RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

CHAPTER – 1 INTRODUCTION

1.1 BACKGROUND

M/s ILC Industries Ltd. (ILC) proposes to set up Mini Steel Plant of 0.2 MTPA capacity with Captive Power Plant of 12 MW near village Kunikere, Tq. & Dist. Koppal in Karnataka State. The Project has received High Level Committee Clearance from Karnataka Udyog Mitra, a Government of Karnataka Organization.

M/s ILC has retained Remedy Environmental Consultants, Bellary for carrying out the proposed Rapid Environmental Impact Assessment (REIA) studies and to obtain Environmental Clearance from Ministry of Environment and Forests (MoEF) and Karnataka State Pollution Control Board (KSPCB) as per the revised EIA notification 2006.

In accordance with the EIA 2006 notification, Form-I along with draft Terms of References (TOR) for EIA report and Pre-Feasibility report of the project submitted to MoEF to determine the comprehensive TOR for the project. Draft Terms of Reference (TOR) have been discussed and finalized during the 86th Meeting of the Expert Appraisal Committee (Industry) held during 20th-22nd October 2008. MoEF has accorded TOR clearance for preparation of EIA report and the same enclosed as Annexure-I with compliances. Based on this TOR, EIA report is prepared.

1.2 LOCATION OF THE PROJECT

The location details and environmental setting around the proposed project site is given in Table-1.1.

Table-1.1: Location Details of Project Site

Sr. No. Particulars Details 1 Latitude 150 18‟ North 2 Longitude 760 13‟ East 3 Elevation above MSL 500 m 4 (a) Climatic conditions Annual Max. Temp: 41.5 oC (IMD, Bellary) Annual Min. Temp: 10.7oC Annual total rainfall: 470 mm 4(b) Climatic conditions Max. Temp: 41.0oC (At the site, during the study Min. Temp: 19.4oC period of Summer 2007) 5 Present land use at the Barren land proposed plant site 6 Nearest highway National Highway-13 at a distance of about 5-km on North side. 7 Nearest railway station Ginigera on South Central Railway at 5 km on North – North East side. 8 Nearest airport Bangalore about 400 km in South East side. 9 Nearest villages Hirebagnal (1.8 km, ENE); ILC Industries Ltd. 1

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Sr. No. Particulars Details Kunikere tanda (2.3 km, WSW); and Kunikere (2.8 km, SW) 10 Nearest Town Koppal (9 km, NW) 11 Water Body Tungabhadra reservoir (2-3 km S) Tungbhadra Left Bank Main Canal (8 km, SE-NE) 12 Water Pond Near Kunikeri (2.8 km, SW) Ginigera (5 km, NNE) Basapur (5 km, NNW) 13 Other Features Rocky boulders, rocky knobs, sheets rocks scattered all over 14 Ecologically sensitive zones No wild Life sanctuary and National Park within 25 km radius. 15 Forest None within 10 km 16 Historical places None within 10 km

The study area to study various environmental attributes is defined as the area within 10 km radius with proposed site as center. The index map of site is depicted in Figure-1.1 while study area map in Figure-1.2.

With respect to the siting criteria for Sponge Iron Plants specified by Central Pollution Control Board (CPCB), following observations has been made:

Sr. No. Parameter Observation 1. Forest land/ ecologically and/or Tungabhadra Reservoir is located 2-3 km in otherwise sensitive areas within 7 S direction of project site. km zone 2. Nearest habitation/village Hirebagnal village at 1.8 km from the site 3. National Highway NH-13 at 5 km from the project site 4. Existence of 1000 TPD plant --- within 10 km radius

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Figure 1.1: Index Map of the Project Site

Proposed Site

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

1.3 MARKET POTENTAIL

The future steel demand and supply situation has been reviewed on the basis of available information as presented in various reports such as the Report of the Working Group on Iron and Steel Industry for the Eleventh Five Year Plan, October 2006, Ministry of Steel and Mines, Government of India.

1.3.1 Future Steel Demand

Projections of the steel demand have been made by various agencies from time to time. The projections made by the Working Group on Iron and Steel Industry for the 11th Five Year Plan had indicated a total domestic finished steel demand in 2007-08 of about 50 million tons which is expected to increase to around 70 million tons by 2011-2012 as shown below:

Projected Demand of Finished Steel (‘000 Tons)

Sr. No Product 2007-08 2010-11 A Long products Bars and rods 16114 22017 Structural 3900 4750 Railways materials 1870 2180 Total (A) 21884 29037 B Flat products Plates 4000 4802 HR coils/sheets 14676 22823 CR coils/sheets 4800 6085 GP/GC sheets 2750 4500 Electrical sheets 400 460 Tinplates 280 300 Total (B) 26906 38970 C Large dia. pipes 1500 2340 Total (A+B+C) 50290 70347 (Source: Report of the Working Group on Iron and Steel Industry for the Eleventh Five Year Plan, October 2006, Ministry of Steel and Mines.).

1.3.2 Anticipated Availability

Taking into consideration the on-going and sanctioned modernisation/ expansion schemes of the integrated steel plants, and allowing for suitable capacity augmentation of the secondary steel-producing sector, the total availability of finished steel by 2007-08 is estimated as around 47 million tons and by the end of the eleventh plan period that is by 2011-12 it is estimated at about 77 Million Tons as given below:

Anticipated Availability of Finished Steel (‘000 tons)

Sr. No Product 2007-08 2011-12 A Long products Bars and rods 15800 26200 Structural 4300 8600 Railways materials 1000 1300 ILC Industries Ltd. 4

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Sr. No Product 2007-08 2011-12 Total (A) 21100 36100 B Flat products Plates 2500 4000 HR coils/sheets 12300 21600 CR coils/sheets 4800 5500 GP/GC sheets 4600 7500 Electrical sheets 200 300 Tinplates 300 500 Total (B) 24700 39400 C Large dia pipes 900 1900 Total (A+B+C) 46700 77400 (Source: Report of the Working Group on Iron and Steel Industry for the Eleventh Five Year Plan, October 2006, Ministry of Steel and Mines.)

1.3.3 Likely Demand-Supply Gap

The above analysis suggests that the country is unlikely to face serious shortages of crude/finished steel for domestic consumption over the period under consideration that is up to the eleventh five-year plan terminal year of 2011-12. During 2007-08, conditions of domestic production of finished steel appear to be a little tight under the current assumptions of low capacity utilization in some of the sub-sectors made in the supply projection exercises. However, it is expected that a fuller and better utilization of the existing capacity, especially in the secondary sector will take care of periodic tightness in supply in the very short run. At the overall level, the projected production will also be able to accommodate possible exports from India. However, for certain categories such as Hot –Rolled Coils and sheets/Plates and Electrical Steel Sheet there may be some deficit of domestic supply primarily due to quality mismatch.

The expected outlay on the dedicated freight Corridor in railways may lead to some shortage of supply, given the current production intentions. However, it may be noted that category wise gaps may not be a cause of worry in the medium term (i.e., 6 years) as the producers have the time and the technological flexibility needed to align their rolling plan and facilities to market conditions.

1.3.4 Apparent Consumption of Bars and Rods

The apparent consumption of bars and rods during the last five years is furnished below:

Apparent consumption of bars and rods (In ‘000 tonnes)

Year Bars & rods Light structural Consumption % growth over Consumption % growth over previous year previous year 2002-03 10180 - 2289 - 2003-04 10614 4.2 2943 28.5 2004-05 11773 10.9 3026 2.8 2005-06 13273 12.7 3509 15.96 ILC Industries Ltd. 5

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Year Bars & rods Light structural Consumption % growth over Consumption % growth over previous year previous year 2006-07 14747 11.1 3785 7.86 (Source: Indian Iron and Steel Statistics – Steel Scenario Year Book)

The average annual growth rate in consumption of bars & rods which was 4.26% during 2003-04 has progressively increased in the last few years and the average growth rate since 2004-05 has been over 10% which is expected to continue in the coming years due to the overall growth in the GDP and growth of the infrastructure. The above growth is expected to continue in future.

The availability of bars and rods from domestic producers is not expected to increase substantially during the next few years as most of the existing units are producing almost at their rated capacities. This is more so in the southern states. Hence it is expected that the demand supply gap will be substantial by the end of FY 2008-09 when the proposed plant of ILC is scheduled to go into production.

In addition to the above domestic supply – demand scenario, India is exporting a substantial quantity of steel products to neighboring countries in the far and Middle East. In the year 2006-07 the total export of bars and rods and structural were around 4 lakh tons.

Considering the above domestic and export prospects, marketing 60,000 Tons of bars and rods to be produced in the proposed complex is not expected to pose any serious problem.

1.3.5 Product – mix

The foregoing analysis shows that a substantial shortfall exists in the categories of long products, both in the form of bars and rods and structural products to meet the demand of the construction industry.

Hence, it is proposed to install a bar and rod mill for producing bars and rods of mild steel in the size range of 8 mm to 32 mm. The sizes and quantities to be rolled will be kept flexible and decided on market demand. A thermo mechanical treatment line will also be installed to produce good strength TMT construction grade bars and rods.

It is to be noted that the above product-mix is primarily intended for evolving the overall project parameters. The actual product-mix of the mill would have to be evolved based on the market requirements that are likely to prevail at the time when the mills goes into operation.

1.3.6 Suggested Plant Capacity and Plant Flow Sheet

Considering the supply-demand gap for long products as discussed above and considering the economic sizes of various production units, a total plant production capacity of 150,000 tons/year is planned. The flow sheet for the plant is given in drawing no. HIQ-3054-02-01 enclosed.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

1.4 ADMINISTRATIVE & LEGISLATIVE BACKGROUND

The principal Environmental Regulatory Agency in India is the Ministry of Environment and Forests (MoEF), New Delhi. MoEF formulates environmental policies and accords environmental clearance for the projects.

As per the latest Notification of the MoEF dated 14.09.2006, new project, expansion or modernization of any activity shall not be undertaken in any part of India unless it is accorded environmental clearance by the central government in accordance with the procedures specified in this Notification. As per the procedure, anybody who desires to undertake any project in any part of India or expansion or modernization of any existing industry, a detailed project report, which shall inter alia include an Environmental Impact Assessment (EIA) report, needs to be submitted. Accordingly, this EIA report for the proposed plant of ILC has been prepared for the perusal of MoEF/KSPCB to judge the environmental viability of the project.

Many State and Central legislation have a bearing on environment but laws on "environment protection" have been notified recently. These laws can be broadly classified in terms of focus areas viz.

• Pollution; • Natural resources; and • Linkage between pollution and natural resources.

The status of key environmental legislations in India relevant to the proposed project is given below: a) New EIA Notification of 14 September 2006 (“EIA 2006”); b) Air (Prevention and Control of Pollution) Act, 1981, as amended in 1987; c) Water (Prevention and Control of Pollution) Act, 1974 as amended in 1978 and 1988; d) Water (Prevention and Control of Pollution) Cess Act, 1977 as amended in 1991; e) Public Liability Insurance Act, 1991; f) Indian Factories Act, 1948 (As amended by Act 20 of 1987); and g) Manufacture, Storage and Import of Hazardous Chemicals, Rules, 1989, MoEF, as amended in 2000. h) Noise (Prevention & Control of Pollution) Rules, 2000

The MoEF is the nodal agency to set policy and standards for the protection of environment along with CPCB. This includes air, noise, water and hazardous waste standards.

Relevant standard for proposed sponge iron plant specified by CPCB are briefed below:

1.4.1 Stack Emission Standards

Particulate matter (PM) : 100 mg/Nm3 (Coal based) 50 mg/Nm3 (Gas based) Combustion efficiency (CE) : shall be atleast 99.9% and of After Burner Chamber (ABC) be computed as below: CE=%CO2/[%CO2+%CO]*100

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

(i) The Kiln off gas stack height should be calculated for proper dispersion of SO2 (with 0.3 the formula of H= 14Q . Where Q= emission of SO2 in kg/h) as per emission regulations Part III of CPCB. Sulphur percentage shall be the percentage of sulphur in coal. The stack height in no case should be less than 45 m. Sampling Portholes and Platforms etc shall be provided as per CPCB regulation.

Adequately designed ESP or Bag Filter or Wet scrubbing system or any other adequate air pollution control system/combination of system should be installed to achieve the prescribed stack emission standards*.

* As installation and operation of Pollution Control Equipment for plants with less than 100 TPD capacity is not economically viable, therefore, it is recommended that plants with less than 100 TPD (total capacity) shall not be permitted in future.

Program for phasing out old plants having capacity less than 100 TPD shall be worked out.

(ii) All Pollution control equipment should be provided with separate electricity meter and totaliser for continuous recording of power consumption. The amperage of the ID fan should also be recorded continuously. Non-functioning of Pollution control equipment should be recorded in the same logbook along with reasons for not running the Pollution Control Equipment (iii) The safety cap/emergency stack of rotary kiln type plant, which is generally installed above the After Burner Chamber (ABC) of feed end column, should not be used for discharging untreated emission, bypassing the air pollution control device.

(iv) In order to avoid bypassing of emissions, interlocking facility should be provided to ensure stoppage of plant if safety cap of the rotary kiln is not in operation.

1.4.2 Stack Emission Standards from de-dusting units

Particulate matter (PM): 50 mg/Nm3

All de-dusting units should be connected to a stack having a minimum stack height of 30 m. Sampling porthole and platform etc. shall be provided as per CPCB emission regulation to facilitate stack monitoring. De-dusting units can also be connected to ABC Chamber and finally emitted through common stack with kiln off-gas emissions.

1.4.3 Fugitive Emission Standards

The fugitive emissions of suspended particulate matter (SPM) should not exceed 1000 µg/m3 at a distance of 10 m (approx.) from the sources, identified and mentioned below, where fugitive dust emissions are anticipated. The measurement may be done, preferably on 8-hour basis with high volume sampler. However, depending upon the prevalent conditions at the site, the period of measurement can be reduced.

Sr. No. Area Monitoring Location 1. Raw material handling Wagon tippler, Screen area, Transfer Points, Stock area Bin area 2. Crusher area Crushing plant, vibrating screen, transfer points 3. Raw material feed area Feeder area, Mixing area, transfer points ILC Industries Ltd. 8

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Sr. No. Area Monitoring Location 4. Cooler discharge area Over size discharge area, Transfer Points 5. Product processing Intermediate stock bin area. Screening plant, area Magnetic Separation unit, Transfer Points, Over size discharge area, Product separation area, Bagging area 6. Other areas Areas as specified by State Pollution Control Board

1.4.4 Effluent Discharge Standards

(a) All efforts should be made to reuse and re-circulate the water and to maintain zero effluent discharge.

(b) Strom water / garland drain should be provided in the plant.

(c) In case of maintenance/ cleaning of the system the settling tanks effluent of wet scrubbing system or re-circulation system is required to be discharged, it should be treated suitably to conform to the following standards. pH - Between 5.5 to 9.0 Total Suspended Solids (TSS) - 100 mg/l Chemical Oxygen Demand (COD) - 250 mg/l Oil and Grease (O&G) - 10 mg/l

1.4.5 Noise Levels Standards

Noise level 6.00 AM- 10.00 PM 10.00 PM-6.00 AM at plant boundary Leq 75 dB (A) Leq 70 dB (A)

1.4.6 Solid Waste Management

1. Char Char should be mixed with coal or coal washery rejects and used as fuel in Fluidized Bed Combustion Boilers (FBC) for generation of power. The plants having capacity more than 100 TPD should install Fluidized Bed Combustion Boilers (FBC) for generation of power. Also the smaller capacity individual Sponge Iron Plants (Capacity upto 100 TPD) and operating in cluster can collectively install common Fluidized Bed Combustion Boilers (FBC) for power generation. The Sponge Iron Plant is free to explore other options / possibilities to use char for generation of power. Char can be sold to local entrepreneurs for making coal briquettes. It can also be mixed with coal fines, converted to briquettes and used in brick kilns.

Under no circumstances char should be disposed off in agricultural fields/other areas. Logbook for daily record, of Char production and usage must be maintained by the industry and the record shall be made available to officials of CPCB/SPCB/PCC during inspection.

2. Kiln Accretions The kiln accretions are heavy solid lumps and can be used as sub- base material for road construction or landfill, after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

3. Gas Cleaning Plant (GCP)/Scrubber Sludge The sludge should be compacted and suitably disposed off after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact.

4. Flue Dust / Fly ash Flue dust is generated from air pollution control system i.e. ESP or any other air pollution control system installed with kiln. Secondary flue dust is also generated from Bag Filters or any other air pollution control equipment installed with Raw Material Handling, Coal Crusher, Cooler Discharge and Product house unit. The reuse/ recycling of the flue dust generated / collected may be explored and suitably implemented.

Fly ash brick manufacturing plant should be installed for fly ash utilization. Fly ash can be utilized in cement making by Cement industry also.

5. Bottom Ash Bottom ash may have objectionable metallic compounds, therefore should be stored in properly designed landfills as per CPCB guidelines to prevent leaching to the sub-soil and underground aquifer.

1.5 SCOPE OF THE STUDY

The study covers zone of 10 km radius area with the proposed plant site as the center. The scope of study broadly includes:

To conduct literature review to collect data relevant to the study area; To undertake environmental monitoring so as to establish the baseline environmental status of the study area; To identify various existing pollution loads due to industrial activities in the ambient levels; To predict incremental levels of pollutants in the study area due to the proposed sponge iron plant project; To evaluate the predicted impacts on the various environmental attributes in the study area by using scientifically developed and widely accepted Environmental Impact Assessment Methodologies; To prepare an Environmental Management Plan (EMP) outlining the measures for improving the environmental quality and environmentally sustainable development; To identify critical environmental attributes that required to be monitored; and To prepare Disaster Management Plan (DMP)

The literature review includes identification of relevant articles from various publications, collection of data from various government agencies and other sources.

1.6 METHODOLOGY OF THE STUDY

Reconnaissance survey was conducted collectively by the environmental consultant. All the sampling locations for monitoring various environmental parameters were identified based on this survey while considering the following aspects:

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Predominant wind directions in the study area as recorded by India Meteorological Department (IMD) at Bellary; Existing topography; location of surface water bodies like ponds, canals and rivers; Location of villages/towns/sensitive areas; Accessibility, power availability and security of monitoring equipment, pollution pockets in the area; Pollution pockets in the area; Areas which represent baseline conditions; and Collection, collation and analysis of baseline data for various environmental attributes.

The field observations are used to:

Set up air quality models; Identify extent of negative impacts on community/natural resources; and Identify mitigation measures and monitoring requirements.

The study also provides framework and institutional strengthening for implementing the mitigation measures. Field studies were conducted during March - May 2008 to cover the pre monsoon season, which will determine existing conditions of various environmental attributes as, outlined in Table-1.2.

Table-1.2: Environmental Attributes and Frequency of Monitoring

Sr Attribute Parameters Frequency of Monitoring No 1 Ambient Air Quality TSPM, RPM, SO2, NOX and Locations: 8 nos. CO SPM, RPM, SO2 and NOx - One 24 hourly sample CO - Three 8 hourly samples 2 Meteorology Wind speed and direction, Primary data: Continuous temperature, relative humidity during study period with and rainfall hourly recording at the plant site.

Secondary data collection from IMD station Bellary 3 Water Quality Physico-Chemical, Biological Sampling at 8 locations for parameters and Heavy Metals surface and ground water quality once during the study period. 4 Ecology Existing terrestrial and aquatic Based on the data collected flora and fauna in 25 kms from secondary sources. radius 5 Noise Levels Noise levels in dB(A) Continuous recording at 6 locations for 24 hours per location during study period 6 Soil Characteristics Parameters related to Once during the study Agricultural and afforestation period at 6 location potential ILC Industries Ltd. 11

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED

MINI STELL PLANT ( 0.2 MPTA) WITH CPP (12 MW)

Sr Attribute Parameters Frequency of Monitoring No 7 Land Use Land use for different Based on Satellite Imagery categories. 8 Socio – Economic Demographic Pattern, Based on the data collected Aspects occupational structure, health from the secondary status etc., sources(2001) 9 Geology Geological history, major Based on the data collected features from the secondary sources 10 Hydrology Drainage area and pattern Based on data collected aquifer characteristics, from secondary sources. recharge and discharge area

1.7 EIA Report Format

The present report is based on compilation of the baseline data generated as above, a description of the production process, assessment of impacts on environmental attributes, preparation of environment management plan and disaster management plan. The contents of the report have been organized in following six chapters:

Chapter-1 - Introduction This chapter provides background information of the project, brief description of the area, market trend & significance of the project and scope and organization of the study.

Chapter-2 - Project Features This chapter deals with the manufacturing process, requirement of major consumables and sources of pollution including proposed control measures.

Chapter-3 - Baseline Environmental Status This chapter presents the methodology and findings of field studies undertaken and data collected from other agencies with respect to meteorology, ambient air, water, soils, noise levels, ecology, land use, socio-economics, geology and hydrology.

Chapter-4 - Impact Assessment This chapter deals with the assessment of impacts envisaged due to proposed project on various environmental attributes.

Chapter-5 - Environment Management Plan (EMP) This chapter provides environment management plan aimed at minimising the adverse environmental impacts due to proposed project. Monitoring programme of various environmental attributes has also been included.

Chapter-6 - Risk Assessment and Disaster Management Plan This chapter deals with possible hazards and risk analysis from the existing plant. This also includes quantification of risks, disaster management plan including on-site and off-site management plan and occupational health and safety.

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COMPLIANCES TO TOR RECEIVED FROM MoEF FOR PROPOSED MINI STEEL PLANT OF M/s ILC INDUSTRIES LTD.

Sr. No. TOR by MoEF Compliance 1 Present land use should be prepared Incorporated in Baseline status as Section based on satellite imagery. 3.2 of Chapter-3 of EIA report of study area 2 Location of national parks / wildlife No National Park / Wildlife Sanctuary / sanctuary within 10 km. radius should Reserved Forest is located within 10 km specifically be mentioned. radius of the project 3 Permission and recommendations of the Not Applicable State Forest Department regarding impact of proposed expansion on the surrounding reserve forests, if any should be included. 4 Actual land requirement, classification of Barren land of 46.37 acres is acquired. land, acquisition status, rehabilitation and Land break up is tabulated in Table-2.2 of resettlement as per the policy of the Govt. Chapter-2. of Karnataka should be incorporated. 5 Site-specific micro-meteorological data Site specific meteorological data collected using temperature, relative humidity, for period March – May 2008. The data is hourly wind speed and direction and tabulated and presented in wind rose in rainfall should be collected. Section-3.5 of Chapter-3 of EIA report. 6 A list of industries containing name and The data is tabulated in Section-3.13 of type in 25 km radius should be Chapter-3 of EIA report. incorporated. 7 Residential colony should be located in Not Applicable upwind direction. 8 List of raw material required and source The data is tabulated in Section-2.4 of should be included. Chapter-2 of EIA report. 9 Manufacturing process details for all the The data is provided in Section-2.3 of plants viz. Sponge iron plant, EOF, LRF, Chapter-2 of EIA report. billet caster, bar and rod mill, CPP etc. should be included. Details of facilities with their capacities proposed alongwith quantity of products to be produced should also be included. 10 Ambient air quality at 8 locations within the Ambient air quality monitoring is carried study area of 10 km., aerial coverage from out at 8 locations including one at project site with one AAQMS in downwind downwind direction. direction should be carried out. 11 The suspended particulate matter present This is Proposed Plant. Not applicable. in the ambient air must be analyzed for the presence of poly-aromatic hydrocarbons (PAH), i.e. Benzene soluble fraction. Chemical characterization of RSPM and for incorporating of RSPM data. 12 Impact of the transport of raw material and The data is provided in Section-4.3.6 of finished product on the surrounding Chapter-4 of EIA report. environment should be assessed and provided

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Sr. No. TOR by MoEF Compliance 13 Determination of atmospheric inversion The data of inversion level has been level at the project site and assessment of obtained from IMD and the same is ground level concentration of pollutants presented in the report in Section-3.5.4 of from the stack emission based on site- Chapter-3 of EIA report. Site specific specific meteorological features. Air quality metrological data is used for the modeling modeling for steel plant for specific purpose. The modeling results are pollutants needs to be done. presented in Section-4.3.4 of Chapter-4 of EIA report. The mixing heights published by CPCB for project area are considered. 14 Plant-wise air pollution control measures The data is provided in Section-2.9.1 of proposed for the control of gaseous Chapter-2 of EIA report. emissions from all the sources should be incorporated. 15 A note on control of fugitive and secondary The data is provided in Section-2.9.2 of emissions from as per CPCB guidelines Chapter-2 of EIA report. from all the sources should be incorporated. 16 One season data for gaseous emissions Not applicable during winter season is necessary. 17 Permission for the drawl of 22.33 LPD Consent letter to withdraw water from water from borewells/Tungbhadra dam Tungbhadra back water is attached as backwater from the concerned department Annexure-III to Chapter-2. Water balance and water balance data including quantity is given in Table-2.12 of Chapter-2. of effluent generated, recycled and reused and discharged should be provided. Methods adopted/to be adopted for the water conservation. 18 Surface water quality of nearby rivers (60 Surface water quality is monitored at 8 m upstream and downstream) and other locations. surface drains at eight locations must be ascertained. 19 Ground water monitoring minimum at 8 Ground water is monitored at 8 locations locations and near solid waste dump zone, including project site. Geological features and Geo-hydrological status of the study area are essential as Data on geological features, geo- also. Ecological status (Terrestrial and hydrological status, ecological status are Aquatic) is vital. included as a part of Baseline Status, Chapter-3 of EIA report. 20 A note on treatment of wastewater from Provide in Section-2.9.4 of Chapter-2. different plants including coke oven plant, recycle and reuse for different purposes should be included. 21 Action plan for solid/hazardous waste Provide in Section-2.9.3 and Annexure-III generation, storage, utilization and of Chapter-2. disposal particularly char and fly ash. Assurance that 100 % char will be used in the FBC boiler and copies of MOU regarding utilization of ash should be included. 22 Generation and utilization of waste/fuel Waste gases from Kiln will be used in gases from DRI plant and their utilization WHRB while Char is utilized in FBC boiler in the CPP have to be set out. for generation of power.

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Sr. No. TOR by MoEF Compliance 23 Risk assessment and damage control Refer Chapter-6 of EIA report. needs to be addressed. 24 Occupational health of the workers needs Refer Chapter-6 of EIA report. elaboration. 25 Green belt development plan in 33 % area Refer Chapter-5 of EIA report. and a scheme for rainwater harvesting have to be put in place. 26 Socio-economic development activities Refer Section-2.10 of Chapter-2 of EIA need to be elaborated upon. report. 27 A note on identification and Not Applicable implementation of Carbon Credit project should be included. 28 An Action Plan for the implementation of Refer Annexure-V the recommendations made for the Steel Plants in the CREP guidelines must be prepared. 29 Total capital cost and recurring Refer Table-2.3 of Chapter-2 and Section- cost/annum for environmental pollution 5.6.4 of Chapter-5. control measures should also be included. 30 A tabular chart for the issues raised and Refer Annexure-VI addressed during public hearing/public consultation should be provided. 31 Any litigation / court case pending against Not Applicable the proposal should also be included

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

CHAPTER – 2 PROJECT DESCRIPTION

2.1 INTRODUCTION

This chapter addresses the proposed plant components, process description, basic raw material requirement, utilities and services, infrastructural facilities and sources of waste generation, their quantity, treatment and safe disposal.

2.2 PLANT DETAILS

2.2.1 Configuration

Taking into considerations the current technological advancements and the easily available raw materials, infrastructure, resources & skills, ILC is setting up the Mini Steel Plant Project comprising of following units:

Table 2.1: Components of Proposed Integrated Steel Plant

Sr. No. Unit Capacity 1. Sponge Iron Plant 4x150 Tonnes/day 2. EOF 1 x 25 Tonnes 3. Ladle furnace 1 x 25 Tones 4. Billet Caster (1x 2 strand) 1 x 25 Tones 5. Bar and Rod mill 2,06,000 Tonnes/annum 6. Captive Power Plant 12 MW (WHRB – 4x10 TPH & FBC – 1x25 TPH)

2.2.2 Land Requirement

The total land requirement for the proposed steel plant is 95.00 Acres. The unit wise breakup of the land requirement is given below;

Table 2.2: Land Requirement for Proposed Project

Sr. Parameter Area No. Acres % 1. Sponge Iron Plant 11.9 12.50 2. Captive Power Plant 6.0 6.50 3. EOF 1.4 1.50 4. Rolling Mill 14.3 15.00 5. Non–Plant Buildings 9.5 10.0 6. Green Belt Area 31.4 33.00 7. Roads 1.9 2.00 8. Open space and future 18.5 19.50 expansion Total 95.00 100.00

The plant layout is presented in Figure 2.1.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

2.2.3 Cost of the Project

It will be seen from the table that the total project cost of the expansion facilities works out to about Rs. 321 crores.

Table-2.3: Estimate of Capital Cost (Rs. Lakhs) Description Rs. Crores Land and site development 10.83 Civil work and Structural steel work 19.40 Main Plant and Equipment 185.30 Erection of Plant and Equipment 13.90 Design & Engineering fees 2.28 Spares 4.63 Contingencies @ 10% of above 26.08 Preliminary, Pre-operative, capital issue 8.84 expenses Margin money for working capital 33.60 Interest during construction 15.56 320.42 Total Project Cost Say 321

2.3 UNITS AND PROCESS DETAILS

2.3.1 Sponge Iron Plant: 4x150 TPD

The sponge iron plant will comprise of four (4) ported rotary kilns with pre-heaters and related accessories including waste heat steam generating units. Each Kiln will have a production capacity of 49,500 tons/year based on 330 days operation per year. The total annual production capacity of the plant will be 198000 tons.

 Technological Parameters Of The Sponge Iron Kiln

The major technological parameters of Sponge iron kiln are given below:

Major Technological Parameters - Sponge Iron Kiln

Number of kiln & preheater 4 sets Diameter of kiln and preheaters, m 3.0 Length of kiln and preheaters, m 42 No of Supports 2 Slope, % 2.5 Kiln speed, rpm 0.25-0.75 Diameter of cooler, m 2.3 ILC Industries Ltd. 17

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Length of cooler, m 22 No of Supports 2 Slope, % 2.5 Cooler speed, rpm 0.5-1.5 Production, t/d/kiln (Av.) 100 Generation of DRI fines(-3mm),% 30 Working days per year, no. 330 Shifts per day, no. 3

 Quality Of Sponge Iron Produced

The approximate composition of sponge iron produced in the plant is tabulated below:

Degree of metallisation, % 90 2 FeO, % 10 SiO2 + Al2O3, % 6.0 S, % 0.02 P, % 0.04 C, % 0.20 (max.) CaO, % Trace MgO, % Trace

 Facilities in Sponge Iron Plant

The major facilities in the sponge iron plant will include the following:

Day Bins: The day bin building for the DR kiln will have separate bins for storage of about one day's requirement of screened iron ore (5-20mm), coal (6-25mm), injection coal (3- 25mm) and limestone (2-4mm). Weigh feeders will be provided to draw various materials in the required proportion from the bins and deliver to the conveyers for feeding into the kiln

Rotary kiln with pre-heater and cooler: Two (2) ported rotary kilns each of 3.0 m dia (ID) and 42 m length with matching preheater sections will be provided for reduction of iron ore into sponge iron using non-coking coal as reductant. One kiln with the day bins and raw material preparation system is already installed and the second kiln will be installed as part of this programme of expansion of the mini steel plant.

The kiln will have a slope of about 2.5%. The main drives will be by AC motors with thyristor speed control and an auxiliary drive shall be provided for slow speed rotation during emergencies. The speed of the kilns will be in the range 0.25-0.75 rpm. The kiln will have 1 plain riding ring and one thrust riding ring and will be provided with 2 sets of support rollers at the 2 piers and one set of thrust rollers with bush bearings at thrust riding ring pier. A start up burner using fuel oil will also be provided for initial heating and start up. The other main components of the kiln will include: Feed end and discharge end housing of welded steel construction with refractory lining including feed chute. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end. On board equipment like fans, manifolds, valves, piping, actuators, air inlet ports, slip ring housing, etc. ILC Industries Ltd. 18

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Cooling fans at feed end and discharge end. Start up fuel-on-system Feed end double flap valves and dust valves.

The kiln will be lined with alumina castable refractories throughout its length with dams at feed end and discharge end.

The kiln feed from the charging end will consist of screened iron ore, coal and limestone. Air will be supplied to the kiln through ports provided on kiln periphery over almost ⅔rd length of the kiln. This ensures a controlled combustion resulting in a very even temperature profile. A part of required coal shall be thrown from kiln discharge end. The slinger coal will be discharged from the bins and pneumatically injected into the kiln. Necessary rotary feeder, compressor, piping and valves will be provided for the slinging system.

In the kiln, the iron ore will be dried and heated to the reduction temperature of about 1000 deg. C. The iron oxide of the ore will be reduced to metallic iron by carbon monoxide generated in the kiln from coal. The heat required for the reduction process will also be supplied by the combustion of coal. Thermocouples will be installed along the length of the kiln shell for determination of thermal profile of the kiln. The temperature will be controlled by regulating the amount of combustion air admitted into the kiln through ports with the help of fans mounted on the kiln shell and by controlled coal slinging.

The reduced material from the kiln will be cooled indirectly in a rotary cooler by water spray. The rotary cooler will be of 2.3 m dia (ID) and 22m length and will be supported on two piers with a slope of about 2.5%. The cooler will have a main drive and an auxiliary drive with AC motors. The speed range of the main drive will be from 0.5-1.5 rpm. The cooler will be provided with one plain riding ring and one thrust riding ring along with two sets of supporting rollers with bush bearings at two piers. About 0.5m length at the discharge end of the cooler will act as a screening section which separates all the accretions larger than 50 mm from the reduced material. These lumps will be discharged separately via lump gate. Rest of the material will be discharged on to a conveyor via a double flap valve. The other main components of the cooler will be the following:

Feed end housing (part of reactor to cooler transition) of welded steel construction with refractory lining. Cooler discharge end housing of welded steel construction. Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end. Feed end cooling fan.

The cooler will be lined with castable refractories for about 4m length from the feed end. Bypass arrangement will be provided at the discharge end of the cooler for emergency discharge of materials. The cooled product will be conveyed to the product processing building by a system of belt conveyors. The cooling water will be collected in the trough below the cooler and sent to the cooling tower for cooling. The cooled water will be re- circulated. The rotating parts of the kiln and cooler will be sealed suitably against the stationary parts at the connecting points to avoid leakage of dust laden gases.

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Off-Gas System: Hot waste gases leave the rotary kiln at about 800 deg. C through reactor feed end housing cum dust settling chamber and come to the After Burning Chamber (ABC) where combustibles are burnt completely by supplying excess air.

The off gas leaving ABC at about 850°C is led to a Waste Heat Recovery Boiler (WHRB) to generate steam from waste heat. The gas will then be cleaned in the Electrostatic Precipitator (ESP) before being released to atmosphere through ID fan and stack.

During process disturbances or any problems with the waste heat recovery system or any other emergency situations the off gases are vented to the atmosphere through the bypass system.

Product Processing Facilities and Product Storage Bins: The product from the cooler discharge contains sponge iron, chars and spent limestone/dolomite. The product from the cooler can either be stored in a surge bin or sent to the product processing building. Provision shall be kept to by-pass the surge bin and stockpile the product on ground. Product from surge-bin can be withdrawn through vibrating feeder and fed to the Product Processing Building.

In the Product Processing Building, the product will first be screened in a double deck screen having 3 mm and 20mm screens. The screened product, i.e. +3mm to +20mm and - 3mm fraction shall be subjected to magnetic separation. The magnetic fraction of 3 to 20mm will be stored in separate product storage bins. Char generated in the plant shall be stored separately for use as fuel in the power plant.

2.3.2 Steel Making Facilities

The induction furnace – continuous casting route is proposed to be adopted for the plant.

 Production Programme

The production programme of steel melt shop is given further:

Production Programme of Steel Melt Shop

No. of operating days/ year 330 Production - Liquid steel, tons/ year 220,000 - Continuous cast billets, tons/ year 213,400 Steel grades produced Mild steel

 Steel Making Equipment

The steel making equipment include three (3) Induction Furnaces having a power rating of 7000 KW each to meet the annual requirement of liquid steel. To match the production from furnaces a single 4-strand continuous billet-casting machine has been considered. The availability of the plant has been considered as 330 days per year. The plant will operate for 7 days a week on 3-shifts/day. The technological parameters of induction furnaces are tabulated below:

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Parameters of Medium Frequency Induction Furnace

Sl. No Parameter Unit Value/Feature 1 Liquid steel production T/yr 220,000 2 No. of furnaces No. 3 ( 2 crucibles each) 3 Type of furnace A.C, medium frequency, coreless, - twin shell each with common power pack per furnace 4 Nominal transformer rating per KW 7000 furnace 5 Average heat weight T 20 6 Average heat time, approx. Min. 120 7 Heats/day/furnace(Max) No. 12 Heats/day/furnace(Normal) No. 10 8 Charge mix, approx. - DRI % 70 - Scrap % 30 9 Method of charging By hopper and table feeder on - - DRI furnace floor Scraps & Pig Iron By Crane 10 Steel grades Mild Steel (Plain carbon - commercial grades) 11 Steel Refining In Ladle Refining Furnace 12 Pollution control measures Fume hoods, ducting, bag filters,

fan and chimney.

