EXPANSION OF JSW STEELenvironmentclearance.nic.in/writereaddata/Online/TOR/22...7 Cold Rolling Mill -3 of 2.3 MTPA capacity(New) 8 Larger capacity Lime and Dolo Calcining plants (f

EXPANSION OF JSW STEEL

16 MTPA to 18 MTPA

PRE-FEASIBILITY REPORT

JSW STEEL LIMITED, VIJAYANAGAR WORKS

AT

TORANAGALLU, DISTRICT BELLARY, KARNATAKA June 2018 Project Proponent

EXPANSION OF JSW STEEL

16 MTPA to 18 MTPA


JSW STEEL LIMITED, VIJAYANAGAR WORKS

AT

TORANAGALLU, DISTRICT BELLARY, KARNATAKA June 2018 Project Proponent

JSW STEEL LIMITED 18.0 MTPA Crude Steel Production


1

CONTENTS

Sl.No. DESCRIPTION PAGE NO.

1. 2. 3.

4. 5 6. 7. 8. 9.

Executive Summary

Introduction of the Project

Project description Site Analysis Planning Brief Proposed Infrastructure Rehabilitation & Resettlement Implementation schedule & cost estimate Analysis of proposal

1-1 – 1-3

2-1 – 2-8

3-1 – 3-25

4-1 – 4-5 5-1 – 5-3 6-1 – 6-8 7-1 8-1 – 8-4 9-1



2

List of Figures

Figure no. Details

Fig 3.1 Location of proposed facil ities in the expansion project Fig 3.2 Plant lay out showing the location of proposed facilities Fig 3.3 Process flow for manufacture of finished steel products Fig 4.1 Road and Railway connectivity Fig 6.1&2 Location of proposed expansion of crude steel capacity

List of Tables

Table no.

Details

1.1 New and proposed changes in facilities proposed 1.2 Proposed changes in existing facilities 1.3 List of facilities at 18 MTPA 2.1 India – Steel consumption scenario (Million Tons) 2.2 Major market segments - 2030

2.3 Major market segments - 2030 3.1 Changes/Additional facilities in the proposed project 3.2 Optimization of facilities at 16.0 MTPA stage 3.3 Design basis of Pellet Plants 3.4 Typical analysis of raw materials for pellet production 3.5 Design basis of Blast Furnace 3.6 Typical raw material analysis (Dry basis) 6.1 List of species of plants/shrubs in and around JSWSL 8.1 Cost estimates : 18.0 MTPA expansion of crude steel at Vijayanagar 8.2 Cost estimates : Environmental control measures at 18.0 MTPA

List of Annexures

Annexure no. Details

Annexure 1 Environment clearance for expansion from 10 MTPA to 16 MTPA, Dated : 01.10.2015

Annexure 2 Amendment for Environment clearance for expansion from 10 MTPA to 16 MTPA, Dated : 09.06.2016





1-1

1 EXECUTIVE SUMMARY

1.1 INTRODUCTION

JSW Steel ltd, formerly known as Jindal Vijayanagar Steel ltd. (JVSL), is

the flag ship company of OP Jindal group of industries. This integrated steel

plant at Toranagallu is the most modern, technologically efficient, eco-friendly

and the largest integrated steel plant in India.

JSW Steel ltd now intends to enhance the steel manufacturing capacity

approved by MoEF&CC from 16.0 MTPA to 18.0 MTPA and produce a wide

variety of steel products to meet the requirements of the customers. The

expansion facilities will be built within the existing integrated steel plant

complex. With this expansion, JSW Steel will be in a stronger position to supply

a wide variety of steel products to the consumers in south and central India. The

product mix that will be offered by JSWSL will then include semis like billets and

blooms, flat products, long products, wire rods, re bars, light & heavy sections,

and value added cold rolled and coated products.

Over the years, JSWSL has grown from a crude steel capacity of 1.2 MTPA in

1999 to 10 MTPA by 2011. Currently, JSWSL is implementing its expansion plan

of enhancing crude steel capacity from 10 MTPA to 16 MTPA approved by

MoEF&CC vide environment clearance J-11011/489/2009 lA-II(I) dated 01st

October 2015 and subsequent amendments in 9 th June 2016 and 29 th May 2018

(Annexure-1 and Anneure-2). Some of the facil ities which were originally

belonging to JSWSL were developed as new entities with respective core

expertise and the environment clearance was transferred to these companies

vide amendment dated 28th Feb 2018 (Annexure-3).

The original proposal of expansion of crude steel capacity at Vijayanagar from

10 MTPA to 16 MTPA, primarily involved in setting up of two 3.0 MTPA Blast

furnaces like the existing BF 3&4 units which were set up during the expansion

of the steel plant from 4.0 MTPA to 10.0 MTPA.

JSW Steel, Vijayanagar currently has an installed capacity of 12 MTPA crude

steel. During 2017-18, the crude steel production was 11.4 MTPA. As a part of

its expansion program to enhance the capacity to 16 MTPA, JSW Steel is in the

process of setting up additional facilities which will take the crude steel capacity

to 13 MTPA by Dec 2019.

However, with the upgradation of BF-1 and planned upgradation of BF-3 to

country’s largest blast furnace of 5560 m3 BF, the capacity of crude steel is



1 EXECUTIVE SUMMARY (cont’d)

1-2

being enhanced from 10 MTPA to 13 MTPA. JSW Steel is currently in the

process of installing a similar Blast furnace of 5560 M3 capacity in India at

Dolvi.

Keeping in view of the advantages of larger blast furnaces and JSW Steel’s own

expertise developed over the years in operating large blast furnaces, it is

proposed to install a large blast furnace of 5560 m3 in place of 4100 m3 blast

furnace proposed in the original project of expansion of capacity from 10 MTPA

to 16 MTPA. With this major change together with optimization of existing and

proposed facilities, the capacity of crude steel is being enhanced from 16 MTPA

to 18 MTPA.

In the proposed expansion, new steel finishing facilities (BRM, WRM and Cold

Rolling complex) and changes in the capacity and configuration of some

production facilities (BF, BOF, EAF, HSM) is being proposed.

The details are given in Table 1-1.

Table 1-1 NEW AND PROPOSED CHANGES IN FACILITIES PROPOSED

Production Facility

1 Pellet Plant-3 of 6.8 MTPA (in place of Sinter Plants 6) & SP-5 of 2.3

MT in place of 1.75 MTPA)

2 Blast Furnace-5 of 5500 m3 volume (in place of 4019 m3)

3 SMS-4 Larger size 350 T BOFs (from 2X200t to 2X350t)

3 Zero Power Furnace (in place of 1.2 MTPA EAF)

4 Hot Strip Mill-3 (enhancement from 3.6 to 5.0 MTPA)

5 Bar & Rod Mill-2(New)

6 Wire Rod Mill -2(New)

7 Cold Rolling Mill -3 of 2.3 MTPA capacity(New)

8 Larger capacity Lime and Dolo Calcining plants (from 8X300tpd to

4X600 tpd) (changes in configuration)

9 Oxygen Plants(new) – 3 nos

10 New ash pond for gypsum(FGD) and bottom ash

Over the years, there have been several changes in the quality of raw

materials, improvements in operational practices and efficient management of

resources by way of efficient use of energy, water and wastes. This has resulted

in necessities to modify some of the existing facil ities by relocation,




1-3

reconciliation of capacities of production facilities and re configuration with ot

any change in overall capacity of steel making. The details are given in Table 1-

2.

Table 1-2 PROPOSED CHANGES IN EXISTING FACILITIES

Facility Remarks

1 Shifting of OBP-1(dry process) to OBP-2(wet Process)

No change in

overall capacity

There are no changes in all other facilities both existing or those planned under

the 16 MTPA expansion and yet to be executed.

With the above, the list of facilities at 18 MTPA will be as follows and is

presented in Table 1-3.



