tata steel limited environmental impact assessment of the expansion ...

TATA STEEL LIMITED

ENVIRONMENTAL IMPACT ASSESSMENT

OF

THE EXPANSION OF CRUDE STEEL PRODUCTION

FROM 9.7 MTPA TO 11.0 MTPA CAPACITY IN

JAMSHEDPUR, JHARKHAND

AUGUST 2015

M. N. DASTUR & COMPANY (P) LTD CONSULTING ENGINEERS

KOLKATA

TATA STEEL LIMITED Environmental Impact Assessment

M. N. DASTUR & COMPANY (P) LTD of the Expansion of crude steel production from 9.7 MTPA to 11.0 MTPA Capacity

in Jamshedpur, Jharkhand

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COMPANY PROFILE

M. N. Dastur & Company (P) Limited was founded in 1955 by

Dr. Minu Nariman Dastur, the pioneer in providing consulting

engineering services in India. The company offers integrated design and

engineering consultancy services, from concept to commissioning, for a

wide range of projects related to metallurgical, mining, chemical, oil &

gas, cement, power, environment, infrastructure and other allied

industries. DASTUR specialises in project planning and appraisal,

economic evaluation, design and detailed engineering, procurement

assistance services, supervision of construction and erection,

environmental engineering and pollution control, energy management

and optimisation, human resources development, and management

consultancy. DASTUR has a dedicated team for Project Management

services.

Dastur Business & Technology Consulting (DBTC), a division of

DASTUR, offers specialized and end-to-end expertise to enable clients

meet the needs of a rapidly changing global business and technological

environment.

Over the years, DASTUR has built up a multidisciplinary team of

over 1,600 professionals and technical staff with varied experience, fully

abreast of the state-of-the-art technologies, with intimate understanding

of the latest trends, combining creativity with initiative. DASTUR provides

a unique blend of experience and talent, catering to the specific

requirements of each project.

DASTUR is internationally recognised as one of the largest

independent consulting engineering organisations in the world. DASTUR

is headquartered in Kolkata with offices in Chennai, Mumbai, Bangalore,




Disclosure (Contd)

- 2 -

New Delhi, Bhubaneswar, and Hyderabad. International operations are

based out of Dsseldorf in Germany, Tokyo in Japan, Abu Dhabi in UAE

and New Jersey in USA.

DASTUR has earned global appreciation for its dedication and

teamwork. Today, DASTUR is synonymous with excellence in engineering

consultancy and business & technology consulting services.

Accreditations:

ISO 9001-2008 - Management System certified organization. ISO 27001:2013-Information Security Management System

certified organization. Environmental Engg. Dept. accreditated under NABET

(National Accreditation Board of Education & Training). Certification on third party inspection (ISO 17020:2012) in

progress. Certification on HSEMS (OHSAS 18001:2007 & ISO

14001:2004) in progress.

The principal areas of operation are as follows:

Process Engineering

Geology, Mining and Beneficiation

Chemicals

Materials Handling

Iron and Steel

Agglomeration

Coke oven & By-products

Ironmaking

Blust Furnace

Direct Reduction

Calcining Plant

Ferroalloys

Steelmaking

Rolling Mills




Disclosure (Contd)

- 3 -

Non-Ferrous Metals

Aluminium

Copper

Zinc

Mineral Sands

Civil Engineering

Structural Engineering

Layout, Transportation & Logistics

Electrical Engineering

Instrumentation, Automation & Communication

Power & Energy

Cement & Lime

Oil & Gas

Refractories

Water System and Waste Water Management

Utility Systems Engineering

Environmental Engineering

Housing

Cost Engineering

Inspection and Quality Assurance

Project Management

Construction Management

Operational Assistance

Business & Technology Consulting




Disclosure (Contd)

- 4 -

M N Dastur offers diverse services ranging from integrated

engineering, management consultancy to various studies as elaborated

below.

RANGE OF SERVICES

Studies Concept Note Market Surveys Site selection studies Master Plan studies Feasibility Report Techno-Economic

Feasibility studies Basic Engineering

Report Detailed Project Report Productivity Review Due Diligence studies Energy Audit Technology Evaluation

Integrated Engineering Services

Basic Engineering Shop and Plant General

Layout Vendor Drawing Scrutiny Bulk Material Handling Architecture Civil Engineering Structural Steelwork Electric Power Systems Automation and

Computerisation Instrumentation and

Control Systems Piping Systems Environmental Control

Systems Heating, Ventilation, Air-

Conditioning Systems Communication Systems Roads, Drainage and

Sewerage Systems

Management Consultancy

Corporate Planning Manpower Planning Market Studies Recruitment and

Human Resource Development

Financial Assessment Organisation &

Methods, and Management Information Systems

Valuation of Assets Lenders Engineering

Environment

Management Services

Environmental Impact Assessment

Locational Evaluation Environment Audit &

Compliance Social Environmental

impact Assessment (SEIA)

Environment Management Planning

Risk Assessment & Disaster Management Plans

Environmental Pollution Control Measures

Rain water harvesting Greenbelt Development

Planning and Landscaping

Project Management Project Governance Procurement Management

Services Planning, Monitoring and

Control Construction Management Project Risk Management Cost Monitoring and

Reporting Contract Management Management Information

System Project Closure

Inspection & Quality

Assurance Inspection of plant

and equipment of different industries

Inspection of technological, flyover and building structures

Inspection of Power Distribution, Shop Electrics, Instrumentation, Automation, Power Electronics and tele-Communication items

Inspection of Spares and Consumables

Inspection of Refractory Materials

Inspection of Pipelines Vendor Assessment




Disclosure (Contd)

- 5 -

Evaluation of Pollution Standards

Strategic Environment Assessment

Hydro-geological study Social Cost Benefit

Studies Other Environmental

Management services

Approval of welding

electrodes Inspection of unfired

pressure vessels under SMPV rule

Inspection of IBR valves, pipes and pipe fittings

Expediting and follow up services

Site Services

Construction Planning

Planning of Construction facilities

Constructability Study

Construction Supervision

Quality Audit

Safety Audit

Bill Certification

Assistance during Commissioning and Performance Guarantee Tests

Assistance and Support during 'Ramp-up'

Contract administration and Claim Settlement

Safety Surveillance

Implementation of database management system on safety observations and Safety management system

Material management

Implementation of Material indenting system (for Free-issue items)




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TABLE OF CONTENTS

Page

SUMMARY .. 18 pages 1 - INTRODUCTION Details of the Project Proponent .. 1-3 Glimpse of the Project .. 1-5 Initiation of the Expansion Plan .. 1-6 Objective for the Proposed Expansion .. 1-6 Status of Pre-Project Statutory Clearance .. 1-7 Scope and coverage of this Report .. 1-8 Structure of this Report .. 1-8 Authorisation .. 1-9 Acknowledgement .. 1-9 References .. 1-10

2 - PROJECT DESCRIPTION Project objective .. 2-1 Project location & infrastructure .. 2-1 Water requirement .. 2-2 Power requirement .. 2-4 Captive power generation .. 2-4 Transport linkages .. 2-5 Plant layout .. 2-6 Production plan .. 2-6 Technology and process description .. 2-7 Material flow .. 2-8 Raw materials and chemicals .. 2-9 Production facilities .. 2-11 Brief description of the project .. 2-13 Coke plant .. 2-13 Sinter plant .. 2-14 Pellet plant .. 2-15 Hot metal production from blast furnace .. 2-15 Steel melting shop .. 2-17 Existing facilities .. 2-17 Break-up of crude steel production .. 2-18 Mills and lime plant .. 2-20 Fuels .. 2-21 Storage facilities .. 2-22 Oxygen, nitrogen and argon .. 2-23 Compressed air and instrument grade air .. 2-23




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TABLE OF CONTENTS (Continued)

