EXECUTIVE SUMMARY FOR PUBLIC HEARING OF PROPOSED SPONGE IRON, CAPTIVE POWER PLANT & FERRO ALLOY PLANT

Near Chikkantpura, Tq. Sandur, Dist. Bellary, Karnataka

Submitted by: PADMAVATI FERROUS LIMITED Vidyanagar, Toranagallu Tq. Sandur, Dist. Bellary Karnataka

JUNE 2007

Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

1.0 1.1

INTRODUCTION The Company

M/s Padmavati Ferrous Limited (PFL) is proposing to set up Sponge Iron Plant, Ferro Alloy Plant and Captive Power Plant based on waste heat energy. The Project is approved from Karnataka Udyog Mitra. PFL has Ferro Manganese (capacity 8,000 TPA) and Silicon Manganese (capacity 10,000 TPA) units at Jindal Steel Works (JSW) ancillary industrial area, Vidyanagar near Toranagallu, Taluka Sandur, District Bellary in Karnataka state. PFL is ancillary unit of JSW which is leading steel manufacturers in India having 3.8 MTPA Integrated Steel Complex at Vidyanagar. Vidyanagar is about 7.5 km from proposed plant location at Chikkantapura. JSW and PFL have signed MoA dated 02.01.07 as per that JSW shall provide PFL all raw materials like iron ore pellet, coal fines and dolomite free of cost for converting iron ore pellets into DRI. This MoA is valid for 8 years. 2.0 2.1 PROJECT DETAILS Project Site

The proposed unit will be located near village Chikkantapura, Taluka Sandur, District Bellary in Karnataka state. PFL has acquired 28 acres of land for proposed project. Layout of proposed plant is depicted in Annexure-I. The site area is approachable by road from JSW plant, which is about 7.5 km. National highway No.63 (Karwar-Chennai) is also about 5 km from plant site while nearest railway station is Toranagallu at 7.5 km on South Central Railway. The nearest town is Bellary while airport is Bangalore at about 400 km from the site. 2.2 Project Cost

The overall project cost of the project would be Rs.98 Crores of which Rs.12 Crores would be towards pollution control. 2.3 Plant Configuration

PFL is proposed to set up Sponge Iron Plant, Captive Power Plant and Ferro Alloy Plant in continuation with their existing activity in the premises of JSW and with reference to MoA dated 02.01.07. Configuration of proposed plant is given below: Sr. No. 1. 2. 3. Unit Sponge Iron Plant Captive Power Plant Ferro Alloy Plant (Silicon Manganese Ferro Manganese) Capacity 4 x 100 TPD 12 MW 37,100 TPA & (16100 & 21000) Page - 1

Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

2.4 2.4.1

Process Details Sponge Iron Plant

PFL will be using the Coal Based Rotary Kiln Process for producing Sponge Iron. Sponge Iron is direct reduced Iron (DRI), which is produced from Iron ore pellet without phase change, i.e. at solid-state, Iron oxide reduced into pure Iron. 2.4.2 Ferro Alloy Plant

This process deals with production of Ferro Alloy through electro thermic process in submerged arc furnaces. The charge of ores and carbon is continuously fed at the top of the furnace. The molten metal and slag are tapped at regular intervals from fixed tap holes. 2.4.3 Captive Power Plant

Power plant is based on waste heat recovery system. It will be configured with 4 nos. of Waste Heat Recovery Boilers (WHRB) of capacity of 10 TPH each & 1 No of 27 TPH Fluidized Bed Combustion Boiler (FBC) to produce 12 MW power. Manufacturing process is shown in Annexure-II. 2.5 2.5.1 Major consumables Raw material Raw Material i. Iron Ore Pellet ii. Coal iii. Dolomite i. Coal ii. Char i. Mn ore ii. Coke iii. Other Source JSW

Parameter Sponge Iron Plant

CPP Ferro Alloy Plant

JSW and in-house JSW / Sandur ores, Manganese ore (I) Ltd./ Local Market

2.5.2

Water

JSW will supply water to proposed plant. The unit wise water requirement is given below: Sr. No. 1 2 3 4 Location Sponge Iron Plant Captive Power Plant Ferro Alloy Plant Domestic Total Requirement, m3/day 120 300 240 100 760

