comparison of measured noise (Leq) at monitoring locations to that of predicted noise levels (Leq) will be made and mitigatory measures will be recommended to conform to regulatory ambient noise standards. Baseline noise levels in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc will be monitored. The potential noise level exposure will be determined and evaluate for acceptable limits of exposure.
Mitigation Measures
The potential mitigation measures will be addressed to reduce noise levels by control at source, provision of greenery to absorb noise during its propagation, isolation of high noise generating sources, use of protective measures especially in high noise areas.
4.9 Impact on Ecology
Impacts on aquatic species especially during dry season will be assessed particularly those which are endangered. The parameters, which are of concern, are TSS, TDS, heavy metals, oil and grease, pH and temperature. The assessment will also include impacts of chlorinated organic chemicals. The impact of site preparation activities involving site clearing, excavation, earth moving, dewatering or impounding water bodies and developing burrow and fill areas will be assessed. Recommendations will be made to mitigate such adverse impacts as soil erosion and habitat loss. In addition, impact of fugitive and stack emissions will be assessed on the surrounding species of economic/genetic/biological importance.
5.0 Environment Management Plan
An EIA report based on three months non-monsoon field data generation will be prepared for the purpose of getting clearance from MoEF&CC. EIA/EMP will be prepared based on one season data. The Environment Management Plan (EMP) will include all the mitigatory measures proposed under each significant environmental attribute. Further, a suitable greenbelt development plan for the project site will be included in the EMP report.
6.0 Disaster Management Plan and Occupational Safety
A Disaster Management Plan (DMP) for dealing emergency situation arising due to fire, explosion, leakages of hazardous substances, etc. in the project will be prepared. The plans include storage, handling, transportation etc. for the hazardous materials to be used in the proposed project. Occupational risk involved during construction and operation of the project will be assessed and necessary safety and
51
protective measures were spelt out. The DMP include both onsite and off site emergency preparedness plans.
7.0 Post Study Monitoring Plan
The Post Project Monitoring (PPM) plan will be prepared considering the following:
i. The proposed pollution control measures for air, wastewater and solid waste hazardous/non-hazardous) disposal;
ii. Waste minimization, wastewater management, waste reuse and resource recovery, waste segregation to make the treatment and disposal cost effective;
iii. The monitoring requirements for ensuring the statutory as well as process data is collected; and iv. The organizational / institutional set-up required for effective environment management plan implementation and post-project monitoring will be suggested along with the budgetary requirements.
52
PRE FEASIBILITY REPORT FOR THE PROPOSED 0.5 MTPA HOT METAL PLANT (PIG IRON) 3 MTPA PELLET PLANT NEAR DIMBULI VILLAGE, CIRCLE MANOHARPUR, WEST SINGHBUM DISTRICT, JHARKHAND STATE
Submitted to:
Ministry of Environment, Forest & Climate Change New Delhi
Submitted by:
M/s.Vedanta Limited (Formerly Sesa Sterlite Ltd) Goa
July, 2018 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
TABLE OF CONTENTS
Sr.No. Contents 1 Executive Summary 2 Introduction of the project 3 Project Description 4 Site Analysis 5 Project Brief 6 Rehabilitation and Resettlement (R&R) Plan 7 Project Schedule & Cost Estimates Figures Figures-1 Index Map Figures-2 Study Area Map Figures-3,4 Process Flow Sheet
2 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
1.0 Executive Summary
Sr. Description Details No. 1 Name of the Project Vedanta Limited proposes 0.5 MTPA Hot Metal (Pig Iron) Plant, 3MTPA pellet plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand 2 Location of the Plant Vedanta Limited is planning to set up a Greenfield project at Dimbuli Village, Circle Manoharpur, West Singhbum District, Jharkhand State. The Latitude and Longitude of the site are: Latitude: 22°21’41.9” to 22°22’32.56”N Longitude: 85°12’57.84” to 85°13’59.93”E 3 Total land requirement for the 439.09 acres Proposed project 4 Total Water requirement & The estimated make up water requirement Source for the project is 9000 m3/day which will be drawn from Koina river. Total water quantity is 3.3MCM annually. 5 Rehabilitation and Resettlement The land will be acquired as per the Right to Fare compensation and transparency in land acquisition, rehabilitation and resettlement act, Jharkhand rules. 6 Manpower Direct employment: 1500 Indirect employment:5000 7 Estimated Cost of the Project Rs. 1700 Crores 8 Total Power requirement & Power will be taken from grid. 30 MW Source (approx.) Waste Heat Recovery Power plant is proposed. Required power for plant operation is approx. 28 MW
3 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
2.0 Introduction of the Project/Background Information
2.1 Identification of Project and Project Proponent
Vedanta Limited, formerly known as Sesa Sterlite Limited (SSL)/ Sesa Goa Ltd, a Vedanta group company is one of the world’s largest global diversified natural resource majors, with operations in zinc-lead-silver, oil & gas, iron ore, copper, aluminium and commercial power.