1-1

List of facilities as existing now after amendments and those proposed in the expansion to 18 MTPA

Sl

no

Name of the

Unit

Facilities at various stages of expansion in MTPA Total Capacity

(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity

( at 18 MTPA) 4 -MTPA

4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

1 Ore beneficiation

Plant - product

OBP-1

1 X 4.5

OBP-2

1X 2.5 ,

1X 5.0 &

1 X 7.5,

Nil

1 X 4.5

1X 2.5

1X 5.0

1 X 7.5

19.5

OBP-1 facilities to be

Relocated

to OBP-2

19.5

2 Pellet Plants PP1- 1- 5.0 PP-2- 5.0 Nil PP 1 & 2

2 X 5 .0 10

PP-3

6.8 16.8

3 Sinter Plants SP1 SP 2 -2.3

SP 3- 7.5

SP4 -2.3

SP5 -1.75

SP6 -5.75

SP1-6

3X 2.3

2 X 5.75

1 X 1.75

20.15

SP-5: 2.3

SP-6: deferred in lieu

of PP-3

14.95

4 Coke Oven – NR

CO 1 &2

2 X0.64

1.28

Nil

Dismantling of

Existing NR

Coke Oven

0 0 No addition 0

5 Coke Oven –

Recovery type Nil Coke 3 - 1.5 CO 1&2 -1.5

CO 1-5

2X1.5

1X2.0

1X3.0

8.0 No addition 8.0

6 Hot metal –Corex Corex 1 & 2

2X0.8 Nil Nil

Corex 1- 2

2 X 0.8 1.6 No addition 1.6

7 Hot metal-Blast

Furnace

BF-1-2.5

BF-2-2.17

BF 3 & 4

2 X 3.0

BF-3- 4.4

BF-5- 3.0

BF 1 -5

1X 2.5

1X 2.17

1X4.4

2X 3.0

15.07 BF-5 of 3.0 MTPA to

be built as 4.5 MTPA 16.57




1-2

Sl

no

Name of the

Unit


(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity

( at 18 MTPA) 4 -MTPA 4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

8 Pig Casting

Machines (TPD) 1200 7200 3600 12000 12000 MGP-5000 tpd 17000

9 Crude steel - BOF,

EAF & auxiliaries

SMS1

3.80

SMS2

6.0

SMS2 -6.4 SMS 3 & 4-

5.6

2X200T BOF

+2X1.2 EAF

SMS1-4 1X3.8

1X6.4

1X3.0

1X2.6

15.8

SMS-3: In place of 1

EAF, 1 ZPF is considered

SMS-4 will be changed

from 2 x 200T to 2 x

350T & will operate at

4.8 mtpa

18

10 Lime Kiln (TPD) LCP-1

4x300

LCP-2

4X300

,4X600

LCP-3

4 x 600

LCP 1- 4

8 X 300

8 X 600

7200 No addition 7200

11 Slab Caster 3.2 6.4 SMS-3-1 X1.6

SMS-4-1X3.6

Slab Caster 1-

4

14.8

14.8

SMS-4 slab caster

changed from 1 x 3.6

mtpa to 2 x 2.5 mtpa

16.2

12 Billet caster Nil SMS-2

1.5

SMS-3

3.0 4.5 4.5 4.5

13 HSM HSM 1

1X4.0

HSM-2

1X5.2

HSM-3

1X3.6

HSM1-3

12.8 12.8

HSM-3 upgraded to

5.0 14.2

14 Plate Mill Nil Nil Nil Nil Nil No addition Nil

15 Pipe Mill Nil 0.4 Nil 1X 0.4 0.4 No addition 0.4

16 Wire rod mill Nil WRM-1

1x0.6

WRM-2

1.2

WRM 1-2

1X0.6, 1X1.2 1.8 No addition 1.8

17 Rebar & Section

mill Nil

BRM-1

1X1.0 Nil

BRM-1

1.0 1

New BRM-2 of 1.2

MTPA 2.2




1-3

Sl

no

Name of the

Unit


(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity


4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

18 Cold Rolling Mill

Complex

CRM-1- 1.8

CRM-2-2.3 Nil

CRM1&2

4.1 4.1 CRM-3 of 2.3 MTPA 6.4

19 Galvanizing Lines Nil Nil

CGL-1-

4X0.25

CGL-2-

2X0.45 -

CGL 1&2

4X0.25

2X0.45

1.9 No addition 1.9

20 Color Coating Line Nil- 0.5 Nil 0.5 0.5 No addition 0.5

21

Power Plant and

process steam

boilers in MW

CPP 1X100 CPP-2

1X130

all gas

CPP 3 &4

2X300

gas+coal

CPP5-1X660

coal

CPP 1-5

1X100, 1X130,

2X300,1X660


22 Incinerator (kg/hr) Nil 2 X 250kg/h 250kg/h 2 X 250kg/h 1000kg/h No addition 1000kg/h

23 Slag Grinding and

mixing unit CP-1

1X 0.2 Nil

CP-2 1X2.0

CP-1&2

1X0.2 1X2.0

2.2 No addition 2.2

24 Oxygen Plant (Out

sourced)

1x2500

TPD=2500

TPD

2x1800

TPD +

1X900 TPD

2X1800 TPD

1 X 2500 TPD

10600 TPD 1 x 2060(TP)

2 x 2200 14860 TPD 4 X1800 TPD

1 X 900 TPD

25 Township (nos) 2 Units 2 Units 2 units 6 units 6 units 1 unit 7 units



2-1

2 - INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

India is the 3rd largest producer of crude steel globally with a total crude Steel

Production of over 102 Mt in 2017-18. Indian economy is rapidly growing with

special focus on infrastructure and construction, promoting further growth of

steel industry

JSW Group is a $ 12 bil lion leading conglomerate , with presence across India,

USA, South America & Africa, the JSW Group is a part of the O.P. Jindal Group

with strong footprints across core economic sectors , namely Steel, Energy,

Infrastructure, Cement, Ventures and Sports.

JSW Steel currently has a capacity of about 18 MTPA steel in its three steel

plants located at Vijayanagar(Karnataka), Dolvi(Maharashtra) and Salem (Tamil

nadu). JSW is also planning to enhance its capacity by scaling up existing

plants and planning on install ing new projects to produce 40 MTPA. Globally,

JSW owns a steel plant, plate and pipe mill in the US, and mining assets in the

US, Chile and Mozambique. JSW have integrated cutting-edge technology,

innovation, R&D with sustainability and community initiatives in their journey of

development.

JSW Steel, Vijayanagar currently has an installed capacity of 12 MTPA crude

steel. During 2017-18, the crude steel production was 11.4 MTPA. As a part of

its expansion program to enhance the capacity to 16 MTPA, JSW Steel is in the

process of setting up additional facilities which will take the crude steel capacity

to 13 MTPA by Dec 2019.

The original proposal of expansion of crude steel capacity at Vijayanagar

from 10 MTPA to 16 MTPA, primarily involved in setting up of two 3.0 MTPA

Blast furnaces like the existing BF 3&4 units which were set up during the

expansion of the steel plant from 4.0 MTPA to 10.0 MTPA.

However, with the upgradation of BF-1 and planned upgradation of BF-3 to

country’s largest blast furnace of 5560 m3 BF, the capacity of crude steel is

being enhanced from 10 MTPA to 13 MTPA. JSW Steel is currently in the

process of installing a similar Blast furnace of 5560 M3 capacity in India at

Dolvi. Keeping in view of the advantages of larger blast furnaces and JSW

Steel’s own expertise developed over the years in operating large blast

furnaces, it is proposed to install a large blast furnace of 5560 m3 in place of



2 - Introduction of the Project (cont’d)

2-2

4100 m3 blast furnace proposed in the original project of expansion of capacity

from 10 MTPA to 16 MTPA. With this major change together with optimization of

existing and proposed facil ities, the capacity of crude steel is being enhanced

from 16 MTPA to 18 MTPA.

2.2 Brief Description of the Nature of the Project

The brief profile of the expansion project is as follows:

Hot Metal 18.17 MTPA

Crude Steel 18.00 MTPA

Saleable products

Hot Rolled Coils/Plates 14.20 MTPA

Cold rolled products 6.40 MTPA

(Cold rolled annealed & galvanized coil,

color coated coil. Tinplate coil, Silicon

steel)

Long Products (Bar, Wire Rod,) 4.00 MTPA

The proposed production of crude steel and subsequent rolling would be

accomplished via Blast Furnace (BF)-Basic Oxygen Furnace (BOF)-Caster

route, followed by hot, cold rolling.

The project falls under category A, Section 3 (a) of EIA Notification

September 2006 and amendment thereof vide Notification No. S.O 3067 (E)

dated 1st December 2009.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY

In 2017-18, production of crude steel was about 102.2 MTPA in the country with

a growth of approximately 5.5% over 2016-17. India’s per capita steel

consumption is 61 kg, much lower than the global average of 208 kg. India’s

consumption of finished steel products has grown by

3.4 per cent in 2017-18 compared with 2016-17. With some of the measures

taken by the Government, India has become a net exporter of steel products.

Indian economy is rapidly growing with key focus on infrastructure and

construction sector. Several initiatives mainly, affordable housing, expansion of

railway networks, development of domestic shipbuilding industry, opening of

defense sector for private participation, and the anticipated growth in the

automobile sector, are expected to create significant demand for steel in the

country.




2-3

Major factors which carry the potential of raising the per capita steel

consumption in the country are listed below:

Infrastructure improvement initiatives, such as ‘Smart Cities project’,

'Housing for All by 2022', ‘Atal Mission for Rejuvenation and Urban

Transformation (AMRUT)’,

Manufacturing growth driven by Make-in-India initiative,

Encouraging use of Made in India steel for various projects and

levying of anti-dumping duties on certain steel products from Brazil,

Russia, China, Korea, Japan and Indonesia.