 Process Description

Scrap will be charged into the crucibles for generating the hot heel for DRI charging. Necessary carbon in the form of petroleum coke will be added into the crucibles to ensure the availability of necessary carbon in the bath. Pig iron also will be used for maintaining proper operating conditions. Once the molten bath has been formed and the minimum temperature of the bath has been achieved, sponge iron will be charged in small batches and the slag formed will be removed periodically. After the completion of charging of sponge iron a sample will be drawn to determine the composition of the bath. After achieving the desired melt analysis, the temperature will be raised to the tapping temperature taking into account additions of predetermined amount of Ferro alloys to achieve the required tapping composition of the melt. The ladle furnace will be used for further refinement of steel as well as to act as a buffer between the continuous casting machine and the induction furnace. In the ladle furnace the liquid steel is rinsed with argon and nitrogen while making ladle additions to achieve specific compositions.

Plant return scrap from various generating points and purchased scrap will be transported to the scrap bay of steel melting shop.

EOT cranes with magnets will be provided in the scrap bay for unloading and loading of scrap in scrap buckets. The scrap buckets will be weighed in the scrap bay. Scrap will be stored on furnace working platform near the furnace for charging.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Sponge iron from the sponge iron plant will be conveyed by trucks to the melt shop and manually charged into the furnace.

 Auxiliary Facilities

The following major auxiliary facilities will also be provided in the steel melt shop:  EOT cranes for Ladle Handling.  EOT cranes for handling scrap, additives, refractories etc.  Ferro-alloys and additives storage, handling and supply system  Steel ladles and steel ladle preparation facilities  Temperature measurement and sampling facilities  Refractory storage systems, crucible, ladle and tundish relining system  Make up and closed circuit water supply, cleaning and storage system  Services facilities, such as, compressed air, fuel, gases, etc.  Electrics, instrumentation, etc.  Pollution control equipment and waste disposal facility

 Raw Materials and Consumables

The annual requirement of major raw materials and consumables for steel making are indicated below:

Requirements of Major Raw Materials and Consumables for Steel Making

Sl. No. Item Annual Requirement, tons 1 Direct Reduced Iron 192,500 2 Return Scrap 9,700 Purchased Scrap 59,600 3 Ferro-alloys 3300 4 Pet coke 4000

2.3.3 LRF Station

LRF unit is provided for alloying, desulphurisation, and homogenization of temperature and composition of the steel tapped into the steel ladle. The LRF unit also acts as a buffer unit for timely sending of heats to continuous casting shop with required temperature. The required grade of steel shall be produced at LRF station. LRF unit of capacity 25 T with 6500 MVA transformers will be installed. The design parameters of LF unit are given below.

Sl. No Item Unit Parameter 1 Heat size T 25 2 Type of unit - Ladle housed on the ladle car with water- cooled cover. 3 Transformer MVA 6500 capacity 4 Heating rate 0C/min 5 5 Treatment time Min 45 (depends on grade of steel)

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Sl. No Item Unit Parameter 6 Main functions of - Alloying, Heating, Desulphurisition LRF Homogenization of chemistry and temperature Holding of Liquid steel incase of emergency. Steel cleanliness 7 Fume collection & Bag filters with ID fan and chimney cleaning 8 LRF station output Various grades of steels.

 Process flow

The scrap is preheated from the heat of off gases coming from E.O.F. This preheated scrap is charged into furnace for making liquid steel along with the hot metal.

In view of preheating of scrap, EOF takes large amounts of cold charge than BOF. Typically it takes up to 40 % cold charge in total input charge. The heat energy available during steel making process is used to preheat the scrap. The oxygen for refining is blown through supersonic lances, submerged tuyers and through atmospheric injectors. The evolved CO is combusted to CO2 by atmospheric injectors / supersonic lances. The typical flow rate of oxygen through supersonic lance is 1200 Nm3/hr, with a speed more than 360m/sec. Unlike in BOF, intermediate de-slagging is done in EOF.

The hot metal is charged in to the EOF furnace through the hot metal charging crane into the charging launder, which is a part of the EOF furnace body. The scrap pre heater assembly box, which is kept on the furnace top, the fingers get opened and preheated scrap (from previous heat) falls into the EOF furnace. The blowing of oxygen starts through supersonic lances, through tuyers, through atmospheric injectors. Mean while, all the required additives such as lime, dololime, DRI will be added into EOF. New scrap box is kept on the furnace top for preheating to next heat. The cycle time of EOF is around 45 minutes. After the process, the furnace is tilted and steel is tapped through the launder to the steel ladle. The ferro alloys will be added into ladle (for deoxidation) while tapping the steel. For the present process, 70 % hot metal with 30% cold charge is considered. The cold charge may consist of in-house generated scrap, DRI, and if required purchased scrap. The charge mix can be varied depending on the economics and technology of the process. Maximum utilization of hot metal in the furnace with less amount of cold charge is also possible.

This liquid steel will be transferred to ladle handling bay, where the online ladle furnace (LF) treatment is given.

Argon bubbling through porous plug from bottom of the ladle will be carried out for homogenization of temperature and chemical composition. Required amount of ferro alloys are added for obtaining desired grade of steel. After finishing the heat in ladle furnace, the heat is transferred to Continuous casting machine.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

 Technological facilities

 Hot metal handling Hot metal coming from the DRI complex open top ladles is charged into the mixer with the help of hot metal handling crane. From the mixer, hot metal will be collected in to EOF hot metal charging ladle.

 Scrap handling

A separate scrap storage bay is considered for meeting the requirements to EOF shop. The scrap bay will store the purchased scrap and the return scrap. Scrap will be loaded into the scrap charging boxes placed on the car, positioned over the scrap weighbridge by the overhead magnet crane in the scrap bay. Scrap boxes will be brought to the charging bay by the scrap box car. Scrap boxes will be lifted by the scrap-charging crane and placed on the EOF furnace mouth for scrap preheating before being discharged into furnace.

 Flux and Ferro-alloy handling

DRI, coke and other materials will be received in overhead bunkers in the EOF bulk material charging bay from raw material yard by trucks. Lime and calcined dolomite will be purchased from outside agencies. No separate storage sheds are envisaged for ferro alloys and refractories. Sufficient storage will be kept in the bins/ and in shop only, and the same will be obtained form outside as and when required. The E.O.F. shop is designed with furnace feeding bunker system and ladle feeding ferro alloy bunker system. The material for furnace feeding will be charged into the E.O.F through a system of conveyors, weigh-hoppers, charge holding bunkers and chutes. Similarly predetermined quantities of Ferro alloys for ladle feeding from the storage bins will be delivered into steel ladle through a system of weigh-hoppers and chutes.

 Steel handling

Liquid steel will be tapped off from the E.O.F into the casting ladle placed on a self- propelled transfer car. After tapping, ladle will be sent to ladle heating furnace (LF) installed in the ladle furnace bay. From this bay, the ladle will be sent to continuous casting plant.

 Slag handling

The EAF/E.O.F furnace is operated with intermediate slagging off facility. The slag will be poured out from EAF/E.O.F into ground. Hot slag will be dumped into the ground and allowed to cool. Cold slag from the pit will be removed by dumper.

 Secondary refining of steel

One no. of ladle heating furnace unit of 25 t capacity is planned in the ladle handling bay for correction of chemistry of steel, for alloying and raising of steel temperature to meet the requirement of continuous casting.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

 Gas cleaning and recovery

The EOF will be provided with gas cooling and cleaning equipment. EOF is connected to individual I.D fan house system. As the EOF works on the principle of complete combustion, no gas recovery occurs. Only cooling, cleaning and letting into atmosphere will be there.

Gas cooling and cleaning will be wet type gas cleaning, using variable throat venturi scrubber. Recycled water system is envisaged.

2.3.4 Continuous Casting

The continuous casting technology has gained worldwide acceptance mainly because of higher yield, economics of operation and better product quality. Hence it has been chosen for the proposed steel plant for casting the liquid steel into billets.

 Technological Features

A 6/11 m radius, 4-strand, curved mould; radial type design billet caster is proposed. Two self propelled tundish transfer cars will be provided for transferring the tundish from reserve position to the casting position. The continuous casting machine will be equipped with moulds, mould oscillating mechanism, secondary cooling segments, withdrawal and straightening unit, gas cutting unit, dummy bar insertion system, run-out roller tables, cross transfer mechanism and cooling bed. The billets will be marked with the help of the marking unit. The caster will be controlled from the pendant control panels, and also from main control room located on the casting platform and the auxiliary control room near the gas- cutting unit. A control post will also be provided at the end of the run-out roller tables of the continuous casting machine for transfer of billets from the run-out roller tables on to the cooling bed and discharge grid. Other facilities such as tundish preparation repair and assembly of moulds and secondary cooling segments, mould testing etc. will also be provided. The continuous casting machine will work on three shifts basis for 330 operating days in a year. The basic technological parameters of continuous billet caster are furnished below:

Technological Parameters of Billet Caster

Sl. No. Item Parameters 1 Type of machine Curved mould bow type 2 Number of machines 1 3 Number of strands 4 4 Machine equipped to cast 100 and 125 mm.sq billets. 5 Casting Radius 6/11 6 Billet length 2 m or 3 m 7 Type of ladle Bottom pouring with slide gate system 8 Ladle support Ladle stand 9 Heat size 20 t average 10 Type of cutting device Manual, torch cutting 11 Method of discharge On horizontal discharge roller table to cooling beds 12 Steel quality Commercial grades ILC Industries Ltd. 25

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Sl. No. Item Parameters 13 Dummy bar Link type 14 Casting practice Open casting 15 Tundish practice Cold 16 Casting speed Variable 17 Mould Support Short Lever arm oscillation. 18 Withdrawal speed 0 – 6 m/min

The casting cycle time and the basis of selecting the number of strands for the caster are indicated further:

Casting Cycle Time of Billet Caster

Heat size, tons 20 20 Size of cast billet, mm x mm 125 x 125 100 x 100 Casting speed, m/ min 1.9 2.8 Weight of cast billet, Kg/ m 128.4 76 Throughput in four strands, Kg /min 976 851 Sequence casts 3 3 Total metal cast in sequence, tons 60 60 Casting time, min 62 71 Machine Preparation Time, min 45 45 Total Cycle time, min 107 116

Daily Production, Tons 785 724

The tap-to-tap time of the induction furnaces will be matched with the casting cycle time so as to have maximum number of sequential casts.

 Process Description

The ladle will be picked up by ladle handling crane and placed on the ladle stand. A refractory lined tundish, fully dried and fitted with preheated nozzles mounted on tundish car will be moved from the reserve position to the casting position. Prior to the start of the casting operation, the dummy bars will be introduced into the mould. The gap between the dummy bar head and mould walls will be sealed with asbestos chords and small pieces of steel scraps will be placed over the dummy bar head for chilling of initial metal. Water supply to mould, secondary cooling zone and machine cooling will be switched on at this stage. When the liquid steel level in the tundish reaches a predetermined level, the tundish nozzles will be opened. When the metal level in the mould reaches about 100-150 mm from its top the drive of the mould oscillating mechanism as well as withdrawal and straightening unit will be switched on. The withdrawal of dummy bar begins at the minimum speed and gradually increased to normal casting speed within few minutes. The mould will be lubricated with liquid lubricant. During casting operation, the metal level in the mould will be maintained within predetermined limits by adjusting flow of metal into the mould or by adjusting the withdrawal speed.

The liquid metal level in the tundish will also be kept within permissible range by adjusting the opening of ladle slide gate. The partially solidified billets after leaving the mould will pass

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW) through strand guide roller segment where intensive but water spray nozzles will effect controlled cooling of billets. The solidified billets will be guided through withdrawal and straightening unit before entering the gas cutting zone. The dummy bar will be separated from the billet after the gas-cutting unit and will be stored till its introduction is required for start of the next heat. The cast billet will be cut to the predetermined length by oxy-acetylene gas cutting torches. The sized billets will be delivered to the cooling bed through run out roller table and cross transfer mechanism. The billets will be marked on cooling bed by the marking unit for identification/tracking.

The cast billets will be stored in the billet bay. Conditioning facilities have also been envisaged in this bay. During an emergency, the casting operation can continue and the overflow of metal from the tundish will be received into a slag box through the tundish spout and the overflow launder. In case the casting operation has to be stopped, the ladle shall be lifted from the ladle stand and the liquid metal inside shall be poured back into the induction furnace. For chemical analysis of liquid steel, the samples will be taken from the ladle and sent to the laboratory. The samples will also be cut from cast billets and sent to the laboratory for macro etching, sulphur prints and for determining other quality parameters. After the liquid steel in the ladle is emptied, the ladle-handling crane will remove it. The slag from the ladle will be poured into a slag pot kept at the ground level in the ladle handling bay and the empty ladle will be sent to ladle preparation area. At the end of casting, the tundish will be shifted to the reserve position for drainage of remaining slag and metal in it. The empty tundish will be lifted by the crane and transferred to the tundish preparation area where necessary facilities for tundish tilting, cooling, lining, drying etc., will be provided.

2.3.5 Bar and Rod Mill

A single strand bar and rod mill will be installed to produce about 150,000 tons per annum of bars and rods in straight lengths. The input material will be continuous cast billet of size 100 mm x 100 mm. The mill will be designed for rolling billets up to 125 mm x 125mm square.

 Production Programme

The mill will produce mild steel bars and rods in the size range of 8mm to 32 mm dia in straight lengths. The above production will be achieved by operating the mill in 3 shifts a day for 330 days a year.

 Billet size

The trend in modern bar and rod mills is to use heavier billets to obtain improved productivity, yield and quality. In view of the above, it is proposed to use 100mm x 100mm billets. The billet length chosen for the mill is 3 m, weighing about 228 kg.

 Billet requirement

Material losses in the production of rods and bars arise due to scale, cropping, cobbles etc. A yield of 94 percent has been assumed, on a conservative basis for the proposed wire rod mill but in actual practise, improved yields could be obtained in due course, when the operations get stabilised.

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On the basis of 94 per cent yield, the total requirement of billets, after rejections during billet inspection, will be about 160,000 tons per year.

 Mill selection

To meet the production programme given earlier, a single-strand semi continuous mill has been proposed. The mill productivity has been computed on the basis of rolling up to 8 mm dia plain rods through the finishing stands, and the balance collected from the intermediate / finishing train. Based on the starting billet size of 100 mm x 100 mm and the grades of steel to be rolled, a mill with 17 to 19 passes to roll the smallest size of rod (8 mm dia) is proposed. The rolling mill comprises a 3 Hi Break Down Roughing stand of 460 mm dia with tilting table at the delivery side and manipulators, to give 7 to 9 passes. In the breakdown stand the 100 mm square billet is reduced to a 55 mm square section for further continuous rolling. After the breakdown stand the remaining passes are distributed between a 4stand- 300mm intermediate train, a 280 mm 4 stand continuous train and a 2 stand 260mm finishing train. The technological parameters of the proposed wire rod mill are tabulated below:

Technological Parameters of Rolling Mill

Description Parameter Products Rolled Commercial grade TMT reinforcement bars Production Capacity 150, 000 Tons/year Rolling time per year 6600 Hours Yield 94% Product Sizes Dia 8 mm to 32 mm in Straight Lengths Input material & size Mild steel billets of size 100 mm square, length 3 m Type of Mill Semi- continuous Number of strands One Number of passes 17 to 19 Number of stands 19 stands Rolling speed: Up to 16 m/sec Straight lengths Re-heating furnace type Pusher type Capacity, tons/hour 40 Special features Recuperator for fuel optimisation & use of coal gas as fuel. Special features of mill Breakdown mill fully mechanised with tilting table, manipulator etc. Mill design allows quick roll change. Crop and cobble shears for crop and segment cutting in case of necessity. Roller type entry and twisting guides in continuous mill Water quenching system for production of TMT bars. Rake type-cooling bed to provide uniform cooling of bars.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

 Process and Quality Control

The basic quality requirements for the products to be rolled in the bar and rod mill are close tolerance, good surface quality, easily removable scale, minimum decarburisation and a microstructure that would permit the maximum possible reduction between successive draws. In order to meet these requirements, the main production equipment will be selected carefully and provided with necessary instrumentation, cables and automation which will be capable of producing rods of the required quality and tolerance.

The heating furnace will be equipped with suitable instruments and controls for regulating the temperature and furnace atmosphere in order to minimise scaling and decarburisation, and to control the finishing temperature to give the desired microstructure.

In addition billets will be inspected, and if required, conditioned before rolling. Provision will be made to draw samples at regular intervals and check the properties in a well-equipped laboratory located near the rod sampling area in the mill. With these facilities for inspection and conditioning of the starting material and for the quality control during the production stages, it should be possible to produce products conforming to Indian standards.

 Other Mill Facilities

For production of TMT bars a water quenching system is provided.

 Auxiliary Facilities

The auxiliary facilities will include a laboratory with requisite testing equipment, a roll shop with facilities for turning and dressing of rolls, maintenance and assembly of roll chocks, guide and template making and roll storage and repair post for carrying out minor repairs of components.

2.3.6 Captive Power Plant (CPP): (WHRB: 4 x 10TPH & FBC: 1 x 25 TPH)

 Technical Features

The technical parameters of WHRB and the FBC boiler are tabulated below:

Technical Parameters of WHRB & FBC Boilers

Description WHRB FBC Quantity 4 1 Steam capacity at MCR 10 TPH 25 TPH Steam Pressure at Main steam 66 ksca 66 ksca stop valve outlet Steam Temperature at super 490 + 5 Deg.C 490 + 5 Deg.C heater Outlet Steam temperature control 60 to 100% 60 to 100% range

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Description WHRB FBC Boiler type Semi Outdoors, Bi-drum, Semi Outdoor, Bi- water tube, Membrane, drum, water tube, Waste heat recovery Membrane, FBC type, type, natural circulation, multiple biomass fuel and balanced draught fired, natural type boiler with circulation, balanced associated auxiliaries. draught type boiler with associated auxiliaries. Heat Source / Fuel DRI furnace flue gas Fired by coal and coal char. Design code IBR IBR Intended Deaerator Common Deaerator with temperature 120 deg. temperature Boiler designed for firing Not applicable Coal: 100% following fuel combinations Coal Char: up to 30 % Biomass fuels: 40% Steam quality at Main steam Ph – 8.5 header Silica as SiO2 – less than 0.02ppm Total dissolved solid – less than 0.1ppm Electro Static Precipitator Part of the Sponge iron Tumbling hammer kiln type with bottom storage hopper with transformer and associated electrical equipment. Boiler feed pumps 3 numbers of 40 TPH common for all the boilers (2 Working + 1 Standby) Air and Draft system ID fan is part of sponge 1 set of 100% ID, FD, iron kiln. PA fans complete with drives, suitable hoppers etc. Chimney Part of sponge iron kiln One number of Steel chimney 50m height with suitable top and bottom diameter for evacuating FBC flue gases. Boiler structures As per standard code of practice with adequate corridors and staircases.

 Turbo Generator and Auxiliaries

The technical parameters of the turbo-generator and auxiliaries are furnished below:

Technical Parameters of Turbo Generator and Auxiliaries

Number & Rated power output 1 x 12000 KW Type Impulse reaction, condensing, multistage type. ILC Industries Ltd. 30

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Inlet steam pressure 65 ksca Inlet steam temperature 485 No of extractions One for deaerator. Type of condenser Water cooled condenser, condensate pumps and auxiliaries. Turbine exhaust steam 0.2 Kg/cm2 (a) pressure Type of Generator Brushless, air cooled twin bearing type with bottom terminal box for isolated bus-duct termination Generation Voltage 11 KV Excitation control Power factor control and VAR control in synchronised state and voltage control in isolated mode Synchronising and control Auto synchroniser and manual synchronising panel arrangement from panel Protection panel Numeric relays as per standard engineering practice for TG sets of this capacity to be provided. Type of Cooling, Generator Air coolers mounted on the generator Governor Electro hydraulic actuators with Wood ward controller Vibration Monitors Provided Lube Oil System With oil storage tank, main oil pump, electrical motor driven auxiliary oil pump, emergency oil pump, duplex filter with suitable 3 way valves, pressure relieving valves, pressure regulating valves, suction strainer and other items including piping, valves, etc. Air Evacuation system 2x100% Service Ejector, 1 No. Of Start up Ejector, Service ejector coolers and associated piping.

 Electrical System

The details of the various electrical systems in the CPP are:

Details of Electrical System in CPP

Generator Switch 11 kv generator switch board with breakers, PTs, CTs of Board (GSB) adequate rating, protective relaying of pneumatic type for generator incomer, grid incomer, bus couplers, auxiliary transformers, feeders for various plants like DRI plant, SMS, rolling Mill and auxiliaries. Load Control Sub - One auxiliary transformer with secondary bus duct arrangement Station (LCSS) connected to 415V power control switch board with feeders for transformer in comer breakers for two transformers in comers for DG set of capacity 1000 KVA, feeder breakers for boiler and utility MCC along with PTs, CTs, protection and relays as required. Motor Control MCCs with incoming Switch fuse units, feeders for motor loads, Centres CTs, PTs and metering with proper protection systems for ILC Industries Ltd. 31

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

WHRB, ESP & their auxiliaries, FBC, ESP and their auxiliaries, TG and TG auxiliaries, Water systems, Fuel & Ash handling equipment, Lighting and Power DB Capacitor Banks As required Cables and Cable LT cables shall be 3 Cored, Al armoured, PVC sheathed of terminations adequate sizing as per codes for 3 wire system and 3 ½ Cored for 4 wire systems including glands, lugs heat shrinkable termination for size m2ore than , HT cables shall be 3 Cored, Al armoured, XLPE sheathed of adequate sizing as per codes for other than generator and 3 single Core cable for generator with glands, lugs heat shrinkable terminations. Earthing, Lightning Included for the power plant area. Design shall be as per the protection, lighting codes and BIS. systems

 Fuel

The sources of energy for the CPP are: a. Off gases from sponge iron kilns at the exit of „After Burning Chamber‟ b. The char produced by sponge iron kilns and coal fines generated from crushing of coal. c. Bio mass fuels available in the region such as rice husk, waste wood, etc. d. Additional purchased coal

 Description of Thermal Cycle

The thermal cycle that is adopted for generating power in a thermal power plant is the Rankine cycle. In this system, the fuel or heat source is used in steam generators to produce steam at a high-pressure and temperature. The steam is then expanded in turbine coupled to a generator to generate power. This system is reliable, proven and well established.

 Selection of Steam Parameters and Unit Size

In general, adoption of boiler outlet steam conditions with higher pressure and temperature will thermodynamically enable generation of higher kWh per kg of steam admitted to the TG set. Considering the general trend worldwide by various manufacturers of boiler–turbo generator units for small and medium size power generation units and also the general practice adopted in various power plants of comparable size, three probable steam parameters, namely 65 ksca / 485 deg C, 44 ksca /485 deg C and 44 ksca / 440 deg C can be considered for the proposed CPP.

Adoption of steam parameters of 44 ksca /440 deg C would reduce the overall thermal efficiency and consequently increase the fuel consumption. The higher steam parameters of 65 ksca /485 deg C or 44 ksca /485 deg C will result in higher savings of fuel per annum when compared to steam parameters of 44 ksca /440 deg C. Although the initial investment for the main equipment viz. boiler and turbo-generator will be marginally less for steam parameters of 44 ksca/440 deg C when compared to the other two parameters, the increased efficiency and savings in running cost will offset the increased initial investment in the long run. ILC Industries Ltd. 32

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

In view of the above, the choice is between 65 ksca/485 deg C and 44 ksca /485 deg C. The evaluation of these two sets of steam parameters reveals marginal difference with respect to operating efficiency and economic factors. But for 65-ksca/485 deg C there are a number of reputed manufacturers of equipment and they have standardised models. This would enable procurement of the equipment from wide range of suppliers at a competitive price. Hence, 66 ksca /490 deg C at the boiler super heater outlet is chosen as steam parameters for the proposed CPP. The corresponding steam parameters at the turbine inlet will be 65 ksca /485 deg C.

 Configuration of CPP

As mentioned earlier, considering the quantum of thermal recovery potential available in the waste gases and the waste materials such as char etc. from the sponge iron kilns, the CPP should be a combination of waste heat recovery and fuel fired system to exploit the full potential of available waste energy and also generate adequate power to meet the full power requirements of the steel plant.

WHRB‟s will be installed after the ABC of each sponge iron kiln in shunt configuration with gas conditioning tower. The flue gases after ABC will be taken to the unfired furnace chamber of the WHRB and then flow over banks of super heater, convective evaporator and economizer before being discharged to atmosphere through ESP and chimney of the kiln. In case of shutdown/breakdown of WHRB, flue gases will pass through the gas-conditioning tower.

In the fluidised bed combustion (FBC) boiler envisaged, combustion of fuel particles is achieved in suspension with an inert aggregate of bed material such as sand. Combustion air will be fed through air nozzles from underneath into the sand fuel bed. Oil burner will be provided for start up and low load flame stabilization. The flue gases will pass over various heat transfer surfaces to ESP and then finally be discharged into chimney by ID fans. The boiler will have its own ESP, ID fan and chimney.

Condensate extraction pumps will pump the condensate from the condenser of the TG to a common deaerator. Feed water from the deaerator will be pumped to the waste heat recovery boiler as well as FBC boiler by boiler feed pumps.

The steam generated from all the boilers will drive the steam turbines through a common steam header. Considering the above the power plant will comprise of the following major facilities: 4 Nos. waste heat recovery boilers one for each kiln each with a capacity of 10 TPH at 66 Ksca and 4900 C in bypass configuration at the down stream of ABC to recover sensible heat of kiln off gases. 1 No. Fluidized bed combustion (FBC) boiler utilizing coal fines and char as fuel with a capacity of 25 TPH (MCR) at 66 Ksca and 4900 C One turbo generator with a rating of 12 MW with steam inlet conditions of 65 Ksca at 4850 C with air cooled condenser.

All necessary boiler and TG auxiliaries including deaerator and boiler feed pumps with associated system, electrics such as generators, transformers, switchgear, water supply

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW) facilities, instrumentation and controls, auxiliary service systems such as fuel handling, ash handling and disposal, telecommunication, fire fighting and miscellaneous facilities.

 Demineralised Water System

A Demineralised (DM) Water Plant of capacity around 5 cum/hr is envisaged to meet the boiler feed water requirements of the CPP. The main facilities in the demineralised water plant include multi grade filter, ultra filter system, RO system and mixed bed with regeneration arrangement etc. A DM water storage tank of capacity 200 cum will be provided.

 Auxiliary Cooling & Service Water System

A water system to meet the auxiliary cooling water requirements & general purpose water requirement of the CPP will be provided complete with cooling tower, pumps, pipe work and accessories. The capacity of the systems is shown in the water system schematic drawing enclosed.

 Fuel Handling System

A system for fuel handling and feeding to the FBC boiler consisting of belt conveyers and other handling equipment is envisaged. The system will be complete with necessary electrics and accessories.

 Ash Handling System

Ash handling system consisting of belt conveyers for dry ash disposal and submersible conveyers for bottom ash complete with ash storage silo is envisaged. The ash collected in the ash storage silo will be periodically evacuated by trucks and dumped in the waste disposal area.

 Ventilation and Air conditioning

Fresh air system with adequate air changes as per code of practice will be provided for the TG building and electrical rooms. Control room shall be air-conditioned.

 Auxiliary Facilities

The TG building will be provided with a 25/5 ton HOT crane for maintenance. Other auxiliary facilities will include telecommunication and public address system.

 Fire Protection System

The fire protection system for the proposed power plant will be complete in all aspects against facing any eventuality due to fire. The system comprises of following equipment / sub-systems:  Hydrant system for all the areas of the plant.  Portable fire extinguishers in other areas within the plant.  Alarm and detection system for electrical and control room

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

2.4 RAW MATERIAL

Total raw material requirement in plant considering 330 working days are tabulated below:

Table-2.4: Specific Consumption & Gross Quantities of Raw Materials

Raw Material Specific Consumption Gross Quantity per ton of product (TPA) Sized iron ore for SI plant 1.8 331400 Non-coking coal for SI plant 1.3 231700 Non-coking coal for CPP -- 15000 Non coking coal for Coal gas -- 16400 plant Limestone for SI plant 0.04 8000 Steel Scrap / Pig Iron for IF -- 59600 Ferro-alloys for IF 0.015 3300 Pet Coke for IF 0.02 4000 Fuel oil for SI, IF & RM -- 1730

Coal & coke will be imported & can be conveyed through Chennai / Panji Port. Iron Ore Mines are located in Koppal and Bellary District itself & are is approximately 35 km from the Project Site. Limestone and scrap are available plenty in domestic market.

2.5 POWER

Maximum and average power requirement of the steel plant: The maximum electric power requirement of the plant is estimated as around 12.6 MW. The details of requirement are given below:

Table-2.5: Plant Power Requirement

Consumer Approximate Connected load, KW SMS - Induction furnaces, 3 x 7000 KW 21000 Sponge iron plant 2000 SMS – Ladle furnace 4000 CCM and other Auxiliaries of SMS 1500 Wire rod mill and auxiliaries 3000 Other plant auxiliaries 1000 CPP auxiliaries 1200 Total 33700

Considering a simultaneous operating factor of 85%, the average power requirement of the plant is expected to be around 29 MW.

The power generation capacity of the CPP will be 12 MW, which can meet part of the power requirements of the mini-integrated steel plant. The balance power requirement of the plant will be met from the grid. ILC will have a contract with the grid for drawl of about 27000 KVA of power.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

A DG set of capacity 1000 KVA is also proposed for meeting the emergency power requirements of the steel plant and black start requirement of the power plant

2.6 WATER

The source of water for the plant is the back waters of the Tungabadra dam running at a distance of about 3 km from the proposed site. ILC have a sanction to draw around 46.18 LLPD (192 m3/hr) of water from this source for the plant. The sanction letter is attached as Annexure-2.

The make up water requirement of the plant is given in Table-2.6.

Table-2.6: Plant Make Up Water Requirement

Parameter Requirement, m3/hr Sponge Iron Plant 20 Induction furnace and continuous casting plant. 21 Captive Power Plant 12 Rolling Mills 15 Miscellaneous uses such as for ablution block, 2 drinking water, losses etc Total 70

Water system for the plant is shown in Figure-2.3.

2.7 FUEL

Fuel oil is required for start up of the sponge iron kilns; start up of the FBC boiler and in the reheating furnace in the Rolling Mills. The total fuel oil requirement for the above uses is estimated to be about 1730 tonnes/year. This will be procured from the nearest terminal of any of the major suppliers e.g. HPCL, IOCL or BPCL.

In addition to fuel oil, about 200 tonnes/year of LDO / HSD will be needed for the ladle pre- heaters in SMS and for the transport equipment in the plant. Suitable storage tanks with metering devices for these fuels will also be provided

2.8 MANPOWER REQUIREMENT

It is estimated that the total requirement of manpower including all categories for the whole organisation will be around 362. Approximate area-wise manpower requirement is given below:

Table-2.7: Approximate Area-Wise Manpower Requirement

Department Shift Total per Total on General I II III weekday payroll Administration, sales 12 2 2 2 18 22 and works office ILC Industries Ltd. 36

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

RMHS and Sponge 5 15 15 15 50 65 Iron plant SMS & Concast 8 20 20 20 68 85 Rolling mills 8 20 20 20 68 85 CPP 4 8 8 8 28 35 Services, transport, 10 15 15 15 55 70 lab etc Total 47 80 80 80 287 362

2.9 POLLUTION CONTROL

The different sources of pollution from the proposed mini steel plant are given below:

Table-2.8: Sources of Pollution

Sr. Section Feed Material Operation Pollutants Type of No. and Fuel Pollution 1. Sponge Iron Plant Iron ore, coal, Reduction of Dust, SO2, Air Pollution dolomite iron ore NOx 2. Steel making shop Hot metal, Steel making, Heat, dust Air Pollution fluxes, ferro refining & alloys continuous casting of slabs Particulate Water dust laden Pollution water 3. Hot rolling mill Billets and Hot rolling of Heat, SO2, Air Pollution blooms, fuel oil billets / bloom NOx Noise Noise Pollution Air and Water particulate Pollution laden mill effluent 4. Captive Power By product fuel Steam Heat, SO2, Air Pollution Plant gas and coal generation NOx as fuel and power generation Noise Noise Pollution Waste water Water of DM plant Pollution Cooling tower Water blow down Pollution

2.9.1 Air Pollution

The likely sources of air pollution from the proposed plant are revealed from Table-2.8. The unit wise air pollution control equipments proposed are as given Table-2.9. ILC Industries Ltd. 37

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Table-2.9: Air pollution Control Measures

Sr. No. Location/Shop Facilities 1 DRI kiln ESP 2 DRI screen Dust extraction system comprising 3 Ore screening & coal crushing, of suction hood, duct, bag filters, screening fan, stack etc. 4 Different conveyor transfer points in raw material handling systems 5 Raw Material Storage area Dust suppression system with water spray 6 SMS – EOF Adequate natural ventilation by proper design of the building and provision of local fume extraction systems in furnace operating zones. The fume extraction system will comprise movable roads, ducting, dry cyclone, bag filter, fan and chimney. 7 Rolling Mill Chimney of adequate height for Reheating Furnace. Adequate natural ventilation by proper design of the building. 8 Power Plant ESP for cleaning the flue gases from the FBC boiler. Dust extraction systems for conveyor transfer points, crusher and screen house with hoods, bag filter and fans.

2.9.2 Fugitive Emissions

To control fugitive emission, an elaborate dust extraction system has been proposed for all transfer points, starting from transferring raw material into ground hoppers to charging material including crushing and screening. Several suction hoods planned at all relevant material transfer points lead the dust through a bag filter into a stack. The dust collected in bag filter hopper will be recycled in the process.

For fugitive emissions from the stockpile area, plantation is proposed to arrest whatever little emissions are expected. For the other areas, dedusting systems, consisting of air blower, bag filters, hoods and ducts are proposed to take care of fugitive emissions.

The proposed air pollution control measures for fugitive emissions are tabulated in Table- 2.10.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Table-2.10: Air Pollution Control Measures for Fugitive Emissions

Sr. No. Fugitive Emission Control Technique Control Equipments Sources 1 Active storage plies Watering Water sprinkler on Wind screens yard Plantations 2 Conveyor & Transfer Water Sprays Dust Separation Points Hooding & system Ducting Bag Filters 3 Product Handling Wind screen Bag Filters Hooding & Ducting 4 Loading & Unloading Wind screens Water sprinklers on Water sprays yard 5 Internal Road Water spray Dust Separation Transportation Concrete /Tar system Road Bag Filters Plantation 6 Waste gas Heat recovery WHRB Dust collection Electrostatic Precipitator 7 Waste sites Chemical -- stabilizers Vegetable cover Windscreens Plantations

2.9.3 Solid Wastes

The unit wise solid waste generation, their quantity and disposal/reuse in the mini steel plant is tabulated in Table-2.11:

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Table-2.11: Solid Waste Generation

Sr. Location Nature of Category of Waste & Quantity, Dry Disposal / Reuse No. Waste Composition Basis (TPD) A Sponge Iron Plant 1 Below Dust Settling Chamber / Sludge DRI fines, Coal Dust 6.5 Use in road making / Filling at Wet Scrapper Low Levels 2 Kiln & Cooler Dust Sealing Dust Coal Dust 110 Sell to fly ash bricks carriage, From Heat Exchanger manufacturers. & ESP, De-dusting system 3 Product Separation System Fines DRI Fines, Coal Dust 121 Reuse in CPP (Char) B Captive Power Plant 1 From Fluidized Bed Fly Ash Fly Ash 50 Sell to cement manufacturing Combustion (FBC) Boiler plant / brick manufacturing plant C Induction Furnace 1 Furnace Slag FeO,SiO2 90 Use in road making / Filling at Low Levels Dust FeO,SiO2 2.5 Filling at Low Levels D Rolling Mill 1 Mills Mill Scale 13.0 Reuse in process as scrap Total 262.2

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OFPROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

The solid wastes generated from the plant will be collected in bunkers through Bag Filters and magnetic separation systems. The dust with fly ash, which is collected below heat exchanger, ESP & the fly ash collected from the FBC, will be stored in the solid waste disposal yard for which area will be earmarked. This fly ash will be sold to cement plants.

The Sludge collected also will be stored in the solid waste disposal yard. Char will be collected in the product house and will be used in boiler of CPP.

2.9.4 Water Pollution

The plant employs re-circulating water systems for both direct and indirect cooling of equipment. During use in direct cooling, the water becomes contaminated. Therefore the pollutants will be removed before the water is cooled and re-circulated. Typical major pollutants of concern are suspended solids, oil and grease. Treating and reusing the water thus minimises the consumption of fresh water for make-up.