Page

2 - PROJECT DESCRIPTION (Contd) Plant operation .. 2-24 Plant automation .. 2-24 Manpower .. 2-24 Construction activities .. 2-25 Environmental pollution mitigation measures .. 2-25 Air pollution control (APC) measures .. 2-25 Non-point fugitive dust emission control .. 2-26 Point source dust emission control .. 2-27 NOx emission control .. 2-27 CO emission control .. 2-27 Plant stack emission .. 2-27 Design target for APC measures .. 2-28 Noise pollution control measures .. 2-30 Wastewater management and discharge .. 2-30 Management measures of minimize wastewater discharge .. 2-31 3 - DESCRIPTION OF THE ENVIRONMENT Study area .. 3-1 Agenda of baseline study .. 3-1 Description of environmental setting of the study area .. 3-3 Physico-chemical aspects .. 3-3 Land environment .. 3-3 Regional settings .. 3-3 Topography and geomorphology .. 3-3 Topography .. 3-3 Seismology .. 3-5 Drainage .. 3-5 Geology .. 3-5 Hydrogeology .. 3-7 Water situation in Jamshedpur .. 3-8 Ground water resources .. 3-10 Surface water .. 3-11 Soil .. 3-11 Landuse and landcover .. 3-13 Water environment .. 3-16 Surface water quality .. 3-16 Ground water quality .. 3-16 Waste water uality .. 3-21




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Page

3 - DESCRIPTION OF THE ENVIRONMENT (Contd) Air environment status .. 3-22 Climate .. 3-22 Site-specific micro-meteorology .. 3-22 Mixing height .. 3-24 Ambient air quality (AAQ) .. 3-25 Basis of location of AAQ stations .. 3-26 Parameters recorded .. 3-26 Ambient air quality as recorded .. 3-26 Noise .. 3-30 Biological environment .. 3-31 Habitats within the study area .. 3-31 Climatic factor for vegetation .. 3-31 Locations for biological sampling and monitoring .. 3-32 Terrestrial ecological status (TES) .. 3-33 Methodology .. 3-33 Qualitative survey of terrestrial flora .. 3-33 Forest .. 3-33 Vegetations in forest area .. 3-34 Vegetations in non-forest area .. 3-34 Dominant tree species in the study area .. 3-35 Medicinal plants in the study area .. 3-35 Agricultural pattern of the study area .. 3-35 Quantitative survey of terrestrial flora .. 3-36 Species density, frequency & abundance .. 3-36 Species richness, evenness & diversity index in the study area .. 3-36 Rare, endemic and endangered plant species .. 3-37 Terrestrial Fauna .. 3-37 Aquatic ecological status (AES) .. 3-37 Methodology .. 3-37 Aquatic flora .. 3-38 Planktonic population .. 3-38 Aquatic fauna .. 3-40 Ambhibian .. 3-40 Fish fauna .. 3-40 Semi aquatic birds .. 3-41 Human environment .. 3-41 Infrastructure .. 3-44 Industries in the area .. 3-44 Housing .. 3-44 Medical facilities .. 3-44




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Page

3 - DESCRIPTION OF THE ENVIRONMENT (Contd) Socio-economy and life style .. 3-45 Community safety .. 3-45 Education .. 3-45 Aesthetics .. 3-46 Photographs - List of industries .. 3-47 4 - ENVIRONMENTAL IMPACT ASSESSMENT Objectives of EIA .. 4-1 Scoping of EIA .. 4-1 Environmental impacts and mitigation measures .. 4-1 Scoping of impacts .. 4-1 Impact during construction period .. 4-2 Mitigation measures during construction period .. 4-3 Impact on land environment .. 4-4 Mitigation measures for land environment .. 4-4 Impact on soil quality .. 4-5 Mitigation measures for soil quality .. 4-5 Impact on ground water resource and quality .. 4-5 Mitigation measures for avoiding ground water contamination .. 4-5 Impact on surface water resource .. 4-6 Impact on receiving body of the plant waste water.. 4-8 Mitigation measures .. 4-8 Impact on air environment .. 4-6 Non-point fugitive dust emission .. 4-10 Fugitive dust emissions control in open areas .. 4-10 Fugitive dust emissions control in closed areas.. 4-11 Fugitive emissions control at sinter plant .. 4-12 Fugitive emissions control in pellet plant .. 4-12 Fugitive dust emissions control of stack house and cast house of BF .. 4-12 Fugitive dust emissions control of BOF shop .. 4-13 Other supporting means of fugitive emissions control .. 4-13 Point source emission control .. 4-13 Sinter plant .. 4-13 Pellet plant .. 4-13 Blast furnace .. 4-14 BOF .. 4-14 SO2 control .. 4-14




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Page

4 - ENVIRONMENTAL IMPACT ASSESSMENT (Contd)

NOx control .. 4-14 CO emission control .. 4-15 Control of PCDD/F .. 4-15 Control of oil smog .. 4-15 Vehicular emission control .. 4-16 Prediction of ambient air quality (AAQ) .. 4-16 Impact due to plant noise .. 4-22 Mitigation measures for noise attention .. 4-22 Impact due to solid waste generation .. 4-23 Mitigation measures for solid waste .. 4-23 BF slag .. 4-24 LD slag .. 4-24 Flue dust .. 4-26 Mill scale and sludge .. 4-27 Lime fines and refractory waste .. 4-27 Hazardous solid waste .. 4-27 Management of E-waste .. 4-28 Impact on biological environment .. 4-29 Impact on terrestrial ecology .. 4-29 Mitigation measures for terrestrial ecology .. 4-29 Impact on aquatic ecology .. 4-29 Mitigation measures for aquatic ecology .. 4-29 Impact on safety .. 4-30 Mitigation measures for safety .. 4-30 Additional mitigation measures .. 4-30 Rain water harvesting (RWH) .. 4-31 Greenbelt development .. 4-31 Impact assessment of human environment .. 4-32 Impact on local economy .. 4-32 Impact on physical environment .. 4-32 Impact on social environment .. 4-33 Environmental mitigation cost .. 4-33 5 - ANALYSIS OF ALTERNATIVE TECHNOLOGIES 6 - ENVIRONMENTAL MONITORING PROGRAM

Monitoring .. 6-1 Management response on the monitoring results .. 6-2 Environmental data processing system .. 6-3 Environmental laboratory .. 6-3 Estimated monitoring CAPEX & OPEX .. 6-3




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Page 7 - ADDITIONAL STUDIES Additional risk assessment .. 7-1 Objectives .. 7-2 Definition of environmental risks .. 7-3 Identification of hazards .. 7-3 Environmental risk evaluation .. 7-5 Safety during construction .. 7-9 Risk management measures .. 7-10 Electrical safety .. 7-10 Fire prevention .. 7-10 CO detection and prevention .. 7-11 On-site emergency plan .. 7-11 Accident statistics .. 7-11 Safety inspections .. 7-11 Off-site emergency planning .. 7-12 Testing of emergency planning .. 7-12 Disaster Management Plan (DMP) .. 7-13 Public consultation .. 7-15 Resettlement & Rehabilitation (R&R) .. 7-15 8 - PROJECT BENEFITS Corporate Social Responsibility (CSR) .. 8-1 Livelihood and employability .. 8-3 Education .. 8-4 Health .. 8-5 Local infrastructure development .. 8-5 Ethnicity .. 8-6 9 - ENVIRONMENTAL MANAGEMENT PLAN (EMP) Application regulations .. 9-1 Organisation .. 9-2 Planning .. 9-5 Budgeting .. 9-5 Occupational health care and safety .. 9-5 Adaptation of Environmental Management System (EMS) standards .. 9-8 Training .. 9-9 Eco restoration .. 9-9 Green House Gas (GHGs) emission inventory and management .. 9-9 Audit .. 9-10 Environmental impact statement .. 9-10




