Shyam Steel Industries LTD English

Proposed 2.
0 MTPA Iron Ore Beneficiation, Pellet Plant along with Producer Gas Plant (Coal Gasification Plant) and Captive Power Plant of 50MW (WHRB-3.5 MW & FBC-46.5 MW) at Village Thiaberna & Juniyani, Tehsil: Bonai, Dist: Sundergarh, Orissa by M/s Shyam Steel Industries Ltd. Executive Summary of REIA/EMP
EXECUTIVE SUMMARY
M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar
Proposed 2.0 MTPA Iron Ore Beneficiation, Pellet Plant along with Producer Gas Plant (Coal Gasification Plant) and Captive Power Plant of 50MW (WHRB-3.5 MW & FBC-46.5 MW) at Village Thiaberna & Juniyani, Tehsil: Bonai, Dist: Sundergarh, Orissa by M/s Shyam Steel Industries Ltd. Executive Summary of REIA/EMP
CHAPTER I : PROJECT DESCRIPTION 1.1 Introduction to Project:
M/s Shyam Steel Industries Limited (SSIL), is a flagship company of Shyam Steel Group, a Public Limited Company having its corporate office at Shyam Towers, EN-32, Sector-V, Salt Lake, Kolkata- 700091 and existing steel units at Angadpur, Gopalpur & Howrah in West Bengal proposes to set up 2.00 MTPA Iron Ore Beneficiation and Pellet plant along with Producer Gas Plant (Coal Gasification Plant) and 50 MW Power Plant (3.5 MW Waste Heat Recovery + 46.5 AFBC) will be at Village: Thiaberna and Juniyani village in Bonai Tehsil of Sundergarh District in Orissa to produce iron pellets as per the market demand. The EIA Study has been carried out by M/s Visiontek Consultancy Services, Bhubaneswar which is based on the three months field data generated at site during April 2010 to June 2010 covering Summer Season and the same data has been used in assessment of impacts. 1.2 Project Highlights
Basic highlights of the proposed project are presented in the following Table No. 1. Table No. 1 Project Highlights Sl. No. 1. 2. 3. 4. 5. 6. 7. Features Name of the Company Proposed Project Promoter Constitution Name of the Product Production Capacity Location Description M/s Shyam Steel Industries Ltd. 2.00 MTPA Iron Ore Beneficiation and Pellet plant Sri Shyam Sunder Beriwala Public Limited Company. Iron ore Concentrate, Pellet, Producer Gas and Captive Power 2.0 Million Ton Per Annum At: Thiaberna and Juniyani village, Dist: Sundergarh State: Orissa 8. Site Coordinates 2105530N latitude and 840 5428 E longitude.
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9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Project Cost Process Technology Nearest National Highway Nearest Railway Station Nearest Airport Nearest River Climate Maximum Temperature Minimum Temperature Annual Rainfall Project Area Area reserved for Solid Waste Disposal Area reserved for green belt development Manpower Requirements Source of Water Qty of Water Requirement Power Requirement Source of Power Major Raw Materials Required Source of Raw Materials
Rs. 984.41 Crores. Proven technology adopted by major Beneficiation and Pelletization Plants in India. Adjacent to NH-23 connecting Highway Tikira Railway Station at 4.5 Km. Bhubaneswar at 295 Km. Brahmani River at 3.0 Km (SW) Hot Summer with mild winter 45.00C 7.0 0C 1230mm 200 acres 63 acres 66 acres 572 (340 Employees and 232 Contract Workers) Brahmani River Fresh water requirement @ 420 m3/hour 25 MW State Electricity Grid and 50 MW Captive power Plant Iron Ore, Bentonite, Limestone, Coke Breeze, Coal. Koira-Tensa-Khandadhar Iron Ore belt, Birmitrapur area of Sundergarh, Gujrat, Steel plants of the region, coal from local mines. Rourkela-Bonai
