Kind attn : Dr. Satish C. Garkotienvironmentclearance.nic.in/writereaddata/Online/EDS/03_Jan_2017...Project Proponent MEC/11/S2/A231/EIA-EMP/2291/R.0. JANUARY, 2017 ENVIRONMENTAL APPRAISAL

Office of DGM (Env.Engg.), 1stFloor of OHSC Building, Rourkela Steel Plant, RourkelaPhone: 08895500625 Fax:

Regd. Office:IspatBhawan, Lodi Road, New Delhi

To : The Member of Secretary of EAC

Ministry of Environment, Forest & Climate Change,

IA Division, Indira Prayawaran Bhawan

Jor Bagh road, Aliganj

New Delhi-110003.

Kind attn :

Dear Sir,

Sub. : Amendment of EC --

Sulphuric Acid Plant of 125 TPDcapacity within the premises of Rourkela Steel Plant at

Rourkela, District – Sundargarh, State

Ref. : Item no. 10.5.1 of Minutes of Meeting of the tenth (10

Committee held on 29

projects. File ref. no. F.

During the above meeting,

respect to the above proposal;

a) Produce data in support of RSP’s claim that there will not be any increase in the pollution load.

b) Submit the details of the clean technology to be adopted for reducing the overall pollution

from the steel plant.

c) To produce a letter approaching SPCB in 2012 and their advice for consideration.

An Environmental Appraisal Report has been prepared addressing all the above points and the

report is enclosed for kind consideration.

In view of the above, we humbly request you to kindly consider our case

modernization of RSP by adding New Sulphuric Acid Plant of 125 TPD capacity

Thanking you sir,

With warm regatrds,

Encl :As above

Steel Authority of India Limited

Rourkela Steel Plant

Rourkela Fax : 0661

Office of DGM (Env.Engg.), 1stFloor of OHSC Building, Rourkela Steel Plant, RourkelaPhone: 08895500625 Fax: 0661-2510183

Regd. Office:IspatBhawan, Lodi Road, New Delhi – 110 003

Ref. No. :

Date :

ecretary of EAC (Industry)

Ministry of Environment, Forest & Climate Change,

Indira Prayawaran Bhawan

Kind attn : Dr. Satish C. Garkoti

Modernization of Rourkela steel plant of M/s SAIL by adding


Sundargarh, State -Odisha.

Item no. 10.5.1 of Minutes of Meeting of the tenth (10th

) meeting of Expert Appraisal

Committee held on 29th

– 31st

August, 2016 for Environmental Appraisal of Industry

no. F. No J-11011/757/2007-IA II(I).

# # #

, the following additional information has been sought by EAC with

Produce data in support of RSP’s claim that there will not be any increase in the pollution load.

Submit the details of the clean technology to be adopted for reducing the overall pollution

produce a letter approaching SPCB in 2012 and their advice for consideration.


report is enclosed for kind consideration.

e humbly request you to kindly consider our case for amendment of EC for

by adding New Sulphuric Acid Plant of 125 TPD capacity.

Yours faithfully,

for SAIL-Rourkela Steel Plant,

Dy. General Manager


Rourkela Steel Plant

Rourkela – 769011 Fax : 0661-2510183

Office of DGM (Env.Engg.), 1stFloor of OHSC Building, Rourkela Steel Plant, Rourkela

No. : 691/EE/59/04,

: 03/01/2017

adding New


) meeting of Expert Appraisal

Appraisal of Industry-I Sector

has been sought by EAC with

Produce data in support of RSP’s claim that there will not be any increase in the pollution load.

Submit the details of the clean technology to be adopted for reducing the overall pollution load

produce a letter approaching SPCB in 2012 and their advice for consideration.


amendment of EC for

Yours faithfully,

Rourkela Steel Plant,

(S N Xess)

Dy. General Manager

ProjectProponent

MEC/11/S2/A231/EIA-EMP/2291/R.0. JANUARY, 2017

ENVIRONMENTAL APPRAISAL REPORT for

MODERNIZATION OF ROURKELA STEEL PLANT

BY

Adding New 125 TPD Sulphuric Acid Plantin place of Old 60 TPD Plant

AT

ROURKELA STEEL PLANT,

DISTRICT SUNDERGARH, ODISHA

MECON LIMITED(A Govt. of India Enterprise)Vivekananda PathPO. DorandaDist – Ranchi, Jharkhand - 834002CERTIFICATE NO: NABET/EIA/1417/SA 007

Environmental Consultant

STEEL AUTHORITY OF INDIA LTD.ROURKELA STEEL PLANTRourkela, Distt. Sundergarh,Odisha - 769011

Quality Council of IndiaQCI

National Accreditation Board forEducation & Trainin

is hereby accorded

Scope of Accreditation

accreditation under the QCI-NABET Scheme for Accreditation ofEIA Consultant Organizations (Version 3)

Sl.No. Name of the Sector Cat.

L. Mining of minerals including Open cast/ Underground mining A

2. Offshore and onshore oil and gas exploration, development & productions A

3 River Valley, Hydel, Drainage & lrrigation projects A

4 Thermal power olants A

5 Nuclear power proiects and processing of nuclear fuel A

6 Coal WasheriesA

7 Mineral beneficiation including pelletisationA

8 Metallurgical industries - (ferrous &nonferrous) - both primary & secondaryA

9. Cement plantsA

10 Coke oven plantsA

LT Oil & gas transportation pipeline (crude and refinery/ petrochemical products), passing

through national parks/ sanctuaries/coral reefs /ecologically sensitive Areas includingLNG terminal

A

12. lsolated storage & handling of hazardous chemicals (As per threshold planning quantityindicated in column 3 of Schedule 2 & 3 of MSIHC Rules 1989 amended 2000) B

13 All ship breaking yards including ship breaking unitsA

L4. Industrial estates/ parks/ complexes/ Areas, export processing zones(EPZs), Special

economic zones (SEZs), Biotech parks, Leather complexes A

15 Ports, harbours, jetties, marine terminals, break waters and dredging A

Highways, Railways, transport terminals, mass rapid transport systemsA

t7. Townships and Area development proiects B

Name of approved EIA Coordinotors and Functionol Areo Experts ore mentioned in SAAC minutes ond RAAC minutes published

on website doted Morch 2, 2016 ond Oct 74, 2075 respectively.

Accreditotion to the above is subject to the EIA reports being prepored by the experts (EIA Coordinotors and Functionol orea Expert)

mentioned in the obove minutes ond complionce to the Terms ond Conditions of Accreditotion

Valid Up to: Februory 4, 2077(Subject to continual compliance to NAB_ET

gf,.RT[f,'lgAT'f, OF" A g gRf,.D IT'ATIONThis is to certify that

Certificale IVg: NABET/ EtA/1477 / sA 007

scheme)

f,p

ROURKELA STEEL PLANT Environmental Appraisal Report for

Modernization of RSP by adding new 125 TPD Sulphuric Acid Plant

© 2017 MECON Limited. All rights reserved Page No. (i)

Compliance to points raised in 10th EAC Meeting dated 29th – 31st August, 2016

Steel Authority of India Limited (SAIL), the leading steel maker in India, has been granted Environmental Clearance (EC) for Expansion cum Modernization of their Integrated Steel Plant from 1.9 MTPA to 4.2 MTPA vide letter no. J-11011/757/2007- IA II(I) dated 29/01/2008. RSP was having 60 TPD Sulphuric Acid Plant, when the plant production capacity was 1.9 MTPA of crude steel. However, in due course of time, to meet the increase in demand of Sulphuric Acid for the new facilities installed during the “1.9 MTPA to 4.2 MPTA Expansion phase” and degradation in condition of existing Sulphuric Acid plant, it was proposed to install a new 125 TPD Sulphuric Acid plant with State of the Art technologies. Subsequently after getting CtE from OSPCB (No: 8428/IND-II-NOC-5621 dated 07/05/2013) RSP has installed a new 125 TPD Sulphuric Acid Plant within the existing premises. However, OSPCB had asked RSP to get clarification about applicability of EC for the Sulphuric Acid Plant from MoEFCC. In view of the above, the issue was discussed in 10th EAC meeting ,29-30th August, 2016 & EAC has asked RSP to submit the following; a) Produce data in support of RSP’s claim that there will not be any increase in the

pollution load.b) Submit the details of the clean technology to be adopted for reducing the overall

pollution load from the steel plant.c) The Proponent should also produce a letter approaching SPCB in 2012 and their

advice for consideration.In view of the above, an Environmental Appraisal Report for the new 125 TPD Sulphuric Acid plant has been prepared addressing all the above issues detailed in the Environmental Appraisal Report and pointwise summary is given below; a) The New 125 TPD Sulphuric Acid Plant has been established with the state of the art

Pollution Control Technologies with a designed SO2 stack emission level of 0.8 kg/Ton (Norm – 2 Kg/ Ton) where as that of old unit was 2.5 kg/Ton(the then Norm - 4.0 kg/Ton). The new unit is also designed based on Zero Liquiddischarge concept. The detailed calculation of pollution load and Ground LevelConcentrations are worked out & given in Chapter-3. The project details are givenin Chapter-2.

b) The details of various clean technologies and other measures implemented incompliance to the EC conditions are detailed in Chapter No. 4. The CertifedCompliance report issued by the Regional Office, MoEFCC, Bhubaneswar is given atAnnexure-5.

c) The CtE application document submitted to OSPCB and other correspondences withOSPCB including copy of CtE dated 07/05/2013 are given at Annexure-3.



© 2017 MECON Limited. All rights reserved Page No. i

CONTENTS

Sl. No. DESCRIPTION PAGE NO. 1.

2.

3.

4.

5.

Introduction

Project Details

Anticipated Environmental Impacts

Clean Technologies & Pollution Control Measures Adopted During Modernization & Expansion Of Plant

Conclusion

1

7

14

26

33



© 2017 MECON Limited. All rights reserved Page No. ii

List of Figure

Figure no.

Details

Fig 1.1 Location of Site Fig 2.1 Lay out of New Sulphuric acid Plant Fig 2.2 Process flow Diagram of Sulphuric acid Plant Fig 3.1 Isopleths of SO2 for the new and old plant Fig 4.1 Solid Waste Utilization

List of Tables

Table no. Details Table 2.1 Major Installed Units Installed/proposed during modernization & expansion of

the plant Table 2.2 Raw material requirement for the new acid units Table 3.1 Stack details from the old and new Sulphuric acid plant Table 3.2 Final GLC values at various AAQ Stations Table 3.3 Meteorological inputs Table 3.4 Predicted ground level concentration at various receptor points Table 4.1 Hazardous waste generation & management



© 2017 MECON Limited. All rights reserved Page No. iii

List of Annexures

Annexure no. Details Annexure 1 EC for Expansion cum Modernization of RSP’s Integrated Steel Plant

from 1.9 MTPA to 4.2 MTPA crude steel. Annexure 2 EC for Modernization of Rourkela Steel Plant by adding 3 MTPA Hot

Strip Mill, 3.3 MTPA Beneficiation Plant and 2 MTPA Pellet Plant and expansion of Special Plate Plant (3000 TPA to 15000 TPA).

Annexure 3 Consent to Establish for installation of new 125 tpd Sulphuric acid plant from OSPCB - All correspondence with OSPCB

3.1 – Appeal to OSPCB asking clarification whether CtE is required or not, dated 15/09/2011.

3.2 -- OSPCB’s clarification about CtE dated 02/02/2012.

3.3 – RSP’s CtE application dated 24/03/2012.

3.4 -- OSPCB’s letter asking clarifications from RSP dated 16/04/2012.

3.5 -- RSP’s clarifications to OSPCB dated 18/06/2012.

3.6 -- Copy of CtE issued by OSPCB dated 07/05/2013.

3.7 -- RSP’s Consent to Operate application to OSPCB dated 23/11/2015.

3.8 -- OSPCB’s directive to RSP for obtaining clarification from MoEF regarding applicability of EC for Sulphuric Acid Plant, dated 29/03/2016.

Annexure 4 Letter from MoEFCC regarding referring of the matter to EAC & asking RSP to submit online application.