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Page

TABLES

Table 2-1 - In-house power generation .. 2-5 Table 2-2 - Existing and proposed production capacities .. 2-7 Table 2-3 - Estimated annual consumption of principal raw materials & additives .. 2-11 Table 2-4 - List of production facilities .. 2-12 Table 2-5 - Charge coke production in MTPA .. 2-13 Table 2-6 - Production of sinter .. 2-14 Table 2-7 - Measures to increase production at sinter plants .. 2-14 Table 2-8 - Enablers for pellet plant .. 2-15 Table 2-9 - Hot metal production (MTPA) and enablers for BFs .. 2-16 Table 2-10 - Enablers for increasing the crude steel production .. 2-18 Table 2-11 - Enablers for increasing production in the mills .. 2-21 Table 2-12 - Annual consumption of fuels .. 2-22 Table 2-13 - Total production of by-product fuel gases .. 2-22 Table 2-14 - Stack emission for all stacks .. 2-29 Table 2-15 - Air pollution mitigation measures of production facilities .. 2-30 Table 3-1 - Details of baseline data monitoring location .. 3-2 Table 3-2 - Ground water level data (M) .. 3-9 Table 3-3 - Ground water resource data .. 3-10 Table 3-4 - Typical soil characteristics in project study area .. 3-14 Table 3-5 - Characteristics of surface water quality .. 3-17 Table 3-6 - Characteristics of surface water quality .. 3-18 Table 3-7 - Characteristics of ground water quality .. 3-19 Table 3-8 - Characteristics of ground water quality .. 3-20 Table 3-9 - Effluent quality monitoring data .. 3-21 Table 3-10 - Summary of site-specific micro- meteorological recordings in Jamshedpur study area .. 3-24 Table 3-11 - Ambient air quality in the study area .. 3-27 Table 3-12 - Recorded noise level in the study area .. 3-30 Table 3-13 - List of sampling locations for biological environment .. 3-32 Table 3-14 - Forests within 10 km radius .. 3-34 Table 3-15 - Evenness & diversity index values in the study area .. 3-36




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Page

TABLES (Contd)

Table 3-16 - List of aquatic macrophytes as observed during survey .. 3-38 Table 3-17 - Planktonic diversity index of monitoring locations .. 3-39 Table 3-18 - Fish fauna reported in the study area .. 3-40 Table 3-19 - List of semi aquatic birds observed during survey .. 3-41 Table 3-20 - Demographic profile of the urban Popu- lation of the project influence area .. 3-41 Table 3-21 - Demographic profile of the rural Popu- lation of the project influence area .. 3-43 Table 4-1 - Estimated control emission inventories .. 4-34 Table 4-2 - Predicted pollution level of ambient air during operational stage .. 4-18 Table 4-3 - Estimated generation of solid waste at 11 MTPA crude steel production stage .. 4-24 Table 4-4 - Budget allocation for greenbelt development .. 4-31 Table 7-1 - Hazard identification of the steel plant .. 7-4 Table 7-2 - Determination of risk potential .. 7-7 Table 7-3 - Environmental risk potential evaluation .. 7-8 Table 8-1 - Breakup of CSR spend (in %) .. 8-2 Table 9-1 - Environmental impact statement at operational stage .. 9-11

APPENDICES

App 1-1 - Terms of Reference (ToR) of EIA .. 1 App 1-2 - Compliance to Terms of Reference (ToR) points .. 12 App 1-3 - Compliance to the previous Public Hearing (Held on 18th June 2009) .. 20 App 1-4 - Prevailing ECs accorded by MoEFCC .. 23 App 1-5 - Certified copy of latest monitoring report of the Regional Office of MoEFCC on the status of compliance condition of all existing ECs .. 40 App 1-6 - Compliance to Consent to Operate .. 41 App 1-7 - Details of NABET Accreditation .. 57 App 1-8 - NABL certificate of monitoring agency .. 60 App 2-1 - Process description .. 61




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Page APPENDICES (Contd) App 2-2 - Consent for water withdrawal .. 68 App 2-3 - Stack emission details - Controlled emission from proposed stacks .. 69 App 2-4 - Stack emission details - Emission for existing stacks .. 70 App 2-5 - Summarised list of air pollution control (APC) equipment/systems for the production facilities .. 71 App 2-6 - Summarised list of proposed wastewater treatment plant .. 72 App 3-1 - Standards - National ambient air quality standards .. 73 App 3-2 - List of floral species in the study area .. 76 App 3-3 - List of avifauna in the records of Jamshedpur Forest division .. 82 App 3-4 - List of wild animals in the records of Jamshedpur division .. 86 App 3-5 - List of Phytoplankton and Zooplankton .. 88 App 3-6 - List of the important industries within study area .. 89 App 6-1 - In-house laboratory equipment list .. 94 App 7-1 - Recommendation of on-site emergency plan.. 95 App 9-1 - Periodic health status of existing employees.. 97 App 9-2 - Sample medical examination report .. 98 App 9-3 - Key initiatives for major occupational hazards .. 101

FIGURES

Fig. 2-1 - Site Location of TSL Works at Jamshedpur .. 2-3 Fig. 2-2 - A snapshot of the project site as shown In the Google Map .. 2-4 Fig. 2-3 - Schematic process steps for iron & steelmaking .. 2-9 Fig. 3-1 - Digital Elevation Model (DEM) of the study area .. 3-4 Fig. 3-2 - Geological Map of Jamshedpur .. 3-7 Fig. 3-3 - Ground water level data .. 3-10 Fig. 3-4 - Satellite Imagery .. 3-13 Fig. 3-5 - Land use pattern of core zone .. 3-15 Fig. 3-6 - Land use pattern of the buffer zone .. 3-15 Fig. 3-7 - Windrose diagram of Jamshedpur study area .. 3-23




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Page FIGURES (Contd) Fig. 3-8 - Diurnal aariations of mixing height at Jamshedpur .. 3-25 Fig. 2-9 - PM10 and PM2.5 level in the study area .. 3-28 Fig. 3-10 - SO2 and NOx Level in the Study Area .. 3-29 Fig. 4-1 - Water balance diagram .. Fig. 4-2 - Common effluent treatment plant scheme .. 4-9 Fig. 4-3 - Predicted 24-hrly average glcs of PM10 in mcg/cu m at 11.0 MTPA stage .. 4-19 Fig. 4-4 - Predicted 24-hrly average glcs of SO2 in mcg/cu m at 11.0 MTPA stage .. 4-20 Fig. 4-5 - Predicted 24-hrly average glcs of NOx in mcg/cu m at 11.0 MTPA stage .. 4-21 Fig. 6-1 - Environmental data processing system .. 6-4 Fig. 7-1 - Environmental risk qualitative analysis flow sheet .. 7-6 Fig. 9-1 - Indicative organisation structure of the proposed environment management department .. 9-4

DRAWINGS

Dwg. 11339-EIA-ENV-001 - Site Location Map Dwg. 11339-EIA-ENV-002 - Topographic Map Dwg. 11339-EIA-ENV-003 - Process Flow Diagram Dwg. 11339-EIA-ENV-004 - Plant General Layout Dwg. 11339-EIA-ENV-005 - Landuse Map of the Study Area Dwg. 11339-EIA-ENV-006 - Stack Location Map Dwg. 11339-EIA-ENV-007 - Industry Location Map Dwg. 11339-EIA-ENV-008 - Monitoring Location Map




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SUMMARY

In accordance with the approved Terms of Reference (ToR) of

Ministry of Environment, Forests & Climate Change (MoEFCC),

Government of India for Environmental Impact Assessment (EIA) of

the proposed expansion of Tata Steel Works from 9.7 million tons

per annum (MTPA) to 11.0 MTPA crude steel, sited in Jamshedpur,

Jharkhand, this summary presents a brief outline of the EIA

findings and the proposed mitigation measures.