29.
Expenditure
on
Pollution
Rs.51.53 crores (Capital) & Rs.10.49 crores (recurring).
Control Measures
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1.3
Plant Configuration
The basic major components of the proposed project are presented below: Table No. 2 Plant Configuration Sl. No. 1 2 3 4 Description Iron Ore Beneficiation Plant. Iron Ore Pellet Plant Power plant-WHRB associated with Producer gas Plant Power Plant - AFBC Capacity 2.0 MTPA 2.0 MTPA 3.5 MW 46.5 MW Product Iron Ore Concentrate Pellet Producer Gas, Power Power
CHAPTER II : DESCRIPTION OF THE ENVIRONMENT 2.1 Introduction
Existing status of the environment on various environmental attributes has been monitored within the 10 Km radial area around the proposed project site during April 2010 to June 2010 representing Summer Season. 2.2 Environmental Setting of the Area
The project site is located at 210 55 30 N Latitude and 840 54 28 E Longitude. The proposed project site is well connected to roads and railway network. The proposed project is located adjacent to NH-23 connecting Rourkela-Bonai Highway. The nearest rail head is at Tikira, which is at a distance of about 4.5 Km from the proposed project site. Nearest Airport at Bhubaneswar, the State Capital of Orissa which is at a distance of 295 Km from the proposed project site. The area is characterized by tropical climate with three distinct seasons namely summer, Rainy and winter. A good quantity of rain showers in the rainy season with an annual average of 1230 mm in the area. The maximum temperature is 45C in summer and 7C winter.The area comes in Seismic Zone-III, which reveals that the area is covered under low damage risk zone. Thus the area is not susceptible to any possible earthquake.
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2.3
Base Line Data
The collected base line data in the study period has been presented in the following sections. 2.3.1 Micro-Meteorology The maximum and minimum temperatures observed in the study period are 38.2 and 12.10C with average relative humidity of 65%. The predominant wind direction is SW with 27.76% of calm condition. 2.3.2 Ambient Air Quality
Various samples have been collected from 8 different locations in the study area. As per the monitoring, PM10, PM2.5, SO2, NOx, CO, BSF in PM10 & BSF in PM2.5 levels were in the range of 46.5-51.3 g/m3, 31.1 34.8 g/m3, 8.1-9.1g/m3, 7.1 to 8.2 g/m3, 79.4 - 112.3 g/m3, 9.3 10.3 g/m3 and 7.7 8.7 g/m3 respectively. The results of the monitored data indicate that the ambient air quality of the region in general is in conformity with respect to rural / residential norms of National Ambient Air Quality standards of Central Pollution Control Board (CPCB), with present level of activities. 2.3.3 Land Use Pattern
The unit has acquired 200.00 acres of land for the proposed Iron ore Beneficiation and Pellet Plant at Village: Thiaberna and Juniyani village, Bonai, Sundergarh. This area does not form part of any National Park, Wild Life Sanctuary and Natural/Biosphere reserve.
Land use / Land Cover of the Study Area