 Treatment Facilities for Contaminated Water

The pollutants present in the wastewater will be reduced to acceptable levels by adoption of the following schemes.  Recirculating water in the process whereby discharged volume is considerably reduced.  Clarifier and sludge pond for removal of suspended solids.  Removal of oil and grease from the contaminated water by means of oil traps and skimming devices

Water from billet caster secondary spray cooling and open machinery cooling will be collected in a scale pit. Oil skimming facility will be provided. The overflow will be pumped through high-rate pressure filters to cooling tower for cooling. Chemical dosing facilities will be included. The water collected in a cold well will be re-circulated to the system by cold well pumps. The waste backwash from pressure filters will be treated in a thickener. Thickener overflow will be recycled while the underflow will be dewatered in vacuum drum filters to produce an inert filter cake. A similar facility will be provided for treatment of direct cooling water for wire rod mill.

 Monitoring of Effluents

The characteristics of the effluents from the proposed mini-steel plant will be maintained so as to meet the requirements of State Pollution Control Board and the minimum national standards for effluent from steel plants. Air quality monitoring will also be undertaken to ensure that the dust pollution level is within limits.

 Disposal of Effluent

As discussed above, the plant has been provided with extensive re-circulation systems to minimise make-up water consumption as far as possible. Other effluent streams such as cooling tower blow down and miscellaneous intermittent water such as floor washings; laboratory effluent etc. will be combined and re-used for greenbelt irrigation, gardening, fugitive dust suppression etc. Plant sewage is segregated from industrial waste and will be treated in septic tanks.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT (0.2 MTPA) WITH CPP (12 MW)

Table-2.12: Water Balance (Quantities are expressed in m3/hr) Sr. Location Make-up Evaporation Blow down / Waste Treatment & Disposal No. losses water generation A Sponge Iron Plant 20.0 16.0 4.0 Recycled to cooling tower B Captive Power Plant 12.0 10.0 2.0 Collected in guard pond and reuse for spraying, gardening etc. C Induction furnace 21.0 21.0 -- D Rolling Mill 15.0 12.0 3.0 Treated in scale pit and recycled E Miscellaneous uses such as for 2.0 0.5 1.5 Collected and treated in ablution block, drinking water, septic tank followed by soak losses etc pit Total 70.0 59.5 10.5

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

2.9.5 Noise Pollution

All equipment, machinery and instruments of the plant would be designed / operated to have a total noise level not exceeding 85 to 90 dB(A) as per the requirement of OSHA (Occupational Safety and Health Administration) standard and the Environment (Protection) Rules.

Since most of the noise generating equipment will be in enclosed structures, the noise transmitted outside would be still lower. Noise pollution will be contained by providing insulating caps and aids at the exit of noise sources, providing acoustic sealing and shock absorbing techniques, and adopting good equipment maintenance practices.

Table-2.13: Expected Noise Levels From the Proposed Plant

Sr. No. Unit Sound Level, dB(A) 1 Induction furnace plant 80 2 Billet casting machine section 80 3 Rolling mill section 85 4 Material handling 75 5 Material charging and conveying 75 6 Compressor 80 7 Pump House 80 8 ID fans 85 9 Power Plant & Cooling Tower 90

2.10 SOCIAL COMMITMENT

Through this Project, ILC intent to develop surrounding villages and provide them following facilities:

Direct & indirect employment opportunities on merit, with particular preference to the families who have sold their respective lands to us Education upto secondary level school Health through Hospital (equipped with emergency needs), Hygiene & Sanitation Drinking water facility Improved road network Gardens/ Play grounds

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

CHAPTER – 3 BASELINE ENVIRONMENTAL STATUS

3.1 INTRODUCTION

This Chapter describes the existing environmental setting within core as well general study area of 10 km radius around the Project site.

The existing environmental setting adjudges the baseline conditions which are described with respect to climate, air quality, hydrogeological aspects, water quality, soil quality, vegetation pattern, ecology, socio-economic profile, land use and places of archaeological importance. This also reflects the impact due to existing industries and other activities prevailing in that area.

Reconnaissance survey of the study area was carried out for selection and finalization of sampling location for monitoring various environmental attributes.

The report incorporates the data monitored for the period of March, 2008 to May, 2008 representing summer season. Secondary data has been collected from various Government, Semi-Government, Public Sector organizations and institutions. The details of the sampling location in the study are given in Table-3.1.1 and depicted in Figure-3.1.1.

Table-3.1.1: Baseline Data Generation

Sr. Environmental Attribute Criteria Adopted No. 1. Landuse pattern General in 10 km study area through Satellite Imagery interpretation 2. Soil Quality Sampling at 6 locations viz: Halvarti (S1), Kunikeri tanda (S2), Hire bagnal (S3), Allanagara (S4), Hire Kasakandi((S5), and Chikkabagnal (S6) 3. Geology and General in 10 km Study Area geohydrology 4. Meteorology Regional pattern through IMD Data and data generated during the study period at the project site 5. Ambient Air Quality Sampling at 8 locations viz: Halavarti (A1), Hirebagnal (A2), Hire Kasinkandi (A3), Allanagara (A4), Chikkabangnal ((A5), Kunikeri Tanda (A6), Ginigera (A7) and Hosa Kanakapura (A8)

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

Sr. Environmental Attribute Criteria Adopted No. 6. Water Quality Surface Water Sampling at 1 location viz: Tungabhadra Reservoir (SW1)

Ground Water Sampling at 8 locations viz: Chikkabangnal (GW1), Kunikera (GW2), Kunikeri Tanda (GW3), Halvarti (GW4), Allanagara ((GW5), Hire Kasinkandi (GW6), Hosa Kanakapura (GW7) and Ginigera (GW8) 7. Noise levels Sampling at 6 locations viz: Halvarti (N1), Kunikeri Tanda (N2), Hirebagnal (N3), Allanagara (N4), Hire Kasinkandi (N5), and Hosa Kanakapura (N6) 8 Ecology 3 Sampling locations for Terrestrial Ecology, viz: Halvarti (TE1), Hirebagnal (TE2) and Hire Kasakandi (TE3)

1 Sampling location for Aquatic Ecology viz: Tungabhadra Reservoir (AE1) 9 Socio-economics and General in 10 km study area through District Census Demography Data of 2001

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

3.2 LAND USE

For establishing the existing land use pattern in the study area, satellite imagery (IRS P6, LISS III) of 31st December 2008 is interpreted and land use map is prepared for 10 km zone. The details are elaborated below:

3.2.1 Methodology

Remote Sensing data is a classic source of information on natural resources for a region and provides a record of the continuum of resource status because of its repetitive coverage. Remote Sensing is a powerful and accurate means of collecting data. The study of satellite imagery gives an excellent opportunity to monitor the quantitative extent of vegetation cover as well as qualitative changes due to changes in environment. This aspect is very significant in understanding the dynamics of the earth surface features and phenomenon such as various ecosystems. The present study has been divided into three steps:

1. Creation of input database. 2. Analysis. 3. Preparation of final output

3.2.2 Data

 Topographical sheet (SOI) scale 1:50,000 No., 57A/3, 57A/4, 57A/7 and 57A/8 were studied for spatial features, ground control points, latitude, longitude and geo-registration of the satellite imageries.  The image used for this study was IRS P6, LISS III, 31st December 2008, Path 98/99, Row 62.

3.2.3 Data Processing

 Image Restoration

Image restoration aims to correct the distorted or degraded image data to create a more faithful representation of the original scene. This typically involves the initial processing of raw image data to correct for geometric distortions and to calibrate the data radio-metrically. Image rectification and restoration procedures are often termed as processing operations because they normally precede manipulation and analysis of the image data to extract specific information.

 Radiometric Correction

First order correction was done by dark pixel subtraction technique (Lilles and Keifer, 1979). This technique assumes that there is a high probability that there are at least a few pixels within an image, which should be black (0% reflectance). However, because of atmospheric scattering, the image system records a non- zero DN value at the supposedly dark shadowed pixel location. This represents the DN value that must be subtracted from the particular spectral band to remove the first order scattering component.

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RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

 Geometric Correction

Raw digital images usually contain geometric distortions so significant that they cannot be used as maps. The source of these distortions range from variation in the altitude, and velocity of sensor platform, to factors such as panoramic distortion, earth curvature, atmospheric refraction, relief displacement and non-linearities in the sweep of a sensor‟s IFOV. The intent of geometric correction is to compensate for the distortion introduced by these factors, so that the corrected image will have the geometric integrity of a map. Images were registered geometrically using toposheet of Survey of India (SOI) on 1:50,000 scale. The common uniformly distributed Ground Control Points (GCP‟s) were marked with root mean square error of one third of a pixel and the image was re-sampled by nearest neighbor method. The data set was then co-registered for further analysis.

3.2.4 Satellite Image Interpretation

The analogue data received from NRSA, Hyderabad was downloaded into the system and a land-use map was prepared. The first step involved was the preparation of standard FCC (using LISS band 4, 3 and 2) and unsupervised classification map of the study area, which was followed by the ground truthing of the image and identification of Ground Control Points for the geo-registration of the images. On screen digitization was carried out using Window based Arcview 3.2 a GIS software and final layouts were prepared. Various thematic layers were digitized on the SOI toposheet-1976 (57A/12 and A/16) scale 1:50,000. The layers are: - Creating 10 Km buffer Digitizing various topographic features - roads, drainage, waterbody, contours, settlements etc.

3.2.5 Reconnaissance Survey & Ground Truthing

Reconnaissance visit was undertaken for broad understanding of the study area. It was vital for obtaining and visualizing the information pertaining to the existing field conditions, assessment of the accessibility of the area, pattern and distribution of vegetation and its composition.

Ground truthing is the process of establishing the correlation between the surface objects and the objects detected, identified, recognized and deduced from the satellite imagery. The occurrence of a particular vegetation type on the ground was correlated with its tonal appearance on satellite images for identification.

3.2.6 Land-use Classification

A hybrid land use classification has been done using unsupervised classification with hundred classes and recoding into final five classes. The bands 3,2,1 were found to be most appropriate. Finally 5 classes were derived and the image of 31st December 2008 was classified. The classified land use pattern for 10 km radius is given in Table-3.2.1 and represented in Figure-3.2.1. The False Colour Composite of the area is presented in Figure-3.2.2 while the classified land use map of the study area is presented in Figure- 3.2.3. ILC Industries Ltd. 47

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

Table-3.2.1: Land-use Classification

Sr. No. Land Use Area, ha Area, % 1 Built-up Area 1028.24 2.75 2 Industry/Institutional Area 194.29 0.52 3 Double Crop 4565.42 12.23 4 Un-irrigated Area 15029.91 40.27 5 Land with/without Scrub 6459.92 17.30 6 Plantation 478.03 1.28 7 Stony/rocky/Barren Area 2325.16 6.23 8 Water Body 7243.49 19.42 Total 37324.46 100.00

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3.2.6.1 Land Use Pattern

Built-up: constitutes about 2.75%. This is represented by habitation mainly at Koppal (NW of site) and Ginigera (N of site).

Industry / Institutional Area: constitutes very little part i.e. 0.52% of study area.

Double crop: constitutes about 12.23%. This area is observed near Tungabhadra reservoir / back water.

Un-irrigated Area: constitutes about 40.27%. This forms the major part of study area.

Land with / without scrub: constitutes about 17.30%. This is found in S-E quadrant of study area.

Plantation: constitutes about 1.28%. This is sparsely occurring in study area.

Stony / rocky / barren area: constitutes about 6.23%. These are scattered in a study area. It is mainly sheet rocks and rocky knobs.

Waterbody: constitutes about 19.42%. The major water body is Tungabhadra reservoir followed by natural ponds near Ginigera (N of site) and Kunikera (SW of site).

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Figure 3.2.2: False Colour Composite (FCC) of The Study Area

2008

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Figure 3.2.3: Classified Land Use Map of Study Area

2008

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3.3 SOIL CHARACTERISTICS

Soil formation is influenced mainly by climate, geology, relief and other biotic interactions. The type of soil observed in the study area is Medium black cotton soil, Red sandy soil and Mixed red and black cotton soil.

Medium black cotton soil is found in the western and northern part of the study area where peninsular gneiss types of rocks are predominant. It is neutral to alkaline in nature having low permeability.

Red sandy soil is found in the southern and southeastern part of the study area. It is light to dark brown in colour. It is neutral to acidic in nature having moderate permeability.

Mixed red and black cotton soil is generally found in northern and northeastern part of study area.

Agricultural economy and rapid industrialization go hand in hand in this area. Hence it is essential to identify the impacts in the study area on the soil characteristics, which would affect the agricultural, and afforestation potential. Accordingly, an assessment of the baseline soil quality has been carried out.

3.3.1 Data Generation

For studying soil profile of the region, sampling locations were selected to assess the existing soil conditions in and around the project area.

The sampling locations have been identified with the following objectives:

To determine the baseline soil characteristics of the study area; To determine the impact of proposed activity on soil characteristics; and To determine the impact on soils more importantly from agricultural productivity point of view.

Six locations within 10-km radius of the proposed project site were selected for soil sampling. At each location, soil samples were collected from three different depths viz. 30 cm, 60 cm and 100 cm below the surface. The details of the sampling locations are given in Table-3.3.1 and are depicted in Figure-3.1.1.

Table-3.3.1: Details of Soil Sampling Locations

Code Location Distance w.r.t. Direction w.r.t. site Center (km) Site S1 Halvarti 3.0 NW S2 Kunikeri Tanda 2.3 WSW S3 Hire bagnal 1.8 ENE S4 Allanagara 3.0 NNE S5 Hire Kasinkandi 4.5 ESE S6 Chikkabagnal 3.2 SSE

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3.3.2 Baseline Soil Status

The analysis of soil samples for all locations is presented in Table-3.3.2. The results are compared with standard classification given in Table-3.3.3.

Table- 3.3.2: Soil Analysis Results

Sr. No. Parameter S1 S2 S3 S4 S5 S6 1. pH 8.3 7.6 7.3 7.5 7.9 7.4 2. Electrical Conductivity 18 59 127 68 146 43 ( S/cm) 3. Nitrogen (Available) 23 18 15 13 29 20 4. Phosphorous (Av) 5 10 9 12 5 16 5. Potassium (Av) 10 8 4 17 9 12 6. Sulphates 39 48 27 64 40 5 7. Iron 18 22 20 17 20 21 8. Organic matter (%) 1.98 1.51 1.30 1.87 2.21 1.09 9. Organic carbon (%) 0.42 0.27 0.31 0.49 0.38 0.25 10. Water Storage Capacity (%) 23 21 17 15 18 19 11. Texture Fine Fine Fine Coarse Coarse Coarse sand sand sand sand sand sand Note: Sr. No.- 3 to 7 are expressed in Kg/ha

Table-3.3.3: Standard Soil Classification

Sr. No. Soil Test Classification 1 pH <4.5 Extremely acidic 4.51- 5.00 Very strongly acidic 5.51-6.0 moderately acidic 6.01-6.50 slightly acidic 6.51-7.30 Neutral 7.31-7.80 slightly alkaline 7.81-8.50 moderately alkaline 8.51-9.0 strongly alkaline 9.01 very strongly alkaline 2 Salinity Electrical Conductivity Upto 1.00 Average (mmhos/cm) 1.01-2.00 harmful to germination (1mmho/cm = 640 ppm) 2.01-3.00 harmful to crops 3 Organic Carbon(%) Upto 0.2: very less 0.21-0.4: less 0.41-0.5 medium, 0.51-0.8: on an average sufficient 0.81-1.00: sufficient >1.0 more than sufficient 4 Nitrogen (Kg/ha) Upto 50 very less 51-100 less 101-150 good 151-300 Better >300 sufficient

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Sr. No. Soil Test Classification 5 Phosphorus (Kg/ha) Upto 15 very less 16-30 less 31-50 medium, 51-65 on an average sufficient 66-80 sufficient >80 more than sufficient 6 Potassium (Kg/ha) 0 -120 very less 121-180 less 181-240 medium 241-300 average 301-360 better >360 more than sufficient Source: ICAR (Indian Council for Agricultural Research)

3.3.3 Analysis

The soil in the study area is observed to be deep and moderately well drained soils. It has been observed that the pH of the soil ranged from 7.3 – 8.3 indicating that the soils are slightly to moderately alkaline in nature. The soil in the study area is predominantly coarse to fine sand. The Electrical Conductivity was observed to be in the range of 18-146 S/cm.

The Nitrogen levels ranged between 13-29 kg/ha. The nitrogen levels of the soils in the region indicate that soils have very less nitrogen levels. The Phosphorus levels ranged between 5-16 kg/ha, which indicates very less to less quantity of Phosphorus. The Potassium values ranges between 4-17 kg/ha indicating that the soils have very less quantity of Potassium. The organic carbon values ranges from 0.25-0.49%, which indicates less to medium quantity of organic carbon. The soil from the study area shows moderate fertility.

3.3.4 Cropping Pattern

The soils in this region yield the crop of Groundnut, Sugarcane, Red gram, Rice and Wheat as cash crops. Other crops grown are Sunflower, Jawar and Bajra. Important fruit crops grown in this area are Mango, Papaya, Banana, Guava and Jamun. Vegetable crops grown are Tomato, Brinjal and Capsicum.

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3.4 GEOLOGY AND HYDROGEOLOGY

3.4.1 Physiography

The study area forms part of Central Karnataka Plateau. The region represents the transitional surface between the Northern Karnataka Plateau of Deccan Trap and southern Karnataka Plateau with relatively higher surface. By and large, this region represents the area of Tungabhadra basin.

The topography of the study area is characterized with rolling plain with small hill ranges made up of granites, Dharwar schists and gneisses. These hill ranges stretches out in northwest to southeast in direction. Patches of sheet rocks are found scattered all over the area with very little natural vegetation. The average ground level of the plains is between 500-530 metres above MSL and that of hills is between 530-730m above MSL.

3.4.2 Drainage

Tungabhadra river is the main river located in southeast direction and is flowing towards east. Several small streams are flowing in the study area; all of them ultimately drain in Tungabhadra River. Natural ponds are found in Ginigera, Kanakapura and Kerehalli village.

3.4.3 Geology

Geology of the study area belongs to Archean age. The study area falls in the Basin of Tungabhadra River. The area is having undulating topography with granite hills composed of Dharwar schists.

Arrangement of strata in study area is given below.

Pleistocene and recent reddish brown and black soils Penninsular Complex Granite porphy Pink and gray gneiss‟s Dharwar Super Group Furryginous Quartzites Granodiorite rock Quartzite Amphibolite

Important minerals found in the study area are copper, corundum, feldspar, galena, gold, illimenite, iron ore, mica, quartz, red ocher, steatite, building stone etc. Quartz deposits are found at Allanagar and Hirebagnallu.

3.4.4 Hydrogeology

The occurrence, nature and movement of groundwater in the district is entirely dependent upon the topographical setting of the area and the geological formations encountered. The black cotton soil areas have the impervious calcareous clay bed below them which prevents the downward movement of water. Whereas, the red loam/sandy soil areas due to their relatively higher porosity and permeability have greater percolation. As the study area receives scanty rainfall, recharge of ground water is greatly affected. Therefore the depth of

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water table in the area ranges from 7m to 10 m below ground level. However the depth of ground water table is found to be much at surface levels in canal command areas. The ground water movement appears to be from north-west to south and from south-east towards Tungabhadra River.

The study of fluctuation in ground water level by the Ground water Board (GWB) reveals that the fluctuation is in order of 1.65 m to 4.42 m with an average fluctuation of 3.13 m. Dug wells located in the valley areas and canal command areas yield better ground water. The medium and deep aquifers are mainly confined between 30 to 80 m depths in the semi weathered to fractured zones.

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3.5 METEOROLOGY

Air quality of the region is governed by the meteorology of that region hence the data recorded is very useful for proper interpretation of the baseline information as well as for input prediction models for air quality dispersion.

The methodology adopted for monitoring surface observations is as per the standard norms laid down by Bureau of Indian Standards (IS: 8829) and India Meteorological Department (IMD). The generated data is then compared with the meteorological data generated by nearest IMD station at Bellary.

Hourly average, maximum and minimum values of wind speed, direction, humidity temperature and rainfall were recorded at the site. This station was in operation from March 2008 to May 2008 covering summer season.

3.5.1 Climatological Data – IMD Bellary

The climate of the region is generally hot. Four prominent seasons are observed namely winter season (December to February), summer season (March to May), monsoon season (June to September) and post-monsoon season (October to November).

The Climatalogical data was obtained from IMD Bellary for the period of ten years (year 1991-1997, 1999 and 2002-2003). The secondary data thus obtained is discussed below.

The wind pattern as per the IMD observations shows that monthly mean wind speed is in the range of 2.8 km/hr observed in the month of November to 10.8 km/hr observed in the month of July. The wind speeds up in velocity during monsoon season ranging between 6.3-10.8 km/hr. The winds are relatively low in the post monsoon and winter season and moderate in summer season. The monthly mean wind speed during post monsoon season ranges between 2.8-3.6 km/hr. In winter season the wind speed is observed in the range of 2.9-3.9 km/hr, while in summer season the wind speed varies from 3.7-6.3 km/hr. The annual wind pattern shows the prominent wind directions as west, northwest followed by east and southeast.

According to IMD Bellary, April is the hottest month in the season with maximum temperature of 41.5oC, while December is the coldest month with mean minimum temperature of 10.7oC. The annual average of maximum and minimum mean monthly temperatures is 35.8oC and 14.9oC respectively. During the summer season the temperature increase rapidly with mean monthly temperature of 41.5 oC in April and mean minimum temperature of 15.0oC in March. Temperature drops a little on the on set of monsoon season and varies between 37.8oC (June) to 16.1oC (September). During post monsoon season the temperature shows further slide and ranges between 34.2oC (October) to 13.6oC (November). In the winter season the temperature is observed between the range of 36.1oC in the month of February and 10.7oC in the month of December.

The average annual relative humidity is found to be in the range of 63% at 0830 hrs and 44% at 1730 hrs. The pre-monsoon period is the driest part of the year with mean maximum relative humidity around 70% at 0830 hrs and 34% at 1730hrs, while the minimum humidity is observed at around 30% at 0830 hrs and 19% at 1730 hrs. The monsoon period is marked with highest humidity of 79% (September) at 0830 hrs and 65% (July) at 1730hrs, while the ILC Industries Ltd. 57

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minimum humidity is observed at around 60% (June) at 0830 hrs and 30 % (September) at 1730 hrs. In post monsoon season the maximum humidity ranges between 79% at 0830 hrs and 69% at 1730 hrs both in the month of October, while minimum is found to be in the range of 66% at 0830 hrs and 46% at 1730hrs both in the month of November. In winter season the maximum relative humidity observed at 0830 hrs is 84% and 60% at 1730 hrs both in the month of December. The minimum value observed at 0830 hrs is of 45% and at 1730 hrs is 22% both in the month of February.

Atmospheric pressure is relatively stable and does not show high variation. The annual average atmospheric pressure was in the range of 960.22 hPa at 0830 hrs and 956.23 hPa at 1730 hrs. In the summer season the mean pressure values at 0830 hrs and 1730 hrs are observed to be in the range of 962.7 to 956.2 hPa and 958.5 to 955.0 hPa respectively. During monsoon season the mean pressure level values at 0830 hrs are in the range of 960.7 hPa in September and 954.6 hPa in July, whereas at 1730 hrs the range is observed to be 956.4 occurring in September and 952.2 hPa occurring in the month of July. The values observed during post monsoon season is observed to be in the range of 960.7-954.6 hPa at 0830 hrs with minimum occurring during July and maximum pressure occurring during September. at 1730 hrs the pressure observed in the range of 956.4 to 952.2 hPa with maximum occurring in the month of September and minimum in the month of June. During the winter season pressure at 0830 hrs and 1730 hrs is observed to be in the range of 965.7 to 960.9 hPa and 965.1 to 956.2 hPa respectively, the maximum occurring in the month of January and minimum in the month of December.

The mean total annual average rainfall received is about 473.17 mm. About 49% of the total annual rainfall is received during the monsoon season. The post monsoon season contributes to 30% of annual rainfall.

The wind pattern as recorded by IMD Bellary is given in Table-3.5.1 while it is shown in Figure-3.5.1 and 3.5.2 respectively for 830 hrs and 1730 hrs. The climatological data is tabulated in Table-3.5.2. Month-wise IMD data regarding temperature, relative humidity, atmospheric pressure and rainfall is presented graphically in Figure-3.5.3 through 3.5.6.

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Table-3.5.1: Wind Pattern – IMD Bellary

Wind Speed Seasonal % frequencies and predominant directions (kmph) Annual Summer Monsoon Post- Winter monsoon Data Recorded at 0830 hr 0 – 1.0 (CALM) 23.3 35.00 9.22 36.7 21.8 1.01 - 19.0 76.1 65.00 88.9 63.3 78.2 20.0 - 61.0 1.00 0.00 2.00 0.00 0.00 >62.0 0.00 0.00 0.00 0.00 0.00 Predominant wind directions 1 W NW W E E 2 NW W SW NE SE 3 E & SE SE & NE NW SE NE Data Recorded at 1730 hr 0 - 1.0 (CALM) 4.2 5.1 1.5 11.0 2.1 1.01 - 19.0 92.9 94.4 90.3 88.9 97.9 20.0 - 61.0 3.0 0.46 8.0 0.00 0.00 >61.0 0.00 0.00 0.00 0.00 0.00 Predominant wind directions 1 W NW W E E 2 NW SE NW NE SE 3 SW & E NE SW SE NE Source: IMD Bellary

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Figure-3.5.1: IMD Wind Rose at 830 Hrs.

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Figure-3.5.2: Wind Rose at 1730 Hrs.

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Table-3.5.2: Climatological Data – IMD Bellary

Mean Monthly Monthly Mean Wind Month Atmospheric Pressure (hPa) Temperature (0C) Relative Humidity (%) Total speed Rainfall (km/hr) (mm) 0830 hrs 1730 hrs 0830 hrs 1730 hrs Max. Min Max. Min Max. Min. Max Min Max Min January 965.7 962.9 965.1 958.0 32.4 10.8 80 64 49 31 3.15 11.7 February 963.7 961.9 960.1 956.4 36.1 11.3 69 45 45 22 3.9 2.8 March 962.7 959.0 958.5 955.0 39.0 15.0 52 31 30 19 3.7 4.47 April 962.3 958.6 956.2 952.8 41.5 17.1 54 30 34 24 4.6 17.1 May 959.7 956.2 954.4 951.1 41.2 18.2 70 31 44 23 6.3 49.1 June 958.3 955.7 954.5 952.2 37.8 17.4 71 60 53 41 10.0 75.8 July 957.4 954.6 953.7 952.4 34.6 17.2 70 66 65 48 10.8 25.7 August 958.5 955.5 955.5 953.8 34.3 16.5 75 67 51 63 9.9 50.6 September 960.7 957.7 956.4 955.7 34.9 16.1 79 66 49 30 7.0 80.5 October 964.2 959.7 959.6 955.2 34.2 15.1 79 69 69 48 3.6 98.7 November 964.5 959.8 960.4 955.3 32.1 13.6 78 66 66 46 2.8 42.7 December 965.1 960.9 961.1 956.2 32.0 10.7 84 60 60 40 2.9 14.0 Source: Meteorological Data- IMD Bellary for the year 1991-1997, 1999, 2002-2003

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Figure-3.5.3: Mean Monthly Temperature – IMD Bellary

Mean Monthly Temperature 50

40

C o 30

20 Max.

Min. Temperature 10

0 Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec

Month

Figure-3.5.4: Mean relative humidity – IMD Bellary

Mean Relative Humidity (%) 100

80

60

40

20 Relative Humidity (%) 0 Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Month

0830 hrs Max 0830 hrs Min 1730 hrs Max 1730 hrs Min

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Figure-3.5.5: Atmospheric pressure levels – IMD Bellary

Atmospheric Pressure Level

970

965

960

955

950

945

Atmospheric Pressure (hPa) Atmospheric Pressure 940 Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec Month

0830 hrs Max. 0830 hrs Min 1730hrs Max. 1730hrs Min

Figure-3.5.6: Mean monthly total rainfall – IMD Bellary

Mean Monthly Total Rainfall

110 100 90 80 70 60 50

40 Rainfall (mm) Rainfall 30 20 10 0 Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec

Month

Monthly Total Rainfall (mm)

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3.5.2 Meteorological Data - Project Site

The meteorological data was recorded at the project site during the study period (March 2007- May 2007) and indicates that the winds were light to moderate with the predominant wind direction as north west followed by north northwest. The maximum wind speed observed during the study period is 21.5 km/hr while minimum wind speed is 0.2 km/hr. The mean wind speed is observed as 3.4 km/hr. Maximum temperatures were observed in the month of May (41.0oC) while the minimum temperatures (19.4oC) were recorded in the month of April. Humidity was observed to be low during the month of March while the maximum humidity was recorded in the month of May. Average Rainfall of 23mm was recorded during the study period. Atmospheric pressure was uniform and not much variation was observed in the morning and evening atmospheric pressure.

The monthly average, maximum and minimum values of the parameters recorded during the study period are presented in Table-3.5.3 while the wind pattern during the study period is presented as wind rose in Figure-3.5.7.

Table-3.5.3: Micro-Meteorological Data - Project Site

Wind Tempe- Atmospheric Month Relative Humidity (%) Speed rature (oC) Pressure (hPa) (Km/hr) 0830 hrs 1730 hrs 0830 hrs 1730 hrs Max Min Max Min Max Min Max Min Max Min Max Mi n March 38.6 20.7 72.4 29.3 50.8 20.5 958.2 948.3 957.4 950.6 18.2 0.2 April 39.8 19.4 78.3 28.7 56.2 22.0 960.4 954.8 954.1 947.3 21.5 0.8 May 41.0 23.1 85.2 31.7 59.4 22.9 957.7 950.5 951.6 945.8 16.9 1.5 Study Period 30.4 54.2 38.6 954.9 951.1 3.4 Average

3.5.3 Conclusions

The India Meteorological Department (IMD) records the data twice a day viz. at 0830 and 1730 hr. The site-specific data have been recorded at hourly interval. On comparison of site specific data generated at site vis-à-vis the IMD data, slight variations were observed. The variations may be due to the frequency, time of recording, height of the station and difference in the locations. In general, the data generated at site when compared with the data recorded at the IMD is observed to be reasonably consistent with the regional meteorology.

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Figure-3.5.7: Wind Rose at Project Site

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3.5.4 Upper Air Data

The upper air climatological data assumes significance as the assessment of air pollutants dispersion is influenced by these conditions. The nearest station to study area recording upper winds, is Bangalore situated at an aerial distance of 350 km from project site and the same data has been presented for the analysis as the upper air data will not change significantly at this distance for the present case.

3.5.4.1 Upper Wind/Upper Air Climatological Data

The upper air climatological data is presented below for ground and elevated inversion layers at 0530 (0000 GMT) and 1730 (1200 GMT).

Inversions and Stable Layers Near Ground

A stable layer could either form at the ground or at an elevation. In the latter case, it becomes necessary to completely define it by its base, top and thickness. The base has been taken as the level at which the lapse rate leading to stability commences, the top, where it terminates with the difference between the two providing the thickness. For the study of frequency distribution of stable layers, the atmosphere within the boundary layer (1.5 km) has been divided in to thirteen layers, first ten are at an interval of 100 m followed by two layers of 250 m each by the Indian Meteorological Department.

Data available on stable layers (ground based and elevated inversions), both for morning (00 GMT) and afternoon (12 GMT) data have been compiled from the data published by India Meteorological Department. Percentage frequencies of stable layers (Inversion) both for ground based and elevated inversions, in respect of Bangalore are tabulated in Table-3.5.4 and 3.5.5. a) Ground Based Inversions

The frequencies, in percent of ground based inversions at 00 and 12 GMT hours are given in Table-3.5.4.

Table-3.5.4: Percentage Frequencies Ground Based Inversions (IMD Bangalore)

Range (m) Pre- Monsoon Post Winter monsoon Monsoon 00 12 00 12 00 12 00 12 GMT GMT GMT GMT GMT GMT GMT GMT 0 - 100 8 3 6 2 5 5 7 3 101 - 200 5 1 0 0 1 0 12 1 201 - 300 1 1 0 0 0 0 5 0 301 - 400 2 0 1 0 0 0 6 0 401 - 500 4 0 0 0 1 0 2 0 501 - 600 11 0 0 0 2 0 7 0 601 - 700 1 0 0 0 0 0 6 0 701 - 800 0 0 0 0 0 0 0 0 801 - 900 2 0 0 0 0 0 0 0 901 - 1000 0 0 0 0 0 0 0 0

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Range (m) Pre- Monsoon Post Winter monsoon Monsoon 00 12 00 12 00 12 00 12 GMT GMT GMT GMT GMT GMT GMT GMT 1001 - 1250 0 0 0 0 0 0 0 0 1251 - 1500 0 0 0 0 0 0 0 0 > 1500 0 0 0 0 0 0 0 0 b) Elevated Inversions

The frequencies in percent of elevated inversions at 00 and 12 GMT hours are given in Table- 3.5.5.

Table-3.5.5: Percentage Frequencies Elevated Inversions ((IMD Bangalore)

Range (m) Pre-monsoon Monsoon Post Monsoon Winter 00 12 00 12 00 12 00 12 GMT GMT GMT GMT GMT GMT GMT GMT 0 - 100 0 0 0 0 0 0 0 0 101 - 200 0 0 0 0 0 0 0 0 201 - 300 1 0 0 0 0 0 3 0 301 - 400 4 0 0 0 2 0 5 0 401 - 500 1 1 3 0 1 0 3 0 501 - 600 19 1 9 7 10 1 24 7 601 - 700 3 0 2 0 1 0 13 1 701 - 800 2 0 2 0 1 1 7 0 801 - 900 4 0 0 1 1 0 10 1 901 - 1000 4 0 2 0 1 1 5 0 1001 - 1250 14 4 10 5 6 10 26 9 1251 - 1500 1 0 4 1 9 2 6 10 > 1500 0 0 1 0 0 0 2 1

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3.6 AMBIENT AIR QUALITY

The ambient air quality within study area around the project site forms the baseline information. The sources of air pollution in the region are vehicular traffic, dust arising from unpaved roads and domestic fuel burning. The prime objective of the baseline air quality study was to establish the existing ambient air quality of the area. This will also be useful for assessing the conformity to standards of the ambient air quality during the operation of the proposed project.

3.6.1 Methodology Adopted for the Study

The baseline status of the ambient air quality has been established through a scientifically designed ambient air quality monitoring network and is based on the following considerations:

Meteorological conditions of the area; Topography of the study area; Representatives of background air quality/pollution pockets for obtaining baseline status; and Representatives of likely impact areas.

Ambient Air Quality Monitoring (AAQM) stations were set up at eight locations with due consideration to the above-mentioned points and as per the MoEF guidelines for AAQM. The location of the selected stations with reference to the project site is given in Table-3.6.1 and depicted in Figure-3.1.1.

Table-3.6.1: Ambient Air Quality Monitoring Locations

Station Name of the Distance w.r.t. Direction w.r.t. Zone Code Station Project site site Center (km) A1 Halvarti 3.0 NW Rural/Residential Zone A2 Hirebagnal 1.8 ENE Rural/Residential Zone A3 Hire Kasinkandi 4.5 ESE Rural/Residential Zone A4 Allanagara 3.0 NNE Rural/Residential Zone A5 Chikkabangnal 3.2 SSE Rural/Residential Zone A6 Kunikeri Tanda 2.3 WSW Rural/Residential Zone A7 Ginigera 5.3 NNE Rural/Residential Zone A8 Hosa 5.0 NE Rural/Residential Zone Kanakapura

3.6.2 Frequency and Parameters for Sampling

The ambient air quality parameters along with their frequency of sampling are given in Table- 3.6.2.

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Table-3.6.2: Monitored Parameters and Frequency of Sampling

Parameters Sampling Frequency Suspended Particulate Matter, SPM 24 hourly sample twice a week for three months. Respirable Particulate Matter, RPM 24 hourly sample twice a week for three months. Sulphur dioxide, SO2 24 hourly samples twice a week for three months. Oxides of Nitrogen, NOx 24 hourly samples twice a week for three months. Carbon monoxide, CO 8 hourly samples for 24 hour twice a week for three months.

3.6.3 Instruments used for Sampling

Respirable dust samplers (RDS) were used for monitoring of Total Suspended Particulate Matter (TSPM), Respirable Particulate Matter (RPM) and gaseous pollutants like SO2 and NOx. Glass tubes are deployed for collection of grab samples of Carbon monoxide. Gas Chromatography techniques have been used for the estimation of CO.

3.6.4 Sampling and Analytical Techniques

The techniques used for ambient air quality monitoring and its minimum detectable levels are given in Table-3.6.3.