&

Minutes of the 10th EAC Meeting held at MoEFCC regarding applicability of EC for the Sulphuric Acid Plant of RSP dated 29th – 31st Aug., 2016

Annexure 5 Certified Monitoring Report of Regional Office of MoEFCC, Bhubaneswar Annexure 6 Existing Environment Status

Executive summary



© 2017 MECON Limited. All rights reserved Page No. ES 1

Executive summary

1.0 INTRODUCTION

Steel Authority of India Limited (SAIL), the leading steel maker in India, has been granted Environmental Clearance (EC) for Expansion cum Modernization of their Integrated Steel Plant from 1.9 MTPA to 4.2 MTPA vide letter no. J-11011/757/2007- IA II(I) dated 29/01/2008.

RSP was having 60 TPD Sulphuric Acid Plant, when the plant production capacity was 1.9 MTPA of crude steel. However, in due course of time, to meet the increase in demand of Sulphuric Acid for the new facilities installed during the “1.9 MTPA to 4.2 MPTA Expansion phase” and degradation in condition of existing Sulphuric Acid plant, it was proposed to install a new 125 TPD Sulphuric Acid plant with State of the Art technologies.

Subsequently after getting CtE from OSPCB (No: 8428/IND-II-NOC-5621 dated 07/05/2013) RSP has installed a new 125 TPD Sulphuric Acid Plant within the existing premises. However, OSPCB had asked RSP to get clarification about applicability of EC for the Sulphuric Acid Plant from MoEFCC.

In view of the above, the issue was discussed in 10th EAC meeting ,29-30th August, 2016 & EAC has asked RSP to submit the following; a) Produce the data in support of RSP’s claim that there will not be any increase in the

pollutin load.b) Submit the details of the clean technology to be adopted for reducing the overall

pollution load from the steel plant.c) The Proponent should also produce a letter approaching SPCB in 2012 and their

advice for consideration.

In view of the above, Environmental Appraisal Report for the new 125 TPD Sulphuric Acid plant has been prepared.

2.0 PROCESS DETAILS

Double conversion Double absorption Process for manufacturing sulphuric acid, commonly known as DCDA process, has been adopted for the production of Sulphuric acid for the present project.




3.0 ANTICIPATED ENVIRONMENTAL IMPACTS

Air Environment

In order to assess the contribution of newly installed Sulphuric acid plant in the prevailing ambient air quality, actual stack monitoring data of old plant and installed stack details of new plant are used. However, the contribution of the old unit in ambient air is already being reflected in the back ground ambient air quality data monitored during Sept - Dec., 2014.

In addition to the measures taken to control pollution new plant , the design emission norms shall be limited to a maximum of 0.8 Kg/ton of sulphur against the statutory norm of 2 Kg/ton.

The maximum GLCs for each grid point were predicted using AERMOD software with respect to SO2. The maximum GLCs derived are 6.2 and 3.1 µg/m3 for Old and New plants respectively due to stack emissions. The maximum values are obtained within/very close to the plant. The final GLC values are given below;

Predicted GLC values at various AAQ Stations (µg/m3)

Station ID

Old 60 TPD Plant

New 125 TPD Plant

Change in conc

A1 0.055 0.036 -0.019 A2 0.034 0.022 -0.012 A3 0.013 0.009 -0.005 A4 0.705 0.374 -0.331 A5 0.175 0.112 -0.063 A6 0.072 0.047 -0.024 A7 0.027 0.018 -0.010 A8 0.447 0.245 -0.202

Max 6.2 3.1 -3.1

After installation of the new Sulphuric acid plant and phasing out the old one, there is an overall decrease in Ground Level Concentration of SO2 values.

Air Pollution Mitigation Measures during operation phase

In order to mitigate various impacts of air pollution, following measures are being implemented in the new H2SO4 plant-

• A 30 m high stack of 0.7 m dia has been provided for proper dispersal of pollutants.




• In order to reduce SO2, SO3 and acid mist in tail gas, two absorption towers havebeen installed with efficiency of 99.9 %.

• The waste heat from the process shall be utilized for Sulphur melting.• A tail gas scrubber has been provided for cleaning gas having high SO2

concentration during startup stage.• The Plant has been designed for SO2 emissions limited to 0.8 Kg/ton (Norm – 2.0)

and Acid mist shall be limited to 70 mg/m3.• Closed facility for storing and handling raw sulphur.

Water Environment

Make-up water requirements for the new acid plant making up to 17 m3/h max. against the old plant’s requirement of 30 m3/hour. Thus no impact on existing water resources is envisaged.

The waste water/effluents generation from the new acid plant is less than 2 m3/hr. All the acid spillages and leakages are collected in the neutralization pit. Using soda ash, the effluent is first neutralized for meeting norms before further utilisation. The treated effluents are then used for road washing/floor washing and fire fighting. There will be no discharge of waste water from new Sulphuric Acid Plant.

Therefore, there is no overall impact on water environment.

Noise Environment

In Sulphuric Acid plant, the main noise producing equipment are air blowers, steam turbines and some pumps. These equipment are placed in closed rooms to reduce the noise level. Therefore, no increase on noise pollution is observed.

Solid Waste

All the wastes are neutralized and then stored in the Secured Land Fill facility of RSP.

4.0 CLEAN TECHNOLOGIES & POLLUTION CONTROL MEASURES ADOPTED DURING MODERNIZATION & EXPANSION OF RSP

RSP incorporated all compliance conditions related to design of equipment while preparation of technical specifications and detailed engineering stage and latest clean technologies implemented for control of overall pollution load of the plant.

1. Coke oven –• Coke dry quenching• Waste heat recovery boiler with Back Pressure Turbo Generator (6.4 MW)• Coke oven gas desulphurization,• Land based pushing emission control system




• Computerized combustion control

2. In Blast furnace –

• Large capacity blast furnace with state-of-the art controls• Top Recovery Turbine (14 MW) for gainful utilization of high pressure BFc gas.• Coal dust injection• Cast house and stock house dust emission control systems.• In house slag granulation in Blast furnace No.5• Power Generation (2x18MW) using Blast Furnace gas in Blast Furnace No.5.

3. 150T BOF converters with gas recovery system and with secondaryemission control systems (Dog House).

5.0 CONCLUSION

The assessment of environmental impact of installation of new H2SO4 plant and phasing out the old unit shows that-

• Reduction of air emissions in respect of SO2.• No impact on water consumption.• No impact on Land environment.• Marginal improvement in air quality in the surrounding areas.• No additional requirement of land, water for the project.

By installing new Sulphuric Acid plant and implementation of new pollution control equipment, there will not be any additional pollution load on the ambient environment.

Environmental Appraisal Report



© 2017 MECON Limited. All rights reserved Page No. 1

1.0 INTRODUCTION 1.1 General

Steel Authority of India Limited (SAIL), the leading steel maker in India, has been granted Environmental Clearance (EC) for Expansion cum Modernization of their Integrated Steel Plant from 1.9 MTPA to 4.2 MTPA vide letter no. J-11011/757/2007- IA II(I) dated 29/01/2008(Annexure-1). As a part of further Modernization of Steel Plant (4.2 MTPA), RSP has proposed to add 3 MTPA Hot Strip Mill, 3.3 MTPA Beneficiation and 2 MT Pellet Plant and Special Plate Plant (3,000 TPA to 15,000 TPA) within the premises of Rourkela Steel Plant. In the 9th EAC meeting held during 27th to 29th July 2016, the proposal was recommended and EC was accorded on 15th December, 2016 for Modernisation of Rourkela Steel Plant. (Annexure-2). RSP was having 60 TPD Sulphuric Acid Plant, when the plant production capacity was 1.9 MTPA of crude steel. However, in due course of time, to meet the increase in demand of Sulphuric Acid for the new facilities installed during the “1.9 MTPA to 4.2 MPTA Expansion phase” and degradation in condition of existing Sulphuric Acid plant, it was proposed to install a new 125 TPD Sulphuric Acid plant with State of the Art technologies. Subsequently after getting CtE from OSPCB (No: 8428/IND-II-NOC-5621 dated 7/5/2013) (Annexure-3) RSP has installed a new 125 TPD Sulphuric Acid Plant within the existing premises. However, OSPCB had asked RSP to get clarification about applicability of EC for the Sulphuric Acid Plant from MoEFCC. In view of the above, a meeting regarding the same was held at MoEFCC, Delhi on 29th August, 2016 (Annexure-4). Based on the meeting, EAC has asked RSP to submit the following-

Prepare data to establish that there will not be any increase in the pollution load. Details of clean technologies to be adopted for reducing the overall pollution load

from the steel plant.

In view of the above, the following Environmental Appraisal Report for the new 125 TPD Sulphuric Acid plant has been prepared taking into consideration the requirement and guidelines of statutory bodies and also SAIL’s requirement.

1.2 Brief of The Project 1.2.1 Importance of the Project

Ammonia is present to the extent of approx. 8 gm/ Nm3 in the coke oven gas generated from the batteries. Removal of ammonia from the coke oven gas is a technological necessity, as presence of ammonia in the gas leads to severe corrosion in gas pipelines and heavy sludging during benzol scrubbing process. At RSP, ammonia from coke oven




gas is removed in the Spray Saturators where acid is sprayed over coke oven gas to produce ammonium sulphate and sold as fertiliser in the brand name “RAJA KHAD”. The bulk requirement of sulphuric acid is in the Ammonium Sulphate Plant for the removal of ammonia from coke oven gas. It is also used for pickling of Hot Rolled Coils for producing Cold Rooled Coils/sheets and also used for water treatment in Power Plant. RSP’s existing Sulphuric Acid Plant of 60 tpd capacity was commissioned in November, 1967 to cater to the needs of CCD, CRM (Cold Rolling Mill) and CPP (Captive Power Plant).The condition of this plant has deteriorated considerably on account of ageing and corrosion requiring urgent replacement. The existing acid plant is also not suitable for operation due to its ageing, poor pollution control and safety conditions. RSP is not able to maintain the required production level of sulphuric acid for meeting the additional requirements of new Coke Oven Battery No.6 & new CCD complex commissioned under recent 4.2 Expansion project. In view of the deteriorating condition of various equipment of the existing acid plant and to meet the additional requirement of acid, a new Sulphuric acid plant of higher capacity (125 tpd) is installed adjacent to existing plant.

1.2.2 Other Alternatives considered:

The following alternatives have been considered before installing the new 125 TPD Sulphuric Acid Plant:

i) Purchasing entire requirement of Sulphuric acid from open market. Merits : Cost of Sulphuric Acid procured from market may be less compared to the production cost from captive sulphric acid plant. The total pollution from Sulphuric Acid can be completely avoided if the sulphuric acid is procured from market. Demerits : Dependence on outside supplier will at times jeopardize operation of the plant as it is unreliable. Availability of 125 tonnes of acid per day from the market on consistent basis may be a regular constraint. In the past RSP has faced problem in purchase and receipt of acid from outside suppliers by road tankers. Further, transportation of acid through tankers is also difficult as reliable Transporters with fleet of tankers are not available at Rourkela. The reliability of consistent supply of 125 tpd Sulphuric acid from outside source is also questionable.

ii) Installation of a new 125 tpd Sulphuric acid plant.

Merits : Continuous and reliable availability of Sulphuric Acid for uninterrupted operation of downstream units of steel plant.




Demerits : Pollution from Sulphuric Acid Plant.

Considering the above, RSP has decided to install a new 125 TPD Sulphuric Acid plant with state of the art pollution control technologies.

1.2.3 Location of the Project The new Sulphuric acid plant is located adjacent to the existing old Sulphuric Acid Plant, inside the existing plant boundary of RSP. RSP is located in Rourkela District – Sundergarh, Orissa North latitude 22o14' and East longitude 84o 52'. Nearest big town is Rourkela and nearest Airport is Ranchi, Jharkhand. Location map is shown in Fig. 1.1a, Fig 1.1b & Fig 1.1c.




Fig 1.1a : Location of site

Rourkela Steel Plant Located in Western Odisha District - Sundergad

Latitude - 20o 12’ N

Longitude - 84o 53’ E

Elevation - 219 mtr above MSL

Temperature - 8o

Minimum

- 48o Maximum

Rainfall - 135 – 220 cms/year

Rourkela




Fig 1.1b: Location of site




Fig 1.1c: Location of Sulpheric acid plant at project site




2.0 PROJECT DETAILS 2.1 GENERAL

Steel Authority of India Ltd. Rourkela Steel Plant (hereinafter referred to as RSP) is based on BF-BOF route for producing iron and steel with total hot metal production to 4.5 Mtpy and steel production capacity of 4.2 Mtpy. RSP has recently installed a new 125 TPD Sulphuric Acid Plant within the existing RSP plant premises.