AREA STATISTICS OF 10 K.M AROUND BONAI AREA TYPE AREA IN HECTARES SETTLEMENT 759.91 CROP LAND 18884.65 AGRICULTURAL PLANTATION 5.12 DENSE FOREST 2503.70 OPEN FOREST 2659.73 SCRUB FOREST 557.79 TREE COVERAGE AREA 3420.96 GUILLED/EROADED LAND 43.98
LAND WITH SCRUB LAND WITH OUT SCRUB RIVER RIVER SAND TANK/WATER BODY TOTAL 2.3.4 Surface Water Quality
280.46 595.04 1167.58 370.15 148.56 31397.63
Total 8 nos. of surface water samples have been collected from the study area. The result of all the surface water collected shows that the values of all parameters for all the samples collected comply with the CPCB standards and do not indicate any deviation from the norms. 2.3.5 Ground Water Quality Monitoring
Eight nos. of ground water samples in the study area have been collected from ground water sources. The water samples were collected and analyzed for physical, chemical and microbiological characteristics as per CPCB guidelines and approved methods. All the samples are conforming to the prescribed drinking water standards. 2.3.6 Noise Level Noise level has been measured at 8 locations. The day time noise levels at all the locations ranged between 53.1 and 59.2 dB (A). The night time noise levels at all the locations ranged between 48.3 and 53.2 dB (A). 2.3.7 Biological Environment There is no Reserve Forest in the study area. The area is covered by natural plants. In the project area, the wild animals as well as other fauna are not seen excepting domestic animals. The study area doesnt form any part of National park, wild life sanctuary, and natural bio-sphere reserve. 2.3.8 Socio-economic Study
The study area consists of 74 villages and total population of the study area is 32079. There are 7144 no. of households in the study area with an average house hold size of 4.4. There are about 16292 males and 15787 females. The SC populations are 1945 (6.0% of
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total population) and ST populations are 20283 (63.2 % of total population) respectively. The average Sex Ratio of the study area is about 969 of females per thousand of males. The total literates of the study area are 13911. The total illiterates of the study area are 18168. The average literacy rate of the study area is 43.0%. It is also observed that the rural population predominates over the urban population. These rural mass of the area is completely dependent on agricultural activities. With the present industrial growth in the District since last few years, the people are more attracted towards the industrial culture to have a better socio economic condition. CHAPTER III ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES 3.1 Impact Assessment
An effort has been made to identify various environmental, social and ecological impacts due to proposed project during construction and operation phases considering present environmental scenario as baseline. The corresponding mitigation measures to take care of the adverse impacts are also discussed in following sections. 3.2 Impacts during Construction Phase & its Mitigation Measures.
During Construction Phase, the Fugitive Dust Emission due to civil work and vehicular movement is not expected to spread too far as water spraying will be carried out to suppress the dust emission at the site and as well as on road. The increase in noise levels due to the movement of vehicles will be taken care of by regulating the movement of vehicles and the impact on the human beings will be taken care of by providing the working people with ear plugs / ear muffs. During monsoon, there is a chance of run off of the debris / mud that will be generated during construction only. This is very much temporary in nature. To reduce the suspended solids, the storm water run offs will be diverted to storm water drains through catch pits. As the proposed site is mostly barren land without much vegetations, there will not be any significant impact on the ecology of the study area. During construction period, the project is likely to generate substantial employment and income.
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3.3 3.3.1
Impact During Operation Phase & Mitigation Measures: Air Environment
Major air emissions are anticipated from operations of Producer gas plant, pelletization unit & power plant boilers. Fugitive dust emission will be due to raw materials handling, loading and unloading of raw materials, conveying and feeding points, vehicular movements, crushing & screening operations etc. The ISCST3 scientific model has been used to predict the proposed air quality on the environment. The results of the modeling study indicates that the maximum increase of GLC for the proposed project is 2.28 g/m3 with respect to the PM, 2.52 g/m3 with respect to the SO2 and 1.74 g/m3 with respect to the NOx which is minimal. The GLC predicted at all receptor locations after the proposed expansion are well within the SPM, SO2 and NOx limit prescribed in NAAQS. The following measures are envisaged for the proposed project.
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Table No.3 Air Pollution Control Measures
Sl Source of No. Pollution