2.2 Brief Description of Nature of the Project
Nature of the Project
The proposed project falls under Category-A, under section 3(A) as per the prevailing EIA Notification, dated 14th September 2006.
Size of the Project
The project cost for the proposed green field project is about Rs. 1700 crores and EMP cost is about Rs. 100 crores. The proposed green field project required 439.09 acres for installation of pellet plant, blast furnace, sinter plant, coke oven heat recovery and waste heat recovery power plant.
Vedanta Limited (Vedanta) is contemplating to establish a green field 0.5 MTPA hot metal plant (Pig Iron), 3 MTPA of pellet plant. The process for production of hot metal is based on blast furnace, sinter plant and coke oven plant. Vedanta is already having 0.832 MTPA pig iron manufacturing unit at Goa along with 1.0 MTPA sinter plant, 0.6 MTPA heat recovery coke plant & 60 MW waste heat recovery plant.
Location of the Project
The proposed project area is located at Dimbuli Village, Circle Manoharpur, West Singhbhum District, Jharkhand State.
2.3 Need for the Project and its Importance to the Country and Region
India is currently the 3rd largest producer of crude steel in the world. In 2016-17 (prov.), production for sale of total finished steel (alloy + non alloy) was 100.74 MT, a growth of 10.7% over 2015-16. Production for sale of Pig Iron in 2016-17 (prov.) was 9.39 MT, a growth of 1.8% over 2015-16. World Steel Association has projected Indian steel demand to grow by 6.1% in 2017 and by 7.1% in 2018 while globally, steel demand has been projected to grow by 1.3% in 2017 and by 0.9% in 2018.
India is expected to become the world's second largest producer of crude steel in the next 10 years, moving up from the third position, as its capacity is projected to increase to
4 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
about 300 MT by 2025. Scope for growth is offered by India’s comparatively low per capita steel consumption and the expected rise in consumption due to increased infrastructure construction and the thriving automobile and railways sectors.
Government has announced a policy for providing preference to domestically manufactured Iron & Steel products in Government procurement. This policy seeks to accomplish PM’s vision of ‘Make in India’ with objective of nation building and encourage domestic manufacturing.
Demand Supply, Gap/Export Possibility
The total production for sale of pig iron was 9.40 MT in 2016-17 as compared to 1.59 MT in 1991-92. Earlier, pig iron was produced primarily by the integrated public sector steel plants, SAIL and RINL. In contrast, the private sector accounted for 92% of total production for sale of pig iron in the country in 2015-16. Production for sale of pig iron for period 1991-92 to 2013-14 is given in Table-1.
TABLE-1 PRODUCTION SALE OF PIG IRON
Year Main Producer Major & Other Producers Grand Total 1991-1992 1.490 0.100 1.590 1992-1993 1.679 0.165 1.844 1993-1994 1.977 0.273 2.250 1994-1995 2.005 0.780 2.785 1995-1996 1.813 1.060 2.873 1996-1997 1.733 1.570 3.303 1997-1998 1.711 1.687 3.398 1998-1999 1.354 1.644 2.998 1999-2000 1.226 1.955 3.181 2000-2001 0.964 2.434 3.398 2001-2002 1.016 3.055 4.071 2002-2003 1.107 4.178 5.285 2003-2004 0.966 3.980 4.946 2004-2005 0.625 2.603 3.228 2005-2006 1.007 3.683 4.690 2006-2007 0.860 4.093 4.953 2007-2008 0.936 4.348 5.284 2008-2009 0.589 5.618 6.207 2009-2010 0.731 5.153 5.884 2010-2011 0.579 5.104 5.683 2011-2012 0.502 4.869 5.371 2012-2013 0.674 0.674 6.870 5 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
2013-2014 0.552 7.398 7.950 Source: Steel Authority of India
The demand of pig iron during 2011-12 emerges as about 6.0 MT. The production for sale of pig iron has increased from 1.6 MT in 1991-92 to 9.39 MT in 2016-17 (prov.).