National Mineral Development Corporation expected to increase the

iron ore production favoring steel production

Emergence of the rural market for steel buoyed by projects like

MGNREGS, development of ‘Rurban Clusters’ under the Shyama

Prasad Mukherjee Rurban Mission, Pradhan Mantri Gram Sadak

Yojana, among others.

As per the National steel policy (NSP) 2017, in order to achieve expected

demand of 300 MT and per capita consumption of 160 kg of finished steel by

2030-31, steel demand would need to grow at a CAGR of around 7-7.5 per cent

during the period against a CAGR of 3.5 per cent-4 per cent over the last 5

years. This would mean that capacity additions planned by most of the major

steel players need to come on stream in next few years.

As per NSP 2017, it is aimed to domestically produce value added steel -

products with focus on exploiting the existing iron ore deposits. These factors

would emphasize on the need for the installation of the proposed projects.

2.3 DEMAND-SUPPLY GAP, IMPORTS VS. INDIGENOUS PRODUCTION,

EXPORT POSSIBILITY & DOMESTIC/EXPORT MARKETS

The total consumption of steel is estimated at 81.52 MT in FY16. Driven by

rising infrastructure development, growing demand for automotives and lower

per capita consumption compared to international average, steel consumption is

expected to reach 104 MT by the end of 2017. The consumption of steel during

FY17 (Q1) was estimated at 61.54 MT. World Steel Association (WSA) has




2-4

projected a growth of Indian steel consumption of 7.1% at 94.91 MT in 2018,

one of the highest growing among the global steel producers.

The projected demand and capacity of finished steel products is as follows:

Overall Steel, MTPA 2025-26 2030-31

Demand 140.0 185.0

Capacity

Current 125.0

Required 185.0 245.0

Deficit 60.0 120.0

Though the country has been traditionally a net importer of steel products all these years, the total export of finished steel increased by 16.7 per cent to 9.621 million tonnes (MT) in 2017-18, as against exports of 8.242 MT finished steel during 2016-17.

The projected demand of consumption of steel products is given below in

Table 2-1

TABLE 2-1 - INDIA - STEEL CONSUMPTION SCENARIO (MILLION TONS)

Item Actual Forecast

2016-17 2020-21 2025-26 2030-31

Crude Steel

Capacity 122 140 185 245

Crude Steel

Production 91 110 150 195

Finished

Steel

Production

80 105 140 185

Domestic

Demand

84 95 125 165




2-5

Item Actual Forecast

2016-17 2020-21 2025-26 2030-31

Exports 8 10 15 20

The National Steel Policy (NSP) 2017 aims to increase export of steel

and reduce import to nil by 2030. As of March 2017, the capacity utilization of

steel producers is set to increase with strong export demand and signs of revival

in domestic sales.

Steel products find application in multifaceted sectors mainly dominated by

areas of infrastructure & transport. Among the many drivers of demand, the

following are having maximum influence in triggering consumption of finished

steel products like Bars & Rods, Structural and Plates:




2-6

Product/Category Application

Bars & Rods

Infrastructure - House Building

Fasteners & Wires

Bright Bars

Structural Infrastructure - High rises

Industrial Construction

Plates

Infrastructure – Bridges

Railways - Wagons, Coaches, Tankers

Industrial Construction

Defence Production

Energy - Boilers, Pressure Vessels, Penstocks

HR Products

Tube making industry

Railways - Wagon & Coach

Automobiles

Industrial Machinery

CR Products

White goods - Refrigerators, Air-conditioners

Automobiles

Silos & Containers

Precision Tubes

Furniture

Galvanized,Coated,

Tin Plate, Silicon

Steel (NGO)

Automobiles

Consumer durables

Food Industries

Electrical Appliances & machine

Construction

Packaging & Furniture

The NSP 2017 provides an overview of the segmental composition of the

projected Indian market for the year 2030-31 with quantitative estimates of the

likely demand and their associated growth rates adopted for the study. A

summary of the leading segments of the domestic market is furnished in the

Table 2-2 and Table 2-3 below.




2-7

TABLE 2-2 - MAJOR MARKET SEGMENTS - 2030

Market Segments Demand

(Million Tons) % Share

Infrastructure

(Project Construction) 90 39%

Construction

(Real Estate & Buildings) 45 20%

Engineering & Fabrication 43 19%

Energy 11 5%

Automotive 10 4%

Sub-total

(Major Segments) 199 87%

Other Segments

(Railways, Ship Building,

Defence, Gas Pipelines,

Packaging etc.)

31 13%

Total 230 100%

TABLE 2-3 - MAJOR MARKET SEGMENTS - 2030

Market Segments Annual Growth (%)

Infrastructure (Project Construction) 16%

Oil & Gas Pipelines 11.3%

Defense 9.8%

Automotive 9.7%

2.4 EMPLOYMENT GENERATION DUE TO THE PROJECT

In the construction & operation phases of the proposed project, both

direct & indirect deployment of local work force would be facilitated. The nature




2-8

of employment opportunities would involve contractual & casual labor work for

semiskilled & unskilled local skilled staff and direct employment for skilled

locals.

It is estimated that there would be a requirement of around 1200-1500

casual and contract workers, during the phase of construction. Subsequently in

the operation phase, approximately 1200 employees would be directly

employed.



3-1

3 - PROJECT DESCRIPTION

3.1. TYPE OF PROJECT INCLUDING INTERLINKED PROJECT

The proposed project is a brown field expansion project involving the

expansion of crude steel capacity of the integrated steel plant of JSW steel at

Vijayanagar from 16 MTPA to 18 MTPA, within the existing land area available

with JSW Steel. The increase in capacity is being planned by installation of large

capacity Blast furnace and improvement in productivity in some of the existing

manufacturing facilities, with consequent reduction in overall pollution.

3.2. LOCATION

JSW Steel, Vijayanagar is located at Toranagallu, Sandur Taluk, Ballari

district in the state of Karnataka. The existing integrated steel plant of JSW Steel

limited is situated between 15o 10' - 15o 12' N latitude and 76o 38' - 76o 40'E

longitude. The steel plant is located at 29 km from Bellary, 33 km from Hospet

and about 340 km from Bangalore by road. Nearest railway station to the steel

plant is Toranagallu. Broad gauge railway lines between Guntakal and Hubli are

passing through this station. The eastern port of Chennai is 460 km and western

port of Goa is 430 km. A glimpse of the location of the steel plant; lay out of the

plant; photograph of existing plant; location of proposed facil ities in the

expansion project is shown in Fig. 3-1.

3.3. DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF

SELECTING THE PROPOSED SITE

The expansion of crude steel capacity is being planned by upgrading

capacity of existing blast furnaces during their campaign repair and installation

of a 4.5 MTPA large capacity blast furnace in place of a smaller furnace of 3.0

MTPA. This is a brownfield expansion, within the available land area and utilizing

existing infrastructure. Alternative site was not examined.



3 - Project Description (cont’d)

3-2

FIG. 3-1 - SITE LOCATION MAP

Pla




3-3

3.4. SIZE OR MAGNITUDE OF OPERATION

The proposed project after its completion will facilitate in production of

18.0 MTPA of crude steel along with value added long and flat steel products to

meet the increasing demand of the customers and country`s infrastructure

development. The proposed facil ities wil l be set up in an area of about 450 acres

within the existing steel plant complex.

3.4 LAYOUT

The plant lay out showing the location of the proposed facilities is shown

in Fig-3.2

Fig-3-2 Location of Project site and surrounding 10 km area

3.5. PROJECT DESCRIPTION WITH PROCESS DETAILS

The basis of earlier expansion of crude steel capacity from 10 MTPA to

16.0 MTPA was based on the premise of installing two Blast Furnaces each of

3.0 MTPA. However, the first 3.0 MTPA expansion from 10 MTPA to 13 MTPA

has been realized by augmenting the capacity of BF-1 and BF-3 during their

respective campaign repairs. The BF-1 capacity has been enhanced from 0.9

MTPA to 2.5 MTPA and BF-3 from 3.0 MTPA to 4.5 MTPA by installing the

Country`s largest Blast furnace of 5560 m3, expected to be commissioned by

Dec 2019. JSWSL is also in the process of setting up a similar capacity Blast

furnace at its Dolvi unit, the first such furnace in India.

Considering the advantages of large capacity Blast furnaces, in terms of higher

productivity, energy efficiency and environment friendliness, it is now proposed

to install a 4.5 MTPA Blast furnace in lieu of BF-5 of 3.0 MTPA proposed at the

16 MTPA stage of expansion. This will lead to enhancing the capacity from 13




3-4

MTPA to 17.5 MTPA (in place of 13 MTPA to 16.0 MTPA as proposed earlier).