1
Mitigation Measures
Fugitive Emissions from Raw Material Handling (transportation, loading & unloading, material transfer points, loading hoppers) will be controlled by Water Sprinkling, DFS & Bag Filters Indurating Machine: Dust Extraction systems comprising ESPs / West Scrubbers, centrifugal fan and motor, duct work including suction hoods, duct supports, stack dust hopper etc. The flue gas will be routed through ESPs and tall stacks connected after Waste Heat Recovery Boilers. SPM, SO2 & NOx from Coal Combustion : ESP connected to tall stack as per CPCB Formula H = 14 Q0.3 Fugitive Dust from Coal Stacking, Reclaiming, Crushing & Feeding : DFS, Bag Filter Fugitive Dust from Coal Storage Area : Water Sprinklers. For fly ash handling from ESP, Dense phase pneumatic conveying system with ash conditioner will be installed. Bottom Ash from the boilers will be carried through a submerged belt conveyor to silo The dust and tar laden gas is first treated in a Scrubber using water as a scrubbing media to remove major amount of dust and tar. The scrubbed gas is further treated in a Wet ESP to reduce tar and dust content in order to achieve an outlet emission of SPM less than 5 mg / Nm3. The pressure of coal gas leaving the Wet ESP will be boosted, using a booster compressor to level of 1.5 Kg / Cm2 (g)
Iron Ore Beneficiation Plant Pellet Plant
Waste Heat Recovery Boiler AFBC Boiler
Coal Gasification Plant
3.3.2
Noise Environment
The noise pollution management will be taken up in the following manner By selecting low noise generating equipment, which would have below 85 dB (A) noise level at 1 m distance. This is taken care at the equipment design stage. By isolating the noise unit from the working personnel's continuous exposure by providing acoustic aids for plant personnel. By administrative & safety measures, providing noise level monitoring, remedial measures, providing noise safety appliances to the working personnel.
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By these measures, it is anticipated that noise levels in the plant will be maintained below 85 dB (A). 3.3.3 Water Environment:
The company envisages zero discharge system for the proposed Iron ore Beneficiation and Pellet Plant. Plant will consume fresh water @ 420 m 3/ hr for its plant operation. The discharge of waste water from the different plant units and its treatment method is described below. There will be no waste water from Iron Beneficiation, Pellet, Coal Gasification unit. Cooling water will be completely recycled. Waste water from the Beneficiation Plant will be treated in Thickener and clarified water will be recirculated with make up water.. Blow down water from cooling tower & boiler of power plant will be routed to guard pond and reused for green belt development. Regeneration effluent from DM plant will be treated in neutralization pit and routed to guard pond and reused for green belt development. Domestic Effluent will be treated in STP & treated water will be reused in dust suppression and green belt. A total of 78 m3/hr of waste water will be generated from the total plant which will be treated and reused confirming to zero discharge norms. Measures for Conservation of Water Resources To conserve the precious environmental resource like water, company has proposed to implement
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rain
water
harvesting
scheme
to
reuse
the
collected
rain
water
@214037m /year. 3.3.4 Solid Waste Management
The beneficiation and pelletization plant along with producer gas and AFBC captive power plant will consume enormous quantities of mineral raw material & fossil fuel like iron ore, limestone, bentonite, coal, coke etc and hence will generate huge amount of solid waste in the form of dust, tailings, sludge etc. Therefore the solid waste management & disposal is really a hard task. But SSIL with its comprehensive EMP envisages maximum reuse, recycling of the waste so that considerably less amount of solid waste, non-polluting in nature will be disposed in secure land fill.
Units Beneficiation AFBC Plant
Solid Wastes Tailings
Qty in TPA 1076950 118650
Solid Waste Management Will be taken to tailing pond. 45.0 acres of area is earmarked for tailing pond. Disposed in Ash Disposal Area of 15.0 acres. Used in Cement Plant Making Fly Ash Bricks Ash will be disposed in an area of 3.0 acres. Tarry Wastes will be sold to outside parties for road construction.
Power Ash
Coal Gasification Plant
a. Ash a. Tar
27800 900
3.3.5
Green Belt Development
33% area has been earmarked for green belt development. Pollution tolerant species are recommended for the green belt development in and around the plant to mitigate the pollution impacts. 3.4 Environmental Monitoring
Monitoring of different Environmental Parameters will be carried out regularly as per the schedule and the activity will be coordinated by the Environmental Management Cell (EMC). There will be an environmental laboratory to analyze the environmental parameters of the samples collected. Methodologies which are to be followed for testing will be as per CPCB guidelines. 3.5 Environmental Management Cell
EMC will look after and maintain all pollution control systems, organize necessary environmental monitoring and maintain records. Annual environmental audit and hazardous waste audit will be carried out by a third party duly authorized by State Pollution Control Board. Environmental Management Department Personnel will be provided specialized training on Environmental Management. SSIL will also implement ISO 14001 i.e. Environmental Management System (EMS) for proper management of the environment. The directives from statutory authorities and prevailing regulation will
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govern the periodicity of monitoring. The action plan of EMP will be updated every year with respect to the results achieved and to plan activities up to next year. CHAPTER IV RISK ASSESSMENT & DISASTER MANAGEMENT PLAN 4.1 Risk Assessment
