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FORM V (See rule 14)
ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE 31ST MARCH-2015
BMM Stage II - 2 MTPA Integrated Steel Plant:
PART A
i. Name and address of the owner: Mr. B.K. Ganesh Occupier of the industry Director & Occupier, Operation or process BMM Ispat Ltd, Danapura Tq- Hospet, Dist- Bellary. ii. Industry category Primary - (STC Code) Secondary- (STC Code) iii. Production category Units - DRI Plant : 4 x 500 TPD) Beneficiation Plant : 1.3MTPA Pellet Plant : 1.2 MTPA
Captive Power Plant : 1X70MW Captive Power Plant : 2x70 MW iv. Year of establishment: Aug 2011 v. Date of the last environmental statement submitted. : 14.08.2014
PART B
Water and Raw Material Consumption: Production during 2014-15 (1st Aril 2014 to 31st March 2015)
i. Water consumption in m3/A
Process:
Sl. No.
Unit Water consumption
1 DRI Plant 4,23,883 m3/A 2 Power Plant (1X70MW) 2,64,317 m3/A 3 Iron Ore Beneficiation Plant 4,05,832 m3/A 4 Pellet Plant 3,27,619m3/A 5 Power Plant (2X70MW) 2,55,645m3/A
Cooling : (included in the above list) Domestic : 21600 m3/A
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Specific water consumption
Name of Products
Process water consumption per unit of products
During the current financial year (2013-
14)
During the current financial year (2014-15)
DRI Plant 1.41 m3/ton 0.996 m3/ton Power Plant-1X70MW 0.70 Ltrs/KWh 0.66 Ltrs/KWh Iron Ore Beneficiation Plant
0.565 m3/ton 0.422 m3/ton
Pellet Plant 0.328 m3/ton 0.592m3/ton Power Plant-2X70MW 0.373 Ltrs/KWh 0.259 Ltrs/KWh
ii. Raw material consumption Name of Product
Name of raw materials*
Consumption of raw material per unit of output
During the previous financial year (2013-14)
During the current financial year (2014-15)
DRI (4X500TPD) Iron Ore Iron ore pellet Coal Limestone Dolomite
0.09 1.41 0.94
0.04
0.07 1.45 0.98
0.047
Power-70MW Flue Gas from Kiln Coal Dolochar Rice Husk Bed material
0.237Kg/Kwh 0.038 Kg/Kwh 0.0001 Kg/Kwh 0.0008 Kg/Kwh
0.40 Kg/Kwh 0.059Kg/Kwh 0.0003Kg/Kwh 0.0018Kg/Kwh
Iron Ore Beneficiation
Iron Ore
1.008 1.34
Pellet Iron Ore concentrate Bentonite Limestone Coal Dolamite Furnace oil Coke
1.17 0.006 0.018 0.038 0.014 0.01
0.0084
1.19 0.007 0.019 0.037 0.016 0.002 0.0069
Power -2X70MW Flue Gas from Kiln Coal Dolochar Rice Husk Bed material
0.26Kg/Kwh
0.036 Kg/Kwh 0.003 Kg/Kwh
0.60Kg/Kwh 0.093Kg/Kwh 0.0012Kg/Kwh
0.00026Kg/Kwh * Industry may use codes if disclosing details of raw material would violate contractual obligations, otherwise all industries have to name the raw materials used.
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PART.C
Pollution discharged to environment/unit of output (Parameter as specified in the consent issued) Pollutants
Quantity of Pollutants discharged (mass/day)
Kg/day
Concentration of Pollutants discharged
(mass/volume)
Percentage of variation from
prescribed standards with
reasons
a. Water Zero Discharge of waste water
b. Air SID- kiln 1&2 73.4 kg/day 75 mg/Nm3 56.34 % Below SID- kiln 3&4 78.7 kg/day 74 mg/Nm3 53.18% Below Power Plant (70MW: WHRB 40MW & FBC 30MW)
148.2 kg/day 65 mg/Nm3 48.55 % Below
Beneficiation Plant Nil Nil Nil Pellet Plant 237.9 kg/day 43 mg/Nm3 60.35 % Below Power plant( 2X70MW)
506.9 kg/day 45 mg/Nm3 12.00% Below
PART.D
HAZARDOUS WASTES (as specified under Hazardous Wastes (Management & Handling Rules, 1989)
Hazardous Wastes Total Quantity (Kg) During the previous
financial year (2013-14) During the current financial
year (2014-15) 1.From Process Used Oil:
a) Power Plant -1x70MW
b) DRI plant
c) Iron Ore Beneficiation Plant
d) Pellet Plant
e) Power plant-2x70MW
Resin from DM Plant
2. From Pollution Control Facilities
3900 Lts /annum
1330.5 Lts /annum
4489.6 Lts /annum
NIL
6000 Lts /annum
NIL
4800 Lts /annum
2320 Lts /annum
6850 Lts /annum
2450 Lts /annum
7550 Lts /annum
NIL
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PART- E
SOLID WASTES: Solid Wastes
Total Quantity
During the previous financial year (2013-14)
During the current financial year (2014-15)
i) DRI plant a. From process
Fly Ash /dust :53990 TPA Coal dust : 15000 TPA Dolochar : 38990 TPA
b. From Pollution Control Facility
Fly Ash /dust : 47250 TPA Coal dust : 12000 TPA Dolochar : 35250TPA
c. 1) Quantity recycled or re- utilised within the unit
2) Sold 3) Disposed/Stored
All the Qty. of Coal dust is reused in process. All the dolochar produced was utilised in CFBC boiler for power generation
47250 TPA
All the Qty. of Coal dust is reused in process. All the dolochar produced was utilised in CFBC boiler for power generation
53990TPA
ii) Power Plant-1X70MW a. From process --- b. From Pollution Control Facility
Fly ash – 16,762 TPA Fly ash –34864.49TPA Bed ash –3873.83TPA
c. 1) Quantity of recycled or re-utilised within the unit 2) Sold 3) Disposed
5,400 TPA
30,000 TPA
NIL
NIL
34864.49TPA
3873.83TPA iii) Beneficiation Plant a. From process Tailing – 1,59,493TPA Tailing –1,92,090 TPA b. From Pollution Control Facility
- -
c. 1) Quantity of recycled or re-utilised within the unit 2) Sold 3) Disposed/stored
- -
Stored in a tailing ponds iv) Pellet Plant a. From process - b. From Pollution Control Facility
Ash/dust -481 TPA Ash/dust - 600TPA