Glimpse of the Project

Capacity before Expansion .. 9.7 MTPA Crude Steel Capacity after Expansion .. 11.0 MTPA crude steel

Process route .. Production of hot metal through blast furnace followed by basic oxygen furnace (BOF) for conversion of hot metal to liquid steel, followed by Rolling in Caster & Rolling Mills (BF-BOF route)

Site .. Within the existing Steel plant

boundary of area 717 Ha at Jamshedpur, East Singhbhum, Jharkhand

Iron Ore Source .. Existing source, i.e, sized iron

ore and ore fines produced at the captive mines, namely Noamundi Iron Mine (NIM), Joda East Iron Mine (JEIM), Khondbond Iron Mine (KIM) and others.

Water Source .. No additional withdrawal of fresh

water from River Subarnarekha. Additional make up water requirement would be met through recycling from existing water system.

Electric Power .. Additional in-plant generation

from extra by-product gases and external sources such as Power Grid Corporation of




Summary (Contd)

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India Limited (PGCIL), Tata Power Company Limited (TPCL), Jojobera Power Plant and Damodar Valley Corporation (DVC).

Estimated Investment .. Project cost - Rs. 1,632 crores Env. Mgmt. - Rs. 195 crores ESC - Rs. 50 crores Total - Rs. 1,877 crores

Completion Period .. Two (2) to three (3) years after grant of Environment Clearance

1. Tata Steel Limited, Jamshedpur, has proposed to augment the

capacity of hot metal production from 10.55 MTPA to 12.5

MTPA, resulting in higher production of crude steel and

finished rolled outputs.

2. The major three steps of expansion of this 108 years old plant,

from 4 MTPA to 5 MTPA, then 5 MTPA to 6.8 MTPA and 6.8

MTPA to 9.7 MTPA production of crude steel, is almost on

the path of implementation and operation. Now, with the

present plan of expansion, the subsequent crude steel

production would be 11.0 MTPA.

3. The proposed expansion would purposefully and effectively

utilize the existing adequate infrastructure & trained human

resource, thereby contributing to countrys growing demand

for steel.

4. As required by the present EIA Notification of MoEFCC dated

14th September 2006 and its subsequent amendments

thereafter for obtaining EC, Tata Steel has submitted online

application for grant of Terms of Reference (ToR) of EIA for

this proposed expansion on 7th August 2014. The meeting

for obtaining ToR was held on 19th September 2014 and 9th

January 2015, after which ToR was granted vide letter No. F.

No. J-11011/691/2007-IA.II(I) dated 28th April, 2015.




Summary (Contd)

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5. The additional production of about 1.3 MTPA crude steel

would be realized by augmentation of the production

capacities of following plant units; namely, Sinter Plant,

Pellet Plant, Steel melting shop & the Mills, revamping of

Blast furnace D & E, the installation of a new Lime plant of

600 TPD.

6. The enhanced production would be achieved by

improving productivity of the respective unit, stretching

the capacity of the technological unit to the possible

extent, de-bottlenecking of the process facilities and

addition of enablers as required.

7. This augmentation project would be taken up within the

existing plant of 717 ha (between 224611 and 224808

North latitude and 861130 to 861336 East longitude)

and no additional land would be required. Hence there would

be no Rehabilitation & Resettlement (R&R) issues related to

this project.

8. Water requirement for this expansion project would be

approx. 3.70 MGD (700 cum/hr). No additional make-up

water would be required to be drawn from River

Subarnarekha over and above the permissible limit of 33.3

MGD. The additional make-up water required by the

expansion would be made available from the plants existing

water system through recycling and reviewing the clarified

make-up water requirement.

9. The additional plant annual energy consumption for the

proposed augmentation of production capacity would be

around 690 Million kWh, which would be met from in-plant

generation from by-product gases as well as external sources

such as the Ramchandrapur-Baripada 400 kV line of Power

Grid Corporation of India Limited (PGCIL) through Bulk




Summary (Contd)

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Power Receiving Substation (BPRS), Tata Power Company

Limited (TPCL), Industrial Energy Limited (IEL), Jojobera

Power Plant and Damodar Valley Corporation (DVC).

10. The in-house power generation would be from CDQ of

Battery 5,6,7,10 & 11 amounting to about 55 MW and from

BF top gas pressure recovery turbine (TRT) of F-I blast

furnaces totaling to approx 47 MW. Captive power plants

(PH#3-5) would generate approx 147.5 MW and about 18 MW

would be generated by waste heat recovery from sinter plants

3 & 4. The total in-plant power availability of 267.5 MW and

the requirement of power purchase would be about 685.5

MW. To maximize the utilization of by-product gases, TSL

would explore the possibility to install an efficient power

plant of adequate capacity.

11. The existing capacities and proposed production plan of the

project is given below:

At 9.7 MTPA

stage (Existing) At 11.0 MTPA

stage (Proposed) Intermediate Products

Coke Production

(charge) 3.4 3.4

Sinter Production (net) 8 9

Pellet Production (net) 6 8

Calcined Lime 1.2 1.4

Hot Metal 10.55 12.5

Crude Steel 9.7 5% 11.0 5%

Captive power (MW) 189.5 267.5

Saleable Products

Long Products 1.24 1.74

Flat Products 5.83 7.00

Semis 2.37 2.06

Note: The above stated product-mix is tentative and may vary marginally depending on the market demand




Summary (Contd)

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12. The raw materials required would be iron ore (lumps &

fines), coking coal, limestone, dolomite & anthracite and

additives like limestone, dolomite, bentonite, etc. The

relative share of iron ore is about 60%, coal about 27% and

balances 13% accounts for additives. The overall raw

materials consumption rate would be about 3.26 t/t of crude

steel. . It is envisaged that the existing raw materials

supply sources of Tata Steel would continue to act as

raw materials linkages for meeting the estimated

requirements for the 11.0 MTPA expansion stage

13. The production units and capacities at 11.0 MTPA stage

would be as follows:

Production Unit Facilities at 9.7

MTPA stage

Production at 9.7

MTPA stage Facilities at 11.0

MTPA stage

Production at 11.0

MTPA stage Coke Ovens and

By-products Recovery Plant

(COBP)

COB # 5-11 3.4 MTPA COB # 5-11 3.4 MTPA

Sinter Plant SP#1-4 8.0 MTPA

SP#1-4 9.0 MTPA

Pellet Plant 1 unit 6.0 MTPA 1 unit 8.0 MTPA

Blast Furnace

BF# C,F,G,H ,I 10.55 MTPA Hot Metal

BF# C,D,E,F, G, H , I 12.50 MTPA Hot Metal

Lime/dolo Plant Kiln#1-9 3600 TPD Kiln#1-10 4200 TPD

LD Shop LD#1-3 9.7 MTPA

Crude steel LD#1-3

11.0 MTPA Crude steel

New bar Mill 1 unit 0.6 MTPA New bar Mill 1 unit 1.0 MTPA Wire Rod Mill -1 unit 0.37 MTPA Wire Rod Mill -1 unit 0.5 MTPA

Merchant Mill 1 unit

0.265 MTPA Merchant Mill 1 unit 0.43 MTPA

Hot Strip Mill -1 unit 3.55 MTPA Hot Strip Mill -1 unit 4.3 MTPA

TSCR 1 unit 2.34 MTPA TSCR 1 unit 2.65 MTPA

Rolling Mill

Cold Rolling Mill 1 unit

2.19 MTPA Cold Rolling Mill 1 unit

2.19 MTPA

Captive Power

PH # 3 By- PH # 4 product PH # 5 gas TRT-BF G,H, I

147.5 MW

42 MW

PH # 3 By- PH # 4 product PH # 5 gas TRT-BF G,H, I,F CDQ -Battery 5, 6, 7, 10 & 11 Waste heat recovery from Sinter Plant 3 & 4

147.5 MW

47 MW

55 MW

18 W




Summary (Contd)

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14. The total thermal energy requirement (excluding electrical)

for various process operations is estimated at 21.9 GJ/tcs.