Table-3.6.3: Techniques used for Ambient Air Quality Monitoring

Sr. Parameter Technique Technical Minimum No. Protocol Detectable Limit ( g/m3) 1 Total Suspended Respirable Dust Sampler IS-5182 (Part-IV) 1.0 Particulate Matter (Gravimetric method) 2 Respirable Respirable Dust Sampler IS-5182 (Part-IV) 1.0 Particulate Matter (Gravimetric method) 3 Sulphur Dioxide Modified West and Gaeke IS-5182 (Part-II) 4.0 4 Nitrogen Oxide Jacob & Hochheiser IS-5182 (Part-VI) 4.0 5 Carbon Monoxide Gas Chromatography IS-5182 (Part-X) 0.01-ppm

3.6.5 Presentation of Results

Various parameters like 98th percentile, maximum, minimum and average values have been computed from the monitored data for all the AAQ monitoring stations. The summary of these results for each location is presented in Table-3.6.4 while details are given in Annexure-II. These are compared with the standards prescribed by Central Pollution Control Board (CPCB) for Industrial and residential zone tabulated in Table-3.6.5.

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Table-3.6.4: Summary of Ambient Air Quality Concentration Sr. No Location TSPM RPM SO2 NOX CO (µg/m3) (µg/m3) (µg/m3) (µg/m3) (ppm) 1 Halvarti Maximum 108.0 61.0 15.4 17.3 0.084 Minimum 63.0 39.0 7.5 8.9 0.028 Average 80.4 48.4 11.5 12.2 0.051 98th Percentile 105.0 60.0 15.3 16.5 0.083 Standard Deviation 12.1 6.1 2.2 2.0 0.015 2. Hire Bagnal Maximum 99.0 59.0 14.1 17.4 0.114 Minimum 76.0 46.0 10.5 12.9 0.064 Average 85.2 51.4 12.2 14.5 0.074 98th Percentile 97.0 58.0 14.0 16.8 0.104 Standard Deviation 5.4 3.3 1.0 1.2 0.011 3. Hire Kasinkandi Maximum 168.0 69.6 18.2 20.6 0.068 Minimum 80.0 44.8 10.3 12.9 0.022 Average 132.5 56.6 14.3 16.4 0.048 98th Percentile 165.0 69.0 18.2 20.4 0.067 Standard Deviation 22.5 7.0 2.2 2.1 0.011 4. Allanagara Maximum 117.0 61.0 17.3 18.6 0.071 Minimum 68.0 42.0 10.2 10.8 0.016 Average 86.2 52.8 13.4 14.3 0.044 98th Percentile 112.0 60.0 16.9 18.0 0.069 Standard Deviation 12.0 4.0 1.8 2.1 0.016 5. Chikkabangnal Maximum 98.0 57.0 18.4 19.5 0.062 Minimum 52.0 39.0 9.9 11.8 0.011 Average 73.6 47.1 13.8 14.8 0.039 98th Percentile 95.0 57.0 17.7 18.4 0.061 Standard Deviation 10.0 5.5 2.2 1.5 0.014 6. Kunikeri Tanda Maximum 105.0 55.0 15.3 16.8 0.047 Minimum 61.0 41.0 8.9 13.2 0.036 Average 80.2 47.5 10.9 15.0 0.040 98th Percentile 99.5 54.0 14.8 16.8 0.046 Standard Deviation 9.6 3.4 1.6 0.9 0.003 7. Ginigera Maximum 172.0 51.9 17.8 35.9 0.098 Minimum 140.0 38.3 9.8 17.6 0.019 Average 151.1 43.3 12.6 26.3 0.034 98th Percentile 170.0 51.0 17.1 35.1 0.073 Standard Deviation 8.8 3.6 2.0 4.7 0.016 8. Hosa Kanakapura Maximum 121.0 54.0 14.3 15.9 0.070 Minimum 74.0 37.0 8.2 11.8 0.034 Average 91.5 46.1 11.9 13.5 0.052 98th Percentile 117.5 53.5 14.3 15.6 0.069 Standard Deviation 11.1 4.2 1.8 1.0 0.011

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Table-3.6.5: Ambient Air Quality Permissible Limits Specified By CPCB

Zone RPM SPM SO2 NOx CO (24-hr. avg.) (24-hr. avg.) (24-hr. avg.) (24-hr. avg.) (8-hr. avg.) g/m3 g/m3 g/m3 g/m3 mg/m3 (ppm) Industrial 150 500 120 120 5.0 (4.36) Residential / 100 200 80 80 2.0 (1.75) Rural Sensitive 75 100 30 30 1.0 (0.87)

Graphical representation of the ambient air quality monitoring results for each of the location is given in figures below.

Figure-3.6.1: Ambient Air Quality Status at Halvarti, A1

Ambient Air Monitoring Results at Halvarti Village

1000.0 108.0

100.0 80.4

63.0 3

61.0

48.4

39.0

17.3

15.4

12.2

11.5 8.9

10.0 7.5

1.0 Concentration in µg/m in Concentration

0.1 0.084

0.051 0.028

0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

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Figure-3.6.2: Ambient Air Quality Status at Hirebagnal, A2

Ambient Air Monitoring Results at Hirebagnal

0

2

.

0

.

.

0

4

.

0

.

.

99

85

76

59

51 4

100.0 46

5

.

9

2

.

.

5

.

.

3

17

14

14.1

12

12 10 10.0

1.0

114

.

074

064

0

.

. 0 0.1 0

0.0 Concentration in in µg/m Concentration TSPM RPM SO2 NOx CO

Parameters Maximum Minimum Average

*CO values are given in ppm

Figure-3.6.3: Ambient Air Quality Status at Hire Kasinkandi, A3

Ambient Air Monitoring Results at Hire Kasinkandi Village

1000.0

168.3

132.5

3 79.9

100.0 69.6

56.6

44.8

20.6

18.2

16.4

14.3 12.9 10.0 10.3

1.0

0.1 0.068

Concentration in µg/m in Concentration 0.048 0.022

0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

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Figure-3.6.4: Ambient Air Quality Status at Allanagara, A4

Ambient Air Monitoring Results at Allanagara Village

1000.0

3

117.0

86.2 68.0

100.0 61.0

52.8

42.0

18.6

17.3

14.3

13.4 10.8 10.0 10.2

1.0

0.1 0.071

0.044

Concentration in µg/m in Concentration 0.016 0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

Figure-3.6.5: Ambient Air Quality Status at Chikkabangnal, A5

Ambient Air Monitoring Results at Chikkabangnal Village

1000.0

3 98.0

100.0 73.6

57.0

52.0

47.1

39.0

19.5

18.4

14.8

13.8 11.8 10.0 9.9

1.0

0.1 0.062

Concentration in µg/m in Concentration

0.039 0.011 0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

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Figure-3.6.6: Ambient air quality status at Kunikeri Tanda, A6

Ambient Air Monitoring Results at Kunikeritanda Village

1000.0

3

105.0 80.2

100.0 61.0

55.0

47.5

41.0

16.8

15.3 15.0

13.2 10.9 10.0 8.9

1.0

0.1

Concentration in µg/m in Concentration 0.047

0.04 0.036

0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

Figure-3.6.7: Ambient air quality status at Ginigera, A7

Ambient Air Monitoring Results at Ginigera Village

1000.0

171.8 3

151.1 139.5

100.0

51.9

43.3

38.3

35.9

26.3

17.8 17.6 12.6 10.0 9.8

1.0

0.1 0.098

0.034

Concentration in µg/m 0.019 0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

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Figure-3.6.8: Ambient air quality status at Hosa Kanakapura, A8

Ambient Air Monitoring Results at Hosa Kanakapura Village

1000.0

121.0

91.5 3

100.0 74.0

54.0

46.1

37.0

15.9

14.3

13.5

11.9 11.8

10.0 8.2

1.0 0.07

Concentration in µg/mConcentration 0.1

0.052 0.034

0.0 TSPM RPM SO2 NOx CO Parameters

Maximum Minimum Average

*CO values are given in ppm

3.6.6 Conclusions

The observations based on a perusal of the survey results are summarized below:

TSPM: The 98th percentile concentration of TSPM ranged between 95.0 -170 g/m3 at all the locations during study period. The maximum value for SPM is observed as 171.8 g/m3 at the Ginigera during the study period. The next highest SPM value was recorded as 168.3 g/m3 at Hire Kasinkandi. As all the locations fall under residential/rural zone, the concentrations are compared with the respective limit set by CPCB for rural and residential zone. Thus, the concentrations at all the locations are found to be well within the prescribed CPCB limit of 200 g/m3.

RPM: The 98th percentile concentration of RPM ranged between 51-69 g/m3 at all the locations during study period. The maximum value for RPM is observed as 69.6 g/m3 at the Hire Kasinkandi during the study period. The next highest RPM value was recorded as 61.0 g/m3 at Halvarti and Allanagara. As all the locations fall under residential/rural zone, the concentrations are compared with the respective limit set by CPCB for rural and residential zone. Thus, the concentrations at all the locations are found to be well within the prescribed CPCB limit of 100 g/m3.

th 3 SO2: The 98 percentile concentrations of SO2 ranged between 14.0-18.2 g/m at all the 3 locations during study period. The maximum value for SO2 is observed to be 18.4 g/m at 3 Chikkabangnal. The next highest SO2 value is observed as 18.2 g/m Hire Kasinkandi at

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the. The trend shows relatively lower concentrations at all the sampling locations when compared to the standard limit of 80 g/m3 for residential, rural and other areas.

th 3 NOx: The 98 percentile concentrations of NOx ranged between 15.6-35.1 g/m at all the locations during study period. The maximum value for NOx is observed as 35.9 g/m3 at Ginigera. The next highest NOx value is observed as 20.6 g/m3 at Hire Kasinkandi. The trend of NOx values shows similar trend as that of SO2. The values found to be relatively lower when compared to the standard limit of 80 g/m3 for residential, rural and other areas.

CO: The CO levels at all the locations show very low concentration of CO. The range of maximum values observed was between 0.047 to 0.114 ppm during the study period.

3.7 WATER QUALITY

Water quality of ground as well as surface water resources within study area has been studied for assessing the water environment and to evaluate anticipated impact of the proposed project. Understanding the water quality is essential in preparation of Environmental Impact Assessment and to identify critical issues with a view to suggest appropriate mitigation measures for implementation. The purpose of this study is to:

Assess the water quality characteristics for critical parameters; Evaluate the impacts on habitat conditions, recreational resources and aesthetics in the vicinity; and Prediction of impact on water quality by this project and related activities.

3.7.1 Methodology

Reconnaissance survey was undertaken and monitoring locations were finalized based on:

Drainage pattern; Location of residential areas representing different activities/likely impact areas; and Likely areas, which can represent baseline conditions.

Ground water sources covering 10-km radial distance were examined for physico-chemical and bacteriological parameters in order to assess the existing ground water quality of the study area. The samples were collected and analyzed as per the procedures specified in 'Standard Methods for the Examination of Water and Wastewater' published by American Public Health Association (APHA). The samples were taken as grab samples and were analyzed for various parameters and compared with the standards for drinking water quality as per IS: 10500 and IS: 2296 applicable for ground and surface water respectively.

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3.7.2 Water Sampling Locations

The water sampling locations are listed in the table below:

Table-3.7.1: Details of Water Sampling Locations

Location Name of Location Type Distance w.r.t. Direction w.r.t. No. Project Site, Km Project Site SW1 Tungabhadra Surface water 3.0 SE Reservoir SW2 Kunikere Surface water 2.8 SW SW3 Ginigera Surface water 5.0 NNE SW4 Basapur Surface water 5.0 NNW SW5 Kunikera Tanda Surface water 2.3 WSW SW6 Chikkbagnal Surface water 3.2 SSE SW7 Hire Kasinkandi Surface water 4.5 ESE SW8 Hosa Kankapura Surface water 5.0 NE GW1 Chikkabangnal Ground water 3.2 SSE GW2 Kunikera Ground water 2.8 SW GW3 Kunikeri Tanda Ground water 2.3 WSW GW4 Halvarti Ground water 3.0 NW GW5 Allanagara Ground water 3.0 NNE GW6 Hire Kasinkandi Ground water 4.5 ESE GW7 Hosa Kankapura Ground water 5.0 NE GW8 Ginigera Ground water 5.3 NNE

3.7.3 Observations

Most of the villages in the project area have open well and bore well facilities, and the residents of these villages make use of this water for drinking and other domestic uses. The study area ground quality is presented in Table-3.7.2.

Ground Water Quality:

As seen from the analysis data, the ground water is slightly alkaline in nature. Total dissolved solids are found to be in the range 294-810 mg/l. Total hardness ranges from 95-374 mg/l, Chlorides in all samples ranges from 26-180 mg/l. Total dissolved solids, total hardness and chlorides are found to be within their respective limits. Sulphates are also found to be within limits in all the water samples. The heavy metal contents such as Chromium, Lead and Iron are found in traces in few water samples. The Total coliforms are found to be present in four water samples whereas E.Coli is detected in all the samples. The physico-chemical and biological analysis revealed that the water as per IS: 10500 standards is fit for drinking only after some preliminary treatment due to presence of coliforms.

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Surface Water Quality:

In the surface water sample all the Physico-chemical parameters analyzed are found to be well within the limits as per IS: 2296. Hardness is found 121-168 mg/l and total dissolved solids as 132 - 654 mg/l. Heavy metals such as Copper, Zinc, Arsenic and Lead are found to be absent. The coliforms count was found to be within the limits. The surface water quality is presented in Table-3.7.3

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Table-3.7.2: Ground Water Quality

Sr. Parameters Units GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 IS:10500 No. Desirable/Pe rmissible 1. PH -- 7.5 7.4 8.2 7.9 8.3 8.2 7.6 8.1 6.5 - 8 5 2. Temperature OC 23 24 22 21 24 23 20 25 $ 3. Colour Hazen <5 <5 <5 <5 <5 <5 <5 <5 5/25 Unobje Unobjec Unobjec Unobjec- Unobjec Unobjec Unobjec- Unobjec- Unobjectiona 4. Odour -- c- - - tionable -tionable -ionable tionable tionable ble ionable tionable tionable Agreeabl Agreeab Agreea Agreeab Agreeab Agreeab 5. Taste -- Agreeable Agreeable Agreeable e le ble le le le 6. Turbidity NTU 0.7 1.2 1.8 0.5 0.3 0.4 0.6 0.3 5/10 Dissolved 7. mg/l 2.4 3.7 2.9 4.6 2.7 3.5 2.1 3.9 $ Oxygen Total 8. Suspended mg/l 11 8 15 19 21 7 14 23 $ Solids Total Dissolved 9. mg/l 537 516 590 694 621 810 676 528 500/2000 Solids 10. Alkalinity mg/l 231 189 146 73 327 209 198 427 200/600 Total hardness 106 222 352 216 198 338 202 130 11. mg/l 300/600 as CaCO3 12. BOD at 270C mg/l 4 8 5 6 4 6 4 3 $ 13. COD mg/l 31 38 61 33 29 59 24 18 $

14. Nitrates as NO3 mg/l 3.7 7.5 4.3 5.1 4.7 3.6 6.8 5.3 45/100 Phosphates 15. mg/l 0.27 0.13 BDL 0.38 0.12 BDL 0.46 BDL $ PO4 16. Chlorides as Cl mg/l 26 59 84 75 121 154 116 180 250/1000 17. Fluorides mg/l 0.86 0.94 1.27 1.06 1.92 0.81 0.73 1.64 1.0/1.5 Sulphates as 18. mg/l 76 61 212 154 198 67 94 187 200/400 SO4 19. Sodium as Na mg/l 26 42 38 49 26 51 24 31 $ 20. Calcium as Ca mg/l 26 58 95 62 38 73 45 31 75/200

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Sr. Parameters Units GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 IS:10500 No. Desirable/Pe rmissible Magnesium as 21. mg/l 10 19 28 15 25 38 22 13 30/100 Mg Total Silica as 22. mg/l BDL BDL BDL BDL BDL BDL BDL BDL $ Si 23. Oil & grease mg/l BDL BDL BDL BDL BDL BDL BDL BDL $ Phenolic 24. mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.001/0.002 Compounds Nos./1 25. Total Coliform 3 Absent 5 3 Absent Absent 2 Absent $ 00ml MPN/ 26. E. Coli 100 3 <2 <2 5 <2 <2 <2 <2 $ ml Chromium as 27. +6 mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05 Cr 28. Lead as Pb mg/l BDL 0.01 BDL BDL BDL BDL 0.03 BDL 0.05 29. Arsenic as As mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05 30. Cyanide as CN- mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.05 31. Iron as Fe mg/l 0.04 0.16 0.19 0.13 BDL 0.10 0.08 0.22 0.3/1.0 32. Zinc as Zn mg/l BDL BDL BDL BDL BDL BDL BDL BDL 5.0/15.0 Cadmium as 33. mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.01 Cd 34. Mercury as Hg mg/l BDL BDL BDL BDL BDL BDL BDL BDL 0.001

$ = Not specified BDL= Below Detectable Limit

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Table 3.7.3: Surface Water Quality

Sr. Parameters Unit Limits as SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 No. per IS 2296 (Class C) 1. Temperature o C N.S 26 31.7 30.1 27.6 30.8 31.0 28.7 29.4 2. Odour -- N.S Unobje- Unobje- Unobje- Unobje- Unobje- Unobje- Unobje- Unobje- ctionable ctionable ctionable ctionable ctionable ctionable ctionable ctionable 3. Taste -- N.S Agreeable Agreeable Agreeable Agreeable Agreeabl Agreeable Agreeable Agreeable e 4. Colour Hazen 300 35 34 32 43 22 26 38 36 5. Turbidity NTU N.S 22 4 6 5 8 7 8 3 6. pH at 25oC - 6.5 - 8.5 8.1 7.2 8.6 8.1 7.5 8.4 7.8 8.5 7. Electrical mmhos/ N.S. 1109 267.1 361.9 228.3 214.6 391.5 341.0 352.7 Conductivity cm 8. T.D.S mg/l 1500 654 155 235 132 120 215 201 205 9. Oil & Grease mg/l 0.1 Nil Nil Nil Nil Nil Nil Nil Nil 10. Hardness mg/l N.S. 134 168 177 121 123 138 184 146 (as CaCO3) 11. Sodium as Na mg/l N.S. 28 23.7 20.9 22.0 15.3 12.4 14.9 16.5 12. Potassium as K mg/l N.S. 4.1 1.95 3.08 2.65 1.07 1.43 2.81 3.35 13. Chlorides as Cl mg/l 600 126 46.9 34.1 51.4 56.8 48.5 42.1 38.5

14. Sulphates as SO4 mg/l 400 108 36.7 46.2 48.3 29.5 39.1 45.6 44.0 15. Nitrates as NO3 mg/l 50 10 Nil Nil Nil Nil Nil Nil Nil 16. Fluorides as F mg/l 1.5 0.84 0.22 0.56 0.35 0.26 0.18 0.43 0.50 17. Calcium as Ca mg/l N.S. 41 36.7 29.7 23.4 20.6 32.5 38.1 26.4 18. Phosphates as mg/l N.S. Nil Nil Nil Nil Nil Nil Nil Nil PO4 19. Magnesium as mg/l N.S. 14 18.7 25.1 15.3 17.5 13.8 21.7 19.5 Mg 20. BOD at 27oC mg/l 30 2.8 8 4 4 3 3 4 3 21. D.O. mg/l 4 3.1 1.6 2.9 1.8 1.5 1.0 3.4 2.7 22. Chemical Oxygen mg/l N.S. 21 12.9 17.6 18.3 14.7 15.1 17.2 19.8 Demand 23. Iron as Fe mg/l 50 0.57 3.14 2.53 2.15 1.68 2.34 3.52 2.09

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Sr. Parameters Unit Limits as SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 No. per IS 2296 (Class C) 24. Copper as Cu mg/l 1.5 Nil 0.19 0.30 0.35 0.28 0.24 0.17 0.20 25. Zinc as Zn mg/l 15.0 Nil 0.36 0.53 0.32 0.48 0.29 0.18 0.38 26. Arsenic as As mg/l 0.2 Nil Nil Nil Nil Nil Nil Nil Nil 27. Cadmium as Cd mg/l 0.01 Nil Nil Nil Nil Nil Nil Nil Nil 28. Chromium as Cr+6 mg/l 0.05 Nil Nil Nil Nil Nil Nil Nil Nil 29. Cyanide as CN mg/l 0.05 Nil Nil Nil Nil Nil Nil Nil Nil 30. Lead as Pb mg/l 0.1 Nil Nil Nil Nil Nil Nil Nil Nil 31. Selenium Se mg/l 0.05 Nil Nil Nil Nil Nil Nil Nil Nil 32. Total oil and mg/l 0.1 Nil Nil Nil Nil Nil Nil Nil Nil grease 33. Total coliform Nos/ 5000+ 274 154 176 128 243 206 162 137 organisms 100ml

NS = Not specified

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3.8 NOISE LEVEL SURVEY

The physical description of sound concerns its loudness as a function of frequency. Noise in general is unwanted/un-desired sound, which is composed of many frequency components of various loudness distributed over the audible frequency range.

The environmental impact of noise can have several effects varying from Noise Induced Hearing Loss (NIHL) to annoyance depending on loudness of noise. The environmental impact assessment of noise from the proposed project, construction activity, and vehicular traffic can be undertaken by taking into consideration various factors like potential damage to hearing, physiological responses, annoyance and general community responses.

Noise survey has been conducted in the study area around the project site covering residential and commercial zones. Noise monitoring has been undertaken for 24 hr at each location. The main objective of noise monitoring in the study area is to establish the baseline noise levels and assess the impact of the total noise generated by the operation of the proposed project.

3.8.1 Identification of Sampling Locations

The noise monitoring has been conducted for determination of noise levels at six locations in the study area. The environment setting of each noise monitoring location is given in Table- 3.8.1 and depicted in Figure-3.1.1.

Table-3.8.1: Details of Noise Monitoring Locations

Station Locations Distance w.r.t. Site, Direction w.r.t. Code Km Site N1 Halvarti 3.0 NW N2 Kunikeri Tanda 2.3 WSW N3 Hirebagnal 1.8 ENE N4 Allanagara 3.0 NNE N5 Hire Kasinkandi 4.5 ESE N6 Hosa Kankapura 5.0 NE

3.8.2 Instrument Used for Monitoring

Noise levels were measured using sound level meter manufactured by Quest Technologies, USA. This instrument is capable of measuring the Sound Pressure Level (SPL) and Leq and octave band frequency analysis.

3.8.3 Method of Monitoring

Noise level monitoring was carried out continuously for 24-hours with one hour interval. During each hour parameters like L10, L50, L90 and Leq were directly computed by the instrument based on the sound pressure levels. Monitoring was carried out at A response and fast mode.

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3.8.4 Presentation of Results

The statistical analysis is done for measured noise levels at five locations in the study area. The parameters are analyzed for L10, L50, L90 Leq Lday, Lnight, and Ldn. These results are tabulated in Table-3.8.2. These are compared with the standards prescribed by Central Pollution Control Board (CPCB) tabulated in Table-3.8.3.

Table-3.8.2: Ambient Noise Levels in the Study Area [dB(A)]

Location Zone L10 L50 L90 Leq Lday Lnight Halvarti Residential 45.9 42.7 40.4 43.2 45.9 38.4 Kunikeri Tanda Residential 46.2 43.8 41.0 44.2 46.4 42.5 Hirebagnal Residential 49.3 46.1 42.7 46.8 47.3 39.2 Allanagara Residential 51.5 48.4 45.3 49.0 50.4 40.6 Hire Kasinkandi Residential 48.8 45.6 42.9 46.1 47.9 43.3 Hosa Kankapura Residential 50.3 47.2 44.8 47.7 49.5 41.0

Table-3.8.3: Ambient Noise Quality Permissible Limits Specified by CPCB

Area code Category of Limits in db(a) leq* area/zone Day time Night time (a) Industrial area 75 70 (b) Commercial area 65 55 (c) Residential area 55 45 (d) Silence zone 50 40

3.8.5 Observations a) Day time Noise Levels (Lday)]

In the study area, the day time noise levels are found to be in the range of 45.9 dB(A)-50.4 dB(A). All the zones fall in the residential zone. The highest noise level of 50.4 dB(A) is recorded at Allanagara. At all the locations the noise levels are well within the CPCB stipulated limits of 55 dB(A) prescribed for residential zone. b) Night time Noise Levels (Lnight)

The night time noise levels are observed to be in the range of 38.4 dB(A) – 43.3 dB(A). The highest noise level is observed at Hire Kasinkandi. At all the locations the noise levels are well within the 45 dB(A) night time limit for residential zone prescribed by CPCB.

The Leq, Lday, Lnight and Ldn noise levels observed in the study area are given in Figure- 3.8.1.

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Figure-3.8.1: Ambient Noise Levels in the Study Area

Ambient Noise Levels in Study Area 53

50

47 Leq

44 Lday Lnight 41 Ldn

Noise Levels, db(A) Levels,Noise 38

35

Halvarti Hirebagnal Allanagara Kunikeri Tanda Hire KasinkandiHosa Kankapura Locations

*CPCB limit for Residential area: Day time: 55 dB(A); Night time:45 dB(A)

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3.9 TRAFFIC STUDY

To quantify the impact of proposed plant on traffic, it is necessary to evaluate the existing load of vehicular traffic. Proposed site is well connected to NH-13 passing about 5 km away from site. This road will be used for transportation of raw material and finished product on the commencement of operation of plant. Monitoring was carried out at one location for continuous twenty four hours. The location chosen on NH-13 is approached road to site.

Monitoring results are tabulated in Table-3.9.1. It reveals that the peak hour traffic was between 9 am to 13 pm in the morning while 8 pm to 12 pm in the evening. The majority of traffic is of heavy vehicles trucks, dumpers etc.

Table-3.9.1: Traffic Monitoring

Time 2/3 Trucks Cars/LCVs Buses From To Wheelers 7.00 am 8.00 am 5 8 3 3 8.00 am 9.00 am 3 3 4 4 9.00 am 10.00 am 5 5 8 3 10.00 am 11.00 am 14 5 8 6 11.00 am 12.00 noon 13 6 3 3 12.00 noon 13.00 pm 5 3 0 4 13.00 pm 14.00 pm 8 5 5 2 14.00 pm 15.00 pm 5 3 7 5 15.00 pm 16.00 pm 5 5 5 3 16.00 pm 17.00 pm 7 6 4 2 17.00 pm 18.00 pm 10 3 1 3 18.00 pm 19.00 pm 1 6 3 4 19.00 pm 20.00 pm 1 5 3 3 20.00 pm 21.00 pm 5 2 3 2 21.00 pm 22.00 pm 4 5 3 1 22.00 pm 23.00 pm 2 6 4 2 23.00 pm 0.00 am 1 5 4 1 0.00 am 1.00 am 0 4 3 0 1.00 am 2.00 am 0 6 0 1 2.00 am 3.00 am 0 6 0 0 3.00 am 4.00 am 0 8 0 3 4.00 am 5.00 am 0 9 0 2 5.00 am 6.00 am 3 10 4 7 6.00 am 7.00 am 8 8 5 3 TOTAL 105 132 77 67

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3.10 ECOLOGICAL SURVEY

The ecological study was undertaken to understand the present status of ecosystem of the area, to predict changes as a result of proposed activities and to suggest measures for maintaining the conditions.

Thus the objectives of ecological study are outlined as follow:

to characterize the environmental components like land, water, flora and fauna; preparation of checklist of flora and fauna to understand their present status; and to identify susceptible and sensitive areas

3.10.1 Methodology of Data Collection

Following methods are being adopted for the ecological study:

generation of primary data through systematic ecological studies in the study area; secondary data collected from publications of various Government agencies like Forest Department, Agriculture Department etc.; and consulting local people for gathering information on ethnobotany, local plants and animals.

This section describes terrestrial ecology of the area based on reconnaissance survey and information gathered from secondary data available for the area.

3.10.2 Review of Published Literature

The most of the region in the district represents: a) Riverine vegetation – along the rivers b) Ruderal vegetation and pastures - this region is largely cultivated. It includes open plains and foothills. c) Southern tropical thorn forests - these are characterized by dry thorny forests and scrublands

Preliminary survey of the study area was carried out and based on various parameters three sampling locations were selected for detailed ecological studies. The sampling locations selected are as follows:

TE-1: Halvarti TE-2: Hirebagnal TE-3: Hire Kasinkandi

3.10.3 Review of Primary Survey Data

The study area is marked with low isolated hill ranges or hillocks which have bare or very sparse vegetative cover. The area has small terrains of protected forests and scrubland. The overall vegetation of this area is scattered scrubland interspersed with grasslands. The

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sampling locations exhibit same vegetation pattern. The riverine vegetation can be easily distinguished from that of dry scrublands.

The dominant species of trees and shrubs found in the scrubland are as follows:

1) Prosopis Juliflora 2) Acacia species 3) Azadirachta indica 4) Anigeissus pendula 5) Ailanthus species 6) Holoptelia species 7) Calotropis procera 8) Capparis deciduas 9) Carissa spinarium 10) Cassia species 11) Catunaregum species 12) Maerua species 13) Maytenus species 14) Ziziphus species

The dominant species of trees and shrubs found along the watercourses are as follows:

1) Ficus racemosa 2) Pongamia pinnata 3) Ficus religiosa 4) Clerodendrum inerme 5) Phoenix sylvestris 6) Cassia fistula

These species are very sparsely distributed. The dominant genera observed were Cassia and Euphorbia followed by Acacia.

Tree species such as Celosia argentea, Acalypha indica, Lepidagathis species, Ageratum species, Euphorbia species, Tephrosia species, Cassia species, Alysicarpus species, Leucas species, Sida species, Boerrhavia species, Polygala species, Amaranthus species, Evolvulus species, Parthenium species, Tridax species are found scattered on pasture lands and along the boundary of agricultural lands.

A "species list" includes both local and scientific names of the plants found in the study area. This list is made by site visits and by consulting published literature. List of flora observed is given in the table below.

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Table-3.10.1: Floristic composition in the study area

Sr. No. Botanical Name Family TREES 1. Acacia chundra Mimosaceae 2. Acacia fernesiana Mimosaceae 3. Acacia ferruginea Mimosaceae 4. Acasia leucophloea Mimosaceae 5. Acacia nilotica Mimosaceae 6. Aegle marmelos Rutaceae 7. Ailanthus excelsa Simaroubaceae 8. Albizzia lebbek Mimosaceae 9. Albizzia procera Mimosaceae 10. Anogeissus pendula Combretaceae 11. Areca catechu Arecaceae 12. Azadirachta indica Meliaceae 13. Balanites aegyptiaca Balantaceae 14. Bauhinia purpurea Caesalpinaceae 15. Bauhinia racemosa Caesalpinaceae 16. Bauhinia variegate Caesalpinaceae 17. Borassus flabellifer Arecaceae 18. Butea monosperma Fabaceae 19. Carica papaya Caricaceae 20. Cassia fistula Caesalpinaceae 21. Cassia siamea Caesalpinaceae 22. Casurina equisetifolia Casurinanaceae 23. Ceiba pentandra Bombaceae 24. Cocos nucifera Arecaceae 25. Cordia dichotoma Boraginaceae 26. Dalbergia latifolia Fabaceae 27. Delonix regia Caesalpinaceae 28. Dolichandrone sp Bignoniaceae 29. Erythrina indica Fabaceae 30. Eucalyptus sp Myrtaceae 31. Euphorbia pulcherrima Euphorbiaceae 32. Euphorbia tirucalli Euphorbiaceae 33. Ficus bengalensis Moraceae 34. Ficus benjamina Moraceae 35. Ficus racemosa Moraceae 36. Ficus religiosa Moraceae 37. Holoptelia integrifolia Ulmaceae 38. Jacarada mimosaefolia Bignoniaceae 39. Kigelia pinnata Bignoniaceae 40. Leucaena leucocephalia Mimosaceae 41. Mangifera indica Anacardiaceae 42. Melia azadirachta Meliacaeae 43. Millingtonia hortensis Bignoniaceae 44. Moringa oleifera Moringaceae

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Sr. No. Botanical Name Family 45. Peltophorum pterocarpum Caesalpinaceae 46. Phoenix sylvestris Arecaceae 47. Pithecolobium dulce Mimosaceae 48. Pithecolumbium saman Mimosaceae 49. Plumeria alba Apocynaceae 50. Polyalthea longifolia Annonaceae 51. Pongamia pinnata Fabaceae 52. Prosopis spicigera Mimosaceae 53. Santalum album Santalaceae 54. Syzigium cumini Myrtaceae 55. Tectona grandis Verbenaceae 56. Terminalia catappa Combretaceae 57. Thespesia populnea Malvaceae 58. Thevatia neriifolia Apocynaceae 59. Wrighitia tinctoria Apocynaceae 60. Ziziphus mauritiana Rhamnaceae 61. Ziziphus xylopyrus Rhamnaceae SHRUBS 1. Abutilon indicum Malvaceae 2. Adhatoda vasica Acanthaceae 3. Aerua lanata Amaranthaceae 4. Agave Americana Agavaceae 5. Agave cantala Agavaceae 6. Alangium Salvfolium Alangiaceae 7. Aloe vera Liliaceae 8. Annona squamosa Annonaceae 9. Asclepias curasavica Asclepiadeceae 10. Caesalpinia bonducella Caesalpinaceae 11. Calotropis gigantea Asclepadaceae 12. Calotropis procera Asclepiadaceae 13. Canna indica Cannaceae 14. Canthium dicoccum Rubiaceae 15. Capparis decidua Capparaceae 16. Carissa spinarium Apocynaceae 17. Cassia auriculata Caesalpinaceae 18. Cassia occidentalis Caesalpinaceae 19. Cassia sophera Caesalpinaceae 20. Clerodendrum indicum Verbenaceae 21. Commiphora sp Burseraceae 22. Croton gibnosae Euphorbiaceae 23. Dodonaea viscosa Sapindaceae 24. Duranta plumieri Verbenaceae 25. Euphorbia ligularia Euphorbiaceae 26. Euphorbia trigona Euphorbiaceae 27. Ficus asperrima Moraceae 28. Helianthus annus Asteraceae 29. Ipomea cairica Convulvulaceae ILC Industries Ltd. 91

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Sr. No. Botanical Name Family 30. Ixora nigricans Rubiaceae 31. Jasminum auriculatum Oleaceae 32. Jatropha gossypifolia Euphorbiaceae 33. Lantana camara Verbenaceae 34. Morus alba Moraceae 35. Musa bulbisianacoila Musaceae 36. Nerium odorum Apocynaceae 37. Oscimum cannum Lamiaceae 38. Oscimum sanctum Lamiaceae 39. Opuntia dillenii Cactaceae 40. Phyllanthus reticulatus Euphorbiaceae 41. Prosopis juliflora Mimosaceae 42. Pupalia lappaceae Amaranthaceae 43. Ricinus communis Euphorbiaceae 44. Solanum melongena Solanaceae 45. Typha angustifolia Typhaceae 46. Vermonia divergens Asteraceae 47. Vitex nigundo Verbenaceae HERBS 1. Acalypha indica Euphorbiaceae 2. Acyranthes aspera Amaranthaceae 3. Ageratum conyzoides Asteraceae 4. Alternanthera triandra Amaranthaceae 5. Alysicarpus bupleurifolius Fabaceae 6. Alysicarpus monilifer Fabaceae 7. Alysicarpus pubescens Fabaceae 8. Amaranthus spinosus Amaranthaceae 9. Arachis hypogaea Fabaceae 10. Bacopa monnieri Scrophulariaceae 11. Bidens pilosa Asteraceae 12. Blumea lacera Asteraceae 13. Boerhaavia diffusa Nyctaginaceae 14. Boerhaavia verticillata Nyctaginaceae 15. Bryophyllum calycinum Crassulaceae 16. Cajanus cajan Fabaceae 17. Caralluma fimbriata Asclepiadaceae 18. Cassia italica Caesalpinaceae 19. Cassia tora Caesalpinaceae 20. Catharanthus roseus Apocynaceae 21. Casia argentea Amaranthaceae 22. Chrozophora plicata Euphorbiaceae 23. Cleome viscose Cleomaceae 24. Colocasia antiqorum Araceae 25. Convolvulus microphyllus Convulvulaceae 26. Corbichonia decumbens Aizoaceae 27. Coriandrum sativum Apiaceae 28. Cyathocline lyrata Asteraceae ILC Industries Ltd. 92

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Sr. No. Botanical Name Family 29. Datura metal Solanaceae 30. Desmodium triflorum Fabaceae 31. Echinops echinatus Asteraceae 32. Eclipta alba Asteraceae 33. Euphorbia geniculata Euphorbiaceae 34. Euphorbia hirta Euphorbiaceae 35. Evolvulus alsiniodes Convulvulaceae 36. Hydrilla verticillata Hydrocharitaceae 37. Hydrocotyle asiatica Apiaceae 38. Indigofera species Fabaceae 39. Lagasca mollis Asteraceae 40. Launaea nudicaulis Asteraceae 41. Lemna species Lemnaceae 42. Lepidagathis cristata Acanthaceae 43. Lepidagathis cusipidata Acanthaceae 44. Leucas aspera Lamiaceae 45. Ludwigia octovalvis Onagraceae 46. Lycopersicum esculentum Solanaceae 47. Mollugo cerviana Molluginaceae 48. Mollugo pentaphylla Molluginaceae 49. Parthenium hysterophorus Asteraceae 50. Phyllanthus nururi Euphorbiaceae 51. Physalis minima Solanaceae 52. Polygala arvensis Polygonaceae 53. Polygala erioptera Polygonaceae 54. Polygonum glabrum Polygonaceae 55. Polygonum plebejum Polygonaceae 56. Portulaca oleracea Portulacaceae 57. Pulicaria wightiana Asteraceae 58. Rhynchosia minima Fabaceae 59. Russelia juncea Scrophulariaceae 60. Senecio sp Asteraceae 61. Sida acuta Malvaceae 62. Sida cordifolia Malvaceae 63. Sida rhombifolia Malvaceae 64. Solanum nigrum Solanaceae 65. Solanum surattense Solanaceae 66. Sonchus oleraceus Asteraceae 67. Striga lutea Scrophulariaceae 68. Tagetes erecta Asteraceae 69. Tephrosia purpurea Fabaceae 70. Tribulus terrestris Zygophyllaceae 71. Tricholepis radicans Asteraceae 72. Tridax procumbens Asteraceae 73. Urena tobata Malvaceae 74. Vernonia cinerea Asteraceae 75. Wedelia chinensis Asteraceae ILC Industries Ltd. 93

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Sr. No. Botanical Name Family 76. Wolffia species Lemnaceae 77. Xanthium strumarium Asteraceae GRASSES 1. Aristida depressa Poaceae 2. Aristida setacea Poaceae 3. Brachiaria distachya Poaceae 4. Chloris barbata Poaceae 5. Cynodon dactylon Poaceae 6. Cyperus compressus Cyperaceae 7. Cyperus distans Cyperaceae 8. Cyperus halpan Cyperaceae 9. Cyperus rotundus Cyperaceae 10. Dactyloctenium aegyptium Poaceae 11. Digitaria ciliaris Poaceae 12. Dimeria ornithopoda Poaceae 13. Eleocharis geniculata Cyperaceae 14. Heteropogan contortus Poaceae 15. Isachne miliacea Poaceae 16. Pennisetum typhoideum Poaceae 17. Saccharum officinarum Poaceae 18. Sporobolus indicus Poaceae 19. Themada ciliate Poaceae 20. Triticum aestivum Poaceae 21. Zea mays Poaceae CLIMBERS 1. Acacia concinna Mimosaceae 2. Argyreia pilosa Convulvulaceae 3. Asparagus racemosus Asparagaceae 4. Capparis zeylanica Capparaceae 5. Coccinia indica Cucurbitaceae 6. Cryptostegia grandiflora Periplocaceae 7. Cucurbita maxima Cucurbitaceae 8. Cuscuta reflexa Cuscutaceae 9. Luffa acutangula Cucurbitaceae 10. Passiflora foetida Passifloraceae 11. Quisqualis indica Combretaceae 12. Sarcostemma bevistgma Asclepidiaceae 13. Tylophora sp Asclepidiaceae 14. Wattakaka volubilis Asclepidiaceae

3.10.4 Terrestrial Fauna

For Studying Animals And Birds In The Study Area Following Means Were Used:

Actual Sighting Pug Marks Calls

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Dropping, Burrows Etc. Interrogating Local People Records From Gazetteer

No Wildlife Sanctuaries Are Situated Within The Study Area. It Was Observed That Wild Life In The Region Is Very Scanty. No Endangered Species Have Been Reported In The Study Area. The Study Area Does Not Show Much Diversity In Both Terrestrial Fauna And Avifauna. This Is Partly Due To Scarcity Of Water And Disappearance Of Forests. The Mammalians Mainly Constitute Domesticated Animals And Rodents. The List Of Wild And Domestic Animals, And Avifauna Sighted In The Area Is Given Below.