2.2 PROJECT SITE AND LAND REQUIREMENT

At present RSP is having 6477.7 Ha (3460.7 Ha for Plant operation and 3017 Ha for township) of land under its possession. The new Acid Plant is installed adjacent to existing Acid Plant as shown in Fig 2.1. Total land area required for the new plant is 2.03 Ha.

Fig 2.1 Lay out of New acid plant




2.3 PROJECT DESCRIPTION

The bulk requirement of sulphuric acid in the Ammonium Sulphate Plant for the removal of ammonia from coke oven gas necessitate setting up of higher capacity of Sulpheric acid plant in place of existing sulphuric acid plant. It is also used for pickling of hot rolled coils for production of cold rolled coils/sheets in Cold Rolling Mills and also used for water treatment in Power Plant. State of the art Double conversion Double absorption Process has been adopted for manufacturing sulphuric acid for the present project.

2.3.1 Existing Plant Facilities Major Installed Units and their productions are given in Table 2.1.

Table 2.1- Major Installed Units Installed/proposed during modernization&expansion of the plant

Department Unit Production(MTPA)

EC accorded

Coke Ovens and Coal

Chemicals - 3 batteries, 5 m Tall, 70 ovens - 2 batteries, 5 m Tall, 80 ovens - 1 Battery, 7 m Tall, 67 ovens

2.17

Beneficiation Plant - With Slime dewatering filter press caking system

3.3

Pellet Plant - Travelling Grate Furnace 2.0 Sinter Plant - SP-1 - 2 X 125 m2 grate area

- SP- 2 - 1 X 192 m2 grate area - SP – 3 – 1 X 360 m2 grate area

6.76

Blast Furnace - 3 BFs of 1139 m3 volume - 1 BF of 1658 m3 volume - 1 BF of 4060 m3 Volume

4.5

SMS SMS – I - 2 X 60/66t BOF - 1 X 60/66t LF - 1 X Single strand Slab Caster SMS – II - 3 X 150t BOF - 3 X 150t LF - 1 X 150t RH-OB - 3 X Single Strand Slab Caster

4.2




- Desulphurization Unit Department Unit Production(MTPA) Rolling Mills - Hot Strip Mill

- 3100 mm Plate Mill - Cold rolling mill complex - ERW Pipe Plant - Spiral welded pipe - Silicon Steel Complex - Special Plate Plant

3.00 1.00 0.641 0.075 0.055 0.255 0.015

Lime Plant - 4 X 250 TPD Kilns- 1 X 350 TPD Kiln

0.4149

Dolo Plant - 1 X 350 TPD Kiln 0.13 Oxygen Plant - 1 X 300 TPD

- 1 X 550 TPD - 2 X 700 TPD - 1 X 1150 TPD on BOO Basis

3400 TPD

OBBP Matching Facilities EC granted on 15.12.2016

Beneficiation Plant 3.3

Pellet Plant 2.0 Hot Strip Mill 3.0

SPP expansion 3000 TPA to 15000 TPA.

2.3.2 Process Details sulpheric acid plant Double conversion Double absorption Process for manufacturing sulphuric acid, commonly known as DCDA process, has been adopted for the production of Sulphuric acid for the present project. Various steps involved in the process are described below step wise. The process flow diagram is shown in Fig 2.2.




Fig 2.2- Process flow Diagram of H2SO4 Plant Sulphur Melting The existing sulphur storage capacity is 1200 Tonnes. A covered sulphur shed of 7 days capacity (about 300 Tonnes) is provided for new acid plant as shown in Fig 2.1. Raw sulphur will be transported from existing godown to new 7 days storage shed by pay loader/tripper truck. Sulphur from this storage will be charged to a hopper placed above the sulphur melter tank. Sulphur will be fed from the hopper to the melter by a vibratory push feeder. The sulphur melter is a steel vessel with three SS steam coils dipped in it and will be provided with a slow moving agitator. Process steam (6-8 Kg/cm2) is passed through the steam coils which help in the melting of sulphur. The agitator acts as a clarifier where ash and other unwanted heavy substances settle at the bottom and molten sulphur overflows into a pre coat pit/dirty sulphur pit and subsequently to pure sulphur pit via filter. The molten sulphur from the storage pit is pumped to the sulphur burner, where it is oxidised.




Sulphur burner and hot gas filter Molten sulphur is sprayed through a nozzle from the top of sulphur burner, where it is oxidised with dry air. Sulphur burns in presence of air forming sulphur dioxide gas of about 9% concentration. The products of combustion (containing sulphur dioxide) are cooled in the Waste Heat Boiler and passed through hot gas filter (Cartridge Filter), where traces of impurities are removed. Converter The sulphur dioxide gas thus produced in the sulphur burner is converted into sulphur trioxide in a converter containing four beds of vanadium pentoxide catalyst. The conversion of sulphur dioxide to sulphur trioxide is an exothermic process:

2SO2 +O2 = 2SO3 At each catalytic bed such a reaction is occurring, thereby evolving heat, and so the gases leaving each catalyst bed are cooled before being fed into the next catalyst bed. The gases leaving the first catalyst bed are cooled in the waste heat boiler. Similarly gases coming out from the second and third catalyst bed are cooled in two different heat exchangers as the heat evolved in the second and third catalyst bed are much less as compared to that in the first catalyst bed. The gases leaving the third catalyst bed are first cooled in Economizers and then fed at the bottom of the intermediate absorption tower for absorption of sulphur trioxide. Sulphuric Acid, with strength of 98.5% sulphuric acid is fed from the top of the tower on a counter-current principle. The gases, which are free of sulphur trioxide from the intermediate absorption tower, are heated to the desired temperature before being fed to the fourth catalyst bed of the converter. The gases leaving the fourth catalyst bed are cooled in Cold Heat-Exchangers before entering the final absorption tower. In this it is possible to achieve conversion of sulphur dioxide to sulphur trioxide up to 99.8% (min). Absorption process The gases coming out of the fourth catalyst bed of the converter pass through Cold Heat-Exchangers before entering the final absorption tower. In the final absorption tower, Sulphuric acid of 98.5% strength is sprayed from the top and gases rise from the bottom. At this stage 99.8 % (min) of sulphur trioxide is absorbed and the rest of the gases pass through the chimney. Acid production The sulphuric acid will be cooled in acid coolers (Plate type heat exchanger) and is circulated in the Drying tower, Intermediate absorption tower and Final absorption tower. The product sulphuric acid is tapped from the outlet of the acid coolers and stored in the existing acid storage tanks.




Energy Aspect A modern sulphuric acid plant can also be treated as an energy positive plant since all reactions taking place are exothermic reactions. The efficient recovery of heat and its proper utilization is vital for economic return from plant. The surplus heat generated is equivalent to 1.1 tonne of saturated steam at 20-22 kg/cm2 per tonne of 100% Sulphuric acid produced and steam hooked to plant grid.

2.4 RAW MATERIAL REQUIREMENT The estimated major raw material requirement for the new acid plant as per material balance is given in Table 2.2.

Table 2.2 – Raw material requirement for the new acid units

1 Raw Material Sulphur 2 Sulphur Content 99.5 % 3 Moisture 0.5 % 4 Ash 0.2 % (Max) 5 Acidity as H2SO4 0.02-0.03 % (Max) 6 Organic Compound 0.2 % (Max) 7 Consumption 330 Kg/T of 100% H2SO4 8 Conversion Efficiency 99.8 % (Max)

2.5 POLLUTION CONTROL EQUIPMENTS 2.5.1 Air Pollution

The emission regulation of Central Pollution Control Board provides the following emission limits in air for sulphuric acid plants

Sulphur dioxide - 2 Kg/ tonne of 100% acid produced. Acid mist /Sulphur trioxide -70 mg/ Nm3

The emission from the proposed plant are being maintained well below the above limits. Scrubbing of start up gases During start up of the plant, when sulphur dioxide emissions are high, the stack gases will be passed through the tail gas scrubber. The gas is scrubbed with caustic soda in the scrubber before letting out into the atmosphere. This process shall bring down the sulphur dioxide content in the stack gases, during start up, within the permissible limits.




The mist eliminators help in reducing the acid mist content below the prescribed norms. The scrubbing units shall have on-line pH meters with auto recording facility. The height of the stack shall be as per CPCB norm.

2.5.2 Water pollution The accidental acid spillage or leakage from the plant and storage area shall be washed, collected in a neutralization pit and neutralized before using for floor washing, road washing and fire fighting purpoposes. pH meters with the provision of alarm system will be provided to combat any leakage of acid from acid coolers into cooling water. Limestone or soda ash may be used for neutralization. There will be no discharge from the plant.

2.6 UTILITIES CONSUMPTION

The indicative consumption of utilities is as follows: a) Power - 63 kW/t of product b) Make up Cooling Water - 2.0 m3/t of product c) Boiler feed water - 1.1 m3/t of product d) Process water - 0.2 m3/t of product e) Nitrogen (for instrument) - 30 m3/ hr




3.0 ANTICIPATED ENVIRONMENTAL IMPACTS

RSP is currently operating at 4.2 MTPA capacity and few more units are proposed to be added for value addition, for which the environmental clearance has been approved. Taking in account the Pollution, Safety & Techno-economics of the previously installed 60 TPD Sulphuric Acid plant, it was proposed to install a new 125 TPD Sulphuric acid plant and scraping the old 60 TPD Sulphuric acid plant. Accordingly it expected that there must be some changes in the pollution load. The new Sulphuric acid plant is likely to cause some positive impacts on the ambient environment. However, in order to quantify those impacts and to estimate the changed values of pollutant concentrations in future with respect to Air, Water and Land impacts, studies have been conducted. The details of the same are discussed in subsequent paragraphs.

3.1 IMPACTS DUE TO PROJECT LOCATION

The new Sulphuric acid plant is located adjacent to the previously installed 60 TPD plant in an area of about 2.03 Ha. of land which is available on the South western side of the plant. The location is within the plant area and the land is already in industrial use. No significant land excavation has been done to level the land.

3.2 IMPACTS DURING OPERATION PHASE During the operation phase of the new Sulphuric acid Plant, depending upon operating conditions, environmental releases may occur from raw material and product handling, processing, fuel burning, etc. Environmental releases may be in the form of

a) Air emission b) Waste water discharges c) Solid waste disposal d) Noise etc.

These emissions, discharges and disposal may release different primary & secondary pollutants, which may affect air, water, land and ecological environment directly. The post project scenario is given below.

3.2.1 Air Environment The main source of air emissions in a Sulphuric acid plant is the waste gases obtained after the final absorption process. The main composition of this waste gas is SO2. The waste gases are passed through a heat exchanger to capture any waste heat before being channeled out through the process stack. The production process is mostly




automated and takes place in closed containers, so chances of other sources of air pollution in minimum. A 30 m high stack with an internal top diameter of 0.7 m has been provided for proper dispersal of waste gases. The stack height is calculated as per the minimum stack height criteria defined by CPCB based on SO2 emissions. The stack has also been provided with continuous online monitoring system. In addition to the measures taken to control pollution, the design emission norms shall be limited to a maximum of 0.8 Kg/ton of sulphur against CPCB Norm of 2 Kg/ton. Also, as the catalytic conversion process is highly exothermic, after every catalytic conversion bed, the gas is passed through a heat exchanger to capture the heat and is reused in the sulphur melting process. Additionally, a tail gas scrubber has also been installed to clean the waste gases during startup of the plant. The gas is scrubbed with caustic soda in the scrubber before letting out into the atmosphere. The scrubber will be installed with mist eliminators and online pH meters with auto recording facility. A stack of suitable dimension has also been provided as per CPCB norms. There will not be any fugitive dust generation during handling of raw sulphur as the sulphur is stored and being loaded in a closed facility. The stack emissions from Old and New Sulphuric acid plants are given in Table 4.1 below.