This thermal energy would be derived from (i) coking coal,

(ii) coal to be injected into the BF (PCI coal) and

(iii) anthracite. An additional amount of Liquid Propane (LP)

would also be required for ladle heating and gas cutting of

steel products/scraps as and when required.

15. The plant would run for three shifts in a day, each shift of

8 hrs duration, throughout the year, except temporary

shutdown for capital repair or annual maintenance as and

when required. The proposed steel plant would be designed

with Level-4 automation systems to enable the plant and

machineries achieve higher productivity with improved

quality in a planned and coordinated manner.

16. The total manpower requirement would be around 37,000

which include an additional manpower of around 40

personnel for Lime plant. There would be a requirement of

additional contract manpower of the order of 200, during the

construction and augmentation activities.

17. The Construction Workforce during peak period would be

around 2000 in a day, the major labour component of which

would be made available from the local population.

18. All necessary Air Pollution Control (APC) measures have been

implemented for the production of 9.7 MTPA crude steel

through the commissioning and upgradation of pollution

control units. These APC units will also cater for the

increased load associated with the 11 MTPA expansion. The

additional pollution load would be mitigated by adopting

adequate control measures.




Summary (Contd)

- 7 -

19. The issue which are envisaged for this expansion program

are

- Maintaining the PM emission levels from all stacks below prescribed limit of 50 mg/Nm3

- Control of fugitive dust emission.

To keep the dust emission levels within the stipulated

limit, adequate measures would be taken to reduce point

source emission. In order to control the fugitive dust

emission, key fugitive dust emission sources would be

identified and management measures would be implemented.

20. The Plant PM emissions would be within 50 mg/Nm3 for

total of 100 stacks with heights varying between 30 m to 145

m. The emissions of SOx and NOx have been targeted to be

contained within 350 mg/Nm3.

21. The target emission would be achieved by implementation of

adequate emission control measures in the existing

production units which would help in reducing the emission.

Some of the major operating units would be retrofitted with

additional pollution control equipment like bag filters and

upgraded ESP with additional fields so as to cut down the

emissions from the respective units.

22. In order to minimize effluent discharge from Steel Works, all

the waste water from various units would be treated in the

respective effluent treatment plants (ETP) and/or then

further treated in Central Effluent Treatment Plant (CETP)

for primary; secondary and tertiary treatment before

recycling and low end uses like dust suppression, slag

quenching, green belt development. With adoption of the

measures, effluent discharge would reduce to 3 MGD.

23. The present environmental setting for the proposed project

has been ascertained for an aerial coverage of around 10 km




Summary (Contd)

- 8 -

from the project site by several field studies as required by

the ToR of EIA.

24. The study area falling under Survey of India (SOI) Toposheet

Nos. 73-J/1, J/2, J/5 and J/6 is a part of Chhota Nagpur

plateau. The study area in the district is plain land with

gently undulating topography. The Dalma hill range in the

north has got a peak elevation of 926 m above mean sea level

(AMSL). The steel plant and the town are located in the basin

area between Kharkai and Subarnarekha Rivers.

25. The Chhota Nagpur plateau of Jharkhand state represents a

part of Indian peninsular shield, which is a stable cratonic

block of the earths crust. As per IS: 1893 (Part I): 2002 of

Bureau of Indian Standards (BIS), the study area falls within

the seismic zone II (in a scale of Zone I to Zone V, where

Zone V is the highest risk prone area).

26. Geologically, Jamshedpur is located in the North Singhbhum

Mobile Belt, lying between Singhbhum Granite terrain in the

south and the Dalma volcanic belt in the north. The study

area constitutes the eastern segment of the Indian

Precambrian Shield, documenting the crustal evolutionary

history from Archean to mid-Proterozoic time (3.6-1.4Ga).

27. The rock formations in the study area muscovite quartz

schist inter layered with quartzite, hornblende schist and

thin amphibolite sill (designated as Chaibasa Formation).

The existent Dalma belt, displaying a synformal structure,

comprises of a sequence of sedimentary rocks (metapelites,

carbonaceous and ferruginous shale/phyllite, tuffs etc.) at

the bottom, followed upwards by high-Magnesium

volcaniclastics (vitric tuffs), volcanic agglomerate with

ultramafic intrusives (peridotite, pyroxenite) and finally

topped by tholeiitic basalt and basalt breccia.




Summary (Contd)

- 9 -

28. A greater part of the East Singhbhum district is underlain

with Precambrian crystalline rocks. Less than 10 per cent is

covered with semi-consolidated rocks of Kolhan group and

the late tertiary grits, gravels and unconsolidated alluvium of

quaternary age along the lower reaches of the Subarnarekha

River. The weathered residues of the hard rocks as well as

fractures, joints, fissures and other zones of discontinuity

are the principal repositories of ground water in East

Singhbhum district.

29. Groundwater in the study area occurs within the weathered

zone (from top to 15 - 25 m) and in the fracture zones of the

hard rocks present at depth, restricted within 120 m below

ground level (bgl). CGWB data shows that the occurrence of

ground water is at 1.3 to 13.8 m bgl. It also reveals the

increasing trend of stage of development of ground water in

the study area. TSL would not use ground water at any stage

of this proposed expansion. Further, Rainwater harvesting

would recharge the ground water inside the Steel Works and

within the town.

30. The two perennial streams in the study area are the

Subarnarekha and Kharkai Rivers. The primary water source

for the industry and township in the study area is the

Subarnarekha River. However, the people living in the rural

regions of the buffer zone draw water from hand lift tube

wells and dug wells.

31. As per the recent satellite imageries, for the core zone, built-

up area constitutes about 92% of the total area, while

greenery & water bodies consist of balance 8% of the area.

The buffer zone primarily consists of Habitation & Built-up

area and agricultural land, adding up to 69% of the total

buffer zone. Forest land & Industrial area occupies about




Summary (Contd)

- 10 -

15% and 6% of the total land area. Balance 10% comprises of

water bodies, stony area, and others.

32. The soil in the study area can be broadly divided into three

groups; (i) reddish yellow light grey catenary soil; (ii) yellow-

reddish deep soil and (iii) mixed red-yellow black soil rich in

iron content. The soil monitoring results shows that the

texture in general is sandy loam to gravelly sandy loam with

sand content above 60 per cent. Available organic carbon is

3.8-8.5 gm/kg at the monitored locations. The iron content

varied from 16,520 to 35,280 mg/kg. The rate of

mineralisation was low due to low microbiological activity.

33. The total hardness of all surface streams as reported in the

aforementioned Tables ranges from 83 - 232 mg/l. The

average DO level for all surface streams ranges between 4.3 -

6.3 mg/l whereas average BOD level ranges between 5.7 -

10.7 mg/l. Total coliform count ranges from 820 - 2800

CFU/100 ml across various surface water sampling.

34. The total hardness (TH) and total dissolved solids (TDS)

content in ground water were found to be in the range 153

mg/ to 436 mg/l and 369 mg/l to 983 mg/l respectively at

the selected locations. Chromium, lead, arsenic and other

heavy metals are found to be below detection limit (bdl).

35. The effluent water quality was sampled at four (4) locations

inside the Works at discharge point.The total suspended

solids (TSS) content in the effluent were found to be in the

range of 16 to 49.4 mg/l. COD and BOD values lies in the

range of 18 to 52 mg/l and 2 to 16 mg/l respectively.

36. The regional climate of Jamshedpur region is humid tropical.

The day time temperature during March-May exceeds 44C

with humidity 43%. The humidity level rises to a level of




Summary (Contd)

- 11 -

76% in the months of July-August. The average temperature

during the winter season is around 210C with humidity levels

around 60%. The annual average rainfall is around 1,380

mm.

37. Meteorological parameters of the study area was recorded by

temporary continuous weather monitoring station was

installed at the guest house at Kadma, Jamshedpur. The

maximum & average dry bulb temperature was recorded to

be 45.8C and 29.5C respectively. The relative humidity

ranges from 56 per cent, whereas average wind speed lies

between 3.9 m/s. The predominant wind direction is SSE

and total rainfall 139.1 mm.