Risk analysis has been carried out to identify and quantify the risks for the plant equipment & personnel which are supposed to be exposed to accidents resulting from the anticipated hazards in the plant. As per the hazard criteria, the HSD, LDO & Furnace Oil storage and handling facilities at proposed project are categorized under light hazard. Preventive measures will be taken for storage and handling of the above liquid fuels. Proposed risk mitigation measures are described below: The fire service facility should be equipped with: - Smoke and fire detection alarm system. - Water Supply. - Detection system for toxic release. - Fire hydrant installation. - Foam system. - Water Fog and sprinkler system. - Mobile fire fighting equipment - First aid appliances. Periodic maintenance of all protective and safety equipment. Wind socks/ Wind cock should be installed at suitable height and with proper visibility to check the prevailing wind direction at the time of accident. Periodical training/ awareness will be given to work force to handle emergency situation. Periodic mock drills will be conducted so as to check the alertness and efficiency of DMP and corresponding records will be maintained. Signboards including emergency phone numbers and no smoking signs will be installed at all appropriate locations. Plant shall have adequate communication system. All major units/ equipment shall be provided with smoke/fire detection and alarm system.
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All electrical equipments shall be provided with proper earthing. Earthed electrode shall be periodically tested and maintained.
Emergency command structure has been prepared fixing the responsibility of individual persons for rescue operation, medical assistance, mutual assistance and communication to statutory authorities. 4.2 Disaster Management Plan
It is imperative that accidents occurring in the plants due to unforeseen acts and events but this should not affect the surrounding areas and life and wealth present around. Therefore, an onsite emergency plan for prevention and mitigations of accidents will be enough to cater for unforeseen acts and events that may occur. CHAPTER V: ADDITIONAL STUDIES 5.1 Public Consultation
SSIL will make utmost endeavor for the peripheral development activities for the local people and hence hopes cent percent public support for setting up the project. The anticipated project benefits are mentioned in following Chapter-VIII and those will be deliberated by the proponent in the Public Hearing meeting. 5.2 R & R Action Plans
The project is going to come up on 200 acres area. Land acquisition is in continue, there is no existence of displaced habitants in the area acquired so far. No colony will be constructed as workers will be staying in the colony already existing. In future, if any habitants displaced, for Land losers, Rehabilitation and settlement Plan will be implemented as per the Resettlement and Rehabilitation Policy of Orissa State Govt.
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CHAPTER VI : PROJECT BENEFITS 6.1 Project Benefits The proposed project is expected to bring significant socio-economic and environmental benefits both at local and global level as listed below: 6.2 Social Infrastructure Social awareness programme will further improve by the local authority such as sanitation and hygiene, HIV Prevention Program. Through this project, adult education and female education will be provided to the illiterate adults and backward females of the villages in the project surrounding area. The proposed project will set up training centre or tie up with Industrial Technical Institutes to educate local youth as skilled labour. 6.3 Employment Potential
Some employment potential benefits are given below: Expected to employ a peak workforce of about 200 persons (peak demand) and 180 persons (average demand) during construction phase. Long term employment of up to 572 people (including 93 skilled, 30 semi skilled and 128 workers and 232 contract workers) in the operation of the proposed plant. Plus additional jobs generated by local business in the supply of raw materials, finished products and services. 6.4 Benefits to the region and the country:
SSIL will produce iron pellets products as per the national and international market demand. The company will supply its product to domestic & will also export its products to foreign countries thereby improving regional and national economy.
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Shyam Steel Industries LTD English

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Proposed 2.

M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar

CHAPTER I : PROJECT DESCRIPTION 1.1 Introduction to Project:

Rs.51.53 crores (Capital) & Rs.10.49 crores (recurring).

M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar

CHAPTER II : DESCRIPTION OF THE ENVIRONMENT 2.1 Introduction

Base Line Data

Land use / Land Cover of the Study Area

280.46 595.04 1167.58 370.15 148.56 31397.63

M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar

Impact During Operation Phase & Mitigation Measures: Air Environment

M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar

Table No.3 Air Pollution Control Measures

Sl Source of No. Pollution

Iron Ore Beneficiation Plant Pellet Plant

Waste Heat Recovery Boiler AFBC Boiler

Coal Gasification Plant

@214037m /year. 3.3.4 Solid Waste Management

Units Beneficiation AFBC Plant

Solid Wastes Tailings

Qty in TPA 1076950 118650

Coal Gasification Plant

Green Belt Development

M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar

M/s Visiontek Consultancy Services Pvt. Ltd., Bhubaneswar

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