Table-3.10.2: List of Fauna in The Area

Sr. No. Zoological Name Common Name MAMMALS 1. Presbytis entellus Common langur 2. Canis aureus Jackal 3. Canius lupas Indian wolf 4. Rattus rattus House rat 5. Bandicoota indica Bandicoot 6. Herpestes edwardii Common mongoose 7. Suncus caeruleus Musk shrew 8. Rattus norvegicus Field mouse 9. Rhinolopus species Bat 10. Hipposiderus species Bat 11. Pipistrelius species Bat 12. Felis chous Jungle cat 13. Lepus dayanus Common hare 14. Macaca mulata Rhesus macaque 15. Funambulu spennanti Squirrel 16. Macaca radiate Bonnet monkey 17. Hyaena hyaena Striped hyena 18. Tetracerus quadricornis Chousingha REPTILES 1. Calotes versicolor Garden Lizard 2. Hemidactylus brooki Wall Lizard 3. Hemidactylus giganticus Giant Gecko 4. Ptyas mucosus Rat Snake 5. Varanus benghalensis Monitor Lizard 6. Oligodon venustus Wolf Snake 7. Xemochrophis piscator Checkered Keel Back 8. Naja naja Cobra 9. Bungarus coeruleus Krait 10. Vipera russeli Rusell‟s viper AMPHIBIANS 1. Rana tigrina Common Frog 2. Bufo melanostictus Toad AVIAN 1. Passer domesticum Domestic sparrow ILC Industries Ltd. 95

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Sr. No. Zoological Name Common Name 2. Streptopelia decaocto Ring dove 3. Milvus migrans Pariah kite 4. Spizaetus cirrhatus Crested hawk eagle 5. Cloumba livia Blue rock pigeon 6. Accipitar badius Shikra 7. Psiltacula euparia Large Indian Parakeet 8. Upupa epops Hoopoe 9. Centropus cinensis Crow pheasant 10. Merops orientalis Green bee eater 11. Tyto alba Scrrech owl 12. Strptopela chinensis Spotted dove 13. Caprimulgus asiaticus Common night jar 14. Surcogyps calvus King vulture 15. Caracias benghalnse Blue jay 16. Egretta garzetta Little egret 17. Cuculus varius Common hawk 18. Coturnix suscitator Common quail 19. Acrodontherus tristis Indian myna 20. Corvus spledens House crow 21. Corvus macroshynchos Jungle crow 22. Orthotonus sutorias Tailor bird 23. Ploceus phillippinus Weaver bird 24. Alcedo atthis Small blue king fisher 25. Picnonotus cater Red vented bulbul 26. Psittaculla krameri Rose ringed parakeet 27. Lonchura spp Munia

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3.10.5 Aquatic Ecology

Tungabhadra Reservoir is the major water body in the study area. Hence sample was collected from the reservoir to identify planktons.

AE-1: Tungabhadra Reservoir

Phytoplankton

Among the phyto planktons, Aphanizomenon flos-aque is observed as the dominant species. The phyto-plankton species and their abundance in the water sample are given in the following table.

Table-3.10.3: Phytoplankton Species in Tungabhadra Reservoir Water Sample

Sr. No. Phytoplankton species Total Number/ml 1. Aphanizomenon flos-aque 21456 2. Melosira granulate 13682 3. Scenedesmus obliquus 2973 4. Nitzschia subtilis 2750 5. Aphanocapsa delicatissima 6238 6. Euglena acus 2806 7. Fragilaria intermedia 2613 8. Oscillatoria limnetica 2437

Zooplankton

Only Rotifer species was found among the Zooplanktons. They were Brachionus sp and Ephiphanus sp. and the total number found per ml of sample was 3120 and 2984 respectively.

Fishes

Fish species were identified during the field visits in the study area. Some of the common fishes observed are listed below.

1) Cyprinus carpio 2) Silver carp 3) Cirrhina mrigala 4) Labeo fimbriatus 5) Labeo rohita 6) Labeo calbasu 7) Chel sp. 8) Oxygaster sp. 9) Puntius sp. 10) Wallago attu 11) Mystus seenghala 12) Mystus avor 13) Mystus cavaceous 14) Mystus punctatus 15) Channa punctatus

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16) Channa marulus 17) Channa striatus

3.11 SOCIO-ECONOMICS

3.11.1 Introduction

The industrial policy resolution in the year 1956 stressed the need of reducing regional disparities in levels of development in order that industrialization may benefit the country as a whole. This view was further endorsed in the new industrial policy statement (1980) which further felt that revival of the economy was inhibited by infrastructure gaps such as shortage in major industries. The policy also emphasized the need to promote suitable industries in rural areas. The process of industrial transitions where new industrial units are setup in a primarily agrarian economy is bound to create its impact on the socio-economic aspects of the local people. Therefore studies on the socio-economic impact of industrialization on the local population no doubt deserve considerable attention.

ILC has proposed to set up plant near Kunikere village in Koppal Taluka of Koppal District, Karnataka. The present study is being carried out to ascertain the impacts of proposed plant on the socio-economic conditions of local people.

The data required to study the above aspects has been collected from secondary sources.

3.11.2 Methodology

The methodology adopted for the study is based on the following:

Review of secondary data (2001 District Census) with respect to population, occupational structure and infrastructure facilities available in the region.

3.11.3 Review of Socio-economic Profile -2001

The information on socio-economic aspects of the study area has been compiled from secondary sources, which include various public and semi-public offices. The demographic data has mainly been compiled from District Primary Census, 2001 as this document is comprehensive and authentic. The sociological aspects like human settlements, demography and other socio-economic aspects in the study area have been covered in this study. Similarly the economic aspects such as agriculture, industry and occupational structure of workers have also been studied. The socio-economic details are briefly described in the following sections.

3.11.3.1 Settlement Pattern

Study area of 10 km falls in Koppal taluka of Koppal district and Hagaribommanahalli taluka of Bellary district. The study area comprises both rural and urban area. Study area contains 37 villages and 2 urban centres of Koppal taluka of Koppal district while only submerged area of Tungabhadra river of Hagaribommanahalli taluka of Bellary district.

3.11.3.2 Demography

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The overall development in the study area has resulted in urbanization. Presently almost all villages have been experiencing a rapid growth of population.

As per 2001 census, the study area consisted of 137566 persons out of which 73291 inhabited in 37 villages and 64275 persons in urban area. The distribution of population in the study area is shown in Table-3.11.1.

Table-3.11.1: Distribution of Population

Particulars Rural Urban Total Total Population 73291 64275 137566 Male Population 37151 32810 69961 (% with total population) (50.6) (51.04) (50.8) Female Population 36140 31465 67605 (% with total population) (49.31) (48.95) (49.14) No. of Households 13061 11589 24650 Average Household Size 5.6 5.5 5.5 Sex ratio (Female/1000 male) 972 959 966

The configuration of male and females indicates that the males constitute to about 50.8% and females to about 49.1% of the study area population. The sex ratio i.e. the number of females per 1000 males indirectly reveals certain sociological aspects in relation with female births, infant mortality among female children and single person family structure, a resultant of migration of industrial workers. The study area at an average has 966 females per 1000 males.

3.11.3.3 Social Structure

Majority of the people in the study area belong to Hindu religion. They are followed by people belonging to Jain, Muslim and Christian community. The study area also contains scheduled castes (SC) and scheduled tribes (ST). The distribution of population of socially weaker sections in the core area is shown in Table-3.11.2.

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Table-3.11.2: Distribution of Population by Social Structure

Category Rural Urban Total Total Population 73291 64275 137566 Scheduled Castes 14174 7933 22107 % to taluk population 19.3 12.3 16.0 Scheduled Tribes 5895 2260 8155 % to taluk population 8.04 3.51 5.92 Total SC and ST 20069 10193 30262 % to taluk population 27.3 15.8 21.9

In the study area 16% of the population belong to scheduled castes (SC) while 5.92% to scheduled tribes (ST), thus indicating that about 21.9% of the population is formed by SC and ST population. Scheduled caste and Scheduled tribe sections are predominant in rural area.

3.11.3.4 Literacy Levels

The distribution of literates and literacy rates in the study area are given in Table-3.11.3.

Table-3.11.3: Literacy Level

Particulars Rural Urban Total Total Population 73291 64275 137566 Male population 37151 32810 69961 Male literates 20823 22937 43760 Female population 36140 31465 67605 Female literates 11843 17083 28926 Total literates 32666 40020 72686 % of study area literates to total population 44.5 62.2 52.8 Male literacy rate 56.04 69.90 62.54 Female literacy rate 32.76 54.29 42.78

The study area experiences a moderate literacy rate of 52.8%. The male literacy i.e. the percentage of literate males to the total males of the study area is observed as 62.5% while female literacy rate, which is an important indicator for social change, is observed as 42.7% in the study area.

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3.11.3.5 Occupational Structure

The occupational structure of the study area is studied with reference to main workers, marginal workers and non-workers. The main workers include 10 categories of workers defined by the Census Department consisting of cultivators, agricultural laborers, those engaged in live-stock, forestry, fishing etc. mining and quarrying; manufacturing, processing and repairs in household industry; and other than household industry, construction, trade & commerce, transport & communication and other services.

The marginal workers are those engaged in some work for a period of less than six months during the reference year prior to the census survey. The non-workers include those engaged in unpaid household duties, students, retired persons, dependents, beggars, vagrants etc.; institutional inmates or all other non-workers who do not fall under the above categories. The occupational structure of the study area is shown in Table-3.11.4.

Table-3.11.4: Occupational Structure of Study Area

Occupation Rural Urban Total No. % to No. % to No. % to population population population Total Workers 33981 46.3 20650 32.1 54631 39.71 Cultivators 7983 10.8 533 0.82 8516 6.19 Agricultural 10818 14.7 668 1.03 11486 8.34 laborers Household 840 1.14 1571 2.44 2411 1.75 industries laborers Others 7274 9.92 15970 24.84 23244 16.89 Total main 26915 36.72 18742 29.15 45657 33.18 workers Marginal 7066 9.64 1908 2.96 8974 6.52 workers Non-workers 39310 53.63 43625 67.87 82935 60.28 Total 73291 100.00 64275 100.00 137566 100.00 population

Altogether the main workers work out to be 33.18% of the area population. The marginal workers and non-workers constitute to 6.52% and 60.28% of the population respectively.

The distribution of workers by occupation indicates that the workers in the other category are in majority (16.8%) followed by agricultural laborers and cultivators respectively. The cultivators and agricultural laborers together form 14.53% of the total population.

The occupational profile of total main workers and their proportion in total population of the study area is shown in the graphically in the figure below.

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Figure-3.11.1: Distribution of Main Workers in Study Area

Distribution of Main Workers in Total Population

6.52% 6.19%

Cultivators

Agricultural Laborers

Household industries 8.34% laborers Others

Marginal Workers

16.89% 1.75%

Source: District Census Handbook 2001

3.12 HISTORICAL PLACES

The study area does not cover any historical monuments except old sixteenth century temple, Huligamma near Munirabad (10 km, SE of site) and Markendaya temple near Shivpur (10 km, ESE). Picnic spot is developed near Tungabhadra reservoir.

3.13 INDUSTRIAL DEVELOPMENT

The study area has no. of iron and steel industries besides small scale industries. Industrial activity is listed below: Table-3.13.1: List of Industries within Study Area Sr. No. Industry 1 Kalyani Steel Ltd, Ginigera 2 Kirloskar Ferrous Ltd., Ginigera 3 Hospet Ispat Ltd., Allanagara 4 Harekrishna Metallics Pvt. Ltd., Hirebaganal 5 Vanya Steels Pvt. Ltd., Hirebaganal 6 Dhruvdesh Metsteel Pvt. Ltd, Hirebaganal 7 Brundavan Beverages, Hirebaganal 8 Trivista Steel & Power Pvt. Ltd, Hirebaganal 9 KMMI Ispat Pvt. Ltd., Halavarthi

ILC Industries Ltd. 102

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

Table 1: Project Site, A1

Date TSPM RPM SO2 NOx CO (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 01.03.08 78.0 45.0 8.5 10.6 0.042 03.03.08 85.0 51.0 9.1 14.2 0.066 08.03.08 81.0 59.0 10.6 12.8 0.071 10.03.08 97.0 43.0 13.4 11.4 0.051 15.03.08 65.0 41.0 15.1 10.9 0.031 17.03.08 75.0 49.0 10.9 13.8 0.038 22.03.08 79.0 45.0 8.8 15.7 0.054 24.03.08 85.0 39.0 9.4 12.4 0.071 29.03.08 108.0 46.0 10.7 8.9 0.081 31.03.08 94.0 44.0 7.5 10.9 0.056 04.04.08 86.0 40.0 8.9 13.7 0.034 06.04.08 82.0 45.0 12.3 10.5 0.052 11.04.08 77.0 42.0 12.1 9.4 0.041 13.04.08 73.0 55.0 13.8 10.6 0.038 18.04.08 66.0 53.0 11.8 11.3 0.084 20.04.08 70.0 51.0 12.9 12.6 0.054 25.04.08 65.0 54.0 10.8 11.1 0.043 27.04.08 63.0 50.0 9.9 17.3 0.036 02.05.08 74.0 61.0 11.7 14.7 0.028 04.05.08 83.0 57.0 14.5 13.9 0.034 09.05.08 98.0 53.0 10.2 11.9 0.052 11.05.08 102.0 45.0 15.4 10.3 0.049 16.05.08 89.0 54.0 12.6 9.2 0.061 18.05.08 75.0 41.0 13.7 13.7 0.054 23.05.08 72.0 46.0 14.1 12.6 0.057 25.05.08 68.0 49.0 11.3 11.8 0.038 Max 108.0 61.0 15.4 17.3 0.084 Min 63.0 39.0 7.5 8.9 0.028 Average 80.4 48.4 11.5 12.2 0.051 SD 12.1 6.1 2.2 2.0 0.015 98th 105 60 15.3 16.5 0.083 Percentile

ILC Industries Ltd. 103

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Table 2: Hirebagnal, A2

Date TSPM RPM SO2 NOx CO (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 01.03.08 81.0 48.0 11.6 13.5 0.071 03.03.08 86.0 51.0 13.7 14.3 0.066 08.03.08 78.0 53.0 12.8 12.9 0.069 10.03.08 83.0 50.0 11.0 13.1 0.072 15.03.08 88.0 46.0 12.9 14.6 0.082 17.03.08 91.0 48.0 13.2 13.7 0.114 22.03.08 85.0 51.0 13.4 13.5 0.084 24.03.08 80.0 59.0 12.1 14.6 0.091 29.03.08 84.0 57.0 11.8 15.8 0.064 31.03.08 79.0 54.0 10.8 16.1 0.066 04.04.08 82.0 52.0 12.5 15.6 0.068 06.04.08 99.0 50.0 11.3 14.8 0.069 11.04.08 95.0 49.0 12.7 13.6 0.072 13.04.08 89.0 53.0 11.6 13.0 0.079 18.04.08 85.0 55.0 11.9 14.2 0.068 20.04.08 91.0 48.0 14.1 15.9 0.066 25.04.08 88.0 50.0 13.4 17.4 0.064 27.04.08 82.0 46.0 12.6 16.1 0.067 02.05.08 79.0 49.0 11.3 14.8 0.073 04.05.08 76.0 56.0 10.8 13.5 0.082 09.05.08 82.0 54.0 12.7 14.7 0.093 11.05.08 88.0 51.0 12.1 15.1 0.069 16.05.08 87.0 55.0 11.8 12.9 0.067 18.05.08 91.0 49.0 10.5 13.6 0.070 23.05.08 85.0 53.0 11.7 14.8 0.082 25.05.08 81.0 50.0 13.8 15.3 0.068 Max 99.0 59.0 14.1 17.4 0.114 Min 76.0 46.0 10.5 12.9 0.064 Average 85.2 51.4 12.2 14.5 0.074 SD 5.4 3.3 1.0 1.2 0.011 98th 97 58 14.0 16.8 0.104 Percentile

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Table 3: Hire Kasinkandi, A3

Date TSPM RPM SO2 NOx CO (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 08.03.08 161 48.8 16.0 18.6 0.044 10.03.08 154 54.4 17.1 20.1 0.054 15.03.08 80 48.8 13.8 12.9 0.051 17.03.08 93 60.0 12.4 19.4 0.036 22.03.08 100 63.2 11.3 17.5 0.058 24.03.08 119 65.6 10.9 17.0 0.065 29.03.08 140 51.2 15.8 18.2 0.049 31.03.08 112 56.8 17.5 15.4 0.058 04.04.08 127 44.8 14.9 13.4 0.045 06.04.08 114 55.2 14.7 15.3 0.065 11.04.08 161 58.4 18.2 16.1 0.046 13.04.08 143 48.8 13.8 16.9 0.022 18.04.08 168 51.2 18.2 20.6 0.038 20.04.08 156 62.4 12.6 18.9 0.048 25.04.08 135 55.2 14.1 15.3 0.058 27.04.08 122 46.4 15.9 14.7 0.059 02.05.08 129 64.8 16.3 16.8 0.048 04.05.08 110 62.4 12.5 18.6 0.068 09.05.08 141 68.0 10.3 15.2 0.057 11.05.08 134 69.6 14.9 13.1 0.046 16.05.08 128 59.2 13.7 14.6 0.041 18.05.08 141 49.6 12.5 16.4 0.042 23.05.08 123 63.2 14.6 16.0 0.036 25.05.08 162 51.2 10.9 14.4 0.038 Max 168 69.6 18.2 20.6 0.068 Min 80 44.8 10.3 12.9 0.022 Average 132.5 56.6 14.3 16.4 0.048 SD 22.5 7.0 2.2 2.1 0.011 98th 165 69 18.2 20.4 0.067 Percentile

ILC Industries Ltd. 105

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Table 4: Allanagara, A4

Date TSPM RPM SO2 NOx CO (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 05.03.08 76 49.0 13.4 13.4 0.059 07.03.08 81 55.0 14.8 15.2 0.051 12.03.08 94 42.0 12.7 11.7 0.067 14.03.08 71 47.0 11.3 16.8 0.024 19.03.08 84 54.0 13.2 15.9 0.053 21.03.08 96 51.0 12.7 13.8 0.041 26.03.08 106 53.0 13.8 12.6 0.053 28.03.08 79 57.0 14.6 11.5 0.066 01.04.08 91 55.0 13.4 16.7 0.064 03.04.08 85 50.0 16.2 18.6 0.031 08.04.08 97 57.0 16.4 15.4 0.044 10.04.08 117 54.0 17.3 13.8 0.052 15.04.08 88 50.0 15.2 12.1 0.057 17.04.08 75 61.0 13.8 11.0 0.071 22.04.08 77 59.0 13.9 17.3 0.031 24.04.08 82 54.0 10.9 15.4 0.024 29.04.08 95 55.0 13.8 13.6 0.046 01.05.08 93 53.0 11.6 12.0 0.057 05.05.08 102 49.0 12.3 16.8 0.029 07.05.08 89 51.0 13.4 14.3 0.038 12.05.08 68 56.0 12.0 15.8 0.016 14.05.08 75 51.0 10.2 13.9 0.035 19.05.08 91 54.0 11.9 10.8 0.049 21.05.08 86 48.0 12.5 12.5 0.027 26.05.08 72 56.0 15.7 15.7 0.044 28.05.08 70 52.0 11.8 16.2 0.022 Max 117.0 61.0 17.3 18.6 0.071 Min 68.0 42.0 10.2 10.8 0.016 Average 86.2 52.8 13.4 14.3 0.044 SD 12.0 4.0 1.8 2.1 0.016 98th 112 60 16.9 18.0 0.069 Percentile

ILC Industries Ltd. 106

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Table 5: Chikkabangnal, A5

Date TSPM RPM SO2 NOx CO (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 05.03.08 72 42.0 10.9 13.8 0.029 07.03.08 52 46.0 9.9 14.7 0.041 12.03.08 67 51.0 12.7 14.1 0.062 14.03.08 71 57.0 13.2 11.8 0.019 19.03.08 66 42.0 15.8 13.4 0.011 21.03.08 58 39.0 14.1 15.0 0.027 26.03.08 62 44.0 11.4 13.7 0.026 28.03.08 73 53.0 13.8 14.5 0.053 01.04.08 98 41.0 15.9 15.5 0.041 03.04.08 70 49.0 18.4 16.8 0.056 08.04.08 74 52.0 16.7 17.2 0.054 10.04.08 81 48.0 17.0 13.8 0.047 15.04.08 72 40.0 15.2 13.5 0.057 17.04.08 65 46.0 13.8 15.0 0.059 22.04.08 79 42.0 12.4 19.5 0.046 24.04.08 75 45.0 10.9 14.2 0.034 29.04.08 91 41.0 13.7 15.6 0.053 01.05.08 76 55.0 15.7 15.2 0.048 05.05.08 70 57.0 11.9 14.9 0.028 07.05.08 68 52.0 12.8 13.4 0.035 12.05.08 89 49.0 10.7 15.6 0.026 14.05.08 84 53.0 14.6 14.5 0.046 19.05.08 73 43.0 13.4 15.1 0.034 21.05.08 69 40.0 16.3 14.6 0.017 26.05.08 78 46.0 14.9 14.3 0.025 28.05.08 81 51.0 13.5 13.8 0.036 Max 98.0 57.0 18.4 19.5 0.062 Min 52.0 39.0 9.9 11.8 0.011 Average 73.6 47.1 13.8 14.8 0.039 SD 10.0 5.5 2.2 1.5 0.014 98th 95 57 17.7 18.4 0.061 Percentile

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Table 6: Kunikeri Tanda, A6

Date TSPM RPM SO2 NOx CO (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 01.03.08 85 51.0 10.3 15.6 0.039 03.03.08 74 48.0 11.6 14.8 0.045 08.03.08 82 50.0 10.2 15.3 0.041 10.03.08 73 45.0 9.7 14.0 0.038 15.03.08 61 47.0 11.2 15.3 0.040 17.03.08 68 53.0 10.5 14.9 0.036 22.03.08 75 50.0 15.3 16.7 0.041 24.03.08 84 55.0 14.2 14.2 0.044 29.03.08 77 42.0 13.8 15.0 0.036 31.03.08 69 49.0 9.9 14.6 0.038 04.04.08 74 47.0 12.4 15.1 0.042 06.04.08 80 50.0 10.1 14.3 0.036 11.04.08 105 48.0 13.4 16.8 0.044 13.04.08 94 43.0 9.7 14.6 0.039 18.04.08 89 45.0 10.2 13.8 0.041 20.04.08 92 47.0 9.4 16.1 0.038 25.04.08 73 46.0 9.6 15.7 0.039 27.04.08 80 49.0 10.6 14.6 0.041 02.05.08 78 41.0 9.8 15.2 0.045 04.05.08 86 46.0 8.9 15.9 0.038 09.05.08 77 44.0 11.2 13.5 0.037 11.05.08 71 51.0 10.2 13.2 0.042 16.05.08 84 47.0 10.0 14.9 0.047 18.05.08 89 43.0 9.2 15.8 0.039 23.05.08 91 49.0 11.1 16.3 0.042 25.05.08 75 50.0 10.8 13.9 0.039 Max 105.0 55.0 15.3 16.8 0.047 Min 61.0 41.0 8.9 13.2 0.036 Average 80.2 47.5 10.9 15.0 0.040 SD 9.6 3.4 1.6 0.9 0.003 98th 99.5 54.0 14.8 16.8 0.046 Percentile

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Table 7: Ginigera, A7

TSPM RPM SO NOx CO Date 2 (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 05.03.08 146 43.4 11.6 20.8 0.023 07.03.08 141 46.8 12.4 25.9 0.035 12.03.08 146 49.3 13.7 21.7 0.043 14.03.08 151 39.1 12.7 26.9 0.030 19.03.08 164 41.7 10.8 18.1 0.021 21.03.08 140 41.7 11.7 17.6 0.098 26.03.08 146 43.4 13.8 27.3 0.044 28.03.08 151 41.7 10.9 20.1 0.027 01.04.08 161 51.9 11.2 23.8 0.019 03.04.08 142 50.2 17.8 25.7 0.025 08.04.08 146 45.9 15.8 24.1 0.021 10.04.08 141 44.2 13.4 29.6 0.023 15.04.08 148 41.7 11.5 22.3 0.044 17.04.08 172 43.4 10.8 31.5 0.041 22.04.08 158 40.8 11.0 28.6 0.026 24.04.08 143 38.3 12.7 34.2 0.019 29.04.08 154 41.7 15.8 29.6 0.046 01.05.08 162 39.1 9.8 28.9 0.028 05.05.08 142 43.4 16.4 31.2 0.035 07.05.08 147 47.6 11.1 29.7 0.029 12.05.08 153 45.1 12.4 35.9 0.026 14.05.08 149 40.8 10.6 30.4 0.034 19.05.08 152 44.2 12.5 25.8 0.022 21.05.08 161 38.3 13.4 27.6 0.045 26.05.08 167 40.0 12.3 24.7 0.048 28.05.08 149 43.4 11.9 20.9 0.038 Max 172 51.9 17.8 35.9 0.098 Min 140 38.3 9.8 17.6 0.019 Average 151.1 43.3 12.6 26.3 0.034 SD 8.8 3.6 2.0 4.7 0.016 98th 170.0 51.0 17.1 35.1 0.073 Percentile

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Table 8: Hosa Kanakapura, A8

TSPM RPM SO NOx CO Date 2 (μg/m3) (μg/m3) (μg/m3) (μg/m3) (ppm) 05.03.08 84 46.0 12.3 13.5 0.038 07.03.08 97 43.0 13.8 14.3 0.066 12.03.08 83 48.0 14.2 15.2 0.045 14.03.08 102 41.0 12.4 13.4 0.057 19.03.08 95 46.0 10.7 13.1 0.052 21.03.08 88 49.0 11.1 12.8 0.070 26.03.08 74 45.0 13.5 12.0 0.059 28.03.08 85 43.0 14.0 13.9 0.065 01.04.08 91 37.0 10.8 12.1 0.050 03.04.08 97 42.0 11.5 13.4 0.056 08.04.08 78 46.0 13.7 14.1 0.048 10.04.08 81 40.0 12.4 15.0 0.065 15.04.08 86 49.0 13.2 15.9 0.042 17.04.08 95 51.0 12.3 13.7 0.055 22.04.08 92 47.0 11.8 14.6 0.067 24.04.08 101 44.0 10.1 13.9 0.041 29.04.08 91 49.0 14.3 12.4 0.055 01.05.08 106 45.0 13.9 13.1 0.056 05.05.08 121 53.0 12.7 14.2 0.042 07.05.08 114 42.0 13.9 14.6 0.062 12.05.08 90 48.0 11.2 12.9 0.034 14.05.08 81 54.0 9.8 12.3 0.038 19.05.08 77 46.0 8.2 11.8 0.041 21.05.08 83 50.0 10.3 13.7 0.043 26.05.08 96 43.0 9.4 13.5 0.062 28.05.08 91 52.0 8.2 12.7 0.038 Max 121.0 54.0 14.3 15.9 0.070 Min 74.0 37.0 8.2 11.8 0.034 Average 91.5 46.1 11.9 13.5 0.052 SD 11.1 4.2 1.8 1.0 0.011 98th 117.5 53.5 14.3 15.6 0.069 Percentile

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CHAPTER – 4 IMPACT ASSESSMENT

4.1 INTRODUCTION

This chapter presents identification and appraisal of various impacts from the proposed ILC‟s Mini Steel Plant in the study area. The pre-project baseline environmental conditions are presented in Chapter-3.

Generally, the environmental impacts can be categorized as either primary or secondary. Primary impacts are those, which are attributable directly to the project, secondary impacts are those, which are indirectly induced and typically include the associated investment and changed pattern of social and economic activities by the proposed action.

The impacts have been predicted for the proposed plant assuming that the pollution due to the existing activities has already been covered under baseline environmental monitoring and continue to remain the same during the operation of the project. The proposed project would create impact on the environment in two distinct phases.

During the construction phase which may be regarded as temporary or short term; and During the operation phase which would have long term effects.

The construction and operational phase of the proposed plant comprises various activities each of which may have an impact on some or other environmental parameters. Various impacts during the construction and operation phase on the environmental parameters have been studied to estimate their impact on the environment. The details of impact due the project activity on each of the environmental attributes are discussed below.

4.2 IMPACT DURING CONSTRUCTION PHASE

This includes the following activities related to leveling of site, construction and erection of main plant structures and equipment.

4.2.1 Impact on Land Use

The land acquired for the proposed plant is about 95 acres, which is private land. No forestland is involved. The existing land use of the proposed plant site is barren land. The proposed plant area is more or less flat which require minimum cutting and leveling.

The construction of proposed plant would bring in certain immediate changes in the land use pattern of the proposed area as well as in the vicinity. The break-up of proposed land use in the plant site is given in Table-2.2 of Chapter-2.

Further, there will be simultaneous plantation of green belt on about 31 acre of area at the plant site along with the construction activity. This will have positive impact on the surroundings.

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The construction activities would attract a sizable labour population and the influx of population is likely to be associated with construction of temporary hutments. This however would be temporary where the gestation period is short. Local labour force will be employed to the maximum extent possible.

4.2.2 Impact on Soil

The proposed land is having flat profile; therefore the earthwork involved in leveling the land is very less. The maximum topsoil cover thickness at the plant site is about 1 m. The topsoil removed during the leveling will be stacked separately and will be used during the greenbelt development / leveling of site. Vegetation on topsoil is removed prior to commencement of bulk earthwork.

The construction activities will result in loss of topsoil to some extent in the plant area. Apart from very localized constructional impacts at the plant site, no significant adverse impact on the soil in the surrounding area is anticipated.

4.2.3 Impact on Air Quality

During this phase, suspended particulate matter will be the main pollutant, which could be generated due to site development activities and vehicular movement. However, due to increased vehicular traffic there may be slight increase in concentrations of NOx and CO. The approach roads are proposed of WBM and vehicles will be kept in good condition to minimize automobile exhaust.

The impact of such activities would be temporary and restricted to the construction phase. The impact will be confined within the project boundary and is expected to be negligible outside the plant boundaries. Proper upkeep and maintenance of vehicles, sprinkling of water on roads and construction site, providing sufficient vegetation etc. are some of the proposed measures that would greatly reduce the impacts during the construction phase.

4.2.4 Impact on Water Quality

The construction water requirement will be met from bore wells proposed at plant site. Impact on water quality during this phase may be due to fulfillment of water requirement and disposal of sewage generated from the construction camps stationed at the site and spillages of oil & fuel from construction equipments / vehicles.

Since, most of the construction work force will constitute of floating population, the demand of water and sanitation facilities will be less. Local labour force will be employed to the maximum extent possible. Also these camps will be provided with adequate and proper sanitary arrangement. Construction equipments and vehicles will be maintained regularly. The overall impact on water environment during construction phase is likely to be short term and insignificant.

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4.2.5 Impact on Noise Levels

Construction activity and deployment of construction vehicular traffic are likely to cause an increase in the ambient noise levels. The areas affected are those close to the site. At the peak of the construction, marginal increase in noise levels is expected. The typical noise levels of some construction equipment are given in Table-4.1. The peak noise levels from continuous construction activity may be about 90 dB(A). Since there is no habitation with 1 km radius of plant site the impact is considered insignificant. The noise control measures such as provision of covers / caps on the equipment, regular maintenance of the equipment & vehicles, restriction of working hours, provision of earmuffs and earplugs to workers working in high noise area would be taken.

Overall, the impact of noise generated on the environment is likely to be insignificant, reversible and localized in nature and mainly confined to the day hours.

Table-4.1: Typical Noise Levels of Construction Equipment

Description Noise Levels dB(A) Earth Movers Front End Loaders 72-84 Backhoes 72-93 Tractors 76-96 Scrapers, Graders 80-93 Pavers 86-88 Trucks 82-94 Material Handlers Concrete mixers 75-88 Concrete pumps 81-88 Cranes (movable) 75-86 Cranes (derrick) 86-88 Stationary Equipment Pumps 69-71 Generators 71-82 Compressors 74-86

4.2.6 Impact on Terrestrial Ecology

The initial construction works at the project site involves land clearance, cutting, filling and leveling. These activities result in loss of vegetation.

As the land identified for the project is barren, only small number of shrubs / trees will required to cut. Remaining shrubs/trees in the occupied area will be retained as part of the green belt. Therefore, no major loss of biomass is envisaged during construction phase. These impacts are, however, restricted to the early phase of construction.

The removal of herbaceous vegetation generally causes loosening of topsoil. However, such impacts would be primarily confined to the project site during initial periods of the construction phase and would be minimized through adoption of mitigative measures like paving and surface treatment, water sprinkling and appropriate plantation programme. The project site will be extensively landscaped with the development of green belt consisting of a ILC Industries Ltd. 113

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

variety of locally sustainable plant species, which would enrich the ecology of the area and add to the aesthetics.

The constructional activities lead to inward migration of labour force in the area and thus there would be pressure on trees in the area due to increase in fuel demand. In order to prevent felling of trees in the neighboring areas, alternate fuel will be arranged to meet the fuel requirement of labour force.

The increased vehicular traffic coupled with higher noise level due to various constructional activities may drive away the birds from the project site to the neighboring forest area.

4.2.7 Impact on Aquatic Ecology

Tungabhadra reservoir is major water body and is about 3 km away from project site besides localized ponds beyond 3 km.

Adequate sanitation facilities will be provided to construction camp to avoid surface run off. Therefore impact on aquatic ecology is not anticipated.