Further, due to optimization in some of the existing Blast furnaces due to

changes in iron ore quality, the overall hot metal production including from two

Corex units works out to 18.17 Mtpa. Accordingly, it is proposed to enhance the

crude steel production to 18.0 MTPA, as against the 16.0 Mtpa planned earlier.

The proposed production of crude steel and subsequent rolling would be

accomplished via Blast Furnace (BF)-Basic Oxygen Furnace (BOF)/Zero power

furnace(ZPF)-Caster route, followed by hot & cold roll ing for production of flat &

long products. The highlights of the proposed expansion are:

a. Installation of the largest blast furnace of the country to produce

4.5 MTPA of hot metal (in place of a smaller capacity Blast furnace

of 3.0 MTPA proposed in the 16 MTPA expansion)

b. Installation of Zero Power furnace(ZPF), for manufacturing steel

from hot metal & DRI, without use of electrical energy (in place of

Electrical Arc Furnace.)

c. Augment the capacity of BOF from 200 T capacity to 350 T capacity

d. optimization in some of the existing BF units due to changes in iron

ore quality.

e. Installation of 5.0 MTPA HSM in place of 3.6 MTPA unit an new 2.3

MTPA CRM-3

The flowsheet of manufacturing steel is shown in Fig-3.3.(See last page)

The changes or additional facil ities proposed in the expansion and

optimization being carried out in the 16 MTPA units in the propose project to

produce 18 MTPA of crude steel and associated finished products are given in

Table 3-1. and Table 3-2. However, there are no changes in the overall

capacities of following units as proposed in the 16 MTPA stage even at 18.0

MTPA stage.

1. Ore Beneficiation plant : 19.5 MTPA

2. Coke ovens : 8.0 MTPA

3. DRI(Gas based) : 1.2 MTPA

4. Lime Kilns : 7200 tpd

5. Water allocation : 72 MGD

6. Thermal Power Plant : 1490 MW




3-5

TABLE 3-1 – CHANGES / ADDITIONAL FACILITIES IN THE PROPOSED

PROJECT

Facility Capacity,

MTPA

1 Pellet Plant-3, in place of Sinter Plants 6 of 5.75 MTPA) 6.8

2 Sinter Plant of 2.3 MTPA in place of SP-5 of 1.75 MTPA

Additional

0.55 MTPA

3 Blast Furnace-5 of 5500 m3 volume (in place of 4019 m3)

Additional

1.5 MTPA

3 SMS-4 Larger size BOFs(2X200t to 2X350t)

Additional

2.2 MTPA

4 Zero Power Furnace(in place of 1.2 MTPA EAF)

No change in

capacity

5 Hot Strip Mill-3 (enhancement from 3.6 to 5.0 MTPA)

Additional

1.4 MTPA

6 Bar & Rod Mill-2(New) 1.0

7 Wire Rod Mill -2(New) 1.2

8 Cold Rolling Mill-3 (New) 2.3

9 Oxygen Plant(New)

1 x 2060 tpd

2X2200 tpd

10 Ash Pond for Gypsum (FGD) and bottom ash 1 unit

TABLE 3-2 – OPTIMISATION OF FACILITIES AT 16.0 MTPA STAGE

Facility Remarks

1 Relocation of OBP-1 to near OBP-2

No change in

overall capacity

2 Shif ting of OBP-1(dry process) to OBP-2(wet Process)

No change in

overall capacity

3 Larger capacity Lime and Dolo Calcining plants (from

8X300tpd to 4X600 tpd)

No change in

overall capacity

The production facilities would be adequately supported by necessary

modifications if required in the auxiliary facil ities such as raw materials unloading

and storage, proportioning of raw materials, electric power receiving and

distribution stations, various utili ty facilities, water treatment and distribution

system, etc.




3-6

The following write-up gives the details of the additional/modified process

units which are being proposed in the 18.0 MTPA expansion.

3.5.1 Ore Beneficiation Plant: There are two Ore beneficiation plants existing

with a capacity to produce 19.5 MTPA of iron ore concentrate. The OBP-1, which

was installed during the 4.0 MTPA stage of steelmaking was based on dry

grinding of iron ore in three ball mills to produce green pellets. In view of heavy

dust pollution during grinding, all the new beneficiation units installed in the

OBP-2 area were based on wet grinding. The slurry after grinding is thickened

and filtered in special filters to produce pellet feed for the pellet plant.

The OBP-1 unit with dry grinding is planned to be shifted to OBP-2 area with

wet grinding. The iron ore concentrate slurry is pumped to PP-1, where the slurry

is f iltered and used for pellet production. The proposal is to shift the unit to OBP-

2 area. There is no change in the overall capacity of the OBP units, which is 19.5

Mt of beneficiated product.

3.5.2 Pellet Plant

The blast furnace burden will comprise of 42.5% sinter. 37.5% pellet and

20% C-Ore. Pellet is also required for production of DRI in the gas based DRI

plant and as feed material in Corex 1&2. Currently the existing PP-1&2 have an

installed capacity each of 5.0 MTPA and are producing pellets at a rate of 4.0

MTPA each. To meet the total requirement of pellets at 18.0 MTPA stage, it is

envisaged that one pellet plant of 6.8 MTPA capacity would be installed. Pellet

requirement for DR plant, Corex and blast furnaces would be met from these

three pellet plants. The new large capacity pellet plant is being built in lieu

of Sinter Plants 5 & 6, to reduce pollution from sintering process.

Design basis: The design basis considered for pellet plant is given in

Table 3-3.

TABLE 3-3 - DESIGN BASIS OF PELLET PLANTS

Item Value

Number of units, Nos. 1

Gross pellet unit, MTPA 6.8

Screening, % - at BF stock house 10

Operating days/year 350

Grate area4(w) X 204(L) M2 816




3-7

No of Balling discs for green pellet/dia 14Nos /

7.5M Dia

Fuel Used/CV Mixed Gas

1850

Kcal/Nm3

Hood exhaust volume m3/h 28,00,000

Wind box exhaust volume m3/h 13,00,000

The typical analyses of input raw materials (dry basis) for pellet

production are given in Table 3-4.

TABLE 3-4 - TYPICAL ANALYSIS OF RAW MATERIALS FOR PELLET

PRODUCTION

Fe SiO2 Al2O3 CaO MgO LOI

% % % % % %

Iron ore

concentrate

>62 4.0 3.2 1.75 0.6 4

Limestone 0.2 2.5 0.51 49.8 2.8 43.80

Dolomite 1.38 1.67 0.35 32.84 17.72 44.86

Lime - 0.64 0.25 95.00 1.54 3.00

Flue dust 43.13 5.66 3.68 9.44 1.42 16.48

Coke breeze 0.40 7.10 4.26 0.80 0.60 82.84

The indicative chemical analysis of pellet produced would be as follows:

Fe, % .. >62%

CaO/SiO2 ratio .. 0.35%

Al2O3, % .. 3.2

MgO, % .. 0.60

The envisaged physical and metallurgical properties of sinter would be as

follows:

Size range .. 6 - 19 mm Compressive strength .. 250 kg/pellet Tumbling index

+6.3 mm .. 92% -500 micron .. 6%




3-8

The pellet plant would comprise following facilities:

- Slurry storage and filtration units

- Storage and handling of iron ore and return fines

- Storage, handling and preparation of coal, dolomite and bentonite

- Proportioning and mixing

- Balling for production of green pellets

- Induration and cooling

- Product screening

- Product pellet storage

- Auxiliary facilities laboratory etc.

- Process and Plant de-dusting system

- Cranes, hoists and elevator

- Plant electrics

- Instrumentation and Level- 1

- Plant communication system

- Utility system

- Air-conditioning and ventilation system

- Fire fighting system




3-9

3.5.3 Blast Furnace

The requirement of hot metal for Steel Melt Shop at 18.0 MTPA would be

around 18.17 MTPA. The hot metal will be met from the following units:

- Corex1&2 : 1.6 MTPA (installed in inception of the plant)

- BF-1 : 2.5 MTPA (Upgraded during campaign repair)

- BF-2 : 2.17 MTPA (Installed at 4 MTPA stage)

- BF-3 : 4.4 Mtpa (To be upgraded in 2019 from 4019 m3

to 5360 m3)

- BF-4 : 3.0 MTPA

- BF-5 : 4.5 MTPA (Planned to install in l ieu of 3.0 MTPA unit)

The blast furnace BF-3 and the new BF-5 (in lieu of small BF of 4019 m3)

would incorporate all the modern technological features. The design basis of

blast furnace is given in Table 3-8.