38. The prevailing ambient air quality of the study area as

recorded at 8 different locations, depending on the windrose,

exhibits the ambience of an industrialized area. However,

the respirable suspended particulate matters (PM10 & PM2.5),

SO2 and NOx are lower than the permissible values as

stipulated by National Ambient Air Quality Standards

(NAAQS) for rural areas.

39. The forests in the study area are Dhan Chatani Reserve

Forest (R.F), Kudada R.F, Dimna Jhar Protected Forest (P.F),

Nandup P.F, Dalma pahar P.F. The climatic condition of the

study area favours the growth of Sal, Asan, Dhaora, Palash

and Mahua. The forests are of mixed tropical moist

deciduous & evergreen vegetation that tends to become dry

deciduous forest.

40. The dominant tree species in the study area is Sal and the

co-dominant species are- Asan, Kutaja, Mahua, Kendu and

Palas. The medicinal and cultural important flora observed

are Neem, Arjuna, Bel, Amla, Bahera, Tulsi , Basok,

Satamuli, Banyan and Pipal etc. The main agricultural crop




Summary (Contd)

- 12 -

is Rice followed by Maize and fruit plants like Banana,

Mango and Jackfruit etc.

41. None of the plant species observed in the study area can be

considered as rare and endangered as per the IUCN Red

list. Among the recorded plant species, none can be assigned

the status of endemic plant of this region.

42. The aquatic ecosystem in the study area mainly consists of

flora like Ipomoea sp., Cyperus sp., Eichhoria sp. and Lemna

sp. and faunal species of insects (like mayflies, dragonflies,

water spider, water scorpions, mosquito larvae etc), amphibian

(like frog, toad etc), fishes (like Catla, Rohu, Mrigal, Bata,

Puti, Sol, Lata etc) and semi aquatic avifauna (like Pond

heron, Indian cormorant, Little Egret, Pied Kingfisher, White

breasted water hen etc).

43. The study area is an amalgamation of urban and rural areas with

an aerial coverage of 314 sq km around Tata Steel Plant at

Jamshedpur, East Singhbhum district of Jharkhand. The decadal

increase of the urban population and the rural population is 16.66

% and 16.48 % respectively. The sex ratio of the rural population

has significantly increased over the decade and is higher than the

state average of 948.

44. The Project Influence Area (PIA) is characterized by several large

and medium sized industries, educational institutions and medical

centres. The rural settlements in the PIA benefit notably from this

established infrastructure facilities.

45. The growth of factory units and their expansion is perceived as a

beneficial stride for the community. It is an opportunity for the

escalation of ancillary small-medium industries, trade &

commercial establishments, local entrepreneurship and auxiliary

services and professions. Furthermore the proposed expansion




Summary (Contd)

- 13 -

project would facilitate investment to augment and carry forward

the existing social benefit plans.

46. During the stages of construction and operation, an increase in the

level of dust pollution is being apprehended. With the adoption of

stringent environment management and pollution control

measures, the impact would be marginal.

47. The diverse and widespread activities of TSL under the Corporate

Social Responsibility scheme, is noteworthy and globally eminent.

Their social responsibility towards the community encompasses a

defined schedule and participatory planning processes. TSL has

undertaken wide range of initiatives in the sphere of

(i) livelihood & employability (ii) education (iii) health (iv) local

infrastructure development (vi) ethnicity. The PIA is home to multi-

lingual tribes like the Santhals, Mundas, Ho, Kharias and Phorias.

Hence their CSR programmes are oriented around the principle of

Affirmative Action and the focus is aimed at the local scheduled

tribe and schedule caste groups.

58. EIA findings and the mitigation measures to minimize the

negative impacts on environment are summarized below:

Activity

Environ-mental impacts Mitigation measures Benefits

Establishment of Project

Industrial Development,might lead to increase in pollution level

- Water conservation - Pollution control measures - Solid wastes management - Greenbelt development - Social upliftment etc

- Infrastructure improvement;

- Employment generation;

- Revenue earning by the Government in the form of taxes & duties;

- Further scope for economic development of the nearby areas

Construction Temporary

adverse impact due to emission of dusts, discharge of construction wastewater and safety of

- Mechanised construction to reduce the construction period

- Dust abatement by water sprinkling

- Stoppage of noise prone work during night time

- Safety practices and use of Safety appliances

- Prevention of surface stream pollution

- Reasonably clean workzone environment




Summary (Contd)

- 14 -

Activity


construction workers

- Proper management of liquid & solid discharge

Water withdrawal

No additional withdrawal from surface water streams namely Subarnarekha

- Water conservation by closed loop recycling of wastewater after treatment

- Use of treated wastewater in various non-production uses

- Rain water harvesting in ponds

No withdrawal: Further conservation will have positive impact on water resource

Discharge of Plant Wastewater

Adverse, if untreated wastewater is discharged to the nearby stream

- Wastewater Treatment for respective production shops

- Recycling of treated wastewater within the respective plant to conserve water

- Providing CETP for final treatment of treated coke oven effluent, treated plant sanitary wastewater and other bleeds of treated effluents

- The finally treated effluent from CETP would either get reused in the cooling circuit or stored in Guard Pond for other uses such as greenbelt/landscape maintenance

- A part of the treated water from CETP would be further treated in ultrafiltration (UF) & RO plant to further use as make up and for secondary purposes in plant units.

- Reuse of treated wastewater collected in the Pond

- As there would be minimum plant discharge into the surface stream, the quality of surface stream would not be greatly affected.

Air pollution from production processes

Adverse due to emission of heat, dusts, SO2, NOx, CO and VOC

- VOC emission of coke oven batteries would be arrested by modern technological features

- Covered conveying systems for dry raw materials

- Adoption of Coke dry quenching (CDQ)

- Coke oven gas desulphurization

- Water sprinkling and dry fogging for suppression of fugitive dusts

- ESP based workzone fugitive dust extraction devices

- Tall stacks for better dispersion of airborne pollutants

- To keep ambient air less polluted and maintain ambient air quality standard

- Prevent endemic diseases of the community

Workzone noise

Adverse due to noise from rotary/vibrator machines/

- Selection of low noise prone rotary equipment, vibration dampening and dynamically balanced of rotating parts

Operation and maintenance personnel would not get noise exposure more than 85




Summary (Contd)

- 15 -

Activity


equipment, steam ejection etc

- Housing of noise prone equipment in a separate enclosure

- Operation from the noise shield cabins/pulpits

- Administrative control

dB (A) for a continuous period of 8 hrs.

Solid wastes generation

Adverse, if the solid wastes generated are stockpiled in open area for years together

- Maximum practicable processing of solid wastes either by reuse within the plant or by selling or by other gainful use

- To avoid contamination of ground water due to leaching, the storage yard would require concrete liner

- To block minimum land area for solid wastes dumping

- Maximum reuse of solid wastes for commercial/ useful purpose to prevent ground water contamination

Health Adverse on the

occupational health of the working personnel & community people

- On-line monitoring of emissions and wastewater release and corrective actions if pollution level exceeds the design target

- Occupational health care of the plant personnel as per international practice

- Check on the occupational ailments/hazards

- Prevention on the loss of production mandays

Safety Adverse due to

safety lapses - Extensive safety measures for

the plant operation and maintenance, electrical installations, fire safety measures including fire/smoke detection alarms, portable CO detectors and personnel safety appliances

- Avoidance of accidents causing minor to fatal injury of the plant personnel

- Avoidance of dangerous events like gas leak, fire, injuries etc

Peripheral Social Development

Beneficial - Social upliftment programmes in consultation with local people for growth of infrastructure, education, community health & safe drinking water supply and physical environment

- Acceptance of the project by the local population through accountable & transparent measures

- Sustainability of the project by believing in the principle that social responsibility becomes an integral part of the business

- Social upliftment and employment opportunity for the local people

59. For implementation of the proposed environmental mitigation

measures, the estimated total capital expenditure (CAPEX)

would be around Rs. 1877 crores. Rs. 195 crores would be

spent towards various forms of pollution mitigation measures




Summary (Contd)

- 16 -

including greenbelt development, eco-restoration, on-line

monitoring & environmental laboratory and energy

conservation.