4.2.8 Impact on Demography and Socio-economics

The impact of the proposed plant would begin to be felt with the start-up of the construction activities.

The non-workers constitute about 60% of the total population in 10-km radius study area. Some of them will be available for employment in the proposed plant during construction activities.

In addition to the opportunity of getting employment as construction labourers, the local population would also have employment opportunities in related service activities like petty commercial establishments, small contracts/sub-contracts and supply of construction materials for buildings and ancillary infrastructures etc. Consequently, this will lead to economic up-liftment of the area.

4.3 IMPACTS DURING OPERATIONAL PHASE

4.3.1 Impact on Climate

Impact on the climatic is generally envisaged due to exothermic activities. The process involves manufacturing of hot metal, burning of coal etc. which will be taken place in closed reactor followed by cooling. However, the impact is restricted to immediate area only. The emission of exhaust gases having average temperature around 200 C will be emitted from chimney. Chimney will be provided with adequate height for proper dispersion of flue gas to avoid any thermal imbalance. Green belt on about 31 acres of land is also proposed. Hence, insignificant impact is envisaged due to proposed activities.

4.3.2 Impact on Topography

The major envisaged topographical changes would be due to the manmade structures like civil structures and industrial complex including erection of stacks. The plant site is also fairly flat ILC Industries Ltd. 114

RAPID ENVIRONMENTAL IMPACT ASSESSMENT OF PROPOSED MINI STEEL PLANT ( 0.2 MTPA) WITH CPP (12 MW)

and would require less cutting and filling. Thus, the impact would be insignificant. However, it will invite positive benefits in the form of land leveling and tree plantations in the plant vicinity.

4.3.3 Impact on Land use

As mentioned earlier the site area is fallow and barren land. As discussed in Section-4.2.1, the total land acquired is private land and no forestland is involved in the site.

The land use changes are anticipated in the plant site only. The proposed green belt will also usher in a positive land use change. Thus, the impact on the land use during the operation of the project is likely to be insignificant.

4.3.4 Impact on Soil

Most of the impacts of these projects on soils are restricted to the construction phase, which will get stabilized during operational phase.

The soil samples in the study region were collected and the results are tabulated in Table- 3.3.2, Chapter-3 to know the baseline conditions. Increase in chemical constituents of soil is likely through deposition of air pollutants and solid waste disposal. The main air pollutant expected through the stacks will be SPM, SO2 and NOx. However with the help of control equipment‟s, the emission of air pollutants will be reduced to acceptable limits. The raw material handling systems will be provided with control equipment like bag filters etc. Also the off-gases will be treated in gas cleaning plant.

The solid wastes generated from the plant will be sludge, Dust from dedusting equipment, slag, refractory debris and scrap etc. (Refer Section-2.9.3, Chapter-2). As mentioned earlier, solid waste will be reused/recycled. Slag is proposed to be sold to potential cement manufacturing parties. The scrap generated will be reused as charge.

Green belt development / plantation in and around plant will be concurrent to construction activity. Plantation especially around the solid waste dumping yard will arrest the aerial spread of particulate contaminants.

The fugitive dust from the plant is likely to be deposited in the nearby areas. However, the proposed dust extraction and suppression measures at the source will significantly reduce this possibility. Highly favorable meteorological conditions create greater diffusion and dispersion of pollutants and thus the ground level concentrations are expected to be minimum. Further, the erection of proposed plant at this site with the proposed greenbelt comprising diversified species, not only increases the bio-mass, soil fertility, productivity but also helps as pollution sinks and control of soil erosion. Hence, the likely impact on the soil characteristics will be minimal in terms of aerial spread and will not affect the sub-surface soil as all precautions will be implemented during the construction of the plant itself.

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4.3.5 Impact on Air Quality

The proposed plant operation is expected to generate Suspended Particulate Matter (SPM), Sulphur dioxide (SO2) and Oxides of Nitrogen (NOx) as the pollutants. The various measures proposed to minimize the pollution from the plant are described in Section-2.9.1 of Chapter-2.

The impact on ambient air quality is assessed hereunder considering the following:

The air quality impacts have been predicted assuming that the pollution due to the existing activities has already been covered under baseline environmental monitoring; and Site-specific meteorological parameters have been recorded by using continuous recorders. Short-term 24 hourly incremental values (GLCs) were estimated using the site-specific meteorological data for three months.

Prediction of impacts on air environment has been carried out employing mathematical model based on a steady state Gaussian plume dispersion model designed for multiple point sources for short term. In the present case, Industrial Source Complex-Short Term [ISCST3] 1993 dispersion model based on steady state gaussian plume dispersion, designed for multiple point sources for short term and developed by United States Environmental Protection Agency [USEPA] has been used for simulations from point sources.

The model simulation deal with three major pollutants viz. Suspended Particulate Matter (SPM), Sulphur Dioxide (SO2) and Oxides of Nitrogen (NOx) emitted from the proposed plant/stacks.

The options used for short-term computations are: The plume rise is estimated by Briggs formulae, but the final rise is always limited to that of the mixing layer; Stack tip down-wash is not considered; Buoyancy Induced Dispersion is used to describe the increase in plume dispersion during the ascension phase; Calms processing routine is used by default; Wind profile exponents is used by default, 'Irwin'; Flat terrain is used for computations; It is assumed that the pollutants do not undergo any physico-chemical transformation and that there is no pollutant removal by dry deposition; Washout by rain is not considered; Cartesian co-ordinate system has been used for computations; and The model computations have been done for 10 km with 1000-m interval.

The details of stack emissions are given in Table-4.2. In the model, all stacks are considered to assess the cumulative impacts on the ambient air quality.

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Table-4.2: Stack Details

Parameters Unit Stack Attached to Sponge Sponge EOF Rolling FBC Iron-1 & 2 Iron-3 & 4 Mill Boiler Stack height m 45 45 40 35 50 Stack m 1.5 1.5 1.0 0.85 2.0 diameter Stack exit m/s 10.0 10.0 8.0 8.0 15 gas velocity Stack gas Deg.C 100 100 100 100 180 temperature at exit Emission rate mg/Nm3 100 100 100 100 100 of SPM g/s 1.43 1.43 0.51 0.37 3.14 Emission rate mg/Nm3 20 20 80 -- 100 of SO2 g/s 0.29 0.29 0.41 3.14 Emission rate mg/Nm3 25 25 -- -- 50 of NOx g/s 0.36 0.36 1.57

Hourly data recorded at site on wind speed, direction and temperature for three months [March through May 2008] was used as meteorological input. The mixing heights published by CPCB vide their document "Spatial Distribution of Programme Objective Series (PROBES/88/2002- 2003)” for project area for summer season are considered for modeling. Average hourly data for 24 hrs used for modeling is tabulated in Table-4.3.

Table-4.3: Meteorological Data used for Modeling

Hour Wind Direction, Wind Temperature Stability Mixing deg. Speed, m/s deg. K Class Height, m 1 330 1.00 297.4 6 100 2 334 0.78 296.3 6 100 3 328 0.72 295.5 6 100 4 308 1.11 295.4 6 100 5 322 0.75 294.8 6 200 6 266 0.58 294.3 6 200 7 76 0.39 293.1 2 200 8 111 0.61 294.7 2 200 9 304 1.89 298.8 1 500 10 314 2.03 302.7 2 700 11 307 1.78 304.5 1 1000 12 200 1.44 307.4 1 1500 13 304 1.67 309.4 1 1500 14 307 2.08 310.0 2 2000 15 291 2.00 310.2 2 2000 16 286 1.86 310.4 1 1500

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Hour Wind Direction, Wind Temperature Stability Mixing deg. Speed, m/s deg. K Class Height, m 17 174 1.86 309.9 2 1500 18 305 2.11 308.2 3 1500 19 304 1.81 306.2 6 1000 20 315 1.58 304.3 6 800 21 317 1.78 302.8 6 600 22 310 1.67 301.3 6 400 23 242 0.89 299.8 6 200 24 259 0.92 298.0 6 100

The simulations were made to evaluate SPM, SO2 and NOx incremental short-term concentrations due to proposed project. In the short-term simulations, the incremental concentrations were estimated to obtain an optimum description of variations in concentrations within study area.

The predicted results are tabulated below in Table-4.4 and dispersion trend is shown as isopleths in Figure-4.1 through 4.3 respectively for SPM, SO2 and NOx.

Table-4.4: Predicted 24-Hourly Short Term Incremental Concentrations

Pollutants Maximum Incremental Distance, Direction Levels, µg/m3 km SPM 5 1.4 SE SO2 2.21 1.4 SE NOx 1.31 1.4 SE

The predictions indicate that the SPM, SO2 and NOx concentrations are likely to be well within the prescribed limit of 200, 80 and 80 g/m3 respectively for residential and rural zone. Based on the predicted concentrations it can be inferred that area is unlikely to be significantly affected due to the proposed plant.

The maximum incremental GLCs (Refer Table-4.4) due to the proposed project for SPM, SO2 and NOx are superimposed on the baseline concentrations recorded during the study period to arrive at the likely resultant concentrations after implementation of the proposed plant. The cumulative concentrations (baseline + incremental) after implementation of the project are tabulated below in Table-4.5.

Table-4.5: Resultant Concentrations Due To Incremental GLC's

Scenario Incremental Baseline Resultant CPCB Limit for Concentrations, Concentrations,* Concentrations, Residential & g/m3 g/m3 g/m3 Rural , g/m3 SPM 5 172 177 200 SO2 2.21 18.4 20.61 80 NOx 1.31 35.9 37.21 80

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* - Baseline concentrations are considered as maximum value of 98th percentile for that pollutant.

The maximum GLCs for SPM, SO2 and NOx after implementation of the proposed project are likely to be within the prescribed standards of CPCB.

Figure-4.1: Short Term 24 Hourly GLCs of SPM

10000 9000 8000 7000 6000 5000 4000 3000 2000

1000 5.00 0 -1000 4.00 -2000 -3000 -4000 3.00 -5000

-6000 2.00 -7000 -8000 1.00 -9000 -10000 -10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000 0.00

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Figure-4.2: Short Term 24 Hourly GLCs of SO2

10000 9000 8000 7000 6000 5000 4000 3000 2000 2.10 1000 0 1.80 -1000

-2000 1.50 -3000 -4000 1.20 -5000 0.90 -6000

-7000 0.60 -8000 -9000 0.30 -10000 -10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000 0.00

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Figure-4.3: Short Term 24 Hourly GLCs of NOx

10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 1.20 0 -1000 1.00 -2000 -3000 0.80 -4000 -5000 0.60 -6000 -7000 0.40 -8000 0.20 -9000 -10000 -10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000 0.00

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4.3.6 Impact on Traffic

With the implementation of the project the traffic is likely to increase on the existing road network near the plant and its surroundings during construction and operation phase. The raw material and finished products of the proposed plant will be transported by road through NH-13 and railway, railhead at Ginigera on South Central Railway. The impact of the traffic is assessed on the basis of;

Adequacy of the existing road network Impact on air quality

4.3.6.1 Estimated Traffic from Project

Construction Phase

Trucks will be used in transporting construction material (plant components) to the proposed plant site during construction phase. The estimated number of vehicles would be about 20 plying both ways.

Operation Phase

All the raw materials except coal/coke will be brought by road due to availability in nearby area while coal/coke will be transported either by road or by rail. Similarly the finished products will be transported either by road or by rail. In addition the trucks and jeeps will be used for internal movement of the material and staff. Limited number of buses will be put in force for the movement of the staff as per the shift. The details of the likely generated traffic due to the proposed plant are given in Table-4.6.

Table-4.6: Generated Traffic Due To Proposed Project (Operation Phase)

Particulars Consumption/ Mode of No. of Vehicles Production transport per day* (TPA) Raw Materials Iron Ore 3,31,400 100% by Road 40 Coal/coke 2,67,100 100% by Road# 32 Other raw material like 70,900 100% by Road 9 dolomite, lime stone etc. Finished Product 2,06,000 100% by Road# 25 Miscellaneous vehicular movement Staff jeep -- -- 5 Staff Bus -- -- 4 Truck -- -- 2 # Coal and Finished product will be transported from Chennai / Panji Port and Plant respectively till Ginigera Railway station where siding facility is available. Transportation of same from railway station to plant and vice versa will be through road of 4 km length.

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4.3.6.2 Adequacy of the Existing Road network

Traffic from the Proposed Project

The estimated increase in number of vehicles is summarized in Table-4.7.

Table-4.7: Increased Traffic Due to the Proposed Project

Type of vehicle Number of vehicles per Day Construction phase Operational Phase Trucks 20 108 Buses -- 4 Jeeps 10 5 Total PCUs 90 351 Note: PCU factor 3.0 for heavy vehicles is considered.

Existing traffic data

As mentioned in Section-3.9 of Chapter 3, traffic study was conducted at one location on NH-13 for 24 hours. This location is selected considering that the proposed site is approachable from this location to NH-13. The existing PCU works out to be 727 PCU per hour at this location.

Impact

The IRC recommendation on traffic capacity on NH-13 having two lane is 1500 PCU/hr. As mentioned above the operational phase PCU works out to be 351 per hour. There will be marginal increase in traffic during construction phase while considerable during operation phase though the traffic capacity of NH-13 will be within the IRC recommendations. It should be considered that the traffic load estimated during operation phase is for ultimate capacity of plant which will be achieved in next 5 years. By that time existing road condition of NH-13 will be further improve and there will be up-gradation of traffic capacity on same.

4.3.6.3 Dispersion Modeling

With the implementation of the project the traffic is likely to increase on the existing road network near the plant and its surroundings during construction and operation phase. In order to estimate the impacts due to transportation of raw materials and the finished goods dispersion modeling has been carried out by using the air quality model CALINE3 developed by California Department of Transportation. The model is based on Gaussian diffusion equation and uses a mixing zone concept to characterise pollutant dispersion over the roadway. The model has been extensively tested for its predictive capability for traffic related air quality impacts. Given the source strength, meteorology, site geometry and site characteristics, the model can reliably predict pollutant concentrations for receptors located within 300 meters of the roadway, the most important region for estimating the impacts due to the low elevation emissions.

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The long-term variations in air quality scenarios during the project life are expected due to the change in traffic on the highway with time. The existing and the predicted traffic volumes from the plant have been considered to project future air quality scenarios. A longer time horizon has not been considered because of uncertainty in ascertaining the emission factors for various categories of vehicles in future due to the probable change in technology and fuel use.

The averaging time for model predictions is restricted to 60 minutes. The averaging time is so selected because the primary meteorological factors that influence the air quality predictions i.e. wind speeds and directions do not remain steady for longer time periods. Also, during the peak traffic hours, the traffic volumes typically show significant variations over periods longer than one hour.

Due to averaging time of 60 minutes, the project impacts on air quality are essentially assessed based on one hourly standard for CO. Due to non-availability of hourly variations of meteorological conditions over 24 hours, daily average levels could not be predicted for comparison with the relevant standards of NOx. Further scale up factors for estimating 24 hourly average concentrations for 1 hour is not reported. In any case such an exercise requires that the wind is blowing in the same direction for all 24 hours - which is not a practical assumption. NOx levels however have been developed for peak traffic conditions and compared with WHO standard of 400 g/m3 for hourly average. The standards for Hydrocarbons (HC) are not specified by CPCB. The comparison of the predicted concentration of HC in absence of the standards could not be possible. With respect to SPM, vehicular particulate emission levels have not been specified by the Indian Institute of Petroleum (IIP) and CPCB. Further the SPM contributions are dominated by background concentrations as well as traffic induced re-suspension, both of which are difficult to quantify.

Model Input

The Peak Hourly Traffic used for model prediction is tabulated below:

Table-4.8: Peak Hourly Traffic

Time 2/3 wheelers Trucks Cars/LCVs Buses From To 10.00 am 11.00 am 14 5 8 6

The above traffic data and the generated traffic from the project is considered for the modeling purpose.

The vehicle speeds for different categories of vehicles considered for the modeling purpose are provided in Table-4.9.

Table-4.9: Speed of The Vehicles (kmph)

Trucks Buses LCV Cars 2 Wheelers 50 50 60 60 60

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The vehicular emission norms in the year 2005 recommended in Auto Fuel Policy decided by the Inter-Ministerial Task Force (headed by the Chairman, CPCB) have been used to provide the emission factors for the different vehicle types. These Emission factors are as specified in Table-4.10.

Table-4.10: Emission Factors In Gm/Km/Vehicle*

Type of Average Tailpipe Emissions (g/km) Vehicles CO PM NOx Y-2005 Bharat II (Euro III) - Petrol Two Wheeler 1.5 - 1.5 3 – wheelers 2.25 - 2 Light Vehicles 2.2 0.5 0.5 Y-2005 Bharat II (Euro III) – Diesel 3 – wheelers 1 0.1 0.85 Light Vehicles 1 0.08 0.7 Heavy Vehicles 4 0.03 3 * to be multiplied by 1.6 for converting into gm/mile for use in CALINE3 model.

The air quality scenarios were developed for all stability classes using the representative wind speeds (minimum wind speed in the respective stability) for the particular stability class. The meteorological data considered for the modeling studies is given below in Table-4.11.

Table-4.11: Meteorological Data Considered For Modelling

Stability Class Wind Speed (m/sec) A 1.0 B 2.0 C 3.0 D 5.0 E 2.0 F 2.0

For model computations, the receptor locations have been chosen to account for its location with respect to center of the road. The scenarios were modeled for cross wind.

The Ground Level Concentrations (GLC) are computed for distances viz: 50, 100, 150, 200, 250 and 300 m from centre of the road.

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Results Discussion:

Construction Phase

It is observed from the predicted results that the CO, & NOx levels ranges from 0.12 to 10.5 g/m3 and 0.10 to 9.2 g/m3 respectively. The maximum concentrations were observed at 10-m distance from the edge of the road under stability class-A.

Operation Phase

It is observed form the predicted results that the CO & NOx levels range from 0.13 to 19.0 g/m3 and 0.11 to 16.0 g/m3 respectively. The maximum concentrations were observed at 10 m distance from the edge of the road under stability class-A.

Conclusions:

CO Levels

The predicted maximum hourly CO concentration is 19.0 g/m3. On comparison with the hourly standard for CO, which is specified as 4000 g/m3 specified by CPCB, it is seen that no violations of CO standard are expected due to the project. The CO levels in fact will remain well below the standards. The project therefore has insignificant negative impact on ambient air quality in terms of CO.

NOx Levels

The maximum predicted hourly NOx concentration is 16.0 g/m3. The hourly standards for NOx are not specified by CPCB. If the maximum value is converted to 24 hours average (which will be still less), then it will be well below the 24 hour standard (80 g/m3) specified by CPCB. The project therefore has insignificant negative impact on ambient air quality in terms of NOx.

4.3.7 Impact on Water Resources

The water requirement for the proposed plant will be met from Tungabhadra back waters.

The make up water requirement for the plant will be about 70 m3/hr while sanction to withdraw water is for 46.18 LLPD (192 m3/hr).

4.3.8 Impact on Water Quality

The water requirement will be met from Tungabhadra back waters. As mentioned earlier in Section-2.9.3 of Chaptre-2, there will be no discharge of waste water from operation of plant. Waste water after treatment will be either recycled in process or used for spraying/ sprinkling at raw material storages, roads, green belt development

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4.3.9 Impact on Noise Levels

Any industrial complex in general consists of several sources of noise in clusters or single. These clusters / single source may be housed in buildings of different dimensions made of different materials or installed in open or under sheds. The material of construction implies different attenuation co-efficient. In order to predict ambient noise levels due to the proposed plant activity the propagative modeling has been done. For computing the noise levels at various distances with respect to the plant site, noise levels are predicted using a user friendly model the details of which are elaborated below.

4.3.9.1 Details of Noise model

Mathematical Model for Sound Wave Propagation During Operation

For an approximate estimation of dispersion of noise in the ambient from the source point, a standard mathematical model for sound wave propagation is used. The sound pressure level generated by noise sources decreases with increasing distance from the source due to wave divergence. An additional decrease in sound pressure level with distance from the source is expected due to atmospheric effect or its interaction with objects in the transmission path.

For hemi-spherical sound wave propagation through homogenous loss free medium, one can estimate noise levels at various locations, due to different sources using model based on first principles, as per the following equation:

Lp2 = Lp1 - 20 Log (r2 / r1) ...... (1)

Where Lp2 and Lp1 are Sound Pressure Levels (SPLs) at points located at distances r2 and r1 from the source. The combined effect of all the sources then can be determined at various locations by the following equation.

Lp(total) =10Log (10(Lp1/10)+10(Lp2/10)+10(Lp3/10).) ...... (2)

Where, Lp1, Lp2, Lp3 are noise pressure levels at a point due to different sources.

Based on the above equations a user friendly model has been developed. The details of the model are as follows:

Maximum number of sources is limited to 200; Noise levels can be predicted at any distance specified from the source; Model is designed to take topography or flat terrain; Co-ordinates of the sources in meters; Maximum and Minimum levels are calculated by the model; Output of the model in the form of isopleths; and

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4.3.9.2 Input for the Model

The expected noise levels from various units of plant are tabulated in Table-2.13 of Chapter- 2 and the same has been considered for modeling. These noise sources have been defined with respect to plant center while modeling.

4.3.9.3 Presentation of Results

The predicted model results at plant boundary are tabulated in Table-4.12.

Table-4.12: Predicted Noise Levels At Plant Boundary

Sr. No. Plant Boundary Noise Level, dB(A) Direction Distance (m) 1 N 400 39.0 2 NE 775 31.0 3 E 660 32.0 4 SE 770 32.0 5 S 410 39.0 6 SW 760 32.0 7 W 650 33.0 8 NW 780 30.0

4.3.9.4 Observation

It can be seen above table that, noise levels >39 dB(A) are limited to work zone only. At the corners of the plant boundary, noise levels are found to be <31 dB(A).

The nearest village Hirebagnal is located at about 1.8 km in the ENE direction. The baseline noise levels (Leq) recorded at this location is 47.3 dB(A) during day time. Therefore the noise due to operation of the proposed project will not have any bearing on the baseline noise levels due to masking effect.

The operators, workers and other personnel within the plant, however, have to be provided with protective measures. According to the Occupational Safety and Health Administration (OSHA) Standards, the allowable noise level for the workers is 90 dB(A) for 8 hours exposure a day. It could be seen from Table-2.13 that in the plant premises most of the machinery/equipment generate noise levels around 75-85 dB(A). Therefore, adequate protective measures in the form of ear muffs/ear plugs to the workers working in high noise areas will be provided. In addition, reduction in noise levels in the high noise machinery areas could be achieved by adoption of suitable preventive measures such as suitable building layout in which the equipment are to be located, proper foundations, etc.

Further, in addition to the in plant noise control measures, all the open areas within the plant premises and all along the plant boundary will be provided with adequate green belt to diffuse the noise dispersion.

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4.3.10 Impact due to Solid Waste Generation

Solid waste generation and their disposal are given in Table-2.11 of Chapter-2. Solid waste from proposed plant is mainly slag, dust and fly ash.

The slag is non-hazardous in nature and will used as filler in any construction activity or filling at low levels. Coal dust generated from kiln and dedusting will be sold to brick manufacturing plant while dust from furnaces will be used as filler in any construction activity or filling at low levels. Fly ash generated from various points from Boilers will be conveyed to the respective ash silos fitted with a dust conditioner through dense phase pneumatic ash handling system. Unloading system with ash conditioner shall be provided below ash silo for loading on to open trucks. Ash silo will be of Mild Steel construction. One working and one standby compressor shall be provided for supplying the conveying air. Air receiver of suitable capacity shall be provided. Fly ash will be sold to cement / brick manufacturing units.

4.3.10.1 Action Plan For Fly Ash Disposal

Fly ash shall be disposed and sold as per the Guidelines issued by the MoEF. Based on these guidelines the following action plan has been prepared to take care of the fly ash for 10 years.

Table-4.13: Action Plan for Disposal of Fly Ash

Action To Be Taken Period 100 % ash stored in the Ash Disposal area 1st Year of Operation 10% of Fly ash shall be sold for Ash based products 2nd Year of Operation as per Notification S.O 763 (E) 20 % of fly ash shall be sold for Ash based products as 3rd Year of operation per Notification S.O 763 (E) 30 % of Fly Ash shall be sold for Ash based products 4th Year of Operation as per Notification S.O 763 (E) 40 % of Fly Ash shall be sold for Ash based products 5th Year of Operation as per Notification S.O 763 (E) 50 % of Fly Ash shall be sold for Ash based products 6th Year of Operation as per Notification S.O 763 (E) The selling of fly ash shall be increased by 10 % every year. During this period it shall be tried to dispose the stored Fly Ash and also find other prospective buyers for the same.

The dry fly ash will be transported in closed trucks for commercial utilization. Ash can be utilized in the following ways:

Bottom ash can be used as earth filling material. Fly ash can be used for manufacturing of portion of the kiln feed. Fly ash can be used in concrete mix. Fly ash can be underground with clinker to form port land pozzolana cement Fly ash can be used as filler material in bituminous concrete. ILC Industries Ltd. 129

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Fly ash can be used with lime and aggregate for the construction of base courses for highway, airports etc. Fly ash can be used as an adsorbent in treatment of polluted waters and sewage for control of organics, inorganic phosphorous and conditioning of sludge. Fly ash can be used for construction of embankments for highway and railways. Fly ash can be used for manufacturing of bricks.

4.3.11 Impact on Ecology

The baseline flora and fauna has been depicted in Section-3.10 of Chapter-3. There is no wild life sanctuary within the 25 km of the proposed project site. The land acquired for the proposed plant is mainly barren with patches of agricultural land. The impacts are briefly described in the following sections.

4.3.11.1 Impact on Terrestrial Ecology

The impact on terrestrial ecology will be due to emission of pollutants like SPM, NOx and SO2. The gaseous pollutants at a very low dose act as atmospheric fertilizer for the vegetation. However, at higher doses, they are injurious to both vegetation as well as animals.

In the present project adequate stack heights are provided for dispersion of pollutants. As described in the air quality Section-4.3.5, the maximum incremental concentrations of Particulates, SO2 and NOx due to operation of the project will be marginal and the resultant AAQ levels are likely to be within the AAQ standards. Therefore, the impact of these emissions on the surrounding agro-eco-system will be insignificant.

Extensive plantation comprising of pollutant resistant will be undertaken in and around the project site which will serve as not only pollution sink but also as noise barrier. It is expected that with adoption of these mitigatory measures, the impact due to operation of proposed plant will be minimal on the terrestrial eco-system.

4.3.11.2 Impact on Aquatic Ecology

The wastewater generated from the proposed plant will be re-used either in plant or spraying as discussed earlier. There will be zero water discharge from the plant. There will not be any impact on the surrounding aquatic water bodies.

4.3.12 Demography and Socio-Economics

The impacts of the proposed plant would begin to be felt with the start-up of the operational activities.

The present trend of out migration for employment is likely to reduce due to better economic opportunities available in the area; Operation phase will require significant work force of non-technical and technical persons. Migration of persons with better education and professional experience will result in increase of population and literacy in the surrounding villages. Commissioning of plant will result in considerable growth of service sector and will also generate new industrial and business opportunities in the area. As the proposed plant and its ancillary facilities, would act as an active nucleus for new industries and

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business activities, a shift of population towards this center and peripheral area is likely to occur.

The socio-economic impacts discussed in the construction phase of the proposed plant will also be manifested during the operation phase in the following manner.

Increase in consumer prices of indigenous produce and services, land prices, house rent rates and labour prices. Increase in services catering to the additional population will occur due to the setting up of the plant. Improvement in transport, communication, health and educational services. Increase in employment due to large flow of financial and material resources through increased business, trade commerce and service sector. The existing rural environment will gradually get transformed into a semi-urban environment due to economic cultural and infrastructural changes. Thus urban traits in place of traditional rural customs will tend to prevail. This may alter the quiet rural nature of the area to some extent. Social evils may increase resulting in occasional breach of peace. However, such adverse impacts will be minimized through suitable human management and security arrangement in consultation with local administration.

4.3.12.1 Impact on Human Settlement

The impact of proposed plant on human settlement will not significant since there is no displacement of any settlement.

In addition to the first order employment creation and income generation, there are also second order job and income implications for the host community termed as multiplier and linkage effects. Being the major industry in this area, it is quite possible that the social and cultural characteristics of this area could be altered.

Due to the support services requirement of the guest community in the proposed plant, the host community will be benefited by way of generation of employment opportunities, increased demand for the local produce and services. The direct employment provided in the proposed plant will be requiring higher skills and technical knowledge which will be catered to by those migrating from outside. Overall, there will be rise in the income level of the host community.

The surrounding human settlements are likely to experience migration from outside in view of the increased employment opportunities. Considering this aspect, the impact on human settlements will not be significant.

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4.3.12.2 Impact on Civic Amenities

The impact of economic development on civic amenities will be substantial. The area has experienced a good network of roads, communication and provision of amenities like water supply in the village areas. Many villages have been electrified during the last decade. Although the level of existing communications and support services in the area are just adequate, establishment of the proposed project would further strengthen these services. The overall impact is considered to be positive.

4.3.12.3 Impact on Health

Impact on health, if any, will be primarily due to air pollution i.e. emissions of SPM, NOx and SO2, and noise generation. Adequate air pollution and noise pollution control measures will be provided to conform to regulatory standards. Employees working in high noise work place would be provided protective devices like ear plugs/ear muffs for ensuring minimum impact on human health. Further, the medical facilities envisaged for the project employees will also be extended to the local population. ILC will also conduct awareness programs periodically on health aspects and organize health camps at regular intervals in the near by villages.

The environmental management and emergency preparedness plans are proposed to ensure that the probability of undesired events and consequences are greatly reduced and adequate mitigation is provided in case of any emergency.

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CHAPTER – 5 ENVIRONMENT MANAGEMENT PLAN

5.1 INTRODUCTION

The industrial development in the study area needs to be planned with judicious utilization of natural resources within the limits of permissible assimilative capacity. The assimilative capacity of the study area is the maximum amount of pollution load that can be discharged in the environment without affecting the designated use and is governed by dilution, dispersion and removal due to natural physico-chemical and biological processes. The Environment Management Plan (EMP) is required to ensure sustainable development in the area of the proposed ILC Plant. Hence, it needs to be an all encompassive plan for which the proposed industry, Government, Regulating agencies like Pollution Control Board working in the region and more importantly the affected population of the study area need to extend their co- operation and contribution. The identification and quantification of impacts based on scientific and mathematical modeling has been presented in Chapter-4.0. At the industry level, pollution control measures include in-built process control measures and also external control measures at the end of the pipeline before they are discharged into the receiving bodies.

It has been evaluated that the study area has not been affected adversely with present industrialization and urbanization. The proposed project is likely to provide new economical fillip in the region. Mitigation measures at the source level and an overall Management Plan for the study area are elicited so as to improve the supportive capacity of the study area and also to preserve the assimilative capacity of the receiving bodies.

The affected environmental attributes in the region include air quality, water quality, soil, land use, ecology and public health.

The Management Action Plan aims at controlling pollution at the source level to the possible extent with the best available technology followed by treatment measures before they are discharged.

The details of proposed control equipment to be provided are given in Chapter-2. The following additional mitigation measures are recommended in order to synchronize the economic development of the study area with the environmental protection of the region.

In addition to the plant specific control measures, the proposed establishment will follow the following guidelines:

The techno-economic feasibility of adoption of latest technology in the manufacturing process; and The techno-economic feasibility of adopting reuse and recycling technologies to reduce generation of waste to extent possible and optimize the production cost of the hot metal as well controlling pollution at source.

The recycling and re-use of industrial waste not only reduces the waste generated but can be an economic gain to the industry.

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5.2 SUMMARY OF ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION

The summary of anticipated adverse environmental impacts and mitigation measures are given in the Table-5.1.

Table-5.1: Anticipated Adverse Environmental Impacts & Mitigation

Discipline Potential Probable Mitigative Measures Remarks Impacts Source Constructional Impact Water Quality Increase in Loose soil A non-scouring, non- Reduced surface suspended at silting storm water water pollution due to solids due to constructi drain will be laid from erosion. Recharge of soil run-off on site the plant and a rain ground water is water harvesting possible in the structure is proposed region. at a strategic location to arrest the run-off water of the plant site. Air Quality Increase in Leveling Sprinkling of water in The impact will be dust and NOx activity the construction area low, as the main concentration and and unpaved roads. approach road and Heavy Proper maintenance internal roads will be vehicular of vehicles will be tarred. movement done. Noise Increase in Constru- Equipments will be Workers will be noise level ction kept in good provided with equipm- condition to keep the necessary protective ent‟s noise level within 90 equipment e.g. ear dB(A). plug, earmuffs. Terrestrial Clearing of Soil Landscaping and Plantation will be Ecology Vegetation enabling extensive plantation done in consultation activities will be done. with the horticulturist Socio- Additi In flux of 1. Local People Up-liftment of economics onal load on popula-tion will be employed to surrounding area existing the maximum amenities, extent possible Social 2. Increase in conflict ancillary business Operational Impact Water Quality Deterioration Discharge Adequate treatment The plant effluents of surface from facilities are after treatment will be water quality various proposed. reused within the plant plant and the plant units. envisages zero discharge out side the plant premises.

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Discipline Potential Probable Mitigative Measures Remarks Impacts Source Air Quality Increase in Stack High efficiency ESP The resultant air SPM, SO2 emissions and bag filters are quality will conform to and NOx and raw proposed to install. the stipulated levels in material Stacks of adequate standards. ambient air. area. heights are proposed for the proper dispersion of pollutants. All the internal road will be metalled / paved in the plant area to reduce dust emission. Dust suppression measures will be implemented in the raw material handling area. Afforestation programs will be undertaken around the plant area. Solid waste Granulated From the Granulated slag will The solid waste slag, sludges ESPs, de- be sold to cement generated from the from dusting industry. plant will be re-used / treatment equip- Dust from control sold to perspective units and ments, equipment will be re- buyers dust from air Bagfilter used in process. pollution and control treatment equipment. units Terrestrial Impact on Emissions Emission will be Ambient air quality Ecology plant species from controlled as well as will be within limits stack. dispersed through after the operation of appropriate design. plant, no active injury to the vegetation is expected. Aquatic Impact on Treated The wastewater will As all the effluents Ecology aquatic life of waste be provided with will be treated and the water water from adequate treatment. re-used within the bodies. plant The treated effluent plant, there will not will be re-used within be any impact on the the plant premises aquatic bodies. and there will be There is no water zero-discharge from body in immediate the plant. surrounding of the plant. It is at 3.0 km from plant. ILC Industries Ltd. 135

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Discipline Potential Probable Mitigative Measures Remarks Impacts Source Noise Increase in Equipmen Equipment will be Employees working noise levels t in main designed to conform in high noise areas in the plant plant and to noise levels would be provided area. auxiliaries. prescribed by personal protective regulatory agencies. equipments like Provision of green earplugs/ earmuffs. belt would further Acoustically help in attenuating designed enclosures noise. will be provided to noise generating equipments. Demography Strain on Influx of The manpower Overall socio- and Socio- existing people proposed to be economic status of economics amenities like deployed would be the area is expected housing, very less. No to improve. water significant impact is sources and envisaged. Additional sanitation, facilities will be medical and developed by the infrastructure project proponents. facilities.

5.3 ENVIRONMENTAL MANAGEMENT DURING CONSTRUCTION

The impacts during the construction phase on the environment would be basically of transient nature and are expected to reduce gradually on completion of the construction activities.

5.3.1 Site Preparation

Since the project site terrain is almost flat, some minimal leveling may be required. Vegetation on topsoil is removed prior to commencement of bulk earthwork. Construction water is proposed to be drawn from boreholes dug in the site area. During dry weather conditions, dust may be generated by activities like excavation and transportation through un-metalled roads. The dust will be suppressed using water sprinkling and may continue after completion of construction, as there is a possibility of heavy truck movement. The industry will make provision for water sprinklers. As soon as construction is over the surplus earth will be utilized to fill up low-lying areas, the rubbish will be cleared and all un-built surfaces reinstated. Appropriate vegetation will be planted and all such areas will be landscaped.

To prevent unauthorized felling of trees by construction workers for their fuel needs, efforts will be made by the contractor to provide fuel to the construction workers.

5.3.2 Air Quality

During construction period, there is likely hood of generation of dust and NOx emissions. This can be attributed to leveling activity and vehicular movement. The transport vehicles

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using petrol or diesel will be properly maintained to minimize smoke in the exhaust. Water sprinkling is envisaged to address this issue.

Since there is likelihood of fugitive dust from the construction activity, material handling and from the truck movement in the premises of the proposed plant, the industry will go for extensive tree plantation program along the boundaries of the proposed plant site.

5.3.3 Water Quality

During construction period, in rainy season the water quality is likely to be affected. This is likely to increase the suspended solids in the run-off during heavy precipitation. In order to reduce the impact on water quality, temporary sedimentation tanks will be constructed for the settlement of the suspended matter. There is no likely hood of ground water contamination as there will not be any process effluents during construction.