TABLE 3-5 - DESIGN BASIS OF BLAST FURANCE

Item BF-5 at 16

MTPA

BF-5 at 18

MTPA

No. of furnaces 1 1

Volume, cu m (approx.) 4019 5,360 (U.V)

Operating days 350 350

Burden:

Sinter, % 80 42.9

Pellet, % 10 37.6

Ore, % 10 19.5

O2 enrichment, % 8 8

Coke rate (including nut), Kg/thm 332 360

Coal rate, Kg/thm 200 220

Slag rate, Kg/thm 340 400

Coke ash, % 11.8 11

Si in metal, % 0.56 0.4 to 0.7

Capacity of TRT in MW 12 27

No of cast houses 4 4

Blowers (2W+1SB) m3/min 6600 9000

Slag granulation capacity in ton per min 6 8

Design of dust catcher Cyclone Cyclone

Cast House FE system (2 ns) each 900000 1200000




3-10

Stock House De-dusting system m3/h 7,56,000 15,05,000

The major raw materials for blast furnace comprise iron ore, sinter, pellet,

additives and coke from the Coke dry quenching unit. Pulverized coal would be

injected through tuyeres as auxiliary fuel in blast furnace. The typical analysis of

raw materials envisaged is given in Table 3-9.

TABLE 3-6 - TYPICAL RAW MATERIALS ANALYSIS (DRY BASIS)

Fe SiO2 Al2O3 CaO MgO

% % % % %

Sinter 53- 53.8 5.5-5.8 3.1-3.3 11.5-12.5 2.1-2.2

Pellet 61.5-62.5

4-4.5 3.0-3.3 1.3-1.7 0.4-0.6

Sized ore 62.0-63 3-4.0 3.0-3.8 0.4-0.6 0.3-0.6

Quartzite 0.5-1.5 94-96 0.5-1.5 0.2-0.3 0.2-0.3

Limestone 1-2 6-8 1-2 40-48 1.5-2.5

Dolomite 0.8-1.5 8-10 1-2 27-29 17-20

The plant comprises following facilities:

- BF proper

- Cast house

- Slag granulation plant

- Hot blast stoves

- Gas cleaning plant

- Stock house and charging system

- Hot metal handling system

- Cranes and hoists

- Coal dust injection system

- Hot metal granulation and ladle repair shop

- Stock house & Cast house de-dusting system

- Air blowing system

- Plant electrics

- Instrumentation, automation and control system

- Communication system

- Water system

- Utility system

- Fire fighting system

- Air conditioning and ventilation system




3-11

The granulated BF slag would be used for manufacture of cement by JSW

Cement.

The profile of the 3.0 MTPA and 4.5MTPA Blast furnaces are given below

Profile of BF-5 (3.0 MTPA) Profile of BF-5 (4.5 MTPA)

3.5.4 STEEL MELT SHOP

Currently, JSW Steel has three Steel melt Shops.

SMS-1: The shop had 3 BOF converters of 130 T capacity, which has been

upgraded by modifications in lining design to produce 132 T per heat, thus

producing 4.0 MTPA of liquid steel.

SMS-2: The shop had 4 BOF converters of 175 T, which has been upgraded by

volume enhancement to 180 T per heat, thus producing 6.4 MTPA of liquid steel.

SMS-3: The shop has one EAF of capacity 150 T to produce 1.2 MTPA of liquid

steel. EAF utilizes DRI and hot metal to produce liquid steel. There is a provision

for another similar EAF at the 16 MTPA stage and is yet to be constructed.




3-12

To handle the additional quantity of hot metal due to enhancement of capacity of

BF-5, the following changes are proposed at 18 MTPA stage.

SMS -1 & 2: No change

SMS-3 : The EAF-2, which is yet to be installed is proposed to be changed to

Zero Power Furnace(ZPF). This is like EAF but utilizes a larger portion of hot

metal and less DRI. The electrodes are dispensed away and the energy for steel

making is provided by oxygen injection. This unit has capability to produce 1.5

MTPA of l iquid steel from each shop. The details of EAF, currently operational

and the proposed ZPF is given below in Table 3.

Sl.No Descriptions UOM EAF ZPF

1 Heat Size Ton 160 160

2 HM Input % 42 80-85

3 DRI Input % 52 15-20

4 Tapping Temperature deg.cen 1610 1630

5 Metallic Charge t/heat T 203 181

6 Hot Metal t/heat T 85 148

7 Hot Metal t/day T 2250 4,744

8 Coolant (gas based DRI) t/heat T 106 33

9 Coolant (gas based cold DRI) t/day T 2650 1,041

10 Electrical Energy Consumption kWh/tls 275 0

11 Oxygen Consumption Nm3/tls 42 60

12 Electrode Consumption kg/tls 1.07 0

13 Burnt Lime & Dolo Lime kg/tls 88 100

14 Slag kg/tls 320 163

15 Oxygen Blowing min 37.4 37

16 Production time/EAF Day/Year No of Days 320 320

17 Yearly Production/EAF Mtliq/year MTPA 1.5 1.5

18 Type of Lance SIS3.0 SIS 4.0

19 No of Lance No 4 5

20 Total oxygen blowing capacity Nm^3/Hr 12000 20000

21 Tap to Tap time Mins 52 50

22 Primary & Secondary FE System m3/h 25,00,000 28,00,000

SMS-4: In the 16 MTPA stage expansion, this shop was designed to have 2X200

T BOF Converters to produce 2.6 MTPA of liquid steel. With the necessity to




3-13

handle additional hot metal, the size of the BOF Converters has been enhanced

from 200T to 350 T. The 350 T BOF can feed liquid steel to slab caster for higher

productivity.

The technical details of 200 T BOF as proposed earlier at 16.0 MTPA and 350 T

BOF as proposed now at 18 MTPA is given in Table 3-

SMS-4 (at 16.0 MTPA)

SMS-4 (at 18.0 MTPA)

1 No. of converters installed 2X200 2X350

2 Converter operation, days/year 330 330

3

Liquid steel production per day, tons Considering converter availability and utilization, No. of converters operating

10400 18200

4 Liquid steel production per day per operating converter, tons

5200 9100

5 Average tap-to-tap time(min). 50 50

6 No. of heats/day/converter 26 26

7 Liquid steel required per heat, tons

200 350

8 Selected heat size, tons liquid steel

200 350

9 Type of ladle for hot metal transport

Torpedo Torpedo

12 GCP wet or dry Wet GCP Dry GCP

13 Capacity of GCP 300,000Am3/hr 500,000Am3/Hr

14 Secondary FE system, volume 50,00,000 Am3/hr 55,00,000 Am3/hr

15 Gas holders nos and capacity (one)

50000m3 100000m3

16 No of boosters & capacity 2w+1 stand by 3w+1 stand by

Casters 4 2

17 Slab caster; capacity & size

two 1600 mm casters

two 2200 mm twin slab caster

Slab Caster details

19 Heat size, tcs 200 T 350 T

20

Reference slab size for calculation

1200-2200, 800-1600

900-1650

21 Reference casting speed, m/min. .8-2.2 1-2.4meter /min




3-14

22 Throughput, tons/min. 4.5T/Min per strand 9Tons

23 Average casting time, min. 55min 50 min

24 No. of heats in sequence 6 heats to 75 heats

3 heats to 40 heats

25 Preparation time, min. 90min 90 min

3.5.5 Lime Calcining Plant

At 16.0 MTPA production stage of crude steel, it was envisaged that eight

lime Calcining plant and dolomite calcining plant of

300 TPD would be installed to produced calcined lime and dolo, sufficient to

cater to the demand of calcined lime/dolo of the steel melt shops. However,

considering the advantages of 600 tpd kilns, the configuration will be changed

from 8X300 tpd to 4X600 tpd. It may be noted that the 600 tpd TSR kilns of

Cimprogetti was installed for the first time in the world. Over the years, the

technology has been perfected by JSW Steel.

3.5.6 Rolling Mills

The following mills would be installed with production capacities as

follows:

Mills No. and capacity

Hot Strip Mill (HSM-3) 1 x 5.0 MTPA in l ieu of earlier 3.6 MTPA

Rebar mill (BRM-2) 1 x 1.2 MTPA (New)

Wire rod mill (WRM-2) 1 x 1.2 MTPA (New)

Cold Rolling Mill(CRM-3) 1 x 2.3 MTPA (New)

Hot Strip Mill (HSM): Each hot strip mill would be designed for a

production of 5,000,000 tons/year of HR coils.

Input: Cast slab would be used as input for the hot strip mill.