Usage of Pellets in Steel making (Per thm) is increasing due to, decline in availability of good quality Iron Ore lumps & also to adhere to stringent pollution norms put in place by various governments. Global Pellet production capacity which was around 450 million tonnes during 2011 has already crossed 800 million tonnes by mid 2017.
TABLE-1 PELLET PLANT–GROWTH TREND
Year World Wide India Production (MTPA) Production ( MTPA ) 2011-2012 450 2012-2013 500 2013-2014 550 34 2014-2015 650 37 2015-2016 750 47 2016-2017 800 48.5
The domestic steel industry which primarily uses expensive lump ore, is gradually heading towards the usage of sintered ore and pellets. These pellets will cater to the export markets like China, Japan and Korea, besides the domestic iron and steel industry. The overseas markets are heavily dependent on imported iron ore to feed their blast furnaces and DRI (Sponge Iron) kilns. India’s steel production, is going to touch 120 MTPA from the current level of approx. 95 MTPA (growing at an average 8-10 per cent annually) primarily, owing to a rising need for infrastructure. Therefore, it is crucial that the fines generated in iron ore mining are utilized for steel production.
Pelletization in India, believe some industrialists, is forecast to achieve multi-fold growth, as India targets to achieve a capacity of 300 MT of steel by 2030. India’s pellet production capacity has the probability to cross three times of its present production capacity by 2030 which works out to a CAGR of around 9.3 %. The Table 3.7 gives the estimated forecast up to year 2030.
6 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Out of total domestic pellet pallet capacity it is estimated from the present trends that 20 % will be exported and the rest will be utilized indigenously.
National Steel Policy 2017 also gives due recognition to use of pellets in steel making and states:
“Impetus will be given to Pellet industry as it helps in mineral conservation by acting as direct feedstock in Blast Furnace in place of high grade iron ore”.
A mission mode is now imperative to convert the low grade iron ore fines, a byproduct of iron ore mining which hitherto were considered as a mining waste into pellets, which would help alleviate raw material shortage of steel makers to larger extent. There is a big potential in building pellet and beneficiation plants as mineral rich States are insisting on value addition to these huge iron ore fines as waste
Demand Analysis
The demand drivers are: Economic growth;
7 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Demand for water; Smart City, House for All Scheme, Urbanization; Improvement in water supply and sanitation coverage; Awareness on safety and hygiene; Investment by the Central and State Governments in Water and Sanitation schemes; Assistance from external agencies; Inter-linking of rivers; and Export potential
Indian economy is likely to achieve 8 plus percent in 2018-19 and to become fifth largest economy very soon. The outlook is very positive. India stands out as the fastest growing economy in world. The average consumer spending has increased significantly which has fuelled demand for quality infrastructure services like roads, electric power, transportation, water supply, sanitation, communication, etc. Import V/s Indigenous production
Although India started exporting steel way back in 1964, exports were not regulated and depended largely on domestic surpluses. However, in the years following economic liberalization, export of steel recorded a quantum jump. Subsequently, the rapid growth of domestic steel demand has led to a decline in the rate of growth of steel exports from India to ensure that domestic requirements are adequately met. Import of iron steel is given in Table-3. TABLE-3 IMPORT OF IRON STEEL
Year Pig Iron Total Finished Steel Total Value 1991-1992 152 970 1441.32 1992-1993 73 1143 1676.00 1993-1994 21 1119 1613.00 1994-1995 1 1775 2536.00 1995-1996 8 1617 3181.00 1996-1997 15 1632 3053.00 1997-1998 3 1648 2904 1998-1999 2 1194 N.A 1999-2000 3 1678 N.A. 2000-2001 2 1491 2659 2001-2002 2 1373 2560 2002-2003 1 1663 3051 2003-2004 2 1753 3728 2004-2005 8 2293 6244 2005-2006 3 4305 11585 2006-2007 3 4927 15747 2007-2008 11 7029 24977
8 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
2008-2009 8 5841 30509 2009-2010 11 7382 25983 2010-2011 9 6664 26996 2011-2012 8 6863 27017 2012-2013 21 7925 39347 2013-2014 34 5450 30525 2014-2015 23 9320 44994 Source: Steel Authority of India
9 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Employment generation (Direct and Indirect) due to the project
The proposed project will generate direct employment of approx. 1500 manpower including contract labour. It will provide new opportunities for local people also resulting in indirect employment of 5000 manpower. Training programs will be setup for the development of local community as per the work requirement.