Safe and secure camping area will be provided for the migrant laborers during the construction period. Adequate arrangements will be made for water supply, sanitation and cooking fuels. The construction site will be provided with sufficient and suitable toilet facilities for workers to allow proper standards of hygiene. These facilities would be connected to a septic tank and maintained to ensure minimum environmental impact.

5.3.4 Noise Levels

The noise impact on the surrounding population during the construction phase will be within the acceptable limits. High noise generating equipment, if used, will not be operated during the night to eliminate any possible discomfort to the nearby residents. Community noise levels are not likely to be affected because of the vegetation and likely attenuation due to the physical barriers. The following recommendations will be implemented:

Provision for insulating caps and aids at the exit of noise source on the machinery; The use of damping materials such as thin rubber/lead sheet for wrapping the work places like compressors, generator sheets; Shock absorbing techniques will be adopted to reduce impact; Inlet and outlet mufflers will be provided which are easy to design; Ear muffs will be provided to the workers and it will be enforced to be used by the workers; and Greenbelt corridor will be developed along the periphery of the plant.

5.3.5 Ecological Aspects

During construction period, there could be clearing of small vegetation in order to prepare the site for construction. However, this will be mitigated by proper landscaping and extensive plantation along with the construction of the plant. Similarly, there will not be any impact on the aquatic ecology as there are no aquatic bodies in the plant site. A comprehensive green belt programme will improve the ecological condition of the region.

5.3.6 Socio-Economic Aspects

The project proponent is legal owner of the land which is ILC Industries Ltd. 137

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private land and hence there are no rehabilitation issues involved. Additionally local population will be engaged in the construction of the project with will help to uplift the economic status of the study area. 5.4 MANAGEMENT DURING OPERATIONAL STAGE

Environment management at design stage includes all the steps undertaken at the design stage by the project proponents to meet the statutory requirements and towards minimizing environmental impacts.

The design basis for all process units will lay special emphasis on measures to minimize effluent generation and emission control at source. The specific control measures related to gaseous emissions, liquid effluent discharges, noise generation, solid waste disposal etc. are described below:

5.4.1 Air Quality Management

5.4.1.1 Reduction of Emission at Source

Major pollutants envisaged from the proposed plant are Particulates, Sulphur dioxide, Oxides of Nitrogen and Fugitive dust. The baseline ambient air quality levels in the project area are within the permissible limits as specified by regulating agency. The following methods of abatement will be employed for the air pollution control. Dry type Gas Cleaning Plant (with two cyclone de-dusters) to remove coarse dust and Electrostatic Precipitator to remove fine dust with appropriate efficiency will be installed to limit the Particulate (SPM) emission within statutory limit. To facilitate wider dispersion, adequate chimney height will be provided; The waste heat from the furnace exhaust gases will be utilized to generate power of through a Waste Heat Recovery Boiler and Turbo-Generator set; Dry type de-dusting system (bag filters) will be provided to control fume emissions from the furnace runners & ladles and dust emissions from the burden delivery system; The dust from stock bins system will be dispersed into the atmosphere through adequate height of stack; Fugitive dust emissions will be controlled by dust suppression using water sprinkling at source. Adequate green belt will be provided around the plant area and plantation along the internal roads in the plant premises will be undertaken. About 54 acre of land will be brought under green cover; All internal roads will be bituminized to reduce the fugitive dust due to vehicular movement; and Water spraying will be practiced frequently at all dust generating areas viz. roads, raw material yard etc.

In addition to the above, any additional control measures suggested by KSPCB/MoEF will be implemented.

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5.4.1.2 Stack Gas Monitoring

The emissions from the stacks will be continuously monitored for exit concentration of Sulphur dioxide, Oxides of Nitrogen and Particulate Matter. Sampling ports will be provided in the stacks according to CPCB guidelines. 5.4.1.3 Ambient Air Quality and Meteorological Monitoring

The concentration of SPM, SO2 and NOx in the ambient air outside the project boundaries and in the adjoining villages will be monitored as per the direction of KSPCB and MoEF. About four locations will be selected in consultation with KSPCB and monitored at regular intervals.

Meteorological parameters like dry bulb temperature, wet bulb temperature, wind speed, wind direction, rain fall and atmospheric pressure will be monitored.

5.4.2 Water and Wastewater Management

5.4.2.1 Water Conservation

The total water requirement for the proposed plant will be met from the bore wells proposed within plant premises. In order to conserve the water resources, the treated effluents will be re-used in process and spraying / sprinkling at raw material area, roads, green belt.

5.4.2.2 Monitoring of Water Consumption

Continuous efforts will be made to reduce the water consumption and thereby to reduce the wastewater generation. Flow meter will be installed for the entire major water inlet and the flow rates will be continuously monitored. Periodic water audits will be conducted to explore the possibilities for minimization of water consumption.

5.4.2.3 Wastewater Treatment

The effluents can be categorized in to two types namely: i. Process wastewater; and ii. Sanitary wastewater.

The process wastewater will be collected in the guard pond after giving adequate treatment and will be re-used within the plant in furnace area, raw material area, green belt etc.

Similarly, the sanitary effluent from the plant is proposed to be treated in septic tanks, and the treated effluents are proposed to be used for horticultural purposes to the extent feasible.

5.4.2.4 Monitoring of Waste Treatment

All the treated effluents will be monitored regularly for the flow rate and quality to identify any deviations in performance of treatment plants. Appropriate measures will be taken if the treated effluent quality does not conform to the permissible limits.

5.4.3 Noise Level Management

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The noise levels due to the proposed plant will be in the rage of 30-39 dB(A) at the plant boundaries in all the directions. The ambient noise levels in the region are within permissible limits.

The specifications for procuring major noise generating machines/equipment will include built in design requirements to have minimum noise levels meeting Occupational Safety & Health Association (OSHA) requirement. Appropriate noise barriers/shields, silencers etc. will be provided in the equipment, wherever feasible.

Some of the practices proposed to be adopted for noise attenuation at the plant site are as follows:

Use of damping materials such as thin rubber/lead sheet for wrapping the work places like turbine halls, compressor rooms etc.; All the openings like covers, partitions will be designed properly; Inlet and outlet mufflers will be provided which are easy to design and construct; Ear plugs will be provided to workmen working near high noise generating sources; Noise levels will be reduced by the use of absorbing material on roof walls and floors; The industrial / plant area will be thickly vegetated with species of rich canopy.

5.4.4 Solid Waste Management

The main solid waste from the proposed plant will be the slag, dust from air pollution control equipment, coal fines, fly ash, and sludge from treatment units. The quantities of solid waste and their reuse/disposal are given in Chapter-2. The slag will be used as filler in any construction activity or filling at low levels. The coal dust will be used in brick manufacturing while fly ash will be used in cement and fly ash brick manufacturing. The dry dust from the air pollution control equipment will be fed into the furnace or used as filler in any construction activity. The sludge will be used for filling low lying area / road making.

Practices to be adopted for effective solid waste management include the following:

Separate land will be identified for land filling or mined out areas will be used for dumping; Buyers for granulated slag will be identified before commissioning of the plant; The slag and fines will be stacked on a concrete lined surface. The bottom surface will be provided with under-drains so as to collect any leachates during monsoon season; Garland drains will be provided around storage areas; The water samples from the bore holes will be analyzed to assess the impact on ground water quality; Sludge from the septic tanks, which will be biological in nature will be used as manure for green belt development; and Extensive green belt development will be taken up all around the plant, raw material storage etc. This will not only preserve the ecological conditions but also ameliorates the present condition.

5.4.5 Rain Water Harvesting

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Rain water harvesting scheme is proposed which forms the integral part of the plant design. Storm water from roof area will be discharged in storm water drains which are proposed along the internal roads, open spaces. Covered storm water drains are proposed. Water from these drains will be discharged in recharge pits proposed at suitable locations based on the geo-hydrology of the site area. As mentioned earlier water requirement of plant will be met from bore wells proposed within plant premises. Recharge pits will be located adjacent to these bore wells.

Typical section of recharge pit is shown in Figure 5.1.

5.4.6 Green Belt Development

Extensive greenbelt development plan in and around the plant area covering 31 acre of land is proposed. The species of wide varieties will be planted which will help in suppression of fugitive dust, attenuate noise levels and provide aesthetic background. The Greenbelt plan is depicted in Figure-2.1, Plant layout given earlier.

5.4.6.1 Objectives

Implementation of afforestation program is of paramount importance for any industrial development. In addition to landscaping, it will also check soil erosion, make the eco- system more complex and functionally more stable, make the climate more conductive and restore water balance. It can also be employed to bring areas with special problems under vegetal cover and prevent further land deterioration. The main objective of the green belt is to provide a barrier between the plant and the surrounding areas. The green belt helps to capture the fugitive emissions and to attenuate the noise generated in the plant apart from improving the aesthetics of the plant site.

In order to control the industrial pollutants, dense tree plantations are necessary. As the sedimentation pattern of the pollutants, ambient and ground level concentration of pollutants are usually determined by the direction and speed of prevailing wind and vertical and horizontal thermal gradients prevailing in the area, the belt of plantations will be designed accordingly. The width of the tree belt depends on the gaseous emissions, availability of land and site characteristics etc.

Geometry of planting of tree is more important in order to have effective wind break by the plantation. For an effective green belt, a mixture of tree species is necessary and some shrubs and grasses will be inter-cropped. As far as possible, there will be no gaps in the green belt. Where opening is imperative, alignments to roads will be such that open gaps are prevented to overcome funneling action of wind. The proposed tree plantation will cover all most all directions in the proposed plant site. Ornamental plants to beatify the area will also be grown along road sides.

Plantation program will be undertaken in all available areas. This will include plantation in the proposed plant premises, along the internal and external roads and along the administrative buildings and the raw material yards. The local species will be selected. The detailed program for green belt is given below:

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Figure 5.1: Typical Cross-Section of Recharge Pit

PIT WILL BE OF BBM COVERED WITH PCC

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5.4.6.2. Criteria for Selection of Species

Species to be selected will fulfill the following specific requirements of the areas:

Availability of seed material; Tolerance to specific conditions or alternatively wide adaptability to eco-physiological conditions; Rapid growth; Capacity to endure water stress and climatic extremes after initial establishment; Differences in height, growth habits and bole shapes; Pleasing appearance; Capacity to selectively concentrate some materials from the surroundings; Providing shades; Large bio-mass and leave numbers to provide fodder and fuel; Ability of fixing atmospheric Nitrogen; and Improving waste lands.

Certain exotic species like eucalyptus will also be tried along with local or indigenous species in plantation schemes because diversity in species confers stability to the ecosystem.

To undertake plantation on site for different purposes, following steps will be involved:

Raising seedlings in nursery; Preparation of pits and preparing them for transfer of seedlings; and After-care.

5.4.6.3 Recommended Species for Plantation

Local plant species will be used for plantation. Based following are some of the species recommended based on climate and soil characteristics of the study area. The climate of the region is extreme where there is less rainfall as well as extreme heat. Hence in order to have a ground cover, some fast growing species which do not require watering have been recommended for mass plantation. The species are as presented below:

Albizzia lebbek Peltophorum ferrusinum Lannea grandis Mitragyna parviflora Pongamia glabra

The above mentioned species not only resist water stress but also covers the ground quickly and also have a wider soil adaptability. For protecting the environment from dust, temperature, chemicals, emissions the following species have been recommended.

Plant species for Plant Area and its Boundary

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Oogenia oojensis Syzygium cumminii Eucalyptus hybrid Artocarpus hetreophylla Azadirachta indica Polyalthia longifolira Butea monosperma Bauhinia purpuria Bauhinia recemosa Ponqamia glabra Peltophorum ferrusinium Dalbergia sissoo Tecoma stans Tectona grandis Ficus reeligiosa Mimusops elinqi Cassia fistula Bambusa multiplex Tamarindus indica Adina cordifolia Terminalia tomentosa

Plant species for Road side plantation

Euphorbia nivula Pithocolobium dulce Artocarpus hetreophylla Azadirachta indica Polyalthia longiflora Butea monosperma Bauhinia purpuria Bauhinia recemosa Pongamia glabra Peltophorum ferrusinium Dalberqia sissoo Tectona grandis Ficus religiosa Bambusa multiplex Tamarindus indica Bauhinia variegata Bombax ceiba Boswellia serrata Cordia dichotoma Delonix regia Delonix elata Sesbania grandiflora Terminalia catapa Zizhhuphus zuzuba

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Plant species for vacant spaces

Artocarpus heterophylla Azadirachta indica Pongamia glabra Peltophorum ferrusinum Terminalia arjun Dalbergia sissoo Tectona grandis Ficus reliosa Somania saman Mimusops elinqe Casia fistula Bambuea multiplex Tamarindus indica Polyalthia longifolira Butea monosperma Peltophorum ferrusinium Calliandra callothyrus Carissa carandus Delonix regia Sesbania grandiflora Lannea grandis

5.5 ENVIRONMENTAL MANAGEMENT SYSTEM

5.5.1 Introduction

The earlier sections identified measures for environmental protection especially for providing the necessary pollution control to comply with the standards stipulating the limits for emitting pollutants in air, water or on land so that the assimilative capacity is not exceeded.

Standards are stipulated by various regulatory agencies to limit the emission of pollutants in air and water. Similarly, a mandatory practice is recommended for preparing an Environment Statement each year in order to encourage the industries to allow efficient use of resources in their production processes and reduce the quantities of wastes per unit of product.

Hence, Environmental Management System (EMS) is suggested at the industry level for ensuring that the activities, products and services of the region conform to the carrying capacity (supportive and assimilative capacity). This is based on Bureau of Indian Standard Specification IS:13967 (1993): Environmental Management Systems - Specification (equivalent to British Standard BS 7750). Since this is more in line with the quality systems, it is recommended that the proposed plant develop one as outlined in the following sub-sections.

The EMS - its set-up, role and responsibilities - is given subsequently.

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5.5.2 Formation of an Environmental Management System

The environmental management system to be formed by the industry will enable it to maximize its beneficial effects and minimize its adverse effects - with emphasis on prevention. It will be:

Identify and evaluate the environmental effects arising from the industry's proposed activities, products and services to determine those of significance; Identify and evaluate the environmental effects arising from incidents, accidents and potential emergency situations; Identify the relevant legislative and regulatory requirements; Enable priorities to be identified and pertinent environmental objectives and targets to be set; Facilitate planning, control, monitoring, auditing and review activities to ensure that the policy is complied with; and Allow periodic evaluation to suit changing circumstances so that it remains relevant.

5.5.3 Implementation of Environmental Management System

5.5.3.1 Commitment

It is essential that the top management of the industry is committed to development of its activities in an environmentally sound manner and supports all efforts in achieving this objective.

Experience has shown that all attempts to change the processes and production methods, which reduce/prevent wastes and inefficient use of resources, ultimately result not only in environmentally sound practices but also better business returns.

5.5.3.2 Preparatory Environmental Review

An industry with no formal environmental management system will first establish its current position with regards to environment through a preparatory environmental review. This will cover four areas:

Legislative and regulatory requirements; Evaluation and registration of significant parameters and their environmental impacts; Review of existing environmental management practices and procedures; and Assessment of feedback from investigation of previous environmental incidents and non-compliance with legislation, regulations or existing policies and procedures.

The resulting report will address:

The nature and extent of problems and deficiencies; The priorities to be accorded to rectify them; and An improvement program designed to ensure that the personnel and material resources required are identified and made available.

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5.5.3.3 Environmental Policy

The industry's management will actively initiate, develop and support the environmental policy, which is relevant to its activities, products and services and their environmental effects.

Broadly this covers the following:

Be consistent with the occupational health and safety policy and other industrial policies (such as quality policy); Indicate which of the industrial activities are covered by the environmental management system; Be communicated and implemented at all levels of the industry; and Be available publicly.

The corporate policy for Environmental Management is to create sound and eco-friendly environment for sustainable development at all production projects, plan new projects with environment -friendly considerations, plan regulative, ameliorative and mitigative measures to protect environment and fully merge into the overall corporate policy for achieving the targeted business goals of the Corporation.

Objectives: The environmental policy is framed specifically to fulfill the following objectives:

Create a work environment which enhances/motivates production and productivity. Create a residing environment for the enjoyment and peace of employee. Encourage safe and scientific operations and other well-established engineering practices. Promoting awareness amongst the employees and the neighborhood population for adopting environmentally friendly acceptable procedures and restricting environmental degradation and pollution to the barest minimum. Establishing "Eco-label" for its finished products so as to promote domestic and international markets. To achieve communal harmony and peace amongst the employees and the local villagers for heading fast towards "sustainable development". In environmental and ecological planning, information about the context of the issue and about the inter- relationship between nature is infused into the plan making process. Sustaining human fulfillment and the resources that need to be sustained viz.' clean air and water, individual and community welfare and well being, equity, maintaining ecological process and bio-diversity. Meaningful use of and within the leasehold areas and in the immediate neighbourhood.

5.5.3.4 Organization and Personnel

To facilitate the implementation of the EMS, one of the most important aspects relate to the organization and personnel. The related issues are:

Define and document the responsibility, authority and inter-relations of key personnel involved in the implementation of the environmental policy, objectives and environmental management system; Identify the in-house verification requirements and procedures including resources and personnel; ILC Industries Ltd. 147

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Appoint a Management Representative (MR); Communicate to employees at all levels the importance of compliance with the environmental policy, their role and responsibilities in achieving compliance, the potential consequences of departures from the specified procedures and identify and provide appropriate training; and Establish and maintain procedures to ensure that contractors are made aware of the environmental management system requirements and provisions.

5.5.3.5 Environmental Effects

The industry will establish and maintain procedures for:

Receiving, documenting and responding to internal as well as external communications concerning environmental aspects and management; Identifying, examining and evaluating the environmental effects of its activities under normal and abnormal/emergency situations (including risk assessment) and compiling significant effects in a register; and Recording all legislative, regulatory and other policy requirements and codes in a register.

5.5.3.6 Environmental Objectives and Targets

The objectives will be set with a view to realizing gradual and steady improvements in environmental performance through application of best available and economically viable technology.

The areas targeted for improvement will be those where improvements are most necessary to reduce risks (to environment and industry) and liabilities. These will be identified through cost- benefit analysis wherever practicable.

5.5.3.7 Environmental Management Program

The establishment of an environmental management program is the key to compliance with the industry's environmental policy and achievement of the environmental objectives and targets.

It will designate the responsibility for achieving the targets at each level and the means thereof. It will deal with the actions required for the consequences of the industries past activities as well as address the life cycle of development of new products so as to effectively control adverse impacts.

5.5.3.8 Environmental Management Manual and Documentation

The documentation is intended to provide an adequate description of the environmental management system. The manual is expected to provide a reference to the implementation and maintenance of the system.

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5.5.3.9 Operational Control

The management responsibilities will be defined to ensure that the control, verification, measurement and testing of environmental parameters within the industry are adequately co- ordinated and effectively performed.

The control, verification, measurement and testing will be made through documented procedures and work instructions defining the manner of conducting activities, the absence of which can lead to violation of the environment policy.

In the event of non-compliance, procedures for investigation of the causative mechanism will be established and the factors reported for corrective actions.

5.5.3.10 Environmental Management Records

The industry will establish and maintain a system of records to demonstrate compliance with the environmental management systems and the extent of achievement of the environmental objectives and targets. Management records will address the following:

Details of failure in compliance and corrective action; Details of incidents and corrective action; Details of complaints and follow-up action; Appropriate contractor and supplier information; Inspection and maintenance reports; Product identification and composition data; Monitoring data; Environmental training records; and House keeping.

5.5.3.11 Environmental Management Audits

The management audits are to determine whether the activities are conforming to the environmental management systems and effective in implementing the environmental policy. They may be internal or external, but carried out impartially and effectively by a person properly trained for it. Broad knowledge of the environmental process and expertise in relevant disciplines is also required. Appropriate audit programs and protocols will be established.

5.5.3.12 Environmental Statement

As a mandatory requirement under the Environment Protection Rules (1986) as amended through the Notification issued by the MoEF, an Environmental Statement will be prepared annually. This will include the consumption of total resources (raw material and water per ton of product), quantity and concentration of pollutants (air and water) discharged, quantity of hazardous and solid waste generation, pollution abatement measures, conservation of natural resources and cost of production vis-à-vis the investment on pollution abatement. The intention of this statement is:

To identify the process/production areas where resources can be used more efficiently through a comparison with the figures of a similar industry (thereby reducing the consumption per unit of product);

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To determine the areas where waste generation can be minimized at source and through end of pipe treatment (thereby reducing the wastes generated and discharged per unit of product); and To initiate a self-correcting/improvement system through an internal analysis to achieve cost reduction through choice of superior technology and more efficient practices.

5.5.3.13 Environmental Management Reviews

The senior management will periodically review the Environmental Management System (EMS) to ensure its suitability and effectiveness. The need for possible changes in the environmental policy and objectives for continuous improvement will be ascertained and revisions made accordingly.

EMS based on the above objectives will be formulated and implemented at the industry level. Every department will be headed by Sr. Manager / Manager level officer belonging to disciplines like Civil, Mechanical, Electrical, Instrumentation, Chemical, Metallurgical, Information technology etc. The Environment Department will be headed by Manager (Environment) and adequate staff will be provided for establishing environmental controls within the plant.

5.6. IMPLEMENTATION SCHEDULE

5.6.1 Introduction

The mitigation measures suggested above will be implemented so as to reduce the impact on environment due to the operations of the proposed plant. In order to facilitate easy implementation, mitigation measures are phased as per the priority implementation. The priority of the implementation schedule is given in Table-5.2.

Table-5.2: Implementation Schedule

Sr. Recommendations Time Requirement Implementation schedule No. Immediate Progressive 1. Air pollution control Before measures commissioning of - respective units 2. Water pollution Before control measures commissioning of - the plant 3. Noise control Along with the measures commissioning of - the plant 4. Ecological Stage wise preservation and implementation - upgradation Note: [•] indicates implementation of recommendations.

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5.6.2 Monitoring Strategy

The monitoring of various environmental parameters is necessary, which is a part and parcel of the environmental protection measures. A comprehensive monitoring programme is suggested in Table-5.3.

Table-5.3: Monitoring Schedule for Environmental Parameters

Sr Particulars Monitoring Duration of Important parameters for No frequency monitoring monitoring I. Air Quality 1. Ambient Air Monitoring

i. Within plant premises at 2 Twice in a 24 hrly sample TSPM, RPM, SO2, NOx locations week once in ii. Outside plant at 2 a month locations one each on upwind and downwind direction

2. Stack Monitoring Once in a Grab SO2, PM, NOx month II. Water and wastewater Quality 1. Water Quality i. Raw water Once in a Grab Hardness, EC, pH, Chlorides, month Sulphates, SS, Ca, Mg etc 2. Waste water Quality i. Raw effluent Once in a Grab As per KSPCB ii. Treated effluent Month specifications mentioned while issuing „No Objection Certificate‟ III. Noise

1. At the plant boundary in all Once in a year 24 hourly Lday and Lnight eight directions IV. Ecological preservation Seasonal Visual Survival rate and upgradation observations

5.6.3 Infrastructure for Environmental Protection

5.6.3.1 Manpower

The proposed plant will be under administrative control of Plant Manager. The Safety officer with environmental background will assist the Plant Manager and will be responsible for day- to-day issues related to environmental management and effluent treatment system. For effluent treatment system there will be one in-charge, one assistant chemist, operators and supervisors.

The organizational structure for the proposed plant is given in Figure 5.2 and the functions of environmental management cell are given below:

1. Achieve the objectives of the “Environment Protection Policy” ILC Industries Ltd. 151

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2. Collect the information from regular monitoring and create data-base. 3. Analyse the data and decide the thrust area and decide the targets for the same 4. Arrive at practical solution to the environmental problem and work out the Action Plan to solve the same. 5. Prepare monthly statement and budget for environment management programme. 6. Maintenance of pollution control equipment e.g. effluent treatment plant. 7. Greenbelt development and it‟s maintenance. 8. Liaison with regulatory authorities like Karnataka State Pollution Control Board (KSPCB) and Ministry of Environment and Forests (MoEF) on environmental issues.

5.6.3.2 Monitoring equipment and consumable

Monitoring of various environmental attributes mentioned in Table-5.3 for proposed plant would be carried by external KSPCB approved agency.

5.6.4 Budgetary cost

Total cost of the project is 321 crores as mentioned in Chapter-2. The capital cost expected towards environment protection is about 30 Crores.

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CHAPTER – 6 RISK ASSESSMENT & DISASTER MANAGEMENT PLAN

6.1 INTRODUCTION

Risk analysis involves the identification and assessment of risks the neighboring population is exposed to as a result of hazards present. This requires a thorough knowledge of failure probability, credible accident scenario, vulnerability of populations etc. Much of this information is difficult to get or generate.

The proposed plant facilities would be designed and engineered with all possible all possible safely measures and standard code of practices of engineering. In spite of this there may be some design deficiency or due to operation and maintenance faults which may lead to accidental events causing damage to life and property.

In the sections below, the identification of various hazards, probable risks in the ILC plant are addressed which gives a broad identification of risks involved. Based on the risk estimation for fuel and coal storage, disaster management plan has been presented.

6.2 APPROACH TO THE STUDY

Risk involves the occurrence or potential occurrence of some accident consisting of an event or sequence of events. The risk analysis assessment study covers the following:

Identification of potential hazard areas; Identification of representative failure cases; Visualization of the resulting scenarios in terms of fire (thermal radiation) and explosion; Assess the overall damage potential of the identified hazardous events and the impact zones from the accidental scenarios; Assess the overall suitability of the site from hazard minimization and disaster mitigation points of view; Furnish specific recommendations on the minimization of the worst accident possibilities; and Preparation of broad Disaster Management Plan (DMP), On-site and Off-site Emergency Plan, which includes Occupational and Health safety plan.

6.3 FUEL STORAGE AT THE PLANT

Three types of fuels are considered for the proposed Steel Plant at viz: HSD/LDO, Fuel Oil and coal.

Fuel Oil

Fuel Oil will be required for during lightup of the Kiln, Induction Furnace and Rolling Mill @ 1730 tonnes per annum. FO will be stored within plant premises for fifteen days requirement.

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HSD/LDO

HSD will be required for ladder preheater and transportation @ 200 tonnes per annum. HSD/LDO will be stored for five days within plant premises.

Coal

Non-coking coal is the prime raw materials for the production of sponge iron, CPP and coal gas plant. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 950-1050oC.

The coal will be received in the form of lumps and is crushed in the crusher and screened to the required sizes and conveyed to the raw materials storage hoppers by means of conveyors. The coal in the required proportion is drawn from the storage bins by means of special volumetric feeder or electronic weighing equipment and conveyed for feeding into kiln.

Coal will be imported & will be conveyed through Chennai / Panji Port. The coal & coke requirement works out to be 2,63,100 TPA and 4000 TPA respectively. The storage of coal will meet 10 days requirement.

6.4 HAZARD ASSESSMENT AND EVALUATION

A preliminary hazard analysis is carried out initially to identify the major hazards associated with storages and the processes of the plant. This is followed by consequence analysis to quantify these hazards. Finally the vulnerable zones are plotted for which risk reducing measures are deduced and implemented. The major aspects are described below:

Table-6.1: Preliminary Hazard Analysis for Process and Storage Areas

Equipment Process Potential Hazard Provision Storage tanks Storage HSD/LDO Formation of an Dyke walls to be and Fuel Oil explosive atmosphere provided with a provision outside storage of fire detectors in the tank farm, Regular inspections of storage tanks w.r.t. proper earthing, adequate fire fighting, presence of combustible materials and growth wild vegetation EOF Converts charge Re-circulating water In built safety system is (DRI, pig iron/scrap) may come in contact provided in the into hot metal with molten hot metal construction of furnace leading to spurting of with suitable refractory metal or under walls. extreme conditions ILC Industries Ltd. 154

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Equipment Process Potential Hazard Provision explosion may also occur. Charging materials This may occur if raw being rusty and materials are stored in moisturized which may open. However, raw lead to spurting of material in the proposed metal Steel Plant will be covered. Presence of Oil & Fuel supply into the Grease and other furnace will be regulated impurities, which may and will be controlled by lead to unexpected PLC systems. fires. Ladle Furnace Refining the liquid Bursting, Hot metal High level temperature Steel liquid spillage and pressure controllers, Effective care to be exercised while operating and handling ladle Continuous Casting Possible hot liquid Appropriate design and Casting Machine metal spillage maintenance of nozzle connected to Tundish Turbine Converts pressure Mechanical and fire Layout of equipment/ in the flue gas into hazards. machinery is done in mechanical energy. accordance to factory and electrical inspectorate. Generator Converts Mechanical hazards As above mechanical energy and fire hazards in into electrical 1. Lube oil system energy. 2. Cable galleries 3. Short circuits Power Trans- - Fire and explosion All electrical fittings and formers cables are provided as per the specified standards. Switch Yard 220 KVA switch Fire As above yard Switch Yard - Fire in cable galleries As above control room and switch Coal storage Storage of coal for Fire and spontaneous Coal storage yard will be Yard 10 days combustion continuously sprinkled requirement. with water Coal handling - Fire and dust Continuous water bunkers explosions sprinkling Compressor Plant operation Governor failure due to The design precautions of House the failure of pins and safety will be followed in springs leading to manufacture and erection opening of safety of compressors. valves

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Table-6.2: Preliminary Hazard Analysis for the Whole Plant in General

PHA Category Description of Recommendation Provision Plausible Hazard Environmental If there is any All electrical fittings and factors leakage and cables will be provided as eventuality of -- per the specified standards. source of ignition. All motor starters will be flame proof. Highly inflammable A well-designed fire Fire extinguisher of small nature of the protection including size and big size will be chemicals may protein foam, dry provided at all potential fire cause fire hazard powder, CO2 hazard places. In addition to in the storage extinguisher will be the above, fire hydrant facility. provided. network as per TAC guidelines will also be provided.

6.5 RISK MANAGEMENT MEASURES

The risk management measures for the proposed project activities require adoption of best safely practice at the respective construction zones within the work boundary. In addition, the design and engineering of the proposed protection measures for air and water environment as outlines in earlier chapter. The details risk management measures are listed below;

Coal Storage Area:

Coal dust when dispersed in air and ignited would explode. Coal bunkers and stock bins are most susceptible to this hazard. To be explosive, the dust mixture would have:

Particles dispersed in the air with minimum size (typical figure is 400 microns); Dust concentrations must be reasonably uniform; and Minimum explosive concentration for coal dust (33% volatiles) is 50 grams/m3.

Failure of dust extraction and suppression systems may lead to abnormal conditions and increasing the concentration of coal dust to the explosive limits. Sources of ignition present are incandescent bulbs with the glasses of bulkhead fittings missing, electric equipment and cables, friction, spontaneous combustion in accumulated dust.

Dust explosions may occur without any warnings with Maximum Explosion Pressure upto 6.4 bar. Another dangerous characteristic of dust explosions is that it sets off secondary explosions after the occurrence of the initial dust explosion. Many a times, the secondary explosions are more damaging than primary ones.

The dust explosions are powerful enough to destroy structures, kill or injure people and set dangerous fires likely to damage a large portion of the Coal storage area including collapse of its structures.

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Turbo-Generator building of the power plant will be exposed to risks due to similar hazards given below:

1. As per the summary of study of losses in United States for a period of 50 years, probability of fire in Turbo-Generators is one in 185 unit years. Therefore, there is a probability of fire/explosion in Turbo-Generator set once in about 30 years. The likely time however cannot be predicted. The hazardous areas are: Lubrication system; and Hydrogen oil system.

2. Apart from the Turbo-Generator sets, other major hazardous areas in Turbo-Generator Building are: Cable Galleries; Control Rooms; Switch-gears; Oil drums stored at Ground floor level; and Battery Rooms.

PVC cables can be involved in fire. Such fires are known to propagate at speeds upto 20 meter/min. Hence there is a possibility of starting fresh fires in all directions wherever cable runs cross each other or bifurcate. On combustion, every kilogram of PVC compound produces 1000 M3 of highly dense smoke, which mainly contains hydrogen chloride fumes sufficient to produce 1 liter of Hydrochloric acid, which may condense on cooler metallic parts and instruments in presence of moisture damaging them severely. Since length of PVC cables is several kilometers in Turbo-Generator Building, the hazard is tremendous.

Apart from PVC cables, the oil installation is a large one for Turbo-Generator set and can burn furiously spreading fires to cable galleries and other places.

The rapidity of spread of fire may create problems such as safe shutdown of units not involved initially in fire and safe evacuation of personnel, particularly operators and engineers in control rooms.

Turbo-Generator building is a steel structure with no insulation, and in case of a major fire, may collapse as the strength of steel would get reduced by half at temperature of 5500C (yield point of steel) and above.

There will be also serious implications for supply in power grids including its total collapse following major fires.

HSD/LDO Storage:

The major risks will be fire and explosion. All the guidelines specified by TAC and OISD will be implemented while the construction of the HSD storage yard.

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Furnace:

The following procedure has to be laid down to ensure safely of men and the equipment. a) Gas safely man would accompany the team and would test the atmosphere for the presence of CO, before starting the network the work. b) If „CO‟ concentrating is found exceeding the safe limit, the job would be undertaken using necessary safely appliance viz., Oxygen Breathing Apparatus/ Blower type Gas mark. c) Any gas cutting/welding job would be undertaken with clearance from Gas Safely man.

Gas Explosion, Prevention & Preventive Measures:

The following actions would be taken to prevent any gas explosions in case of gas leakage. 1. For jobs on gas lines/equipment, non-sparking copper tools will used. If such tools are not available, grease coated steel tools would be used. Electrical drill & other electrical equipment will not be used as there can give rise to sparks. 2. The gas line would be thoroughly purged with steam before undertaking the job on the same. 3. Naked lights will not be used near any de-pressurized gas main or equipment unless the same has been thoroughly purged. 4. In case of profuse leakage of gas, action would be taken for water sealing ande isolating that portion. 5. The approach road to the gas line complex would be kept free from any obstructions. 6. If gas catches fire due to same leakage, it will be extinguished with plastic clay, steam or water. The portion of gas main affected would be cooled down with water. The valve will not be closed when fire still there and the pressure in the main will be maintained at minimum 100 mm (WC). 7. Gas tapping points of flow or pressure measurement will be cleaned with wooden stick or grease coated wire. If lighting is necessary near gas line, portable spark proof electric lamps of low voltage or explosion proof torch light will be used for enclosed areas.

Hot Metal & Slag:

Sudden break out of molten metal & slag may results in heavy explosion, due to their coming contact with water, there by causing serious burn injuries to persons and damage to equipment. These breakouts may take place from weak portions of the Hearth, Tuyeres & monkeys.

1. Any accumulation of water will be preventive in such vulnerable areas. 2. In case minor leakage, the flow of molten metal & slag will be controlled. 3. If there is major breakout, the area would be cut off and cordoned. 4. Vital connections e. g, water, gas, compressed air, oxygen etc. , would be cut off or regulated, as per requirement.

Steel Melting Shop:

The main hazards arise out of the use of metal and oxygen at the Basic Oxygen furnace and Ladle Furnace. The spillage of hot metal/ slag can cause serious burn injuries and fires. Severe explosions are also caused due to hot metal/ slag falling over a pool of water, ILC Industries Ltd. 158

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resulting in injuries to persons, fire and damage to equipment due to flying of hot splinters & splashing of liquid metal/ slag.

Oxygen:

The oxygen though not itself flammable, supports combustion ands is, therefore hazardous as any combustible material burns internally in its presence. Any oxygen leakage can also cause severe burn injuries if it comes in contact with human body. Similarity, the liquid oxygen, frequently referred to as LOX is liquid at about - 1470C. It is pale blue in colors and is slightly heavier than water. It is classified as a non- flammable gas. However, since it supports combustion, any organic or inorganic combustion, material burns with enhanced intensity in its presence. Apart from this hazards, liquid oxygen due to low boiling points when exposed to atmosphere takes away heat from the surrounding to get evaporate. This results in instants freezing if any contact is made between the body and this material.

The protective material worn for fighting emergencies related to liquid oxygen would not be used near any sources of ignition, as the large volume of gas produced from small amount of liquid would create an oxygen rich atmosphere.

The part of human body coming in contact with liquid oxygen should be sprayed with ordinary water and later treated in a similar way to frostbite treatment. For Fire fighting involving LOX, water is the best extinguishing agent. Water should be sprayed to present rapid boiling and splattering of liquid that may be caused by a straight stream.

Care would also be taken not to direct the water spray on to mechanical relief devices which would results in freezing of water, rendering the devices in-operative.

6.6 DISASTER MANAGEMENT PLAN

Emergencies may occur due to many reasons. It may occur due to natural causes like earthquake, cyclone, flood etc. It may occur due to malfunction of standard working systems or practices. There can be no set criteria for assessing the gravity of a disaster in the abstract since this depends to a large extent on the physical, economic and social environment in which it occurs. What would be consider a major disaster in a developing country, ill equipped to cope with the problems involved, may not mean more than a temporary emergency elsewhere. However, all disasters bring in their wake similar consequences that call for immediate action, whether at the local, national or international level, for the rescue and relief of the victims. This includes the search for the dead and injured, medical and social care, removal of the debris, the provision of temporary shelter for the homeless, food, clothing and medical supplies, and the rapid re-establishment of essential services.