Width, mm .. 800-2200

Thickness, mm .. 230

Length, mm .. 11,000

Unit weight (max), kg .. 40,000

Finished product: The HR coil size would be as follows:




3-15

Width, mm .. 800-2050

Thickness, mm .. 1.2 – 25.0

Coil weight (max), ton .. 40

Mill yield, % .. 98

Each hot strip mill would comprise of the following facilities:

- Walking beam type reheating furnaces

- Primary hydraulic descaler

- One (1) 2-Hi roughing stand with attached edger

- One (1) 4-Hi roughing stand with attached edger

- Crop shear

- Secondary hydraulic descaler

- Seven(7) 4-Hi finishing stands

- Run-out roller table

- Laminar cooling system

- Down coilers

- Walking beam coil conveyor system

Double Side Trimming Shear

• Slitting shear

• Dividing Shear

• Cold Plate Leveller

• Pile transfer

• Heat treatment facilities

Rebar Mill(RBM): The rebar mill would be designed for production of

1,200,000 tons/year.

Input: Continuously cast billets of following size would be used as input to

the rebar mill:

Section, mm .. 150 x 150

Length, mm .. 12000

Finished product: Output from rebar mill would be as follows:

Size .. 8-40 mm dia. rebars

Cut to length .. 6-12 m

Mill yield, % .. 97




3-16

The mill would comprise of the following major facilities:

- Billet Charging grids

- Walking beam type reheating furnace

- Roughing train and intermediate train

- Shears

- No twist blocks

- Water boxes and troughs

- Cooling beds with high speed entry equipment

- Cold shear

- Chain transfer

- Bundle strapping machines

- Bundle unloading stations

Wire Rod Mill(WRM): The Wire rod mill (WRM) would be designed for

production of 1,200,000 tons/year.

Input: Continuously cast billets of following size would be used as input

to the WRM:

Section, mm .. 150 x 150

Length, mm .. 12000

Finished product:

Size .. 5.5-20 mm dia

Mill yield, % .. 97

The mill would comprise of the following major facilities:

- Charging grids

- Walking beam type reheating furnace

- Descaler

- Single strand high speed roughing mill

- Double strand intermediate mill train

- Shears

- Pre-finishing mills

- Wire rod blocks

- Reducing and sizing blocks

- Water boxes and troughs

- Laying heads and pinch rolls




3-17

- Air cooling conveyors

- Reform station with ring distribution

- Coil conveyor

Cold Rolling Complex: an identical cold rolling mill complex like CRM-2

would be installed to produce cold rolled annealed, galvanized coils. The

complex would comprise of the following process units:

3.5.7 Cement Grinding Unit

The additional granulated slag generation will be about 0.8 MTPA. JSW

Cement has surplus capacity at their Vijayanagar Plant to consume this amount

of slag for Portland slag cement making. The clinker required to produce cement

would be procured from outside the plant.

3.5.8 Captive Power Plant

JSW Steel has following facilities for a total generation of 936 MW.

- Captive thermal power plants:

CPP-1 : 100MW,

CPP-2 : 130 MW

CPP-3&4 : 600 MW

CPP-5 : 660 MW (to be installed later)

TRTs of BF1,3&4: 30 MW

CDQ : 76 MW

Further the following power generating units are being installed

CDQ : 98 MW (CDQ of Coke 5&6(rebuilt battery of Coke1&2)

TRT : 42 MW (27 MW from BF-5 & 15 MW incremental of BF-4)

Total : 1076 MW Gross. Net 975 MW

The electrical power requirement at 18 MTPA stage has been worked out to be

1412 MW. The balance electrical power will be met from JSWEL which has an

installed capacity of 860 MW. To have stability of the system, the power system

will be connected to the grid and in case of any shortage, it wil l be drawn from

the grid. JSWSL has an approval for a CPP-5 of 660 MW thermal power plant at

16 MTPA stage of expansion. This facility wil l be set up later.

3.6 RAW MATERIALS

Sources of Raw Materials

The probable sources of major raw materials (indigenous/imported) for

meeting the production requirements are given below.

Major Raw Materials Mode of transport




3-18

Iron ore fines/lumps/CLO Rail/Road/ Pipe conveyor

Coking coal Sea/Rail/Road

PCI coal Sea/Rail/Road

Limestone(SMS grade) Sea/Rail/Road

Fluxes Rail/Road

Other additives Sea/Rail/Road

The plant would produce both long and flat products, which would have

potential for sale in national as well as international markets.

The estimated annual requirements of major raw materials at 18.0 Mtpa is

presented below.

Sl.

No. Major Raw materials

Estimated

Quantity, tons

1 Coking Coal 8,340,000

2 Iron ore (Lump) 7,310,000

3 Iron ore fines (Medium grade) 24, 100,000

4 Iron ore fines(High grade) 1,500,000

5 PCI coal 3,320,000

6 Limestone 6,350,000

7 Dolomite 3,500,000

8 Steam coal 1,500,000

9 Bentonite 150,000

10 Quartzite 370,000

11 Pet Coke for Coke ovens 900,000

3.7 RESOURCE OPTIMIZATION/RECYCLE & REUSE ENVISAGED IN THE

PROJECT

The plant has been designed with state-of-art technology for optimum

consumption of energy & other resources. By product fuel gases would be

reused within the plant as in-plant fuel and also to produce power in the CPP.

Corex gas/Coke oven gas would be used as reductant to produce DRI. In

addition, adopting a compact layout for the Plant would enable to optimise the

utilisation of land, which is another critical resource. By utilising the fines and

scrap generated during the process within the plant for the production process,

usage of raw materials is optimised. Water consumption would also be optimised




3-19

by treatment of water to the extent possible and recycle of treated water as

make-up in the network. Solid byproducts would be reused to the extent feasible.

BF slag and fly ash would be used to produce cement in captive cement

manufacturing unit.

3.8 AVAILABILITY OF WATER AND POWER

Water

JSW Steel receives the make-up water from two sources, viz Tunga

Bhadra Dam (32 MGD through pipeline of 35 KM) and Alamatti dam (40 MGD

through a pipeline of 178 Km). This allocation of a total of 3,30,000 m3/day was

obtained during the expansion of the steel plant from 4.0 MTPA to 10.0 MTPA. In

the expansion of capacity from 10MTPA to 16 MTPA, no additional allocation

was sought.

The total water requirement at 18 MTPA will be as under:

Steel plant : 1,44,000 m3/d

Captive power plant & JSWEL : 93,000 m3/d

Township : 24,000 m3/d

Losses & Evaporation : 40,000 m3/d

Total for JSWSL complex : 3,01,000 m3/d

The recovery of water from the existing seven RO Plants is 22,000 m3/d.

Further, additional 8400 m3/d of RO permeate will be recovered from the ZLD

plant of Coke-5 and a centralized RO plant.

JSWSL has established a Total water management approach, as a result the

water is extensively used by cascading from one process to another, ensuring

zero discharge plant. The existing water allocation of 3,30,000 m3/d is sufficient

to meet the requirements of the expansion up to 18.0 MTPA stage.

3.9 Power

The estimated power requirements of various plant units including utilities

and auxiliary facilities for the Plant at 18.0 Mtpa works out 1412 MW. The

available power from captive and from JSWEL is 1735 MW. Thus, there is

adequate availability of power for the steel plant operations at 18 MTPA stage.

DG sets of adequate capacities are proposed for the plant units as well as

CPP auxil iaries to cater to the requirement of safe shutdown and safety of

personnel during total black-out condition when power supplies to plant network

from both the sources viz. grid and CPP have failed.




3-20

3.10 WASTE GENERATION AND MANAGEMENT

3.10.1 Wastewater generation & Management

Currently, the integrated steel plant complex of JSW Steel, at Vijayanagar

is a Zero Liquid Discharge plant, the only steel plant of this in the world. This has

been achieved through the following measures

- Technologies which conserve water

- Recycle of > 95% treated water back into the process after treatment

using specialty chemicals.

- Cascaded use of water where blow down from one unit is used as

make up in another unit

- Reuse of treated sewage as industrial make up

- Recover good quality water by installing RO Plants. Till now 7 RO

plants are in operation recovering 21,000 m3 of water per day.

- ZLD Plants with a combination of RO plant with evaporator for 100%

recovery of water.

- Use of high TDS water in quenching applications.

It is estimated that about 1000 m3/h of waste water and blow down water will be

generated in the proposed expansion to 18 MTPA stage. This wastewa ter will be

treated in the following units:

- A 300 m3/h ZLD Plant at Coke ovens to treat treated waste water from

BOD Plant to achieve zero liquid discharge.

- Two RO Plants to recover RO permeate, each of 500 m3/h, one near

OBP and another near SMS-4. The RO rejects will be used in slag

quenching and dust suppression in RMHS.

It is proposed to have ZLD at 18 MTPA stage of the plant, preventing any

pollution of the receiving environment.

3.10.2 Solid Waste Management

The estimated generation of major solid wastes at 18 MTPA stage is

tabulated below:

Solid wastes Expected

generatio

n at 18

MTPA

Management Scheme

MTPA

BF Slag 7.2 Granulation in Slag granulation plant of

BFs and used in cement manufacturing

in JSW cement plant. About 3% of the




3-21

BF slag would be air cooled and used

for construction sector after processing

to different sizes.