c. 1) Quantity of recycled or re-utilised within the unit 2) Sold 3) Disposed
All the waste is reused in BP process
All the waste is reused in BP process
V) Power Plant 2X70MW a. From process Bed ash-300 tons Bed ash-400 tons b. From Pollution Control Facility
Fly ash –75000 TPA Fly ash –1,25,000TPA
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c. 1) Quantity of recycled or re-utilised within the unit 2) Sold 3) Disposed
NIL
All fly ash were Sold to cement plant in closed containers
NIL
NIL
All fly ash were Sold to cement plant in closed containers
Bed ash is used for road making
& land fill
PART. F
Please specify the characteristics (in terms of concentration and quantum) of hazardous as well as solid wastes and indicate disposal practice adopted for both these categories of wastes. The fly ash generated in the power plant is being sold to cement industries for cement making through closed containers. Also the fly ash is being used for brick making, for which 2 Nos of fly ash brick manufacturing plants are in operation. Waste Oil is the source of Hazardous waste generation. The waste oil is scientifically collected and stored in barrels. It is propose to mix with furnace oil & use it in furnace, as fuel / smear on metal surface to avoid corrosion. Coal based DRI plants do not handle any hazardous chemicals (as stipulated in Manufacture, Impact & Storage of Handling, Chemicals Rules) nor generate any hazardous waste (Stipulated in Hazardous Waste Management & handling Rules)
PART.G
Impact of the pollution control measures taken on conservation of natural resources and consequently on the cost of production. The industry has concerns for Environment; it has spent Rs. 82.39Lakhs towards Pollution Control/monitoring maintenance & Rs.42.00Lakhs towards CAAQMS Equipment etc., during 2013-14. The industry has spent Rs. 40.0 Lakhs towards Green Belt Development and planted 60,000nos. trees during 2014-2015. Also spent 1.5 crores on the EMS & OHSAS Implementation activities. With regards to handling of fly ash, we are happy to inform that we have commissioned two units of Eco friendly “Automated Bricks/Blocks manufacturing unit”. Ash bricks of 2000 to 4000 No.s and blocks of 1200 per day are being manufactured.
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Water Conservation is practised by recycling/reutilising water from slime ponds and treated DM back wash, seepage recovery from reservoirs. Quantity of recycled/reutilised water is 3,30,000 Cum. Rain Water harvesting 35,000 cum.
PART-H
Additional measures/investment proposal for environmental protection including abatement of pollution. Environmental protection measures adopted are as per norms approved by KSPCB.
PART-I
Any other particulars in respect of environmental protection and abatement of pollution
BMM Ispat Ltd is taking care of all aspects of environment, like air, water noise pollution control etc.,
Water pollution control measures:
1. It is followed zero discharge policy and there is generation of effluent water.
2. Installed 3 nos. STP’s to treat the domestic effluent, one more STP is under construction.
3. Reduced fresh water consumption by 330 million liters of water in the year 2014, in the form
of recycling, reusing and rainwater harvesting etc.,
Air pollution control measures:
1. Installed 12 nos. of ESP’s for various processes and 45 nos. of DE-dusting systems for abating
dust emissions.
2. Installed Dry fog system at transfer chutes & conveyor transfer points.
3. Installed more than 150 nos. of water sprinklers on dumps, on conveyors etc.,
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4. Coal is obtained by Rail way wagons. The industry has provided Wagon Tripler and Dry fog system to arrest fugitive dust.
5. The coal is transported to different users point in closed Conveyer system. Dry fog system / Sprinkler Systems are provided at dust generation sources.
6. The Industry has provided barricades for iron Ore Storage Area on three sides.
7. Regular water sprinkling on unpaved roads.
8. Installed online stack emission monitoring to ensure the emission within the norms.
9. Installed 2nos. of CAAQMS station at the boundaries of the plant to ensure dust levels are
within the permissible limits.
10. Regular air quality monitoring to ensure dust free the work place environment.
Green belt development:
1. Own nursery to cater the sapling needs
2. Yearly 50,000 saplings have been developed and planted in the factory premises.
3. Till date 2,70,000 samplings have been planted.
Implemented EMS & OHSAS management:
1. Taken all the necessary requirements and executed works to implement EMS system like,
providing coloured bins, segregation wastes and it’s disposal, constructed hazardous waste
storage areas, scrap storage areas etc.,
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Green Belt Developments Photographs
Own nursery for development of saplings
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DUST EXTRACTION BY TRUCK MOUNTED
VACUUM OPERATED EQUIPMENTS
VACCUME OPERATED ROAD SWEEPING
MACHINE
WATER SPRINKLING SYSTEM AT SPONGE IRON FOGGING TYPE DUST SUPRESSION SYSTEM
ON RAW MATERIAL HEAP