Table 3.1- Stack details of old and new Sulphuric acid plants

Parameter Unit Old Plant New PlantStack Height m 30 30 Top Diameter m 0.6 0.7 Exit Temperature oC 55 100

SO2 levels Kg/hr 6.25 4.20 g/sec 1.74 1.17

Exit vel m/s 10 9.83

Flow Rate m3/hr 11208 13621 Nm3/hr 10183 10848

SO2 emission rate Kg/ton

2.50 0.80 CPCB Norm 4.0

(Old Norm) 2.0

(New Norm)




It can be seen that the pollution load due to the new Sulphuric acid plant of higher capacity is less than the old plant of less capacity. The effect of the decreased pollution load on the ambient environment is predicted and given in subsequent paragraphs. Impact of stack emission from Sulphuric Acid Plant on ambient air quality In order to assess the contribution of newly installed Sulphuric acid plant in the prevailing ambient air quality, actual stack monitoring data of old plant and installed stack details of new plant are used. However, the contribution of the old unit in ambient air is already being reflected in the back ground ambient air quality data. In the present study it is considered when new plant is operational; the existing plant will be phased out. Due to the introduction of new plant, there will be an increase in pollution load. At the same time, the contribution from the old plant is reduced from ambient air. The result of this is that an overall decrease in ambient air concentration is expected. In order to study the ground level concentrations from both plants and to predict the impact on the ambient air quality due to introduction of new unit, following methodology has been adopted. - The air pollution load emitted from the old Sulphuric acid plant is being reflected in

the air pollutants concentration in the ambient air quality as monitored during one full season around RSP.

- The design norms for stack emission data and stack details of the new Sulphuric acid plant are taken for estimation of GLCs for new plant.

- The monitored data of old plant is considered for estimation of contributions on ambient air quality.

- GLC values at various monitoring stations are estimated considering the new plant and phasing of old plant. The calculation of increased/decreased of pollutant concentration in ambient air quality at individual station.

The prediction of Ground level concentrations (GLC) of pollutants emitted from the above stacks have been carried out using AERMOD Air Quality Simulation model released by USEPA. The impact has been predicted over a 10 km X 10 km area with the proposed location of the stack as the centre. GLC have been calculated at every 500 m grid point. Meteorological data plays an important role in computation of Ground Level Concentration using AERMOD model. Meteorological data of the project site is required for computation of the contribution by the proposed project. The actual monitored site meteorological data for one full season of post-monsoon has been considered. The




meteorological data was generated near the plant site for three months period on hourly basis. As indicated in the earlier section considering the emissions from the stacks of the new and old plant (Table 3.1) using AERMOD, GLCs are predicted. The maximum GLCs for each grid point were predicted with respect to SO2. The maximum GLCs derived are 6.2 and 3.1 µg/m3 for Old and New plants respectively due to stack emissions. The maximum values are obtained within/very close to the plant. The final GLC values are given in Table 3.2. The Isopleths of SO2 for the new and old plant are presented in Fig 3.1.




Fig 3.1 (a) – Isopleths of SO2 concentration for Old Plant




Fig 3.1(b) – Isopleths of SO2 concentration for New Plant







Table 3.2 – Final GLC values at various AAQ Stations (µg/m3)

Station ID

Description of location

Old 60 TPD Plant

New 125 TPD Plant

Change in conc.

A1 Fertilizer Town ship 0.055 0.036 -0.019

A2 Jalda “C” Block 0.034 0.022 -0.012 A3 Latikatha 0.013 0.009 -0.005 A4 Tarakera pump

house 0.705 0.374 -0.331 A5 Udit Nagar High

School 0.175 0.112 -0.063 A6 Tangarpalli 0.072 0.047 -0.024 A7 Kendriya

Vidyalaya, Bondamunda 0.027 0.018 -0.010

A8 Sector 4, RSP Township 0.447 0.245 -0.202

Max 6.2 3.1 -3.1 The day on which the maximum values have occurred and meteorological data of that particular day has been given in Table 3.3. In order to obtain the cumulative impact in future, predicted GLCs due to new proposed units of RSP (viz Beneficiation Plant, Pellet Plant, HSM & SPP) are added to the back ground air quality and the resultant contribution of new H2SO4 plant when it is operational. The final GLC values at each monitoring station are given in Table 3.4.




Table 3.3- Meteorological inputs

Year Month Day Hour

Sensible Heat Flux

Wind Speed

Wind Direction Temperature Relative

Humidity Surface Pressure

W/m^2 m/s degrees K % mb2014 11 8 1 -0.2 0.5 206 292.4 94 994 2014 11 8 2 -0.2 0.5 209 291.2 94 994 2014 11 8 3 -0.2 0.5 197 291.5 94 994 2014 11 8 4 -0.2 0.5 208 291.2 94 994 2014 11 8 5 -0.2 0.5 199 291.1 94 995 2014 11 8 6 -1.2 0.5 272 291.5 94 996 2014 11 8 7 15.7 1 127 291.6 94 997 2014 11 8 8 85.1 1 113 292.4 94 996 2014 11 8 9 143.2 1 108 295.1 84 996 2014 11 8 10 184.4 1.5 104 298.4 61 995 2014 11 8 11 206.8 1.5 97 301.2 53 994 2014 11 8 12 286.4 1.5 68 302.2 49 992 2014 11 8 13 264.2 1.5 69 304.2 43 992 2014 11 8 14 214.2 1.5 37 304.1 39 991 2014 11 8 15 140.1 1.5 83 304.1 38 991 2014 11 8 16 47.4 1 78 304.4 39 991 2014 11 8 17 -0.9 1 268 301.6 59 992 2014 11 8 18 -0.9 1 212 297.4 76 993 2014 11 8 19 -1.2 0.5 272 295.1 80 994 2014 11 8 20 -1.2 0.5 272 294.4 84 994 2014 11 8 21 -0.2 0.5 205 294.4 88 995 2014 11 8 22 -1.2 0.5 275 293.4 90 995 2014 11 8 23 -0.2 0.5 213 293.6 92 995 2014 11 8 24 -0.2 0.5 199 293.4 94 994




Table 3.4 Predicted ground level concentration at various receptor points

Location Code

PM10

Background monitored value including contribution of Old

H2SO4 plant

From proposed HSM,Beneficiation plant, Pellet Plant & SPP Exp. of RSP after phasing out of existing HSM

Total

A1 78.27 0.17 78.38 A2 67.04 0.13 67.13 A3 69.09 0.08 69.15 A4 75.55 0.30 75.74 A5 75.71 0.39 75.99 A6 70.62 0.22 70.76 A7 78.53 0.40 78.88 A8 60.32 0.40 60.55

NAAQS Standard 100

Location Code

SO2

Background monitored value including

contribution of Old H2SO4plant

Resultant concentration due to installation of new H2SO4 Plant

and phasing of old H2SO4 Plant

From proposed HSM,Beneficiation plant, Pellet Plant

& SPP Exp. of RSP after phasing

out of existing HSM

Total

A1 7.41 -0.019 0.37 7.76 A2 8.17 -0.012 0.24 8.40A3 6.08 -0.005 0.12 6.20 A4 8.97 -0.331 0.52 9.16 A5 8.77 -0.063 0.55 9.26 A6 7.69 -0.024 0.40 8.07A7 7.18 -0.010 0.47 7.64 A8 6.66 -0.202 0.43 6.89 NAAQS Standard 80

Location Code

NOX

Background monitored value including contribution of Old

H2SO4 plant

From proposed HSM,Beneficiation plant, Pellet Plant & SPP Exp. of RSP after phasing out of existing hsm

Total

A1 19.74 0.58 20.28 A2 20.92 0.32 21.21 A3 15.66 0.12 15.77 A4 24.64 0.84 25.40 A5 23.31 0.63 23.85 A6 21.70 0.55 22.19 A7 21.26 0.25 21.48 A8 17.33 0.49 17.70

NAAQS Standard 80 *Concentrations are in µg/m3 and of 24 hours averaging time




The above tables reveal that, after installation of the new Sulphuric acid plant and phasing out the old one, there is an overall decrease in Ground Level Concentration of SO2 values. Air Pollution Mitigation Measures during operation phase In order to mitigate various impacts of air pollution, following measures are being implemented in the new Sulphuric acid plant- A 30 m high stack of 0.7 m dia has been provided for proper dispersal of pollutants. In order to reduce SO2, SO3 and acid mist in tail gas, two absorption towers have

been installed with efficiency of 99.9 %. The waste heat from the process shall be utilized for Sulphur melting. A tail gas scrubber has been provided for cleaning gas having high SO2

concentration during startup stage. SO2 emissions shall be limited to 0.8 Kg/ton and Acid mist shall be limited to 70

mg/Nm3. Closed facility for storing and handling raw sulphur.

3.2.2 Water Environment The present water requirement for the plant is around 9473 m3/h. A part of this is being used as make-up water requirements for the new acid plant making up to 17 m3/h max. against the old plant’s requirement of 30 m3/hour. Thus no impact on existing water resources is envisaged. The new sulphuric acid plant of RSP does not envisage any ground water drawal. Hence no impact on ground water availability around the RSP is anticipated. In Sulphuric Acid Plants the wastewater is produced in the form of high TDS, highly acidic water coming out through spillage of leakages of acid in the system. The plant involves exothermic reactions so the heat generated is utilized for producing steam. Water used for high-pressure boilers is de-mineralized. The plant set up for producing DM water involves ion exchange and so the wastewater is generated in regeneration through injection and rinsing process. The water is acidic or alkaline with high TDS. The alkaline water is used for scrubbing and the balance quantity is led to the effluent pit for neutralization. The Blow-down water is used for making brine solutions or making other chemical solutions as per requirement. Cooling tower blow-down water is of TDS around 2000 mg/lit, which is used for domestic service by some plants. Any acidic washings resulting from spillage or leakage are treated with alkaline solution before use for road washing/floor washing and fire fighting.




The waste water/effluents generation from the new acid plant is less than 2 m3/hr. All the acid spillages and leakages are collected in the neutralization pit. Using soda ash, the effluent is first neutralized and it is checked that all the parameters are within the effluent discharge norms for water. The treated effluents are then used for road washing/floor washing and fire fighting. There will be no discharge of waste water from from new Sulphuric Acid Plant. Therefore, there is no overall impact on water environment.

3.2.3 Noise Environment In Sulphuric Acid plant, the main noise producing equipment is air blowers, steam turbines and some pumps. This equipment is placed in closed rooms to reduce the noise level. Therefore, no increase on noise pollution is observed.

3.2.4 Solid Waste The solid wastes generated in Sulphuric Acid plant are as follows- Sulphur Muck Sulphur raw material is generally 99.8-99.9% pure and it contains impurities in the form of hydrocarbons, ash etc. which need to be separated before sulphur is burnt. These impurities are separated either by filtration process or by settling process. The sulphur sludge containing these impurities is removed mechanically or manually. Depending on the purity of sulphur, sulphur sludge is generated in the range of 650 TPA of sulphur used. Catalyst Waste Activity of catalyst in the converter comes-down with time. Hence, it needs to be replaced periodically. Also during the operation some of the catalyst gets converted into dust. During shutdown, while sieving catalyst, the dust is removed. The catalyst waste contains Vanadium Pentaoxide, which is poisonous in nature. About 5% of the catalyst needs replacement every year. Catalyst waste generated from Sulphuric Acid Plant is around 1250 litre/year of Sulphuric Acid, produced. All these wastes are neutralized and then stored in the Secured Land Fill facility of RSP.




3.2.5 Waste Heat Recovery All steps in the production of Sulphuric Acid from elemental Sulphur are exothermic. The liberated heat is dissipated under controlled conditions in such a way so as to maintain optimum gas temperatures in the convertor system, drying and acid absorbing systems, thereby, minimising SO2 at the stack outlet. The waste heat system is completely integrated in DCDA plants. In economisers that cool the gases from third & fourth bed of converter, heat is utilised for preheating feed water for WHB System. Heat generated in Sulphur furnace heats up the feed water and steam is generated at about 250o C temperature. This steam is superheated to about 400o C for cooling the first stage out converter gases. This superheated steam can be used for generating power and saturated steam for process heating.




4.0 CLEAN TECHNOLOGIES & POLLUTION CONTROL MEASURES ADOPTED DURING MODERNIZATION & EXPANSION OF PLANT

RSP has expanded their Crude Steel capacity to about 4.2 MT/y by the year 2015. This has been achieved by addition of following broad facilities and modernisation of existing plant facilities of production capacity 1.9 MTPA. The modernisation and expansion incorporates the latest energy efficient and environment friendly technologies such as seven meter tall coke oven battery with coke dry quenching, high capacity blast furnace (4060 cu. m.), wide slab caster and plate mill. Some key units have come up under the Expansion programme are Rebuilding of existing Coke Oven Batteries # 1,3 & 4 along with introduction of

New Coke Oven battery of 67 ovens, 7 m tall Additional New BF-5 of capacity 4060 m3 and phasing out existing BFs of No. 1& 2 New sinter machine (SP-3) of 1 x 360 m2 1X 150t converter and 2X 150t ladle furnace and new third slab caster in SMS-II Additional Plate mill of capacity 1.0 MT, up gradation of existing HSM to around 1.8

Mt/yr Other associated auxiliary facilities shall also be put up to optimise water and energy

consumption.