Steelmaking

Slag (*)

3.6 Recovery of metallics for in-plant use.

Balance utilized as construction

aggregate, after processing.

Dusts and

sludge(**)

1.70 Reuse in Agglomeration or steel

making area.

Fly Ash 0.50 Currently used in cement making. Will

be continued.

(*)Measures planned for steel slag: There are three types of steel slag

generated in the steel making processes. a. Hot metal treatment slag with high

Sulphur and metallics, b. Converter slag/EAF slag during steel making and c.

ladle furnace slag. One of the major problem with steel slag usage till recently

was mixing of all types of slag, rendering no utilization.

JSWSL has initiated measures to separately dump and treat the slag for their

gainful utilization. HMDS slag is treated for removal of metallics and the

nonmetall ic portion containing lime is used in sinter plant. The ladle furnace slag

is separately treated and is proposed to be briquetted for recycling a portion in

steel making as ladle additive. The balance portion is used in cement making as

a raw material. JSWSL is currently installing these plants both at

Dolvi and at Vijayanagar.

The steel making slag from BOF contains free lime and needs to be treated for

its removal. Such a process is called weathering. Traditionally natural

weathering takes 2-3 years, where as accelerated weathering takes 3-4 months.

JSWSL has developed a technology of steam aging in large pits wherein the

process of weathering is completed in 10 days. The product meets the

specification for aggregates. Further to avoid making large pits and to wait for 10

days, JSWSL is introducing a new technology called steam box type which can

weather steel slag within 10-12 hours within the slag bay itself. Such facilities

are being installed at Vijayanagar and at Dolvi at an estimated cost of Rs 200 cr.

The SMS-4 proposed in the expansion will also have this technology

(**) Dust and sludge:

Following technologies have been developed and implemented at Vijayanagar

for recycling of dust and sludge.




3-22

Mill scale briquetting: A mill scale briquetting plant of 800 tpd has been set up

to recycle iron bearing sludge and dust like DRI, ARP fines, mill scales etc to

high strength briquettes using molasses as the binder. BOF converters. Thus the

recycle skips two processing stages and has huge economic benefits. The

additional volume of such dust generated in the proposed expansion processed

in this facility.

Micro pellet plant: A micro pellet plant of 0.6 mtpa has been set up to process

dust and sludge of medium iron and lime values by converting them to micro

pellets. The micro pellet in sinter plants, which otherwise could not handle such

micro fines due to problem of permeability and high dust emissions.

The process involves mixing all dust and sludge to bring in homogeneity and a

moisture level of about 12%. The mixture is granulated in a high intensity

gyratory type mixer. The micro pellets are cured and used in sintering process.

This unit is being expanded to enhance the capacity to treat the dust and sludge

generated in the proposed expansion to 18.0 MTPA

Waste to wealth plant: A waste to wealth plant of 1500 tpd has been set up to

process dust and sludge of low iron and carbon values by beneficiation. The

concentrate is used in pellet plant, and the low value is sent to existing slime

pond. Such dusts cannot be handled in micro pellet plant as they tend to lower

the Fe values in sintering. It is proposed to install a similar unit to process the

dust and sludge generated in the proposed expansion.

Besides the above, there would be other solid wastes like refractory and plant

debris etc. generated from the proposed steel plant. While some of these can be

recycled in the process, others would be disposed off in environmentally friendly

manner. The hazardous wastes like oily wastes, chrome sludge from CRM, salts

from ZLD unit shall be disposed through authorized re-processors or landfilled.

With these measures, it is proposed to utilize all dust and sludge for recycling.

3.10.3 Air Pollution

Various process operations would generate particulate dusts, volatile

organic carbons (VOCs), oxides of sulphur and nitrogen and carbon dioxide to

the environment. The emission would be from the stacks as well as there would

be fugitive emission of dusts from open & closed areas.




3-23

Fugitive dust emissions generating from the handling and stockpiling of

raw material in open stockyards would be controlled by water sprinkling at

regular intervals. All closed zone working areas such as raw materials handling

zone, conveyor transfer points, dust generation points at screen would be

provided with dust extraction (DE) systems/dry fogging (DF) at several emission

points to control the fugitive dust emissions. DE system shall consist of suction

hood followed by bag filter / ESP, ducts, extraction fans and stack of appropriate

height.

Coke oven: Emissions from coke ovens would mainly result from coal

charging and coke pushing. Fugitive emissions may result from various

leakages from oven doors, charging lids, ascension pipe (AP) covers etc.

Charging emissions would be controlled by High Pressure Liquor Aspiration

(HPLA) injection in goose neck during charging. Coking emissions would be

controlled by efficient sealing of oven doors, water sealing arrangement of AP

cap etc. Land based fume extraction system would be adopted for charging and

pushing emission control. The hot coke would be quenched by coke dry

quenching (CDQ) with recovery of sensible heat for steam generation.

The raw coke oven gas (COG) would be cleaned in by-product recovery

plant with recovery of tar, ammonia and sulphur to make it suitable for use as

plant fuel and as reductant in the DR plant.

Sinter plant: The conventional air pollution systems like DE systems of

sinter stock house based on electrostatic precipitator (ESP) and waste flue gas

cleaning by ESP would be considered. The particulate dust emission from the

product sinter screening units would be controlled by DE systems complete with

duct, fabric filters and stack of adequate height.

Pellet Plant: Emissions from Pellet Plant would be from Induration Process,

which are controlled by installation of Bag Filter / ESP with adequate height of

chimneys.

Blast furnace: In addition to cleaning of BF gas in wet gas cleaning plant

(GCP), which is a process requirement, the main sources of air pollution would be

stock house and cast house. The BF stock house would be provided with DE

systems complete with dust extraction hoods, ESP/ Bag Filter, ID fan and stack of

adequate height. Similarly, the cast house would have separate fume collection

system during tapping of hot metal and slag, would be equipped with FE systems

along with bag filter/ESP for separation of particulates before venting through a

stack of appropriate height.




3-24

Heat recovery from stove waste gas shall be installed for preheating of BF

Gas and combustion air for stoves.

Lime/dolomite Calcining Plant: The emissions arising due the fuel burning

in l ime calcining plant would be collected and taken through a bag filter to separate

out the lime/dolo fines. The lime/dolo fines thus collected would be recycled to the

sinter plant. The kilns in the calcining plant and other dust generation areas would

be provided with separate DE systems, complete with bag filters and stack of

adequate height to clean the particulates.

BOF: Besides BOF gas cleaning, which is basically a process necessity,

secondary emissions would be generated mainly from charging and tapping

operations. The secondary emissions of the steelmelt shop would be controlled by

providing dry ESP.

Ladle Furnace: The primary emissions of LF would be collected by fume

extraction (FE) devices. Dust laden fumes would be indirectly cooled and cleaned

through a bag filter for separation of particulates and the clean gas would be vented

into the atmosphere through a tall stack of adequate height. The secondary

emissions would be controlled through canopy hood extraction, which would be

integrated with the main system to clean the fugitive emissions during charging and

tapping operations. The gas cleaning system would be complete with water cooled

duct, fume and gas cooler, bag house, ID fan and stack of appropriate height.

Caster Area: The water required for cooling the hot cast slabs and bil lets

would generate hot fumes comprising mainly water vapour, hot waste water and

suspended particulates. The slab casting area would be provided with adequate

ventilation in order to have the water vapour properly dispersed.

Rolling Mills: Burning of the by-product fuel gases in reheating furnace

would give rise to the emissions of particulates, SO2 and NOx. NOx emissions

would be controlled by optimizing the excess air supply and proper burner design.

In addition, fume extraction (FE) system would be installed. The flue gas, which is

clean, would be vented through a stack of adequate height after heat recovery.

Cement Grinding Unit: The cement grinding unit would comprise of

raw material storage, handling and feeding facilities, mill system and finished

product storage, handling and packing facilities. The main sources of air

pollution would be fugitive dust emissions from the raw material & product




3-25

handling units, dust emission from the mill exit dust laden gas and SO2 & NOx

emission from the hot air generator. The raw material and product handling

facilities would be equipped with dust extraction systems comprising of bag

filters. The mill exit gas containing particulate matter wil l be passed through a

bag filter to capture dust.

Captive Power Plant: The surplus by-product fuels gases and steam

coal would be burnt in the boilers for generation of power. The flue gas thus

generated from the boiler would be vented through stack of appropriate height.

ESPs would be provided to capture the fly ash generated by the coal fired

burners. Power would also be generated from CDQ, TRT and process steam

from sinter cooler.

Highlights of air pollution: the following are the highlights being planned

in the proposed expansion:

a. Emission standards in line with EU standards

b. Design limit for dust emission from bag filters -< 10 mg/nm3

c. Additional high-performance bag filters in all sinter plants, with

emission limit of < 10 mg/nm3

d. High efficiency ESPs in pellet plant to limit dust to < 10 mg/nm3

e. Switching over to highly polluting sinter plants (SP-5 & 6) to pellet

plant.