3.0 Project Description
Type of project including interlinked and interdependent projects, if any
It is envisaged to establish a green field 0.5 MTPA hot metal plant pig iron, 3 MTPA pellet plant, at Dimbuli Village, Circle Manoharpur, West Singhbhum District, Jharkhand State.
Interlinked Project: Vedanta Limited proposed for 5.0 MTPA iron ore mines at Manoharpur Taluk, West Singhbhum District, Jharkhand State.
Location (map showing general location, specific location and project boundary & project layout) with coordinates.
The index map of the project site is shown in Figure-1 and a map showing 10 km around the project site is shown in Figure-2.
Details of alternative sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted.
The three sites were examined. Important features of these sites are given below:
Parameters Site–I Site -II Site -III Dipa Manoharpur Kharsawan Latitude 22°21’41.9” to 22⁰46'48"N 22⁰26'50.8"N 22°22’32.56”N Longitude 85°12’57.84” to 85⁰50'18"E 85⁰11'49.2"E 85°13’59.93”E
Village in the Vicinity Dimbuli village (0.7 km, Kharsawan (0.2 km, Dipa village (0.4 ENE) NNW) km,S) Bandiram Village(0.5 km, Baradungri (0.2 S) km, N) Didhsah Village Adjacent to plant
Distance from nearest Rourkela (40 km, WSW) City: Chaibasa (23.0km, Rourkela (41.0 city/town Chaibasa (61.0km, NE) S) km, SW) Town: Saraikela (12.6 km, SE) Elevation of the site, 220 MSL 200MSL 240 MSL above MSL Land availability (in 439.09 700.0 612.3 acres) Private/ Government Private and Government Private Private
10 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Parameters Site–I Site -II Site -III Dipa Manoharpur Kharsawan Agriculture land within Yes Yes Yes 1km Barren Single crop Barren Single crop Single Crop Double crop Forest Single Crop land Water body Koina River adjacent to Sanjoy River(6.0 km, S) Koel River(0.1 /Transmission line West boundary Sona Nala (0.2 km, N) km, NW) Koina Koel River(1.8 km, W) Khar Khai River (11.6 River (5.6 km, Karo River (10.4 km, E) km, SE) S) Karo River (4.4 km, NNE) Sapunala (0.9 km, NW) Road connectivity SH-4 Adjacent to site NH-149 (12.6km, SE) SH-4 (1.4 km, W) Rail connectivity Manoharpur(2.0 km, W) Mahali Murup(5.0 km, Posotia (5.1 km, SSW) E) Manoharapur (5.5km, S) Forests within 15 km There are 15 PF and 10 Chandil-Gamharia Forest There are 16 PF RF and 8 RF National parks & Nil Nil Elephant Wildlife sanctuaries Corridor exists Distance from Approx 25 Km Approx 40 Km Approx 140 Km proposed Iron ore mines
11 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Manoharpur r
FIGURE-1 INDEX MAP SHOWING THE PROJECT SITE
12 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
FIGURE-II STUDY AREA MAP 13 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Size or magnitude of operation
Production of 0.5 MTPA of pig iron and 3 MTPA of pellet at Dimbuli Village, Circle Manoharpur, West Singhbhum District, Jharkhand State.
Project description with process details
Blast Furnace and Related Facilities
The following has been considered for 0.5 MTPA Blast Furnace and related facilities:
A. 0.5 MTPA blast furnace B. Sinter plants to produce 1 MTPA of sinters required for the new blast furnace. C. Waste Heat Recovery Coke plant (~0.3 MTPA) and Power Plant (~30MW based on Waste heat of Coke plant and Blast Furnace gas)
A. 0.5 MTPA Blast Furnace:
It is proposed to install a Blast Furnace of 0.5 MTPA capacity in Manoharpur village Jharkhand.
This furnace will be a modern blast furnace equipped with hot blast stoves, bell less top, and pulverized coal injection including O2 enrichment.