Environmental clearance accorded to RSP’s Expansion Project by MoEFCC (F.No. J-11011/757/2007-1A II(I), 29th January 2008. RSP incorporated all compliance conditions related to design of equipment while preparation of technical specifications and detailed engineering stage. Some of the latest clean technologies implemented are 1. Coke oven –

• Coke dry quenching • Waste heat recovery boiler with Back Pressure Turbo Generator (6.4 MW) • Coke oven gas desulphurization, • Land based pushing emission control system • Computerized combustion control

2. In Blast furnace – • Large capacity blast furnace with state-of-the art controls • Equipped with top recovery turbine (14 MW)




• Coal dust injection • Cast house and stock house dust emission control systems. • In house slag granulation in blast furnace No.5 • Power Generation (2x18MW) using Blast Furnace gas

3. 150 t BOF converters with gas recovery system and with secondary

emission control.

4. The various pollution control measuers adopted in different departments are given below;

Department Unit Pollution control measures

Exisitng units for which EC accordedCoke Ovens and Coal Chemicals

- 3 batteries, 5 m Tall, 70 ovens

- 2 batteries, 5 m Tall, 80 ovens

- 1 Battery, 7 m Tall, 67 ovens

- High pressure amonical liquor aspiration (HPALA) system for smokeless charging.

- Zero leakage door & door frames. - High pressure hydro-jet door cleaners of

600 bar min on pusher side and coke side of the battery.

- Spillage coke conveyor system on pusher side platform.

- Extension of chimney height by 5meters and its repair for the existing coke ovens, and provisions for sampling/ monitoring for stack emission.

- Hydro-jet door cleaning mechanisms in Batteries

- Door extractors with mechanical door & door-frame cleaning in Batteries

- Suitable leveler muff to stop ingress of air during leveling operation

- Water sealed AP caps for batteries - Bottom Flooded design with modern

quenching system to achieve less than 4 % coke moisture.

- Land based coke side dust extraction in new coke oven

- H2S recovery in new coke oven - Dust suppression system for wagon

tippler, track hopper, junction houses and at crushing station in new coal handling plant.

- Wide Conveyor belts and suitable troughing angle to prevent coke spillage

Sinter Plant - SP-1 - 2 X 125 m2 grate area - SP- 2 - 1 X 192 m2 grate

area - SP – 3 – 1 X 360 m2 grate

area

ESPs installed for pollution control. Dry fog dust suppression system at all transfer points

Blast Furnace - 2 BFs of 1139 m3 volume - Water spray in skip pits




Department Unit Pollution control measures Exisitng units for which EC accorded

- 1 BF of 1658 m3 volume- 1 BF of 4060 m3 Volume

- DE systems with ESP for sinter screen

area - Installation of carbon monoxide

detectors. - Coal dust Injection (CDI)- in BF

plants(4 &5) - ESP for Stock House de fuming. - 2 no. of ESPs for Cast House in new

BF(5)

SMS SMS – I - 2 X 60/66t BOF - 1 X 60/66t LF - 1 X Single strand Slab Caster SMS – II - 3 X 150t BOF - 3 X 150t LF - 1 X 150t RH-OB - 3 X Single Strand Slab Caster - Desulphurization Unit

Wet scrubbers. Dust extraction systems for conveyor belts at +33 mtr. Platform in SMS 1 LD gas recovery system in SMS#2 DE system with Bag Houses for work zone dust control. Dog House & Secondary emission control system in SMS II

Rolling Mills - 1700 mm Semi-continuous Hot Strip Mill

- 3100 mm Plate Mill - Cold rolling mill complex - ERW Pipe Plant - Spiral welded pipe - Silicon Steel Complex

Fume extraction systems for pickling lines. Pickling fumes exhaust system with alkali scrubbing for neutralization

Lime Plant - 4 X 250 TPD Kilns - 1 X 350 TPD Kiln

DE system for raw materials handling, conveyors, space de dusting for limestone kilns. Dolo Plant - 1 X 350 TPD Kiln

Oxygen Plant - 1 X 300 TPD- 1 X 550 TPD - 2 X 700 TPD - 1 X 1150 TPD on BOO Basis

Accousting chambers for noise control.

OBBP Matching Facilities Water sprays at tipplers. Bag houses, Water Spray systems and Dry fog dust suppression systems for various belt transfer points

Power Plant

ESP based air pollution control system

New proposals – Ammendment of EC recommended Beneficiation Plant 3.3MTPA Material transfer points will be

provided with Dust suppression systems, Dry fog dust suppression systems, Dust Extraction systems like

Pellet Plant 2.0 MTPA




Department Unit Pollution control measures Exisitng units for which EC accorded

ESP & BGs. The indurating furnace gas will be made to pass through electrostatic precipitator (ESP) before being released to the atmosphere. The dust from the ESP hoppers will be transported to a dust storage silo through a centralized Dense Phase Pneumatic conveying system. Dust from the silo will be unloaded to dumper through a telescopic chute to avoid any fugitive emission.

Hot Strip Mill 3.0 MTPA In order to reduce CO & SO2 emission, purified mixed gas is proposed as fuel for the Reheating Furnace of HSM. Low NOx burners shall be used to reduce formation of Thermal NOx Use of computer combustion control models, to optimise furnace firing based on cast material temperature, mill status, off gas analysis, excess air level, etc A stack of suitable height for proper dispersion of flue gases is proposed

SPP expansion 3000 TPA to 15000 TPA. stacks of suitable height for proper dispersion of flue gases is proposed

4.1 Water pollution control

During the modernization, RSP had upgraded/revamped/adopted the systems such that discharge quantity will be reduced by means of recirculation and quality of the discharged water will further improved. However, the water requirements of the newly proposed Hot Strip Mill, Beneficiation Plant, Pellet Plant & Expansion of Special Plant , HSM, will be met by recycling the treated waste water presently discharged from RSP. No fresh water will be drawn. Following pollution control equipment/systems will minimize the water pollution. :




LIST OF WATER POLLUTION CONTROL SYSTEMS

Sl. No.

Location Pollution control systems

1 Coke oven complex Effluent treatment plant with units for neutralisation and for removal of suspended particles

2 SP Settling tanks (primary & secondary) 3 Blast Furnaces Effluent treatment plant for GCPs 4 HRM Scale pit, settling tanks & oil removal system, Effluent

treatment plant 5 Plate Mill Scale pit, settling tanks & oil removal system 6 Cold Rolling Mills Acid regeneration plant along with effluent treatment plant7 Silicon steel Acid regeneration plant along with effluent treatment plant8 Township Oxidation ponds

4.2 Solid wastes

The existing plant generate a number of Solid wastes which containing both Hazardous and non-Hazardous category. Major shops which generate solid wastes are BF, SMS, Coal and coke oven shops and Rolling mills. RSP is recycling most of the wastes generated in the plant.

Fig 4.1 - Solid Waste Utilization

050

100150

Percentage

% Utilization of Solid Wastes (2014‐15)




4.3 Hazardous waste Hazardous Wastes generated from RSP, it’s re-cycling and disposal practices are given in the Table 5.1 below:

Table 4.1 - Hazardous waste generation & management

Sl. No.

Schedule Waste Description Quantity (T/A)

Disposal

1. I Tar Residue from gas Trap & scale

01 Secured land fill

2. I Used oil 99 Storage in impervious pits / containers under covered shed followed by sale to registered recycler / re-processor

3. I Oil sludge waste containing oil

514.4 Storage in an impervious pit under covered shed followed by disposal in final disposal in HW incinerator / Secured Land Fill

4. I Zinc Dross 1054 Storage in impervious pits / containers under covered shed followed by sale to registered recycler / re-processor

5. I Pickling Tank / Bath sludge

55 Secured Land Fill

6. I Tine Plating Line Sludge

1 Secured Land Fill

7. I Acid tar 3 Secured Land Fill 8. I Decanter Tar Sluge 60 Recycle in the coke oven /

secured land fill 9. I Catch pit sludge /

Tarry waste 60 Recycle in the coke oven /

secured land fill 10. I Acid storage tank

sludge 1 Secured Land Fill

11. I V2O5 Catalyst 2 Storage in impervious pits / containers under covered shed followed by sale to registered recycler / re-processor / Secured Land fill

12. I Cleaning solvent sludge

0.5 Secured Land Fill

13. I DM Plant neutralization sludge

5 Secured Land Fill

14. I Chemical sludge from waste water

136.2 Secured Land Fill




Sl. No.

Schedule Waste Description Quantity (T/A)

Disposal

treatment 15. II Sulphur Muck 300 Secured Land Fill 16. II Damaged refractory

lining and residue from furnace

22 Secured Land Fill

17. II Tin Ash 0.1 Storage in impervious pits / containers under covered shed followed by sale to registered recycler / re-processor / Secured Land fill

18. II Dichromate sludge 0.5 Secured Land Fill 19. II Non ferrous waste 0.5 Secured Land Fill 20. II Bag filter dust 0.5 Secured Land Fill 21. II Rejected sand 15 Secured Land Fill 22. II Sand blasting bag

filter dust 1 Secured Land Fill

23. II Grinding waste 0.355 Secured Land Fill 24. II Waste Asbestos 1.0 Secured Land Fill 25. I Flue gas cleaning

residue - Recycle in sinter plant




5.0 CONCLUSION

The assessment of environmental impact of installation of new Sulphuric acid plant and phasing out the old unit shows that- Reduction of air emissions in respect of SO2. No impact on water consumption. No impact on Land environment. Marginal improvement in air quality in the surrounding areas No additional requirement of land, water for the project. By Installing new Sulphuric Acid plant and implementation of new pollution control equipment, there will not be any additional pollution load on the ambient environment.

Annexures

Annexure 1

Annexure 1 Page 1 of 6






ANNEXURE 2









Appeal to SPCB asking Clarification whether CTE is required or not ? (15/09/2011)


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Annexure 3

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3.1

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Clarification about requirement of CTE from MS, SPCB dtd 02/02/2012


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3.2

RSP’s Application for getting CTE from SPCB dated 24/03/2012


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3.3

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SPCB’s letter asking clarifications/data from RSP dtd. 16/04/2012


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3.4


Rourkela Steel Plant Rourkela – 769011

Fax : 0661-2510183

Ref.No. : 691/EE/4/ __ Date : 18/06//2012.

Dear Sir,

Sub : NOC for Sulphuric Acid Plant of Rourkela Steel Plant – Clarifications. Ref : 1) Letter of the Env. Engineer vide ref.no. 7431, dated 16/04/2012. 2) Our earlier application for NOC vide ref.no. 691/EE/4/ , dated 24/03/2012.

# # #

This has reference to the letter of Environment Engineer, SPCB dated 16/04/2012, asking

information/ documents against our application for getting NOC for Sulphuric Acid Plant in Rourkela Steel

Plant. The point wise reply is given below for your kind ready reference;

SN. SPCB’s Point RSP’s reply

1.

You have to clarify if it is an expansion proposal of sulphuric acid plant, is from existing 60 T to 125 T.

Proposal is for new Sulphuric acid plant of capacity 125 TPC at location adjacent to existing Sulphuric acid plant of capacity 60 TPD. After commissioning of new acid plant of capacity 125 TPD, the existing Sulphuric acid plant’s operation will be stopped and will be dismantled and disposed off.

2.

Plant layout map superimposed on revenue map of the area showing all plant facilities, ETP/STP, water reservoir, green belt, hazardous waste/solid waste disposal facility.

Enclosed.

3. Detailed Project Report The hard copy of the detailed project report is enclosed.

4.

Water consumption for various purpose for proposed sulphuric acid plant.

a) Make up water consumption @ 2.9 m3/hr (max) to take care the evaporation and drift losses in cooling tower.

b) Soft Water consumption @ 8.5 m3/hr (max) – for steam generation and acid production.