60. It is presumed that the proposed project would be designed,

engineered and installed with the standard code of practices

of engineering, best practicable safety measures and

environmental safeguards.

61. In spite of adaptation of best engineering of the plant and

facilities, accidental events cannot be ruled out due to some

design deficiency or improper operation and maintenance or

malfunctioning of the various control systems installed. This

may affect life, property and environment.

62. Hazard potentials at this pre-engineering stage of the project

have been identified. Some of the potential hazards may arise

due to failure of effluent treatment plants, fuel gases storage

and handling systems, pollution control systems, electric

short circuits, unsafe storage and handling of oily wastes etc.

63. After design freeze or prior to commissioning, it is proposed to

have HAZOP study with consequences, particularly for

handling of fuel gases and combustible products, to take

further safeguards in the plant engineering and operation

manuals.

64. Safety during construction and operation would be of utmost

importance. The plant would have its own on-site & off-site

management plan to deal with various emergencies. Also,

various aspects of Disaster Management Plan (DMP) have

been discussed and it is suggested to get a DMP report

prepared that would help the plant personnel tackle

disastrous events.




Summary (Contd)

- 17 -

65. TSL would undertake various initiatives under Corporate

Social Responsibility for this project site for uplifting the

socio-economic status of the local people by providing health

and education facilities, skill development, business

entrepreneurship development etc. The total budget allocated

towards Enterprise Social Commitment (ESC) is estimated at

Rs 50 crores for the proposed expansion project.

66. In order to have effective management of the overall

environmental performance of the plant including social

commitments, it is essential to have a comprehensive

environmental management plan (EMP). This plan includes a

proper organization structure, responsibilities, planning,

budgeting, training etc.

67. The operation of the plant would have to comply with the

environmental regulations, public liability, Government

Notifications etc as applicable from time to time for

industrial operation.

68. Without proper organizational set up, EMP cannot be

enforced. It is, thus, proposed to build a suitable

organizational structure having three functional wings,

namely, (i) Environment, (ii) Health and (iii) Safety, for

implementation of the mitigation measures and continuous

improvement on overall performance of the plant. The

organisation would be manned by experienced professionals

in the areas of environment, health and safety (EHS).

69. The functions of EHS cover monitoring, regulatory

compliance, remedial measures planning, budgeting,

implementation and occupational health care and safety.

The organization is required to adopt comprehensive




Summary (Contd)

- 18 -

environmental management, social responsibility

management system and occupational health care systems of

the plant as required by ISO-14001-2004, SA-8000-2008 and

OSHAS-18001-2007 respectively, in addition to quality

management system of ISO-9002.

70. Imparting Training, implementation of programme on

eco-restoration, Green House Gas (GHG) emission reduction

and Research and Development (R&D) for resource

conservation and wastes reduction would be an integral part

of the environmental management.

71. In consideration of the predicted environmental impacts,

mitigation measures, environmental risks and the

implementation of the proposed EMP of the project under

consideration to be sited at Jamshedpur, a matrix of net

environmental impacts is presented at the end. It may be

seen from the EIA matrix of the project that if the proposed

mitigation schemes with effective environmental management

on a continual basis are implemented, the prevailing

environment would not become alarmingly adverse; rather it

would usher in economic development of Jamshedpur region.

72. This augmentation projection has been exempted of Public

Hearing (PH) by MoEFCC. However, as directed by MOEFCC,

the compliance to the previous Public Hearing (PH), held on

18th June 2009 for the expansion from 6.8 to 9.7 MTPA has

been appended with this EIA report.




1-1

1 - INTRODUCTION

Steel plays a vital role in the development of any modern and

emerging economy. The per capita consumption of steel is generally

accepted as a yardstick to measure the level of socio-economic

development and living standards of its countrymen. The Indian

Steel Sector enjoys advantages of domestic availability of raw

materials, i.e. iron ore, coal and cheap labour.

The Indian steel industry has entered into a new

development stage from 2004-05, riding high on the resurgent

economy and growing demand for steel. Rapid rise in production

has resulted in India becoming the 4th largest producer of crude

steel and the largest producer of sponge iron or DRI in the world.

In 2013-2014, the world crude steel production reached about

1,665 million tons (MT) and showed a growth of 1.2% over

2013 (Source: World Steel Association). China remained the worlds

largest crude steel producer in 2014 (about 822 MT) followed by

Japan (about 111 MT), the USA (about 88 MT) and India (about

83 MT) at the 4th position. Presently, steel contributes to nearly

two per cent of the gross domestic product (GDP) and employs over

500,000 people. The total market value of the Indian steel sector is

expected to touch US$ 95.3 billion by 2016.

Steel production in the country has increased at a compound

annual growth rate (CAGR) of 6.9 per cent over 2008-2012.

National Steel Policy 2005 had envisaged steel production to reach

110 million tons (MT) by 2019-20. However, based on the

assessment of the current ongoing projects, both in greenfield and

brownfield, the Working Group on Steel for the 12th Five Year Plan




1 - Introduction (Contd)

1-2

has projected that domestic crude steel capacity in the county is

likely to be 140 MT by 2016-17 and has the potential to reach

149 MT if all requirements are adequately met.

However, in terms of per capita consumption of steel, which

gives an indication of the technological advancement of a nation,

India, with an average figure of 59 kg, lags way behind the world

average of 216 kg. In 2015 structural reforms and improving

confidence will support a further 6% growth in Indian steel demand

but elevated inflation and fiscal consolidation remain key downside

risks to the outlook. As per the report of the Working Group on

Steel for the 12th Five Year Plan, there exist many factors which

carry the potential of raising the per capita steel consumption in

the country. These include among others, an estimated

infrastructure investment of nearly a trillion dollars, a projected

growth of manufacturing from current 8% to 11-12%, increase in

urban population to 600 million by 2030 from the current level of

400 million, emergence of the rural market for steel currently

consuming around 10 kg per annum buoyed by projects like Bharat

Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas

Yojana among others.

The State of Jharkhand has an immense potential for

industrialization with its large deposits amounting to 40% total

minerals of the country. This State is the sole producer of coking

coal, uranium and pyrite. It ranks first in the production of coal,

mica, kyanite and copper in India. It has wide network of rivers,

power plant and industrial bases with about one-third as urban

population. It also houses several esteemed central and state

government institutes e.g. CCL, CMPDI, HEC, NIFFT, NIT, etc. With

its large deposits of minerals, Jharkhand is one of the front-

runners in attracting large number of investors.





1-3

In view of emergent condition of steel production in the

country and the favourable atmosphere of the state, combined with

the enterprising endeavours of Tata Steel Limited (TSL) for

sustainable development, TSL is planning for augmentation of

Crude Steel production from 9.7 MTPA to 11.0 MTPA in their

existing steel works in Jamshedpur, East Singhbhum district of

Jharkhand. It is noteworthy that the additional production, due to

the expansion, would happen chiefly by augmenting the existing

production capacities of few plant units; namely, Sinter Plant,

Pellet Plant, Steel melting shop & the Mills, revamping of two

existing Blast furnaces and installation of a new Lime Plant. The

proposition of this project is particularly encouraged by the

growing demand of steel in the country, specially in the automobile

and infrastructure sector.