B. Sinter Plant:
The availability of the calibrated iron ore lumps is becoming scarce; hence it is proposed to install sintering machines of adequate capacity along with the Blast furnace.
The advantages with the use of sinter is that, it improves the productivity of the blast furnace, lowers the coke rate, allows usage of low iron bearing material and low value coke breeze in the production.
C. Waste Heat Recovery Coke plant and Power Plant (based on waste heat of Coke plant and Blast Furnace gas):
To cater to the coke requirement of blast furnace it is proposed to add coke making capacity of 250,000 TPA with Sesa’s technology of heat recovery, which conforms to the most stringent environment norms worldwide.
The proposed power plant will have capacity of 30 MW and will utilize the waste heat from coke ovens and the excess gas available from the proposed 0.5 MTPA blast furnace.
14 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
The Flow sheet showing blast furnace and related facilities is given in Figure-3.
FIGURE-3 BLAST FURNACE AND RELATED FACILITIES
Technological considerations and plant facilities:
The Blast Furnace shall operate with sized iron ore, Sinter; self-produced coke, fluxes, and additives.
The blast furnace shall have the following major units:
A. Raw material storage yard, stock house, fines handling and main blast furnace charging conveyor B. Blast furnace proper and cast house C. Hot blast Stoves and Waste gas chimney D. Hot blast supply system including hot blast main, expansion joints, E. Bustle main & tuyere stock assembly F. Dust catcher and dust discharge equipment. G. Gas cleaning plant including its water system and sludge tanks and flare stack system H. Cast house slag granulation plant with its water system I. Dry slag pit J. Water cooling system for Blast Furnace and stove valves. K. Stock house de-dusting system, ventilation & air-conditioning system. L. Ladle repair shop M. Pig casting machine N. Instrumentation, automation and process control system O. Blower house and cold blast supply system, PCI P. Compressor, Utilities section, Water System, 15 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Q. Shop electrics & Illumination R. Hoisting and handling facilities S. Effluent & waste handling T. Drainage & sewerage U. Inter plant and pipelines for steam, BF gas, compressed air, Oxygen, Oxygen and Pulverized coal Injection. V. BF control room W. Auxiliary facilities like laboratory, stores etc.
Sinter Plant
Sintering is a process for agglomerating iron ore fines to convert it into lump form suitable for use in blast furnaces. However, sintering has an additional advantage, that it can recycle all ferrous bearing waste material generated in the plant.
The use of sinter is also beneficial as it reduces the coke rate and improves the productivity of blast furnace. However, in the current context apart from the cost saving a sintering plant also has strategic values inceit is expected that with the current growth rate of domestic steel production the availability of lump ore is likely to be constrained.
Thus the sintering plant would ensure a sustained availability of raw materials for blast furnace operations.
Iron ore fines cannot be charged into the blast furnaces since it will reduce the permeability of the burden material and will not allow the reducing gases to pass through the charge material inside the furnace. Blast furnaces need lump feed (preferably in a close size range) only so as to facilitate easy flow of gases through the charge material inside the furnace.
So there on ore fines need to be agglomerated either in the form of sinter or pellets before charging into the blast furnace.
The main advantages of sintering are:
Lower coke rate due to the saving in the heat requirement in the blast furnace since the calcinations of the fluxes take place in the sintering process outside the blast furnace and better reducibility of the charge material.
Higher productivity due to the improved burden permeability from the reduction in the height of cohesive zone.
Ability to recycle their on bearing waste from the plant, e.g., dust catcher fines, “return ore fines”, and low value coke breeze etc.