5. Details of mist eliminator.

Mist eliminators will be suitably provided in acid towers so as to contain acid mist up to 25 mg/NM3 in final stack. The details are; a) Drying tower Mist Eliminator : Pad Type MOC : SS-316 (with

Hostoflon) b) Inter pass Absorption Tower : Vertical Candle Type, MOC- SS

316L (with fiberglass) c) Final Absorption Tower : Vertical Candle Type, MOC-SS 316L

(with fiberglass)

Environmental Engg. Department, 1st Floor of OHSC Building, Rourkela Steel Plant, Rourkela

Phone : 0661-2510395 Fax : 0661-2510183 Regd. Office : Ispat Bhawan, Lodi Road, New Delhi – 110 003.

RSP’s clarifications to SPCB’s queries 18-06-2012


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3.5

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6. Details regarding volume of gas and SO2 concentration.

• Basis : 125 TPD of 100% Sulphuric Acid Production, conversion @ 99.88% and absorption @ 99.99%

• Stack gas : a) Volume : 11457 NM3/Hr. b) Analysis : N2 - 9990 Nm3/hr.

O2 - 1465 Nm3/hr SO2 - 1.4 Nm3/hr. (equivalent to 12 ppm) SO3 +Mist - 0.1 Nm3/hr. (equivalent to 1 ppm or 25 mg/Nm3 of stack gas.

• Technology will guarantee for achieving emission norms for Sulphuric Acid Plant supplied by them.

o SO2 emission/Ton of acid produced – 0.8 kg/T (max) o SO3+ Mist : 25 mg/NM3 of stack gas.

7. Proposed Air Pollution Control Measures

Technology supplier will guarantee for achieving emission norms for Sulphuric Acid Plant supplied by them :

o SO2 emission/Ton of acid produced – 0.8 kg/T (max) o SO3+ Mist : 25 mg/NM3 of stack gas.

These norms are well below the limits set by SPCB. It will be achieved through application of efficient technology for Sulphuric Acid Production. The key highlights will be;

• Improved conversion (more than 99.88%) in five stage converter and use of good quality catalyst. Converter loading will be as per recommendation of Catalyst supplier and they will guarantee for conversion efficiency.

• Improved absorption (% absorption : 99.99%) through well designed acid towers with right selection of tower packing and acid distribution systems. Towers will be fitted with mist eliminators to contain acid mist (detailed in Point 5)

• New Sulphuric Acid Plant will be provided with automation and control system to maintain optimum process parameters for improved conversion and absorption efficiencies.

• The height of the stack emitting Sulphur di Oxide or acid mist shall be of minimum 30 mtr or as per the formula H= 14(Q)

0.3

(which ever is more). Where H is the height of stack in meters, and Q is the maximum quantity of SO2 expected to be emitted through the stack at 110% of the rated capacity of the plant and calculated as per the norms of gaseous emission.

• Online analyzer for SO2 analysis will be provided in stack with continuous monitoring in the control room.

• Alkali scrubber will be provided for scrubbing of stack gas at times during startups when concentration of SO2 remains high due to less conversion. Gases will be scrubbed with caustic solution so as to maintain SO2/SO3 emissions well within norms.

• Automatic Acid concentration controller will ensure right concentration of acid to be used for absorption of SO3. Conductive cell technology will be used in the control loop, which is a proven and much used technology.



8.

Quantity of effluent generation and adequacy of the existing ETP to treat waste water.

In normal operation of the plant, only source of effluent will be blow down of boiler once in a shift. Occasionally, effluent will be generated during washing of leaky acid line packing/flanges. New Sulphuric Acid Plant will be provided with suitable neutralization pit in which acid spillage or leakage from plant will be washed and collected. Effluent in neutralization pit will be neutralized with the application of caustic flakes/lime stone before draining in the sewerage system. In all practical purposes effluent generation is nil, except for the boiler blow down quantity, which will be less than 2 m3 per day. Existing Effluent Treatment Plant (BOD Unit) with a capacity of 150 cub. mtr/hr. will cater to the requirement of new Sulphuric Acid Plant which is at present handling total influent load@ 80 cub. mtr./hr.

9. Quantity of hazardous waste generated and disposal facility.

Hazardous wastes generated from new Sulphuric Acid Plant will be disposed in the newly built Secured Land Fill facility inside RSP. The quantities of hazardous waste material will be as follows;

• Sulphur Muck : 650 T/Year

• Vanadium Pentoxide Catalyst : 1250 lit/year.

You are requested kindly consider our application for NOC and accord clearance so that we can

go ahead with the project.

With warm regards,

Yours faithfully, For Rourkela Steel Plant,

(S N Xess) Asst. General Manager (Env.Engg)

Encl : As mentioned above To : The Environment Engineer, State Pollution Control Board, Orissa, Bhubaneswar. Copy To : 1) The Member Secretary,

State Pollution Control Board, Orissa. Bhubaneswar.

2) The Regional Officer, SPCB, Sector#5, Rourkela.


05/12/2014


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3.6 Consent to Establish obtained from OSPCB



RSP’s letter requesting CTO dated 23/11/2015


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3.7

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3.8 RSP's application for getting "Consent to Operate"


Annexure-4 : Letter from MoEFCC asking to submit online


Ministry of Environment, Forest and Climate Change (Impact Assessment Division)

...........

SUMMARY RECORD OF THE TENTH (10th) MEETING OF EXPERT APPRAISAL COMMITTEE HELD ON 29th – 31st August, 2016 FOR ENVIRONMENTAL APPRAISAL OF INDUSTRY-I SECTOR PROJECTS CONSTITUTED UNDER EIA NOTIFICATION, 2006.

The tenth meeting of the Expert Appraisal Committee (EAC) for Industry-I Sector in terms of the provisions of the EIA Notification, 2006 for Environmental Appraisal of Industry-I Sector Projects was held on 29th – 31st August, 2016 in the Ministry of Environment, Forest and Climate Change. Shri Ashok Upadhyay, Member of EAC has expressed his inability to attend the meeting due to tour abroad. Shri Santosh Raghunath Gondhalekar, Member of EAC has also requested for leave on 29.08.2016. The list of participants is annexed.

The Chairman after welcoming the Committee Members informed that the matter regarding nomination of vice-Chairperson for conducting the business in the absence of Chairperson is pending for a long time. The Chairman asked the Member Secretary to provide the procedure for the same. The Member Secretary informed that Appendix VI of EIA Notification, 2006 reads as under:

“5. The Chairperson shall nominate one of the Members as the Vice Chairperson who shall preside over the EAC in the absence of the Chairman /Chairperson.”

In the light of the above clause, the Chairman floated the name of Dr. Jagdish Kishwan for the position of Vice-Chairman, which was supported by all the members present during the meeting. Thereafter, the Chairperson nominated Dr. Jagdish Kishwan as the Vice Chairperson of the Expert Appraisal Committee (Industry I) in accordance with Clause VI of EIA Notification, 2006. Subsequently, the discussions on each of the agenda items were taken up ad-seriatim.

Confirmation of the minutes of the 9th Meeting

The minutes of the 9th meeting as circulated were confirmed subject to following modifications:

Item No. 9.5.3

Annexure 4


11

10.5 ANY OTHER ITEM

10.5.1 Environmental Clearance for setting up a Sulphuric Acid plant of 125 TPD capacity, M/s Steel Authority of India Ltd. [F. No. J-11011/757/2007-IA II (I).

The proposal was considered by the Expert Appraisal Committee and the project proponent and their EIA and EMP consultant gave a detailed presentation on the salient features of the project. The Proposal is for setting up of a new sulphuric acid plant of 125 TPD capacity. Rourkela Steel Plant (RSP) of M/s SAIL obtained EC for expansion cum modernization (1.9 MTPA to 4.2 MTPA production of crude steel) and hot metal production of 4.5 MTPA on 29.01.2008. The EC is valid till 28.01.2018.

It was envisaged to procure sulphuric acid from market at the time of RSP’s 4.2 MT expansion in 2007-08. So new sulphuric acid plant was not considered during expansion. However, reliable and consistent supply of sulphuric acid from open market was not available; therefore, to meet the requirement of steel plant, a new 125 TPD sulphuric acid plant in place of existing old 60 TPD plant was conceived in 2012.

S. No Sulphuric Acid Plant is required for the following Quantity 1 Recovery of Ammonia from Coke Oven gas and making

Ammonium Sulphate 65.5 T/day

2 Acid Pickling in Cold Rolling Mills 25.0 T/day 3 Water Treatment units 2.0 T/day

Total Acid required 92.5 T/day Capacity of Plant considering 330 working days 116.0 T/ day

and 90% efficiency

The Committee after ascertaining the facts from the project proponent as also the stipulation laid down in the EC letter dated 29.01.2008 opined that the PP has already established the plant; therefore, it is a case of violation. However, the Committee suggested that the PP should produce the data in support of their claim that there will not be any increase in the pollution load and also submit the details of the clean technology to be adopted for reducing the overall pollution load from the steel plant. The proponent should also produce a letter


12

approaching SPCB in 2012 and their advice for consideration. The Committee may take a view in the matter on submission of the above information.



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Annexure 5 MoEFCC - RO's Certified Compliance Report

RSP

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Annexure 6

EXISTING ENVIRONMENTAL STATUS

Site monitoring for “EIA/ EMP Studies for HSM, Beneficiation Plant, Pellet Plant & Expansion of SPP of RSP” was carried out for three months (15th September 2014 – 15th December 2014) covering post-monsoon season to study the environmental attributes. The environmental status has been presented below based on the above study.

1.0 Wind pattern

In the study area winds are predominantly coming from South-Southwest (SSW) sector. During daytime, East is the predominant wind direction (prevailing for about 12.06% of the time) followed by SSW (11.15%) and ESE (7.35%). Calm conditions prevailed for 21.782 % of the time. During night, the predominant wind direction is SSW (28.804%), followed by W (7.428%) and S (5.072%). Calm condition prevailed for 45.56% of the time. Overall (24 hours), the predominant wind direction is also SSW (19.44%), followed by E (7.738%) and S (6.05%). Calm conditions prevailed for 33.928% of the time. During the entire monitoring period the predominant wind speeds were in the range of 0.44 - 2 m/s.

WIND ROSE OVERALL

2.0 Ambient Air quality

The existing ambient air quality, in terms of Particulate Matter (PM10 and PM2.5), Sulphur-dioxide (SO2) & Oxides of Nitrogen (NOx). The monitoring locations are shown in enclosed Exhibt .

1


Ambient Air Quality (AAQ) Monitoring Stations

Sl. No.

Station Code Description

Direction & Distance from the centre of the plant

(km)

Latitude Long

1 A1 Fertilizer Town ship S(2) 22°11'25.02"N 84°51'49.21"E 2 A2 Jalda “C” Block SW(5) 22°10'37.92"N 84°51'9.96"E 3 A3 Latikatha S(10) 22° 7'59.52"N 84°52'42.00"E 4 A4 Tarakera pump house W(3) 22°12'23.57"N 84°49'39.70"E 5 A5 Udit Nagar High School N(1.5) 22°13'24.22"N 84°50'22.87"E6 A6 Tangarpalli SE(2.5) 22°11'54.38"N 84°52'52.63"E7 A7 Kendriya Vidyalaya,

Bondamunda E(6) 22°13'39.96"N 84°54'53.28"E

8 A8 Sector 4, RSP Township N(4) 22°14'43.55"N 84°52'34.67"E

Ambient Air Quality The summarized results of ambient air quality monitoring are given below

Summarized Ambient Air Quality monitoring results Pollutants

Result (µg/m3)A1 A2 A3 A4 A5 A6 A7 A8

PM10 Max 98 89 90 90 97 89 97 88 Min 50 39 41 32 53 40 42 35

Mean 78 67 69 76 76 71 79 62

PM2.5 Max 52 52 48 53 54 49 52 40 Min 37 28 26 16 33 28 26 24

Mean 43 40 35 46 44 36 41 33

SO2 Max 11 13 9 16 16 11 10 11 Min 4 4 <4 5 5 4 <4 5

Mean 7 8 6 9 9 8 7 7

NOX Max 26 33 25 32 49 31 28 28Min 13 11 <10 13 13 11 10 11

Mean 20 21 16 25 23 22 21 17 It is observed that PM2.5, SO2 and NOx values are within the norms. In case of PM10 average values are also within the limits. However, the maximum value at A1, A5 & A7 are slightly higher but still within the norm. This may be due to the localized influence. RSP has installed four no. of continous ambient monitoring stations in and around the plant to monitor variations in the ambient quality in the sourrounding areas apart from the AAQ sampling within the plant premises. The seasonal variations of the prime pollutants PM10, PM2.5, So2 and NOx recorded at Continuous ambient monitoring stations are shown below.