6.6.1 Objectives of Disaster Management Plan

The Disaster Management Plan (DMP) is aimed to ensure safety of life, protection of environment, protection of installation, restoration of production and salvage operations in this same order of priorities. For effective implementation of the Disaster Management Plan, it will be widely circulated and personnel training through rehearsals/drills.

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The Disaster Management Plan would reflect the probable consequential severalties of the undesired event due to deteriorating conditions or through 'Knock on' effects. Further the management will be able to demonstrate that their assessment of the consequences uses good supporting evidence and is based on currently available and reliable information, incident data from internal and external sources and if necessary the reports of out side agencies.

To tackle the consequences of a major emergency inside the factory or immediate vicinity of the factory, a Disaster Management Plan has been formulated and this planned emergency document is called "Disaster Management Plan".

The objective of the Industrial Disaster Management Plan is to make use of the combined resources of the plant and the outside services to achieve the following:

Effect the rescue and medical treatment of casualties; Safeguard other people; Minimize damage to property and the environment; Initially contain and ultimately bring the incident under control; Identify any dead; Provide for the needs of relatives; Provide authoritative information to the news media; Secure the safe rehabilitation of affected area; Preserve relevant records and equipment for the subsequent inquiry into the cause and circumstances of the Emergency.

In effect, it is to optimize operational efficiency to rescue, rehabilitation and render medical help and to restore normalcy.

6.6.2 Major Causes of On-site Emergency

Fire consequences can be disastrous, since they involve huge quantities of fuel either stored or in dynamic inventory in pipelines or in nearby areas. Preliminary hazard Analysis has provided a basis for consequence estimation. Estimation can be made by using various tank fire consequence calculations. During the study of risk assessment, the nature of damages is worked out and probability of occurrence of such hazards is also drawn up. Adequate fire fighting systems as per Tariff Advisory Committee (TAC) and OISD guidelines will be provided and maintained.

6.6.3 Emergency Action Plan

The emergency action plan consists of: First information; Responsibilities of Work Incident Controller; Responsibilities of Chief Incident Controller; Responsibilities for Declaration of Emergency; Responsibilities for Emergency Communication Officer; Responsibilities of key personnel; Responsibilities and action to be taken by essential staff and various teams during emergency; and Responsibilities for All Clear Signal. ILC Industries Ltd. 160

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6.6.3.1 First Information

The first person who observes/identities the emergencies will inform by shouting and by telephone to the Shift Engineer and Fire Station about the hazard. The Shift Engineer will inform to Works Incident Controller, Chief Incident Controller and also telephone operator, who shall communicate it to all key personnel.

6.6.3.2 Responsibilities of Work Incident Controller

The Work Incident Controller on knowing about an emergency immediately will rush to the incident site and take overall charge and inform the same to Chief Incident Controller (Chief Executive). On arrival, he will assess the extent of emergency and decide if major emergency exists and inform the communication officer accordingly. His responsibilities will be to ensure compliance to the duties (1 to 6) listed below.

6.6.3.3 Responsibilities of Chief Incident Controller

The Chief Executive, who is also the Chief Incident Controller, will assume overall responsibilities for the factory/storage site and its personnel in case of any emergency. His responsibilities are to: 1. Assess the magnitude of the situation and decide if staff needs to be evacuated from their assembly point to identified safer places. Declare on-site/off-site emergency. 2. Exercise direct operational control over areas other than those affected. 3. Undertake a continuous review of possible developments and assess in consultation with key personnel as to whether shutting down of the plant or any section of the plant and evacuation of personnel are required. 4. Laison with senior officials of Police, Fire Brigade, Medical and Factories Inspectorate and provide advice on possible effects on areas out side the factory premises. 5. Look after rehabilitation of affected persons on discontinuation of emergency. 6. Issue authorized statements to news media, and ensures that evidence is preserved for inquiries to be conducted by the statutory authorities.

6.6.3.4 Responsibilities for Declaration of Major Emergency

Making the emergency known inside the plant

The major emergency will be made known to every one inside the plant by resounding the alarm. Separate alarms to warn different types of major emergencies such as fire and explosion or toxic gas escape are provided. Public address system is also available throughout the plant.

Announcement will be made by the concerned official/interpreter in local language. Similarly announcement for termination of the emergency will also be announced.

6.6.3.5 Responsibilities of Emergency Communication Officer (ECO)

On hearing the emergency alarm he will proceed to Emergency Control Center. He will:

 Report to Chief Incident Controller and Work Incident Controller and maintain contact with them.

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 On information received from the WIC of the situation, recommending if necessary, evacuate the staff from the assembly points.  Identify suitable staff to act as runners or messengers who are listed in the Essential staff, between him and the Works Incident Controller if the telephone and other system of communication fail due to any reason.  Maintain inventory of items in the emergency control center.  Contact local meteorological office to receive early notification of changes in weather condition in case of gas leak and prolonged action.  Maintain a log of incidents.  Keep in constant touch with happenings at the emergency site and with WIC

6.6.4 Key Personnel

Apart from Works Incident Controller and Chief Incident Controller, other works personnel will have key role to play in providing advice and in implementing the decisions made by the Chief Incident Controller. The key personnel include:

A. Sr. Supdts./Engineer-in-charge responsible for Operation Electrical Maintenance Mechanical maintenance C&I Chemical

B. Head of Personnel and Officers connected with IR and Labour Welfare

C. Head (Technical Service)

6.6.4.1 Responsibilities of Key Personnel

Department Heads

The departmental heads will provide assistance as required by the WIC. They will decide which members of their departments are required at the incident site.

Chief Personnel Manager

He will: a) Report to Work Incident Controller; b) Ensure that all non-essential workers in the affected areas are evacuated to assembly points in consultation with the Chief Incident Controller; c) Receive reports from nominated persons from assembly points, and pass on the absence information services; d) Keep liaison with other coordinators to meet the requirements of services such as materials, security management, transportation, medical, canteen facilities etc. as required during emergency; e) Be in constant touch with the Chief Incident Controller and feed him correct information of the situation; f) Give information to press, public and authorities concerned on instructions from the CIC/WIC; ILC Industries Ltd. 162

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g) Ensure that casualties receive adequate attention at medical center and arrange required additional help and inform relatives of the injured; h) Arrange to inform public on Radio and TV about evacuation etc.; and i) Arrange TV coverage on handling emergency.

In-Charge

On knowing about an emergency, he will report to CIC and assist him in all activities. He will also liaison with all teams.

Medical Officer

Medical Officer will render medical treatment to the injured and if necessary will shift the injured to nearby Hospitals. He will mobilize extra medical help from outside if necessary.

Safety Officer

On hearing the Emergency alarm he will proceed to main entrance/main gate. He will: a. Make sure that all safety equipment are made available to the emergency teams; b. Arrange to control the traffic at the gate and the incident area; c. Direct the security staff to the incident site to take part in emergency operations under his guidance and supervision; d. Evacuate the persons in the plant or in the nearby areas as advised by WIC after arranging the transport through the Transport in-charge; e. Allow only those people who are associated with handling emergency; f. Maintain law and order in the area, if necessary seek the help of police; and g. Maintain communication with CIC/WIC and ECO.

Fire Office

On hearing the emergency, he will reach the fire station and arrange to sound the alarm as per the type of emergency in consultation with WIC, He will: a. Guide the fire fighting crew i.e. firemen and trained plant personnel and shift the fire fighting facilities to the emergency site. Adequate facilities will be made available; b. Take guidance of the WIC for fire fighting as well as assessing the requirement of outside help; c. Maintain communication with WIC, CIC and ECO.

Transport -in-Charge

On hearing the emergency alarm he will immediately report to Work Incident Controller. He will: a. Ensure availability of auto base vehicles for evacuation or other duties, when asked for; and b. Make all arrangements regarding transportation.

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6.6.5 Emergency Plan for Handling Accidents during Fuel Transportation

The need for safety during transport of coal is well recognized. In addition to the rigorous safety practices followed, all necessary safety measures as per international norms and standards will also be implemented during transport of fuel for the Steel Plant.

In the event of an accident, the disaster management is taken up on a war footing as per the procedures under no circumstances, the procedures will be violated. All equipment/communication etc. required for meting the disaster management plan will be taken care.

The safety precautions and practices relate to road tankers designing upkeep of tankers, tanker filling, guidelines while unloading the fuel from the tankers, sealing of tankers will be taken. Further, near the coal storage bunkers also, all the safety precautions like fire extinguishers, fire protection network will be installed.

In spite of the best safety measures, accidents may occur though the possibility is remote. However, an emergency plan to deal with accidents is essential to minimize the ill effect of such accidents. The objectives of the emergency plan are: a. To localize the emergency and if possible eliminate; and b. To minimize the effects on people and property

Whereas localizing the emergency will involve prompt action at the loading, unloading areas and during transport through use of fire fighting equipment, water spray, operation of emergency shut of valves etc. minimizing the impact would involve, rescue, first aid, evacuation, relaying information to public etc. A Transport Monitoring Cell (TMC) is constituted which will monitor: a. Loading and unloading operations of coal; b. Transportation of coal; c. Unloading operations at plant site

Operational Plan

The movement of coal would be monitored by TMC. In addition to monitoring by a line and distance chart using information fed by station masters using the telecom network, mobile cellular telephone network, mobile cellular telephone network installed at strategic locations is considered, if need arises, to inform TMC regarding the movement of rakes. In case of an accident, the nearest fire fighting unit and police would be informed without loosing time.

The TMC will also function as an Integrated Disaster Management Center (IDMC) to co- ordinate and handle any emergency. The IDMC is headed by a senior level officer, supported by transportation/logistics engineer, a senior police officer and a fire service expert. The IDMC will be equipped with the following: a. Adequate number of telephones; b. Radio Equipment; c. Layout plan of the transport corridor for coal to the plant site: ILC Industries Ltd. 164

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Population density in different colour codes; Topographic features; Location of industries/depots especially related to chemical oil, petrol, explosive and other sensitive area; Land Use Plan; Major Structures; Fire stations with telephone nos. and wireless codes; Police Stations, Central Reserve Police battalions, civil defense positions with telephone nos. and wireless code; Emergency local hospitals, general hospitals with telephone nos. and wireless codes; Meteorological information; and Map of approach road network.

The information will be available in the form of maps and charts. In case of an accident, the IDMC will co-ordinate with all concerned agencies in rescue operations. The nearest fire fighting unit (Koppal), police (Koppal) and Government officials will be mobilized to accident site for fire fighting and rescue operation to minimize damage to life and property. . The onsite emergency plan structure is presented in Figure-6.1

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Figure-6.1: On-site Emergency Plan

SITE CONTROLLER EMERGENCY CONTROL ROOM

SAFETY OFFICER INCIDENT INCIDENT EMERGENCY EMERGENCY EMERGENCY CONTROLLER CONTROLLER COORDINATOR COORDINATOR COORDINATOR (Production) (Utilities, Stores (Rescue, Fire Fighting) (Medical, Mutual aid, (Essential Services) etc) Rehabilitation, Transport & Communication)

SHIFT IN-CHARGE SHIFT IN-CHARGE SHIFT IN-CHARGE

OPERATOR OPERATOR ELECTRICIAN, FIRST AID, ELECTRICIAN, PUMP OPERATOR TRANSPORT-DRIVER, PUMP OPERATOR TELEPHONE-OPERATOR

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6.7 Off-Site Emergency Preparedness Plan

The task of preparing the Off-Site Emergency Plan lies with the district collector, however the off-site plan will be prepared with the help of the local district authorities. However, it can be observed from the risk modeling that the damage contours will be within the plant boundary and therefore on-site emergency plan has more significance. The off-site emergency preparedness plan should be based on the following guidelines.

Off-site emergency plan follows the on-site emergency plan. When the consequences of an emergency situation go beyond the plant boundaries, it becomes an off-site emergency. Off-site emergency is essentially the responsibility of the public administration. However, the factory management will provide the public administration with the technical information relating to the nature, quantum and probable consequences on the neighboring population.

The off-site plan in detail will be based on those events, which are most likely to occur, but other less likely events, which have severe consequence, will also be considered. Incidents which have very severe consequences yet have a small probability of occurrence should also be considered during the preparation of the plan. However, the key feature of a good off-site emergency plan is flexibility in its application to emergencies other than those specifically included in the formation of the plan.

The roles of the various parties who will be involved in the implementation of an off-site plan are described below. Depending on local arrangements, the responsibility for the off-site plan should be either rest with the works management or, with the local authority. Either way, the plan should identify an emergency co-ordinating officer, who would take the overall command of the off-site activities. As with the on-site plan, an emergency control center should be setup within which the emergency co-ordinating officer can operate.

An early decision will be required in many cases on the advice to be given to people living "within range" of the accident - in particular whether they should be evacuated or told to go indoors. In the latter case, the decision can regularly be reviewed in the event of an escalation of the incident. Consideration of evacuation may include the following factors: a. In the case of a major fire but without explosion risk only houses close to the fire are likely to need evacuation, although a severe smoke hazard may require this to be reviewed periodically; b. If a fire is escalating and in turn threatening a store of hazardous material, it might be necessary to evacuate people nearby, but only if there is time; if insufficient time exists, people will be advised to stay indoors and shield themselves from the fire; c. For release or potential release of toxic materials, limited evacuation may be appropriate down wind if there is time. The decision would depend partly on the type of housing "at risk". Conventional housing of solid construction with windows closed offers substantial protection from the effects of a toxic cloud, while shanty house, which can exist close to factories, offer little or no protection.

The major difference between releases of toxic and flammable materials is that toxic clouds are generally hazardous down to much lower concentrations and therefore hazardous over greater distances. Also, a toxic cloud drifting at, say 300 m per minute covers a large area of land very quickly. Any consideration of evacuation should take this into account. Although the plan will have sufficient flexibility built in to cover the consequences of the range of accidents identified

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for the on-site plan, it will cover in some detail the handling of the emergency to a particular distance from each major hazard works.

6.7.1 Aspects proposed to be considered in the Off-Site Emergency Plan

The main aspects, which will be included in the emergency plan, are:

Organization Details of command structure, warning systems, implementation procedures, emergency control centers. Names and appointments of incident controller, site main controller, their deputies and other key personnel.

Communications Identification of personnel involved, communication center, call signs, network, and lists of telephone numbers.

Specialized knowledge Details of specialist bodies, firms and people upon whom it may be necessary to call e.g. those with specialized chemical knowledge, laboratories.

Voluntary organizations Details of organizers, telephone numbers, resources etc.

Chemical information Details of the hazardous substances stored or procedure on each site and a summary of the risk associated with them.

Meteorological information Arrangements for obtaining details of whether conditions prevailing at the time and whether forecasts.

Humanitarian arrangements Transport, evacuation centers, emergency feeding treatment of injured, first aid, ambulances and temporary mortuaries.

Public information Arrangements for (a) dealing with the media press office; (b) informing relatives, etc.

Assessment of emergency plan Arrangements for: (a) collecting information on the causes of the emergency; (b) reviewing the efficiency and effectiveness of all aspects of the emergency plan.

6.7.2 Role of the Emergency Co-ordinating Officer

The various emergency services should be co-ordinated by an emergency co-ordinating officer (ECO), who will be designated by the district collector. The ECO should liase closely with the site main controller. Again depending on local arrangements, for very severe incidents with major or prolonged off-site consequences, the external control should be passed to a senior local authority administrator or even an administrator appointed by the central or state government.

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6.7.3 Role of the Local Authority

The duty to prepare the off-site plan lies with the local authorities. The emergency planning officer (EPO) appointed should carry out his duty in preparing for a whole range of different emergencies within the local authority area. The EPO should liase with the works, to obtain the information to provide the basis for the plan. This liaison should ensure that the plan is continually kept upto date.

It will be the responsibility of the EPO to ensure that all those organizations which will be involved off site in handling the emergency, know of their role and are able to accept it by having for example, sufficient staff and appropriate equipment to cover their particular responsibilities. Rehearsals for off-site plans should be organized by the EPO.

6.7.4 Role of Police

Formal duties of the police during an emergency include protecting life and property and controlling traffic movements.

Their functions should include controlling bystanders evacuating the public, identifying the dead and dealing with casualties and informing relatives of death or injury.

6.7.5 Role of Fire Authorities

The control of a fire should be normally the responsibility of the senior fire brigade officer who would take over the handling of the fire from the site incident controller on arrival at the site. The senior fire brigade officer should also have a similar responsibility for other events, such as explosions and toxic release. Fire authorities in the region should be appraised about the location of all stores of flammable materials, water and foam supply points and fire-fighting equipment. They should be involved in on-site emergency rehearsals both as participants and, on occasion, as observers of exercises involving only site personnel.

6.7.6 Role of Health Authorities

Health authorities, including doctors, surgeons, hospitals, ambulances and so on, will have a vital part to play following a major accident and they will form an integral part of the emergency plan. For major fires, injuries should be the result of the effects of thermal radiation to a varying degree and the knowledge and experience to handle this in all but extreme cases may be generally available in most hospitals. For major toxic releases, the effects vary according to the chemical in question, and the health authorities should be apprised about the likely toxic releases from the plant which will unable then in dealing with the aftermath of a toxic release with treatment appropriate to such casualties.

Major off-site incidents are likely to require medical equipment and facilities additional to those available locally and a medical " mutual aid " scheme should exist to enable the assistance of neighboring authorities to be obtained in the event of an emergency.

6.7.7 Role of Government Safety Authority

This will be the factory Inspectorate available in the region. Inspectors are likely to want to satisfy themselves that the organization responsible for producing the off-site plan has made adequate arrangements for handling emergencies of all types including major emergencies. ILC Industries Ltd. 169

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They may wish to see well documented procedures and evidence of exercise undertaken to test the plan.

In the event of an accident, local arrangements regarding the role of the factory inspector will apply. These may vary from keeping a watching brief to a close involvement in advising on operations in case involvement in advising on operations. In cases where toxic gases may have been released, the factory inspectorate may be the only external agency with equipment and resources to carry out tests. The off-site emergency organization chart for major disaster is shown in Figure-6.2.

6.8 OCCUPATIONAL HEALTH AND SAFETY

Large industries, in general and proposed Steel Plant in particular where multifarious activities are involved during construction, erection, testing, commissioning, operation and maintenance, the men, materials and machines are the basic inputs. Along with the boons, the industrialization generally brings several problems like occupational health and safety.

The industrial planner, therefore, has to properly plan and take the steps to minimize the impacts of industrialization and to ensure appropriate occupational health, safety including fire plans. All these activities again may be classified under construction and erection and operation and maintenance. The proposed safety plan is given below:

6.8.1 Occupational Health

Occupational health needs attention both during construction and erection and operation and maintenance phases. However, the problem varies both in magnitude and variety in the above phases.

Construction and Erection The occupational health problems envisaged at this stage can mainly be due to constructional accident and noise. To overcome these hazards, in addition to arrangements to reduce it within TLV's, personal protective equipment‟s will also be supplied to workers.

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Figure-6.2: Off-Site Emergency Plan

FOR ATION

ADMINISTRATION)

CONTROL CENTER IN IN CENTER CONTROL WITH THE AREA FOR FACILITIES DIRECTING COORDINATING CONTROL EMERGENCY ACTIVITIES. FOR ARRANGE OF REHABILITATION INJURED PERSONS FOR ARRANGE AND MEDICAL, FOOD, HYGIENIC REQUIREMENTS. FOR ARRANGE TRANSPORT FROM EVACUATION RESIDENTIAL WHEN LOCATION REQUIRED. MAINTAIN COMMUNICATION II FACILITIES THE WITH CONDITIONS OFTHE HELP TELEPHONE DEPARTMENT

EMERGENCY PROVIDE

REHABILITATION

(LOCAL (LOCAL DISTRICT 1. AUTHORITIES/ 2. 3. 4. RESPONSIBILITIES

ACTION. URE

TECHNICAL

TECHNICAL TECHNICAL TO INFORMATION SERVICES EMERGENCY REQUIRED. AS CAUSES INVESTIGATE OFDISASTER. THE SUGGEST PREVENTIVE FOR MEASURES FUT

ALL FURNISH

RESPONSIBILITIES (FACTORY BOARD, CONTROL POLLUTION INSPECTORATE, TECHNICAL EXPERTS FROM INDUSTRY RESEARCH INSTITUTIONS) TRAINING AND 1. 2. 3.

PLAN THE COORDINATE AND CONTROL WILL

PERSON AFFECTED. PERSON MEDICAL PROVIDE TREATMENT.

FIRST AID TO THE THE TO AID FIRST

MEDICAL / AMBULANCE / MEDICAL

EPO

RESPONSIBILITIES 1. 2.

OFTOXIC S

FIRE BRIGADE FIRE

PREVENT THE SPREAD. THE PREVENT LEAKS THE PLUGGING CHEMICALS GAS THE REDUCING EFFECT FUMES. AND GASES SAVAGE AND RESCUE OPERATION.

CONTAIN THE FIRE AND AND FIRE THE CONTAIN

1. 2. 3. RESPONSIBILITIES

ACTION FOR PLAN HANDLINGOFF SITE EMERGENCY

ACUATION OF OF ACUATION

POLICE

COMMUNICATE THE THE COMMUNICATE ABOUT INFORMATION OTHER TO THE MISHAP AGENCIES. TO SUPPORT PROVIDE AS AGENCIES OTHER REQUIRED. MANAGEMENT TRAFFIC OFF CORDONING BY AREA. THE THE ARRANGE EV ADVICE ON PEOPLE SITE FROM CONTROLLER/E.P.O. THE TO BROADCAST AS COMMUNITY E.P.O. BY ADVISED OF RELATIVES INFORM CASUALTIES.

1. 2. 3. 4. 5. 6. RESPONSIBILITIES

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Operation and Maintenance:

The problem of occupational health, in the operation and maintenance phase is due to noise hearing losses. Suitable personnel protective equipment will be given to employees. The working personnel will be given the following appropriate personnel protective equipment:

Industrial Safety Helmet; Crash Helmets; Face shield with replacement acrylic vision; Zero power plain goggles with cut type filters on both ends; Zero power goggles with cut type filters on both sides and blue color glasses; Welders equipment for eye and face protection; Cylindrical type earplug; Ear muffs; Canister Gas mask; Self contained breathing apparatus; Leather apron; Aluminized fiber glass fix proximity suit with hood and gloves; Boiler suit; Safety belt/line man's safety belt; Leather hand gloves; Asbestos hand gloves; Acid/Alkali proof rubberized hand gloves; Canvas cum leather hand gloves with leather palm; Lead hand glove; Electrically tested electrical resistance hand gloves; Industrial safety shoes with steel toe; and Electrical safety shoes without steel toe and gumboots.

Full fledge hospital facilities will be made available round the clock for attending emergency arising out of accidents, if any. All working personnel will be medically examined at least once in every year and at the end of his term of employment. This is in addition to the pre- employment medical examination.

6.8.2 Safety Plan

Safety of both men and materials during construction and operation phases is of concern. The preparedness of an industry for the occurrence of possible disasters is known as emergency plan..

Keeping in view the safety requirement during construction, operation and maintenance phases at Steel Plant, the project proponent would formulate safety policy with the following regulations:

To allocate sufficient resources to maintain safe and healthy conditions of work; To take steps to ensure that all known safety factors are taken into account in the design, construction, operation and maintenance of plants, machinery and equipment; To ensure that adequate safety instructions are given to all employees;

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To provide wherever necessary protective equipment, safety appliances and clothing, and to ensure their proper use; To inform employees about materials, equipment or processes used in their work which are known to be potentially hazardous to health or safety; To keep all operations and methods of work under regular review for making necessary changes from the point of view of safety in the light of experience and upto date knowledge; To provide appropriate facilities for first aid and prompt treatment of injuries and illness at work; To provide appropriate instruction, training, retraining and supervision to employees in health and safety, first aid and to ensure that adequate publicity is given to these matters; To ensure proper implementation of fire prevention methods and an appropriate fire fighting service together with training facilities for personnel involved in this service; To organize collection, analysis and presentation of data on accident, sickness and incident involving personal injury or injury to health with a view to taking corrective, remedial and preventive action; To promote through the established machinery, joint consultation in health and safety matters to ensure effective participation by all employees; To publish/notify regulations, instructions and notices in the common language of employees; To prepare separate safety rules for each types of occupation/processes involved in a project; and To ensure regular safety inspection by a competent person at suitable intervals of all buildings, equipment‟s, work places and operations.

6.8.3 Safety Organization

Construction and Erection Phase

A qualified and experienced safety officer will be appointed. The responsibilities of the safety officer includes identification of the hazardous conditions and unsafe acts of workers and advise on corrective actions, conduct safety audit, organize training programs and provide professional expert advice on various issues related to occupational safety and health. He is also responsible to ensure compliance of Safety Rules/ Statutory Provisions. In addition to employment of safety officer by Steel Plant, every contractor, who employs more than 250 workers, will also employ one safety officer to ensure safety of the worker, in accordance with the conditions of contract.

Operation and Maintenance Phase

When the construction is completed the posting of safety officers would be in accordance with the requirement of Factories Act and their duties and responsibilities would be as defined there of.

6.8.4 Safety and Quality Circle

In order to fully develop the capabilities of the employees in identification of hazardous processes and improving safety and health, safety and quality circles would be constituted in

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each area of work. The circle would consist of 5-6 employees from that area. The circle normally will meet for about an hour every week.

6.8.5 Safety Training

A full fledged training center will be set up at the plant. Safety training would be provided by the Safety Officers with the assistance of faculty members called from Corporate Center, Professional Safety Institutions and Universities. In addition to regular employees, limited contractor labors would also be provided safety training. To create safety awareness safety films would be shown to workers and leaflets would be distributed. Some precautions and remedial measures proposed to be adopted to prevent fires are:

Compartmentation of cable galleries, use of proper sealing techniques of cable passages and crevices in all directions would help in localizing and identifying the area of occurrence of fire as well as ensure effective automatic and manual fire fighting operations; Spread of fire in horizontal direction would be checked by providing fire stops for cable shafts; Reliable and dependable type of fire detection system with proper zoning and interlocks for alarms are effective protection methods for conveyor galleries; House keeping of high standard helps in eliminating the causes of fire and regular fire watching system strengthens fire prevention and fire fighting; and Proper fire watching by all concerned would be ensured.

6.8.6 Health and Safety Monitoring Plan

All the potential occupational hazardous work places would be monitored regularly. The health of employees working in these areas would be monitored once in a year for early detection of any ailment due to exposure to hazardous chemicals.

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CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL PROTECTION (CREP) FOR SPONGE IRON PLANT

Sr. No. Parameter Compliances 1.0 Air Pollution 1.1 Stack Emission from Kiln

1. Adequately designed ESP or any other adequate air pollution control system/combination of ESP will be provided. system should be installed to achieve the prescribed stack emission standards.

As installation and operation of Pollution Control Equipment for plants with less than 100 TPD capacity is not economically viable, therefore, it is recommended that plants with less than 100 TPD shall not be permitted in future.

Program for phasing out old plants having capacity less than 100 TPD shall be worked out by the State Pollution Control Board

2. All Pollution control equipment should be provided with separate electricity meter and totaliser Will be complied

for continuous recording of power consumption. The amperage of the ID fan should also be recorded continuously. Non-functioning of Pollution control equipment should be recorded in the same logbook along with reasons for not running the Pollution Control Equipment.

3. The safety cap/emergency stack of rotary kiln type plant, which is generally installed above the Will be complied After Burner Chamber (ABC) of feed end column should not be used for discharging untreated emission, bypassing the air pollution control device.

4. In order to prevent bypassing of emissions Will be complied through safety cap and non-operation of ESP or any other pollution control device, software controlled interlocking facility should be provided on the basis of real time data from the plant control system, to ensure stoppage of feed conveyor, so that, feed to the kiln would stop automatically, if safety cap of the rotary kiln is opened or ESP is not in operation. The system should be able to take care of multiple operating parameters and their inter relations to prevent any possibility of defeating the basic objective of the interlock. The system should be foolproof to prevent any kind of tempering. The software based interlocking system, proposed to be installed by industry should be get approved by the concerned State Pollution Control Board, for its adequacy, before installation by the industry.

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Sr. No. Parameter Compliances

5. Mechanical operated system for timely Will be complied collection and removal of the flue dust generated in ESP or any other pollution control device shall be installed 1.2 Stack Emission from de-dusting units All de-dusting units should be connected to a stack having a minimum stack height of 30 m. Sampling Will be installed porthole and platform etc. shall be provided as per CPCB emission regulation to facilitate stack monitoring. De-dusting units can also be connected to ABC Chamber and finally emitted through common stack with kiln off-gas emissions 1.3 Fugitive Emission The measurement may be done, preferably on 8-hour Will be complied basis with high volume sampler. However, depending upon the prevalent conditions at the site, the period of measurement can be reduced. 2.0 Effluent Discharge i. All efforts should be made to reuse and re- Zero discharge plant circulate the water and to maintain zero effluent discharge. Will be complied ii. Storm water / garland drain should be provided in the plant. 3.0 Noise Control The industry should take measures to control the Noise Will be provided Pollution so that the noise level standards already notified for Industrial area are complied. 4.0 Solid Waste Management Char :

Char should be mixed with coal or coal washery rejects and used as fuel in Fluidized Bed Combustion Boilers Char will be reused in FBC boiler. (FBC) for generation of power. The plants having capacity 200 TPD and above should install Fluidized Bed Combustion Boilers (FBC) for generation of power. Also the smaller capacity individual Sponge Iron Plants (Capacity upto 100 TPD) and operating in cluster can collectively install common Fluidized Bed Combustion Boilers (FBC) for power generation. The Sponge Iron Plant are free to explore other options / possibilities to use char for generation of power. Char can be sold to local entrepreneurs for making coal briquettes. It can also be mixed with coal fines, converted to briquettes and used in brick kilns.

Under no circumstances char should be disposed off in agricultural fields/other areas. Logbook for daily record, of Char production and usage must be maintained by the industry and the record shall be made available to officials of CPCB/SPCB/PCC during inspection. Kiln Accretions: The kiln accretions are heavy solid lumps and can be Will be complied used as sub- base material for road construction or landfill, after ascertaining the composition for its

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Sr. No. Parameter Compliances suitability and ensuring that it should not have any adverse environmental impact. Gas Cleaning Plant (GCP)/Scrubber Sludge

The sludge should be compacted and suitably disposed Will be complied off after ascertaining the composition for its suitability and ensuring that it should not have any adverse environmental impact. Flue Dust / Fly ash

Flue dust is generated from air pollution control system i.e. ESP or any other air pollution control system Flue dust will be reused in process installed with kiln. Secondary flue dust is also generated from Bag Filters or any other air pollution control equipment installed with Raw Material Handling, Coal Crusher, Cooler Discharge and Product house unit. The reuse/ recycling of the flue dust generated / collected may be explored and suitably implemented.

Fly ash brick manufacturing plant should be installed for Fly ash will sold to local brick fly ash utilization. Fly ash can be utilized in cement manufacturers. making by Cement industry also.

Bottom Ash

Bottom ash may have objectionable metallic compounds, therefore should be stored in properly designed landfills Will be complied. as per CPCB guidelines to prevent leaching to the sub- soil and underground aquifer.

General

(a) Solid waste management program should be prepared with thrust on reuse and recycling. Solid waste Will be complied. disposal site should be earmarked within the plant premises. The storage site of solid waste should be scientifically designed keeping in view that the storage of solid waste should not have any adverse impact on the air quality or water regime, in any way.

(b) The various types of solid wastes generated should be stored separately as per CPCB guidelines so that it Will be complied. should not adversely affect the air quality, becoming air borne by wind or water regime during rainy season by flowing along with the storm water. 5.0 Raw Material handling and Preparation (a) Unloading of coal by trucks or wagons should be Will be complied carried out with proper care avoiding dropping of the materials from height. It is advisable to moist the material by sprinkling water while unloading.

(b) Crushing and screening operation should be carried out in enclosed area. Centralized de- dusting facility Will be complied (collection hood and suction arrangements followed by de-dusting unit like bag filter or ESP or equally effective method or wet scrubber and finally discharge of emission through a stack) should be

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Sr. No. Parameter Compliances provided to control Fugitive Particulate Matter Emissions. The stack should confirm to the emission standards notified for de-dusting units. Water sprinkling arrangement should be provided at raw material heaps and on land around the crushing and screening units. (c) Work area including the roads surrounding the plant Will be complied shall be asphalted or concreted. d) Enclosure should be provided for belt conveyors and Will be provided transfer points of belt conveyors. The above enclosures shall be rigid and permanent (and not of flexible/ cloth type enclosures) and fitted with self- closing doors and close fitting entrances and exits, where conveyors pass through the enclosures. Flexible covers shall be installed at entry and exit of the conveyor to the enclosures, minimizing the gaps around the conveyors. In the wet system, water sprays/ sprinklers shall be provided at the following strategic locations for dust suppression during raw material transfer: - Belt conveyor discharge/ transfer point - Crusher/screen discharge locations 6.0 Waste Heat Recovery Boiler (WHRB)

Sponge Iron Plants of capacity more than 100 TPD kilns WHRB are proposed. shall use Waste Heat Recovery Boiler (WHRB) for generation of power. 7.0 Cooler Discharge and Product Separation Unit

Permanent and rigid enclosures shall be provided for belt conveyors and transfer points of belt conveyors. Will be provided Dust extraction cum control system preferably bag filters or ESP to arrest product loss in cooler discharge and product separation area shall be installed. 8.0 Char based Power Plant

For plant having capacity of 200 TPD of cumulative kiln capacity, the power production through FBC boiler using FBC boiler is proposed for power char as a part of fuel, is a viable option. Power generation. generation through FBC boiler using char as a part of fuel be implemented in a phased manner within 4 years of commissioning and targeting for 100% utilization of char.

Individual Sponge Iron Plants of capacity upto 100 TPD and located in cluster can install a common char based power plant collectively. 9.0 New Sponge Iron Plants

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Sr. No. Parameter Compliances

(i) No New Sponge Iron Plant will be commissioned Will be complied. Pollution control without installation of Pollution control systems as stipulated in the Standards. The concerned State equipments are proposed and Pollution Control Board will accord consent to standards will be complied. operate only after Physical verification of the adequacy of the Installed pollution control systems for meeting the standards and stipulated conditions in the consent to establish.

(ii) All new kilns shall have the independent stack with the kiln or multi-flue stacks in case two or more kilns are Separate stacks are provided joining the same stack for better dispersion of attached to each kiln. pollutants.

(iii) Any entrepreneur having more than 2x100 TPD kiln may install WHRB for power generation, as it's a Power generation is proposed techno-economic viable option. using WHRB and FBC Boiler.

For plants having capacity of 200 TPD or more, power generation using char in FBC Boiler as part of fuel is techno-economic viable option, therefore, new plants must install FBC boiler for power generation at the time of installation of the industry.

(iv) Any new sponge iron plant being installed along with Will be complied the other downstream facilities of converting the sponge iron into steel with/without further processing the steel should meet the target of 100% utilization of sensible heat of DR (Direct Reduction) Gas and Char for power generation. Wet scrubbing system for kiln off-gas treatment for such plants should not be opted. 10.0 General Guidelines

(a) Extensive plantation/Green belt shall be developed along the roads and boundary line of the industry. A Will be complied minimum 15 m width Green Belt along the boundary shall be maintained. However, the green belt may be designed scientifically depending upon the requirement and local and mix species of plants may be selected for the green belt.

(b) Monitoring of stack emissions, fugitive emissions, Will be complied. trade effluent and noise level shall be done as per CPCB regulations.

(c) Pollution control systems shall be operated as an integral part of production to ensure minimum Will be complied. emissions. Pollution Control System shall start before conveyor operation/operation of plant. Similarly pollution control system shall be stopped only after completion of conveyor operation/operation of plant so that possibility of dust settlement in ducts can be eliminated. Continuous evacuation of dust (from Dust catchers, ESPs, Bag filter hopper etc.) shall be organized. 11.0 Siting Guideline for Sponge Iron Plants

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Sr. No. Parameter Compliances

Siting of new sponge iron plants shall be as per

respective State Pollution Control Board guidelines. However the following aspects shall also be considered:

a. Residential habitation (residential localities/ village) and ecologically and/or otherwise sensitive Hirebagnal village at 2.0 km from areas: A minimum distance of at least 1000 m (1.0 the site. km) to be maintained.

b. The location of Sponge Iron Plant should be at least 500 m away from National Highway and State National highway is 5 km from the Highway . project site

c. Radial distance between two Sponge Iron Not Applicable Plants should be 5 km for plants having capacity 1000 TPD or more

d. Sponge Iron Plants can be established in designated industrial areas / Estates as notified by Not Applicable State Govt.

e. If any plant/clusters of plants are located within 1 km from any residential area/ village they may be Not Applicable shifted by State Pollution Control Board/ State Govt. in a phased manner for which a time bound action plan is to be prepared by SPCBs.

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