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Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

Under ground water reservoir of capacity 18,000 m3 is proposed to store water. Separate water treatment plant for power generation & process / drinking water shall be provided. R.O. plant 10 m3/hr capacity is also proposed. 2.5.3 Power

The power requirement for the project is estimated around 22 MW, which will be met through CPP of 12 MW & from M/s. JSW of 10 MW. DG of capacity 2 x 750 KVA are also proposed as standby arrangement in case of an emergency. 2.5.4 Fuel

Initial light up of kiln will require diesel at the rate of 2.5 kL/ per Kiln. DG set will also require diesel at the rate of 75 to 120 liter per hour in case of an emergency. 2.5.5 Manpower

The total manpower requirement during plant operation will be of 220 personnel. Available manpower at the local level will be utilized to the maximum extent possible. 3.0 BASELINE ENVIRONMENTAL STATUS

A study area encompassed by a circle of 10 km radius around the proposed plant site is considered to know the baseline environmental status of various environmental attributes, for the winter season covering December 2006-February 2007 period. 3.1 Meteorology Meteorological parameters measured are wind speed and direction, temperature and relative humidity, continuously at one hour interval The observations are: Predominant wind direction : SE (22.9%) followed by ESE (20.8%) Predominant wind speed : 4.6 km/hr Temperature : 15.2 33.4C Relative Humidity : 78 - 26% Air Quality Monitoring at six locations for Total Suspended Particulate Matter (TSPM), Respirable Particulate Matter (RPM), Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx) and Carbon Monoxide (CO) The monitored concentrations of these above pollutants are: TSPM : 57 - 175 g/m3 RPM : 15 - 84 g/m3 SO2 : 9.4 15.1 g/m3 NOx : 10.9 16.8 g/m3 CO : 0.051 - 0.096 ppm The monitored concentrations are found within the prescribed limits of rural and residential areas specified by Central Pollution Control Board (CPCB). Page - 3

3.2

Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

3.3

Water Quality Sampling and analysis carried out for six ground water locations The analyzed values are: TDS : 168 -439 mg/l Hardness : 53 - 162 mg/l Chlorides : 58 - 95 mg/l Sulphates : 22 - 61 mg/l Calcium : 15 to 38 mg/l Magnesium : 7 to 15 mg/l Iron : 0.19 to 0.58 mg/l Heavy metals like : BDL Zn, Pb, Cu, Al The analysed values are found within the permissible/desirable limits of IS:10500 incase of ground water. Noise Level Levels measured at six locations covering various zones like residential and industrial. Monitored values are: Daytime noise levels (Ld) Commercial zone : 61.9 dB(A) Residential zone : 43.2 49.1 dB(A) Night-time noise levels (Ln) Commercial zone : 50.5 dB(A) Residential zone : 32.4 38.9 dB(A) Compared with standards specified by MoEF: Commercial zone : 65 dB(A) and 55 dB(A) respectively for Day and Night Residential zone : 55 dB(A) and 45 dB(A) respectively for Day and Night Land Use using Satellite Imagery Land Use using satellite imagery IRS P6, LISS III, 5th January 2007, Path 98/99, Row 62. Land Use Built-up Area Degraded Forest (Reserved/Protected Forest) Industry/Institutional Area Double Crop Un-irrigated Area Land with/without Scrub Plantation Quarry/Mining Area Stony/rocky/Barren Area Area, ha 1009.39 5660.99 1598.68 3694.68 6267.90 11400.98 245.72 313.96 1588.25 % 3.12 17.50 4.94 11.42 19.37 35.24 0.76 0.97 4.91 Page - 4

3.4

3.5

Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

Water Body Total 4.0 4.1

574.80 32355.36

1.78 100.00

POLLUTION AND MEASURES Air Pollution

Air pollution mainly due to burning of coal at various stages of process. Particulate Matter (PM), SO2 and NOx are the main pollutants. Gas cleaning plant (GCP), electro static precipitator (ESP) and bag filters / de-dusting equipments are proposed to discharge of contaminated gas into atmosphere. Stacks of adequate height are proposed for proper dispersion of flue gas. Incremental ground level concentrations of these pollutants due to operation of plant are predicted using air quality models. The predicted ground level concentrations for PM, SO2 and NOx are found as 1.86 g/m3, 2.85 g/m3 and 1.98 g/m3 respectively. These are superimposed on the monitored baseline concentrations to get the likely resultant concentrations of these pollutants in the study area and are 169.86 g/m3, 17.65 g/m3 and 18.68 g/m3 respectively. These resultant concentrations are found within the prescribed limits of 200 g/m3 for PM, 80 g/m3 for SO2 and 80 g/m3 for NOx specified for rural /residential area by CPCB. 4.2 Water Pollution