Pellet Plant & Related Facilities
The following has been considered for 3 MTPA pellet and related facilities:
A. Pellet plant
The pellet plant will make the iron ore concentrate into a product of oxide pellet. The capacity of pellet Plant will be 3.0 MTPA. On the basis of the technological considerations, selection of 16 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
processes for the proposed 3.0 MT/yr capacity iron ore pelletization complex is as indicated below:
1. Raw material storage and handling facilities, 2. Additive Grinding Additive bin storage and grinding in ball & roller mill 3. Mixing of feed materials 4. Balling for production of green balls 5. Induration including preheating and cooling. 6. Hearth layer separation unit 7. Intermediate Pellet stock pile (Single Boom Stacker System) 8. Wheel and boom Reclaimer for reclaiming of Pellets 9. Rapid Wagon Loading System 10. Truck Loading System 11. Process fans and Electro static precipitators (ESP) 12. Conveyors, Junction houses and Conveyor galleries 13. Plant dedusting facility 14. Water supply facility 15. Compressed air facility 16. Fuel facilities 17. Steam facility 18. Emergency power from DG set 19. Fire protection system 20. Chiller plant 21. Power distribution 22. Electrics 23. Instrumentation & Automation 24. Illumination & telecommunication 25. Air conditioning & Ventilation 26. Fire fighting pump house 27. Laboratory 28. Landscaping, Environment facility 29. Administrative & worker’s office building 30. Control room 31. Car and two wheeler parking shed 32. Roads and paved area 33. Drainage and sewerage
Process Details
The process of pelletization involves bulk handling and storage of raw materials - mainly iron ore fines, coal, limestone, dolomite, bentonite etc; preparation of raw materials by grinding and mixing with adequate moisture content; balling of the prepared mixture and hardening of the pellets in a specially designed furnace. The main plant facilities include additives grinding, mixing, balling, induration and product load out besides the auxiliary and service facilities. Process flow diagram is attached as Figure-4.
Raw material will be stored in storage area and will be sent to day bins/ storage bins using conveying system after processing which involves drying, grounding etc. The materials will be mixed in controlled way in mixing machine for proper mixing before sending it to balling unit.
17 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
The mixed material is conveyed and distributed to mixed material bins which are installed directly above the pelletizing discs. The charging of these bins is done automatically in accordance with a pre-set time schedule. A control loop, governed by the filling degree of the bins is superimposed on this schedule for determining the direction of feed. This bins filling degree is measured by load cells. Belt weigh feeders will be provided at the outlet of each bin to draw out required quantity of material. The material discharged from each mixed material bin is effected by a vibrating mouth and controlled by a weigh feeder which is equipped with a variable speed drive, thus feeding the adjusted amount of mixed material onto the palletizing discs. Bag filters will be used for controlling dust emission.
The mixed material will be continuously discharged from the bins and fed to balling discs by means of flutters. The flutter has two functions, namely, the disintegration of any compacted material as well as the distribution of the mixed material on the balling disc. Controlled quantity of water shall be added to the balling discs to adjust the final moisture content of the green balls. Green pellets are formed on the disc. The discs are provided with variable speed drive and controlled water spray to aid and control green ball formation. The green pellets produced are discharged onto the green pellet collecting belt conveyor. This belt conveyor ensures smooth handling of the green pellets. A weigher is installed in this belt for weighing the total amount of green pellets discharged from the pelletizing discs, which is one of the parameters for the indurating machine speed control. The green pellets from above belt conveyor are discharged to double deck roller feeder (screening unit) through series of reversible and wide conveyors.
Green balls (green pellets) will be indurated on a traveling grate indurating machine. The traveling grate indurating machine consists of an endless chain of pellet cars moving on tracks. One of the process prerequisites for obtaining a uniform product quality is a uniform bed height which is ensured by automatic control of the grate speed as a function of the green pellets feed rate by a series of ultrasonic level sensors. A grate bar cleaning device is located near the lowering station on the return track of the travelling grate. To avoid thermal shocks to grate bars, green pellets are charged over a layer of indurated pellets, called 'hearth layer’. Pallet sidewalls (both sides) are also protected from excessive heat, with indurated pellet called 'side layers'. The three feed components are charged onto the pallet cars in the following order. First, hearth layer is fed onto the indurating machine followed by simultaneous feeding of side layers (both sides) and green balls onto the pallet car that has already been loaded with hearth layer earlier. Green pellets are subject to the following thermal zones during the process of induration: - Up draught drying zone (UDDZ) - Downdraught drying zone (DDDZ) - Preheating zone (PHZ) - Firing (induration) zone (FZ) - After firing zone (AFZ) - Up draught cooling zone I (UCZ-I) - Up draught cooling zone II (UCZ-II)
Following drying of green pellets in the updraught and downdraught drying zones, the dried pellets will be preheated to a progressively higher temperature to initiate 'artificial magnetite oxidation' and sulphur, burning due to coke breeze present in the mix. The pellets will then be fired at approx. 1300°C to provide the recrystallization and slag bonding which will impart adequate strength to the pellets, an unfired short section designated as 'after firing' allows the heat front to completely penetrate into the bottom of the bed thereby eliminating sudden quenching of pellets and consequent deterioration of properties. Cooling of indurated pellets 18 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
will be accomplished by up draughting ambient air through the pellet bed supplied by a cooling air fan. The cooled pellets will leave the indurating machine at 100°C or less.