Details of the Project Proponent

Tata Steel Limited, formerly Tata Iron and Steel Company

Limited (TISCO), is an Indian multinational steel-making company

headquartered in Mumbai, Maharashtra, India, and a subsidiary of

the Tata Group. It was the 11th largest steel producing company in

the world in 2013, with an annual crude steel capacity of

25.3 million tonnes, and the third largest steel company in India

with an annual capacity of 9.7 million tonnes after SAIL and JSW.

Founded by Jamshedji Nusserwanji Tata in 1868, the Tata

group is a global enterprise comprising over 100 operating

companies in seven business sectors: communications and

information technology, engineering, materials, services, energy,

consumer products and chemicals. The group has operations in

more than 100 countries across six continents, and its companies

export products and services to 150 countries.





1-4

Tata Steel has manufacturing operations in 26 countries,

including Australia, China, India, the Netherlands, Singapore,

Thailand and the United Kingdom, and employs around 80,500

people. Its largest plant is located in Jamshedpur, Jharkhand. In

2007 Tata Steel acquired the UK-based steel maker Corus which

was the largest international acquisition by an Indian company till

that date. It was ranked 486th in the 2014 Fortune Global

500 ranking of the world's biggest corporations. It was the seventh

most valuable Indian brand of 2013 as per Brand Finance. On

16 February 2012 Tata Steel completed 100 years of steel making

in India.

Looking further into the future, the company plans to

continue to increase its capacity significantly through both

brownfield and greenfield developments. The first phase of the

6 million tonnes per annum greenfield project in Kalinganagar,

with stage-wise commissioning expected to start in Financial Year

2015-16. The Company is focused not only on the execution of the

plant facilities but also on addressing the socio-economic

infrastructure needs of an industrial enterprise of this scale.





1-5

Glimpse of the Project

Capacity before Expansion .. 9.7 MTPA Crude Steel Capacity after Expansion .. 11.0 MTPA crude steel Product mix ..

Sl. No. Facilities Existing Units

Production (MTPA)

Units After Expansion

Production (MTPA)

i Coke Oven Battery# 5 to 11 3.4 Battery# 5 to 11 3.4

ii Sinter Plant SP# 1 to 4 8.0 SP# 1 to 4 9.0

iii Pellet Plant 1 unit 6.0 1 unit 8.0

iv Blast Furnace BF- C,F,G,H,I 10.55 BF- C,D,E,F,G,H,I 12.50

v BOF LD# 1 to 3 9.7 LD# 1 to 3 11.0

vi Lime Kilns Kiln# 1 to 9 3600 TPD Kiln# 1 to 10 4200 TPD

vii New bar Mill 1 unit 0.6 1 unit 1.0

viii Wire Rod Mill 1 unit 0.37 1 unit 0.5

ix Merchant Mill 1 unit 0.265 1 unit 0.43

x Hot Strip Mill 1 unit 3.55 1 unit 4.30

xi Thin Slab & Continuous Caster (TSCR)

1 unit 2.34 1 unit 2.65

xii Cold Rolling Mill (CRM)

1 unit 2.19 1 unit 2.19

Note: The total finished product from all of the Mills will be





1-6

Electric Power .. Additional in-plant generation from extra by-product gases and external sources such as Power Grid Corporation of India Limited (PGCIL), Tata Power Company Limited (TPCL), Jojobera Power Plant and Damodar Valley Corporation (DVC).

Estimated Investment.. Project cost - Rs. 1,632 crores Env. Mgmt. - Rs. 195 crores CSR - Rs. 50 crores Total - Rs. 1,877 crores Completion Period .. Two (2) to three (3) years after grant of Environment Clearance

Initiation of the Expansion Plan

Tata Steel Limited, Jamshedpur, has now proposed to

augment the capacity of hot metal production from 10.55 MTPA to

12.5 MTPA, resulting in higher production of crude steel and

finished rolled outputs. Now, with the present plan of expansion,

the subsequent crude steel production would be 11.0 MTPA. It is

noteworthy that the additional production would happen by

augmenting the production capacities of few plant units; namely,

Sinter Plant, Pellet Plant, steel making shop & the Mills, revamping

of Blast furnace D & E, installation of a new Lime Plant.

Objective for the Proposed Expansion

The principal objective of this Brownfield Expansion plan is

to gain a key hold on the total market share of steel business with

minimum investment & time span, thereby avoiding the

complications involved in setting up a separate Greenfield project.

The proposed expansion would purposefully and effectively utilize

the existing adequate infrastructure & trained human resource,

thereby contributing to countrys growing demand for steel. This

proposed expansion would help Tata Steel to further achieve

economies of scale. Though there would be additional effect on

Environment, Tata Steel would continue to address such issues





1-7

with stronger commitment to excellence in sustainable

development at par with its peers across the globe. Tata Steel

aspires to be the most trusted and preferred domestic supplier of

value added steel with world class quality of products and services.

Status of Pre-Project Statutory Clearance

As required by the Environment (Protection) Act, 1986 and

its subsequent amendments thereafter, Tata Steel is required to

obtain Environmental Clearance (EC) of the proposed expansion

project from the Ministry of Environment, Forest and Climate

Change (MoEFCC), Government of India and Consent To Establish

(CTE) from the Jharkhand State Pollution Control Board (JSPCB),

prior to commencing any construction activities at the site.

Accordingly, as required by the present EIA Notification of

MoEFCC dated 14th September 2006 and its subsequent

amendments thereafter for obtaining EC, Tata Steel has submitted

online application for grant of Terms of Reference (ToR) of EIA for

this proposed expansion on 7th August 2014. The meeting for

obtaining ToR was held on 19th September 2014 and 9th January

2015, after which ToR was granted vide letter No. F. No.

J-11011/691/2007-IA.II(I) dated 28th April, 2015 furnished in

Appendix 1-1 for reference and Compliance to the ToR is given in

Appendix 1-2. The compliance to the previous Public Hearing (PH),

held on 18th June 2009 for the expansion from 6.8 to 9.7 MTPA

would also be appended in Appendix 1-3 of this Report as

mentioned in the MoEFCC letter referred above.





1-8

Scope and Coverage of this Report

The proposed expansion from 9.7 MTPA to 11.0 MTPA crude

steel would take place in the existing steel works at Jamshedpur,

Jharkhand. Previous ECs accorded by MoEFCC, certified copy of

latest Monitoring Report of the Regional Office of MoEFCC on the

status of compliance condition of all existing ECs and status of

compliance of Consent to Operate are enclosed in Appendices 1-4,

1-5 and 1-6 respectively. Baseline data generation for the EIA

study has been carried out from Feb-May15. During the EIA study,

the prevailing environmental set up comprising of air, water and

land environment, ecological and the human environment are

evaluated in the study area as mentioned in the ToR, particularly

on their present mode of living and other societal elements. Once

these impacts are assessed at the project conceptualization stage,

mitigation measures by proper engineering have been suggested to

mitigate the negative impact, along with formulating CSR measures

for overall societal upliftment, the project after implementation

would then cause minimum degradation of the environment and

satisfy the stakeholders.

In view of the above stated scope for undertaking EIA of the

proposed project, the present report has been prepared in

accordance with the ToR of EIA firmed up by the MoEFCC and

addressing all the issues emerged during previous PH held in

18th June 2009, as the project is exempted from PH procedure by

EAC.





1-9

Structure of this Report

This Report is prepared in line with the suggested generic

structure of EIA prescribed by MoEFCC. There are nine (9)

Chapters complete with Summary, relevant Tables, Figures,

Drawings, Photographic Exhibits and Appendices.

Following this Introduction Chapter, the project details is

discussed in Chapter-2; Chapter-3 presents the Present

Environmental Setting; Chapter-4 describes Environmental

Impacts and Mitigation Measures; Chapter-5 discusses about the

alternative technologies, Chapter-6 presents the Environmental

monitoring program, Chapter-7 details out the additional studies,

Chapters 8 & 9 discusses the project benefits and the EMP. The

summary of the EIA Report and Disclosure of the Consultants

engaged are also part of this report.

The various field data as recorded within the study

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