Water is mainly required for cooling of machineries in the proposed plant. Wastewater generation from plant will be in the form of blow down at the rate of 26.6 m3/day and from wet scrapper dust settling chamber at the rate of 12 m3/day. The domestic waste will be generated at the rate of 60 m3/day. Total waste water of 110 m3/day will be collected and treated in sewage treatment plant. Treated waste will used for dust suppression and green belt development. 4.3 Solid Waste Generation

Solid waste generation from process will be in the form of slag (87 TPD), fly ash (24.6 TPD), sludge from GCP (7.2 TPD) and dust from bag filter (56.6 TPD). Slag is proposed to be sold to potential cement manufacturing parties. Fly ash will be sold to cement / brick manufacturers while sludge and dust generated will be used as for filling low levels and sold to brick manufacturers respectively. 4.4 Noise Pollution

Furnace, power plant and cooling tower, compressors, fans, pumps etc. are the sources of noise generation within the plant premises. The likely noise levels are 80-90 dB(A). Noise modeling is carried out to know the noise levels at plant boundary. These are observed in the range of 30 -41 dB(A). The proposed plantation around and within the plant site will help in further reducing the noise levels. Page - 5

Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

4.5 5.0

Other Issues Private land is acquired, hence no problem of resettlement and rehabilitation Direct employment opportunities to local people during construction as well as operational phase. Also indirect employment in ancillary activities. Better infrastructural facilities by way of development/improvement of roads, availability of water and power to the villages vicinity of the plant. Routine medical check up of the people working in the plant area. MANAGEMENT PLAN Implementation schedule of mitigation measures (air, water, ecology) has been indicated for the construction and operation phase. Environment cell supported by fully equipped laboratory is proposed. Rain water harvesting will be implemented Environmental monitoring schedule as per norms for various environmental attributes. Green belt development on approximately 10 acres of land around the plant boundary and block/avenue plantation within plant area FIRE SAFETY

6.0

A full fledged fire hydrant system is designed for the proposed plant covering the area like main process areas, raw material and product storage areas, tank farms, treatment plant, main and rear entrance gate, HT transformer, utility section etc. A firewater storage tank of sufficient capacity will be provided. Besides well-planned fire hydrant system, first Aid Fire Fighting equipment like CO2 extinguisher will be provided at each section of the plant. Fire alarms would be located in the storage and main process area. 7.0 HEALTH AND GENERAL SAFETY

All employees will be trained in safe work practices and provided with necessary protective equipment. Usage of protective equipments and adherence to safe practices will be insisted upon all activities of operation including shutdown and maintenance. On site emergency plan approved by factory inspector will be made available at site and all members will be trained.

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Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

Annexure-I: Plant Layout

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Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

Annexure-II: Manufacturing Process

Figure 1: Process Flow Chart Sponge Iron Plant Raw Material Feeding at Ground Hopper Coal & Iron Ore

Coal Lime Stone Bin Coal Bin

Sized Iron Pellet Iron Pellet Bin

Setting up of proportion of mixed Raw Materials for Kiln feed

Processed in rotary kiln at 1050 oC with air control Indirect cooling in rotary cooler with Water Spray

Screening of mixed product (Sponge Iron and unburnt Coal)

Sponge Iron Lumps +Char Drum type magnetic separator

Sponge Iron Fines + Dolo Char Drum type magnetic Separator

S.I. Lumps Bin

Char Bin

Fines Bin

Dolo Char Bin

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Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

Figure 2: Process Flow Chart Ferro Alloy Plant

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Environmental Impact Assessment of Proposed Sponge Iron Plant, CPP & Ferro Alloy Plant of Padmavati Ferrous Ltd.

Executive Summary For Public Hearing

Figure 3: Process Flow Chart Captive Power Plant

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