The induration process is characterized by maximum recovery of heat from the cooling zone as well as firing zone of the traveling grate machine. This calls for recirculation of hot gases through ducts to different process zones using fans. Process fans mainly cooling air fan, updraft drying fan, wind box recuperation fan, hood exhaust fan, wind box exhaust fan, hood sealing fan and combustion air fan will be used for channeling of process gas.
The indurated and cooled pellets are discharged from the indurating machine on to a product conveyor through a product discharge bin/two vibrating feeders. This belt conveyor discharges product pellets into a hearth layer (HL) separation bin, having two outlets each equipped with a gate & vibrating feeder which is controlled by the discharge bin level. From one bottom outlet, the amount of pellets required as hearth & side layer are discharged by a vibrating feeder, controlled by the level of hearth layer bin. HL shall be transported by a series of belt conveyors to hearth & side layer bin above the feed end of indurating machine. From the other outlet of hearth layer bin, product pellets are discharged for transportation to the pellet stock pile. The pellet production is measured by means of a belt weigher installed on the outgoing product conveyor.
Final product will be stored at product storage area and will be dispatched. All other facilities for air, fuel, water, utilities, safety will be used for smooth & safe operation of process.
19 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
FIGURE-4 PROCESS FLOW DIAGRAM FOR PELLET PLANT
20 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Raw material required along with estimated quantity likely source, marketing area of final products, mode of transport of raw material and finished product.
Raw material details for hot metal plant are given below:
Sr.No Raw Material At Sinter Source Mode of Requirement Feed(90%)MT Transport 1 Iron ore fines 730,000 Mine Truck/Rail/ Conveying system 2 High grade 90,000 Mine Truck/Rail/ Conveying lumps system 3 Limestone 68,500 Jharkhand/Orissa/Chhattisgarh Truck/Rail 4 Dolomite 69,000 Jharkhand/Orissa/Chhattisgarh Truck/Rail 5 Coking coal 400,000 Australia/China/South Africa Ship 6 PCI coal 60,000 Australia/China/South Africa Ship 7 Quartz 5,000 Jharkhand/Orissa/Chhattisgarh Truck/Rail
Raw material details for pellet plant are given below:
Sr.No Raw Material Quantity (MT) Source Mode of Requirement Transport 1 Iron ore 3,000,000 Mine Truck/Rail/ Conveying system 2 Limestone 45,000 Jharkhand/Orissa/Chhattisgarh Truck/Rail 3 Dolomite 45,000 Jharkhand/Orissa/Chhattisgarh Truck/Rail 4 Bentonite 24,000 Jharkhand/Orissa/Chhattisgarh Truck/Rail 5 Coal ( 52,500 Australia/China/South Africa Ship Anthracite/Cok e breeze) Resources optimization/ recycling and reuse envisaged in the project, if any should be briefly outlined.
Solid Waste
The solid wastes to be generated from the blast furnace unit are:
Slag: In processes of iron making slag is generated and will be granulated using high pressure water jets and sold to cement plant as a raw material for producing high quality cement.
Dust from dust catcher: Flue dust generated in the dust catcher of gas cleaning system will be used as raw material in the sinter plant for making sinter.
Dried Sludge of gas cleaning settling tank: Dried sludge of effluent treatment plant will be used as raw material in the sintering plant for making sinter.
Ore & Coke fines: Ore and coke fines generated in handling raw material and dust extraction system will be used in the sintering plant for making sinter.
21 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Liquid waste
There are no liquid effluents in blast furnace unit as all process water is suitably treated and recycled.
Used oil of the equipment’s in the plant will be collected & disposed to the authorized recycler as used oil, a hazardous waste under hazardous waste management & handling rules, for which the authorization will be obtained from regulatory authority.