2


Seasonal variation of average concentrations of pollutants

3.0 Water environment

a) Surface water quality:

Water samples have been collected once during monitoring period from eight (8) locations, which are listed in below.

Surface water locations Station Code

Description Distance from the centre of the

plant (km)

Latitude Longitude

SW1 Gurdhi nallahs (Inlet of Lagoon) E (0.5) 22°12'55.24"N 84°50'29.61"ESW2 Out let of Lagoon(Tarakera) E (3) 22°12'27.87"N 84°49'49.38"ESW3 Upstream of effluent discharge

point (100m) of Brahmini River E (3) 22°12'18.74"N 84°49'37.07"E

SW4 Downstream of effluent discharge point (100m) of Brahmini River

E (3) 22°12'5.40"N 84°49'42.42"E

SW5 Koel river downstream of Township

N (6) 22°16'26.76"N 84°50'34.62"E

SW6 Koel river upstream of Township N (6) 22°16'5.21"N 84°52'55.78"ESW7 Koel River before confluence with

Sankh W(4) 22°14'57.86"N 84°47'47.23"E

SW8 Sankh River before confluence with Koel

W(4) 22°14'54.91"N 84°47'16.11"E

As indicated above the major portion of the inlet water of the lagoon is effluent water, parameters were analyzed and compared with as per the General standards for discharge of Environmental Pollutants Part -A of MOEF&CC . Also Samples were also collected at 100 m U/s up stream and down stream of effluent discharge point and compared with Water Quality Criteria as per Central Pollution Control Board. Water sample is also collected from Koel River from which required water is being drawn for RSP Township.

020406080

100120

Seasonal Variation of Average Concentration of pollutants

PM10 PM2.5 SO2 NOx

3


Results of Surface Water Analysis

Sl. No.

Parameters 100 m Upstream of

discharge point of Brahmini

River (SW3)

100 m Downstream of discharge point

of Brahmini River

(SW4)

Koel River D/sOf township

(SW5)

Koel River U/s township

(SW6)

Koel River before confluence

(SW7)

Sankh River before Confluence

(SW8)

1 Colour, Hazen units, Max. <5 <5 <5 <5 <5 <5 2 Turbidity, NTU, Max. <4 <4 <4 <4 <4 <4 3 pH Value 7.0 7.0 7.0 7.0 7.0 7.0 4 Dissolved Oxygen (as O2), mg/l 6.5 6.5 6.2 6.2 6.1 6.1 5 BOD, 5 days at 20° C, mg/l 2 2 2 2 2 3 6 Total Hardness (as CaCO3), mg/l, Max. 76 92 100 72 68 76 7 Iron (as Fe), mg/l, Max. 0.2 0.22 0.25 0.53 0.41 <0.18 Chloride (as Cl), mg/l, Max. 12 19 19 12 10 10 9 Fluoride (as F) mg/L, Max. <0.1 0.58 0.22 <0.1 0.4 <0.1 10 Dissolved Solids mg/l, Max. 152 170 176 140 146 154 11 Calcium (as Ca), mg/l, Max. 18 24 24 16 19 1912 Magnesium (as Mg), mg/L, Max. 8 8 10 8 5 7 13 Copper (as Cu), mg/l, Max. <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 14 Manganese (as Mn), mg/l, Max. <0.04 <0.04 <0.04 <0.04 <0.04 <0.04 15 Sulphate (as SO4), mg/l, Max. 10 30 14 5 13 9 16 Nitrate (as NO3), mg/l, Max. 3 2 2 1 4 2 17 Phenolic Compounds (as C6 H5OH), mg/l Max. <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 18 Mercury (as Hg), mg/l, Max. <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 19 Cadmium (as Cd), mg/l, Max. <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 20 Cyanide (as CN), mg/l, Max. <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 21 Lead (as Pb), mg/l, Max. <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 22 Zinc (as Zn), mg/l, Max. <0.005 <0.005 0.079 <0.005 <0.005 <0.005 23 Total Chromium (as Cr), mg/l, Max. <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 24 Alkalinity (as CaCO3) mg/l, Max. 84 68 88 84 80 92 25 Aluminium (as Al) mg/l, Max. <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 26 Coliform organisms, MPN/100ml 380 390 310 330 340 380 27 Boron (as B), mg/l, max. <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 28 Sodium Absorption Ratio 0.39 0.5 0.48 0.36 0.42 0.40

4


All parameters are analysed as per drinking water standards. However, the results are compared with water quality criteria prescribed by CPCB. The analysis results of surface water shows at all locations all parameters are within the limits prescribed for water quality criteria as per CPCB. Water from these sources is used for drinking after conventional treatment and disinfection

b) Ground water

To assess the impact due to existing plant present quality of groundwater is necessary. Covering all these aspects, ground water analysis studies have been carried out. Eight (8) nos of monitoring stations were selected to analyse Ground water which are given in below.

Ground Water sampling locations

Station Code

Description Distance from the centre of

the plant (km)

Latitude Longitude

GW1 Sitalpara dump area W (1) 22°13'17.46"N 84°50'41.88"EGW2 Tarapur dump area SW (1) 22°12'8.46"N 84°50'12.06"EGW3 Fertilizer town ship S (3) 22°11'22.92"N 84°51'40.62"EGW4 Buridih village SE (2) 22°11'44.28"N 84°52'11.58"EGW5 Steel Township NE(7) 22°16'24.67"N 84°50'33.67"EGW6 Basanti Colony N(1.5) 22°13'26.46"N 84°50'19.50"EGW7 Kendriya Vidyalaya,

Bondamunda E(6) 22°13'41.06"N 84°54'52.72"E

GW8 Jalda “C” Block SW(6) 22°10'39.19"N 84°51'10.04"E

Results of ground water analysis are compared with norms prescribed in IS-10500: 2012 (Drinking Water Specification). At all locations, pH was found to be in the range of 6.5 – 7. Chloride & Sulphate were found to be in the range of 17 – 89 mg/l and 4-136 mg/l respectively. Iron is found marginally exceeding the limits in the samples collected at Sital para, Tarapara area, fertilizer, Basanti colony and Buridih village. Total Hardness was found to be maximum extent of 340 mg/l which is marginally exceeding the desirable limits in the sample collected from Buridih. However, the station is located on upstream side of the ground water flow with reference to plant location. High values of harness may be attributed due to the nature of the rock present at the monitoring area. All other parameters are within the drinking Water Quality standards specified in IS 10500.

5


Results of Ground Water Analysis S. No

Parameters Norms(10500) GW1 GW2 GW3 GW4 GW5 GW6 GW7 GW8 Requirem

ent **Per. limit

Essential Characteristics 1 Colour, Hazen Units. 5 25 <5 <5 <5 <5 <5 <5 <5 <5 2 Odour Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 3 pH value 6.5 to 8.5 No Relaxation 7.0 7.0 6.5 6.5 6.5 7 6.5 6.5 4 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable 5 Turbidity, NTU, Max. 1 5 <4 <4 <4 <4 <4 <4 <4 <4 6 Total Dissolved Solids, mg/l, max. 500 2000 368 224 446 542 300 108 134 494 7 Aluminium (as Al ), mg/l 0.03 0.2 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 8 Boron (as B), mg/l, max. 0.5 1 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 9 Calcium (as Ca), mg/l, max. 75 200 64 35 48 48 56 19 14 53 10 Chloride (as Cl),mg/l, max. 250 1000 89 27 29 62 83 17 33 68 11 Copper(as Cu), mg/l, max. 0.05 1.5 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 12 Fluoride (as F), mg/l, max. 1.0 1.5 <0.1 1.23 1.18 0.9 1.0 <0.1 0.67 1.02 13 Iron (as Fe), mg/l, max. 0.3 No Relaxation 0.46 0.41 0.39 0.37 0.20 0.32 0.11 0.22 14 Magnesium(as Mg), mg/l, max. 30 100 16 6 18 54 24 3 7 15 15 Manganese (as Mn), mg/l, max. 0.1 0.3 0.06 0.15 0.12 <0.04 <0.04 <0.04 <0.04 0.05 16 Nitrate (as NO3), mg/l, max. 45 No Relaxation 8 <1 <1 5 26 3 4 3

17 Phenolic compounds(as C6H5OH), mg/l, max. 0.001 0.002 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001

18 Sulphate (as SO4), mg/l, max. 200 400 54 4 30 68 31 5 16 62 19 Total alkalinity( as CaCO3), mg/l 200 600 112 132 268 268 60 52 36 248 20 Total hardness(as CaCO3), mg/l, max 200 600 224 112 192 340 240 48 64 192 21 Zinc (as Zn ), mg/l, max. 5 15 0.319 0.298 0.109 0.285 0.026 0.072 0.007 0.045 22 Cadmium (as Cd), mg/l, max. 0.003 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 23 Cyanide (as CN), mg/l, max. 0.05 No relaxation <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 24 Lead (as Pb), mg/l, max. 0.01 No relaxation <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 25 Mercury,(as Hg), mg/l, max. 0.001 No relaxation <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 <0.0005 26 Nickel (as Ni), mg/l, max. 0.02 No relaxation <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 27 Total arsenic ( as As), mg/l, max. 0.01 0.05 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 28 Total chromium (as Cr), mg/l, Max. 0.05 No relaxation <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

29 Total Coliform bacteria, MPN/100ml Not

detactable in 100ml sample -

<1.1 <1.1 <1.1 <1.1 <1.1 <1.1 <1.1 <1.1

GW1- Sitalpara dump area GW2- Tarapur dump area GW3- Fertilizer town ship GW4- Buridih village GW5- Steel Township GW6- Basanti Colony GW7- Kendriya Vidyalaya, Bondamunda GW8- Jalda “C” Block * Requirement (Acceptable limits) ** Permissible limits in the absence of alternate source

6


4.0 Baseline status of Existing plant

RSP is submitting the compliance status of the steel plant periodically to OSPCB and MoEFCC regional centre. The certified compliance status is enclosed as Annexure 5. Emissions from Stacks

Stack emissions monitoring is being conducted at regular intervals by RSP. The results of the stack monitoring for major stacks recently conducted are given below.

Stack emissions from Different Units of RSP

Dep

t Stack Location

Stack Height

Stack Dia.

Prodn. Temp Flow (at 25oC)

*PAH (BaP)

VOC SPM SO2 NOx CO load

Units Mtr. Mtr. Pushgs/ day

oC ThNm3/hr. g/m3 g/m3 mg/ Nm3

mg/ Nm3

mg/ Nm3

Kg/T of

Coke

Coke

Ov

ens Batt#1 100 3.4 85 239 253 BDL BDL 45 138 288 2.73

Batt#2 90 3.4 72 238 252 BDL BDL 48 295 392 2.85 Batt#3 90 3.4 Put down for rebuilding on 10/06/2011 Batt#4 100 3.4 99 240 250 BDL BDL 47 223 178 2.73 Batt#5 100 3.4 94 233 255 BDL BDL 48 388 274 2.97 Batt#6 100 8.04 68 251 1401 BDL BDL 35 328 194 1.54 Norm 50 800 500 3.00

Dep

t. Stack Location

Stack Height

Stack Dia.

Prodn. Flow(at 25oC)

Temp. SPM SO2 NOx CO

Units Mtr. Mtr. Tonnes/day ThNm3/hr. oC mg/ Nm3

mg/ Nm3

mg/ Nm3

% vol/vol

Bla

st F

urna

ces

BFc#1 60 3.0 S/D S/D S/D S/D S/D S/D S/D BFc#2 60 3.0 S/D S/D S/D S/D S/D S/D S/D BFc#3 60 3.0 1714 191 291 31 64 76 0.26 BFc#4 70 3.8 2446 306 305 36 83 85 0.28 Norm 50 250 150 1

Dep

t. Stack Location

Stack Heigh

t

Stack

Dia.

Prodn. PC equip. Installed

Flow (at 25oC)

Temp.