Availability of water its sources, Energy/power requirement and sources should be given
Water Requirement
Water Requirement for the proposed project is given below-
Sr. No Details Re-circulated water Make Up Total make (m3/hr) water up (m3/hr) (m3/day) 1 pellet plant 7700 200 4800 2 pig iron 4300 160 3840 3 drinking water & 15 360 sanitation for 1500 persons along with plantation & gardening. Total 9000
22 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Make up water requirement is 9,000 Cum/day. Required 3.3 MCM per annum water for the proposed plant shall be met in required quantity from neighboring river Koina.
Power Requirement
A 30 MW Waste Heat Recovery Power plant is proposed, which will be located adjacent to coke oven batteries. the plant is expected to operate at a plant load factor of 70%. The Plant will use closed cycle water system.
It is proposed to utilize blast furnace and coke oven gases as a fuel for boiler. Approximately 28 MW of generated power will be utilized.
Plant will be connected through electric grid for power requirement.
Schematic representations of the feasibility which give information of EIA purpose.
Detailed schematic representations of the feasibility covering the purpose of EIA will be given in the Environmental Impact Assessment report.
4.0 Site Analysis
Connectivity
Public Road: The proposed site is located on state highway SH-4.way SH-4. The proposed plant site is approx. 40 km from Rourkela.
Manoharpur railway station is at a distance of 2.0 km and Rourkela airport is at a distance of 42 km from the project site.
23 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Land form, land use and land ownership/
The total land requirement for the proposed project would be 439.09acres. The area is fairly flat. The land is mostly un irrigated, wasteland and single crop. The area proposed for the project has been identified excluding the habituated area and also the forest area. Break-up of the current land use for the proposed plant is given below: Government land: 41.01 acres Private land: 398.08 acres Total area: 439.09 acres Government of Jharkhand vide letter no 05/U.Ni (MoU/Vedanta Ltd)-31/2015 dated 22 Nov 2017 has confirmed to MoEF&CC that the 439.09 acres of land is under process of acquisition/allotment/transfer to Vedanta Limited. This land is being transferred for industrial purpose.
Topography
General topography of site is flat with minor undulating terrain. The elevation of the project site is about 220 m above msl.
Existing Infrastructure
The proposed project is green field, no infrastructure exist in the proposed site.
5.0 Planning Brief
Plant facilities to produce 0.5 MTPA of hot metal and 3 MTPA of Pellet plant, will be installed. There will be temporary housing sites for the construction workers and construction officers with in the plant site area
Land use planning (break up along with greenbelt etc)
The proposed project is located in an area of 439.09 acre. The land break up details is given below: TABLE-2 LAND USE BREAKUP
Sr. No Particular Area in 1 Road,Rail 30Acr es 2 Water storage 60 3 Raw material storage 40 4 Green belt 145 5 Process units including ancillary and auxiliary 100
6 Administrative complex 9.09 7 Wagon Loading 10 8 Free Area 45 Total 439.09
24 Pre- Feasibility Report for the Proposed 0.5 MTPA Hot Metal Plant (Pig Iron), 3 MTPA Pellet Plant at Dimbuli Village, Manoharpur Taluk, West Singhbhum District, Jharkhand
Assessment of Infrastructure Demand (Physical & Social)
Vedanta proposes to establish a green field 0.5MTPA hot metal plant Pig iron and 3 MTPA pellet plant at Dimbuli Village, Circle Manoharpur, West Singhbhum District, Jharkhand State.
Hence, all infrastructures facilities will be provided for the proposed project. The road facility is already available which shall be strengthened and maintained. Infrastructure facilities like road transport, rail transport, Post & Telegraph, Telephone, Banks etc. are basics for each and every area. These facilities already exist in the surrounding area.
With the start of proposed project, various employment opportunities will be generated. Several persons will be benefited with contract works, employment through contractor, canteens, different kind of shops and transport related business avenues. Skill development, social awareness, self help groups, improvement in education & health sector will be carried through various CSR programmes. It will help in uplifting social and financial position of local people.
6.0 Rehabilitation and Resettlement (R&R Plan)
The land will be acquired as per the Right to Fare compensation and transparency in land acquisition, rehabilitation and resettlement act, Jharkhand rules.
7.0 Project Schedule and Cost Estimates
The proposed project will be commenced after getting prior permissions from MoEF and State Govt. competent authorities.
It is scheduled to complete the construction of the proposed project within 18 months to 24 months from the zero date.
Estimated cost of the project is Rs.1700 Crores.
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