SPM SO2 NOx

Units Mtr. Mtr. Tonnes/day

ThNm3/hr. oC mg/ Nm3

mg/ Nm3

mg/ Nm3

SP #

1

Process ESP Strand#1

100 5.1 ESP Under Shutdown

7


Dep

t. Stack Location

Stack Heigh

t

Stack

Dia.


Flow(at 25oC)

Temp.

SPM SO2 NOx

Process ESP Strand#2

100 5.1 ESP

Addl. ESP 80 4.0 ESP Old ESP 60 3.5 ESP

SP#

2 Process

ESP 120 5.5 5641 ESP 902 139 66 152 162120 5.5 2983 902 138 40 149 165

Space De Dusting ESP

80 4.0 5879 ESP 268 70 64 41 3580 4.0 4452 268 78 42 36 33

SP#

3

Process ESP Path#1

120 5.5 7573

ESP 902 151 37 255 191

Process ESP Path#2

120 5.5 7573

ESP 902 158 44 183 179

Space ESP

80 4.0 7573 ESP 268 62 43 38 33

Norm 150 - -

Dep

t. Stack Location

Stack Height

Stack Dia.


Flow (at 25oC)

Temp. SPM SO2 NOx

Units Mtr. Mtr. T/ day

ThNm3/ hr.

oC mg/ Nm3

mg/ Nm3

mg/ Nm3

SMS#

1

Wet Scrubber Stack#1

90 1.8 1080 Wet Scrubber 38,465 83 36 37 43

Wet Scrubber Stack#2

90 1.8 1080 Wet Scrubber 38,465 81 39 43 45

SMS#

2 B#1 72.2 3.174 6007 Bag House 132,589 71 43 31 39 B#2 72.2 3.174 6007 Bag House 52,183 68 41 37 42 Norm 100 No norm

Dep

t Stack Location

Stack Height

Stack Dia.


Flow (at

25oC)

Temp.

SPM SO2 NOx

Units Mtr. Mtr. Tonnes/day ThNm3/hr.

oC mg/ Nm3

mg/ Nm3

mg/ Nm3

Silic

on

Stee

lMill TA line 60 2.0 78 - 189 214 23 11 23

Decarb line 60 2.0 26 - 67 101 81 40 44AP Line 60 2.0 169 Alkali

Scrubber - - 36 63 58

8


Ammonia Cracking Unit

60 2.5 17420X 1000 NM3 - 242 208 28 21 24

Norm 150 No norm

Dep

t. Stack

Location Stack Height

Stack Dia.


Flow (at 25oC)

Temp.

SPM

Units Mtr. Mtr. Tonnes/hour.

ThNm3/hr. oC mg/Nm3

Capt

ive

Pow

er P

lant

#1 MP Boiler#1 40.5 3.28 30 ESP 99 123 50

MP Boiler#2 40.5 3.28 30 ESP 100 119 59MP Boiler#3 50 3.28 42 ESP 108 101 39 HP Boiler#1 102 4.35 S/D ESP 225 S/D S/DHP Boiler#2 102 4.35 25 ESP 225 106 28HP Boiler#3 & #4 40 3.00

HP Boiler#5 102 4.35 90 ESP 259 151 37HP Boiler#6 102 4.35 90 ESP 259 153 32

Norm 100

Fugitive Emissions

a) Coke Ovens :

BATTERY NO. PLD PLL PLO CHARGING EMISSIONS

* BaP (Top of the

Batt.)

* BaP (Other areas

of Batt.) Units % % % Sec ng/m3 ng/m3Battery # 1 9.73 0.95 0.54 44 2587 586 & 268 Battery # 2 5.28 0.98 2.18 243 4763 967 & 392 Battery # 3 Shut down for Rebuilding on 10/06/2011 Battery # 4 3.94 0.56 NIL 46 4682 635 & 335 Battery # 5 9.4 0.76 NIL 48 2954 1862 & 386 Battery # 6 3.17 0.32 NIL 13 - - NORM 10 1 4 50 5000 2000 Note: Batt#2 is an old Battery and has no HPLA system *BaP monitoring is done once in a year

b) Blast Furnaces : SN. Location Date of

Monitoring PM10 SO2 NOx CO (1hr.) Lead (Pb)

Units g/m3 g/m3 g/m3 g/m3 g/m31. BF#1 cast house S/D S/D S/D S/D S/D S/D2. BF#2 cast house S/D S/D S/D S/D S/D S/D 3. BF#3 cast house 16/12/2014 3920 80 83 4790 0.43 4. BF#4 cast house 18/12/2014 3960 85 91 4870 0.465. BF#5 cast house 20/12/2014 1590 78 87 2840 0.16

Norm (µg/m3) 4000 200 150 10000 2

9


c) Steel Melting Shops :

SN. Location Date of Monitoring

PM10 SO2 NOx CO (1hr.)

Lead (Pb)

Units g/m3 g/m3 g/m3 g/m3 g/m3

1. SMS#1 – LD floor 11/12/2014 3870 86 88 4270 0.432. SMS#2 – BOF floor 12/12/2014 3980 98 96 4360 0.45

Norm (µg/m3) 4000 200 150 10000 2

Work Zone Air Quality

LOCATION PM2.5 PM10 SO2 NOx CO Pb NH3 Arse-nic

Nickel Ozone Ben-zene

PAH * BaP

Noise Day/ Night

Units g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 g/m3 ng/m3 ng/m3 g/m3 g/m3 ng/m3 dB(A) EED Building 28-44 38-80 23-41 32-52 980-

1060 0.02-0.06

12.6-14.2 BDL BDL 14.5-

16.7 BDL 0.12 72.2/66.3

RDCIS building 32-46 42-82 29-48 35-54 1020-

1140 0.03-0.08

13.8-16.7 BDL BDL 15.4-

17.8 BDL 1.0 73.5/67.6

PMPH building 35-49 45-82 34-51 38-56 1060-

1160 0.05-0.09

14.5-16.9 BDL BDL 15.7-

18.5 BDL 0.4 73.6/68.3

BOD Plant building 28-54 49-86 55-62 52-64 1120-

1230 0.06-0.15

17.5-22.4 BDL BDL 16.9-

23.5 BDL 1.0 74.7/68.5

TOP#2 building 31-56 56-88 57-66 55-68 1160-

1380 0.06-0.18

17.8-23.5 BDL BDL 17.2-

24.3 BDL 0.6 74.8/68.2

OBBP Building 31-53 52-84 43-55 47-67 1090-

1270 0.05-0.09

16.8-18.4 BDL BDL 16.2-

19.8 BDL 0.2 74.2/67.9

Steel Town 23 39 28 29 562 NT 13.2 BDL BDL 16.4 BDL 1.0 54/44Residential

Norms 60 g/m3

90 g/m3

80 g/m3

80 g/m3

4000 g/m3

1.0 g/m3

400 g/m3 6 ng/m3 20

ng/m3 100

g/m3 1

ng/m3 1.0

ng/m3

Ind. : 75/70 Resi : 55/45

PM, SO2 and NOx in all the monitored stacks of Coke Ovens are within the MOEF&CC norm. From the above it can also be seen that the PM emissions in all the monitored stacks of Blast Furnace, Lime plant and other Mill stacks are within the MOEF&CC norm of 100 mg/m3. There are six High pressure boilers and three medium pressure boilers (MP) in the Power Plant Unit. MP boilers are coal fired boilers. All High pressure boilers except 3& 4 can fire coal, gas and oil. 3&4 are gas based boilers. SPM values in all the cases are within norms.

Effluent quality

The existing plant is generating effluents at the rate of 853.54 m3/hr and discharging through 9 no. of drains, called outfalls, into “Gurdhi Nalla”. Gurdhi Nalla carries the total

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wastewater coming from the plant to a lagoon for tertiary treatment. Finally the wastewater is being discharged from lagoon into River Brahmani. The effluent quality of the individual out falls, the water quality of the lagoon and Effluent water Quality of Individual units are given in below.

Effluent quality discharged through the Outfalls

SN. PARAMETER Norm Lagoon

inlet Lagoon Outlet

Avg. Avg. 1. pH 6 – 8.5 8.0 7.7 2. Total Suspended Solids (TSS) 100 131.6 173. Chloride as (Cl) 1000 35.3 37.24. Sulphate as SO4 1000 62.3 57.25. Free Ammonia 5.0 1.93 1.54 6. Ammonia as NH3-N 50 18.8 12.17. Phenol 1.0 0.27 0.128. Cyanide 0.2 0.16 0.089. Biochemical Oxygen Demand (BOD3) 30 18 7 10. Chemical Oxygen Demand (COD) 250 72 38 11. Copper 3.0 0.146 0.013812. Zinc 5.0 0.3423 0.158013. Oil & Grease 10.0 6.6 2.3 14. Boron 2.0 NT NT 15. Total Residual Chlorine 1.0 NT NT16. Arsenic 0.2 NT NT17. Cadmium 2.0 NT NT 18. Chromium Cr+6 0.10 NT NT 19. Total Chromium 2.0 0.0043 0.002720 Lead 0.1 0.0131 0.011821. Selenium 0.03 NT NT 22. Mercury 0.01 0.0018 0.0015 23. Dissolved Phosphates 5.0 0.05 0.0424. Total Kjeladal Nitrogen 100 9.06 5.8225. Nickel 3.0 0.1882 0.015026. Iron 3.0 2.6 2.2 27. Nitrates 10.0 1.8 1.6

(Units: all in mg/lit except pH)

11


Effluent Quality of Different units SN. Dept.’s Location pH TSS O&G Cyanide Ammonia Phenol BOD COD 1. Coke Ovens : BOD

Plant Inlet Outlet

9.1 62 8 5.47 445 149.6 294 702

8.4 43 3.5 0.16 28.07 0.11 28 213

2. Sintering Plant#1 7.9 56.75 3.5 0.08 3.05 0.05 12 52 3. Blast Furnaces 7.25 56 6.3 0.14 30.65 0.36 15 87 4. SMS 8.3 45.7 5.5 0.06 1.94 0.07 11 52 5. Rolling Mills 7.87 70 7.5 0.05 1.34 0.02 12 56 Norm for Outlet 6-8.5 100 10 0.20 50.0 1.0 30 250

Effluent Quality of Steel Township

SN. Location pH TSS BOD COD Ammonia

Dissolved

Phosphate

SO4

1. Sector#14 7.9 38 18 54 6.79 0.32 12 2. Sector#22 8.4 52 16 48 2.01 0.14 21

Norm 6-8.5 100 30 250 50 5.0 1000 (All units are in mg/lit except pH)

Quality of treated effluent discharged into Guradhi Nalla from different

Outfalls : SN. Description of the Outlet pH TSS TDS BOD COD O&G Iron Total Cr

1. Out Fall#1 (Locoshed effluent) 7.4 34 223 7 27 3.0 2.0 0.02

2. Out Fall#2 (Near Traffic Gate) 7.9 56.75 177.5 12 52 3.5 2.5 0.02

3. Out Fall#3 (BF, Coke Oven & By-product Plant effluent)

7.25 56 317.5 15 87 6.3 2.87 0.04

4. Out Fall#4 (Neutralisation pit outlet of CRM)

6.9 80.3 382 16 72 5 3.0 0.03

5. Out Fall#5 (Silicon Steel Mill) 7.87 70 127 12 56 7.5 2.75 0.05

6. Out Fall#6 (By product plant effluent) 7.25 5.25 195.5 10 10 1.33 1.66 0.05

7. Out Fall#7 (CRM & HRM effluent) 6.77 65 510 14 59 7.0 2.75 0.04

8. Out Fall#9 (SMS & Pipe Plant’s effluent) 8.3 45.7 130 11 52 5.5 2.75 0.03

9. Out Fall#10 (in between Out Fall#9 and Lagoon inlet)

10.8 9 1210 7 24 1.0 1.0 0.01

NORMS 6-8.5 100 2100 30 250 10 3 2.0 (Units : all in mg/lit except pH)

12


As indicated above effluents discharged through various outfalls are settled first in lagoon. The supernatant effluent is discharged into the river. The analysis results of outfalls indicated that mostly pollutant concentrations are within the limits. However, analysis results of supernatant effluent indicate that concentrations are well within the limits.

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Documents

Kind attn : Dr. Satish C. Garkotienvironmentclearance.nic.in/writereaddata/Online/EDS/03_Jan_2017...Project Proponent MEC/11/S2/A231/EIA-EMP/2291/R.0. JANUARY, 2017 ENVIRONMENTAL APPRAISAL