JSW STEEL LIMITED 18.0 MTPA Crude Steel Production PRE-FEASIBILITY REPORT

3-1


Sl no Name of the

Unit


(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity


4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

1 Ore beneficiation

Plant - product

OBP-1

1 X 4.5

OBP-2

1X 2.5 ,

1X 5.0 &

1 X 7.5,

Nil

1 X 4.5

1X 2.5

1X 5.0

1 X 7.5

19.5

OBP-1 facilities to be

Relocated

to OBP-2

19.5

2 Pellet Plants PP1- 1- 5.0 PP-2- 5.0 Nil PP 1 & 2

2 X 5 .0 10

PP-3

6.8 16.8

3 Sinter Plants SP1 SP 2 -2.3

SP 3- 7.5

SP4 -2.3 SP5 -1.75

SP6 -5.75

SP1-6 3X 2.3

2 X 5.75

1 X 1.75

20.15 SP-5: 2.3

SP-6: deferred in lieu

of PP-3

14.95

4 Coke Oven – NR

CO 1 &2

2 X0.64

1.28

Nil

Dismantling

of Existing

NR Coke

Oven

0 0 No addition 0

5 Coke Oven –

Recovery type Nil Coke 3 - 1.5 CO 1&2 -1.5

CO 1-5

2X1.5

1X2.0

1X3.0

8.0 No addition 8.0

6 Hot metal –Corex Corex 1 & 2

2X0.8 Nil Nil

Corex 1- 2

2 X 0.8 1.6 No addition 1.6

7 Hot metal-Blast

Furnace

BF-1-2.5

BF-2-2.17

BF 3 & 4

2 X 3.0

BF-3- 4.4

BF-5- 3.0

BF 1 -5

1X 2.5

1X 2.17

1X4.4

2X 3.0

15.07 BF-5 of 3.0 MTPA to

be built as 4.5 MTPA 16.57

8 Pig Casting

Machines (TPD) 1200 7200 3600 12000 12000 MGP-5000 tpd 17000



3-2


Sl

no

Name of the

Unit


(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity


4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

9

Crude steel -

BOF, EAF & auxiliaries

SMS1 3.80

SMS2 6.0

SMS2 -6.4

SMS 3 & 4-

5.6 2X200T BOF

+2X1.2 EAF

SMS1-4

1X3.8

1X6.4 1X3.0

1X2.6

15.8

SMS-3: In place of 1

EAF, 1 ZPF is

considered

SMS-4 will be changed from 2 x

200T to 2 x 350T &

will operate at 4.8

mtpa

18

10 Lime Kiln (TPD) LCP-1 4x300

LCP-2 4X300

,4X600

LCP-3 4 x 600

LCP 1- 4 8 X 300

8 X 600


11 Slab Caster 3.2 6.4

SMS-3-1

X1.6

SMS-4-

1X3.6

Slab Caster

1-4

14.8

14.8

SMS-4 slab caster

changed from 1 x 3.6

mtpa to 2 x 2.5 mtpa

16.2

12 Billet caster Nil SMS-2

1.5

SMS-3

3.0 4.5 4.5 4.5

13 HSM HSM 1

1X4.0

HSM-2

1X5.2

HSM-3

1X3.6

HSM1-3

12.8 12.8

HSM-3 upgraded to

5.0 14.2

14 Plate Mill Nil Nil Nil Nil Nil No addition Nil



3-3


Sl

no

Name of the

Unit


(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity


4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

15 Pipe Mill Nil 0.4 Nil 1X 0.4 0.4 No addition 0.4

16 Wire rod mill Nil WRM-1

1x0.6

WRM-2

1.2

WRM 1-2

1X0.6,

1X1.2

1.8 No addition 1.8

17 Rebar & Section

mill Nil

BRM-1

1X1.0 Nil

BRM-1

1.0 1

New BRM-2 of 1.2

MTPA 2.2

18 Cold Rolling Mill

Complex

CRM-1-

1.8

CRM-2-2.3

Nil CRM1&2

4.1 4.1 CRM-3 of 2.3 MTPA 6.4

19 Galvanizing Lines Nil Nil

CGL-1-

4X0.25

CGL-2-

2X0.45 -

CGL 1&2

4X0.25

2X0.45

1.9 No addition 1.9

20 Color Coating

Line Nil- 0.5 Nil 0.5 0.5 No addition 0.5



3-4


Sl

no

Name of the

Unit


(at 16 MTPA)

Facilities

Proposed

(at 18 MTPA)

Total Capacity


4-10 -

MTPA

10-16 -

MTPA

At 16

MTPA

21

Power Plant and

process steam

boilers in MW

CPP 1X100

CPP-2

1X130

all gas

CPP 3 &4

2X300

gas+coal

CPP5-1X660

coal

CPP 1-5

1X100,

1X130,

2X300,1X660


22 Incinerator

(kg/hr) Nil

2 X

250kg/h 250kg/h 2 X 250kg/h 1000kg/h No addition 1000kg/h

23 Slag Grinding and

mixing unit

CP-1

1X 0.2 Nil

CP-2

1X2.0

CP-1&2

1X0.2

1X2.0

2.2 No addition 2.2

24 Oxygen Plant

(Out sourced)

1x2500

TPD=2500

TPD

2x1800 TPD +

1X900

TPD

2X1800 TPD

1 X 2500

TPD

10600 TPD 1 x 2060(TP)

2 x 2200 14860 TPD 4 X1800 TPD

1 X 900

TPD

25 Township (nos) 2 Units 2 Units 2 units 6 units 6 units 1 unit 7 units



3-5



4-1

4 - SITE ANALYSIS

4.1 CONNECTIVITY

Road Connectivity

The site is at 29 km from Bellary, 33 km from Hospet and about 340 km

from Bangalore by road. The site is well connected by roads, including State

and National highways and to the mining area of Sandur.

Rail Linkage

Nearest railway station to the steel plant is Toranagallu. Broad gauge

railway lines between Guntakal and Hubli are passing through this station.

Airport

JSW Steel has an airport adjacent to the steel works with connectivity to

nearby cities of Hyderabad and Bengaluru.

Sea Port

The eastern port of Chennai is 460 km and western port of Goa is 430 km.

Mumbai is about 740 km on the North West.

Location map of the site is shown as Fig. 4-1



4 - Site Analysis (cont’d)

4-2

FIG. 4-1 - ROAD AND RAILWAY CONNECTIVITY

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed site for setting up of the brownfield project is located within

the jurisdiction of Toranagallu village of Sandur taluk in the district of Ballari in

Karnataka. The existing integrated steel plant is situated between 15o 10' - 15o

12' N latitude and 76o 38' - 76o 40'E longitude

The land is industrial land area and is currently in the ownership of JSW

Steel, after the expiry of the lease by Government of Karnataka. The total land

area is about 7640 acres and the proposed expansion is located over an area of

about 450 acres within the overall plant area, utilizing the existing infrastructure

and util ities.




4-3

4.3 TOPOGRAPHY: The topography of the study area is gently sloping from

south to north. The area is in a valley surrounded by small mountain ranges.

The highest elevation of the existing steel plant and the proposed expansion site

is 500m while the lowest is 430m above msl. The site is drained by Narihalla on

the western side and Kaniganahalla on the eastern side. Narihalla and

Kaniganahalla drain into Daroji tank which is the only noteworthy tank in Sandur

taluk with a capacity of 788.28 mcft (22.3million cubic meter) located about 5km

north of the proposed site. Daroji tank also receives water from Tungabhadra

high level canal. Important rivers of Bellary district are Tungabhadra and its

tributaries namely hegari and chikka Hagari, which flow outside the study area.

River Tungabhadra flows on the north side of Toranagallu at a distance about 25

km. The flow of Tungabhadra river and Narihalla nallah is regulated by

respective reservoir authorities and the flow is very less during dry season. The

natural nallah, Kaniganahalla is also dry during the dry seasons.

4.4 EXISTING LAND USE

The present land use is industrial area housing the integrated steel plant

of JSW Steel.

4.5 SOIL

The top layer of the site is characterised by recent sand, murram, with

rectangular pebbles of banded hematite and black cotton soil. This combination

of topsoil ranges from 0 to 1.5 m, below 1.5 m the weathered schist formation is

encountered upto depth of 8m. Beyond 8m the formations are found to be

fractured. The basement/fresh rock occurs beyond 10 m. The general profile

observed in the study area is as follows.




4-4

The above soil profiles was observed from the well and nallah cuttings which

are located in the valley portion of the study area. The recent formation of

murram and black cotton soil are observed to the depth of 0.5m to 1.0m. It

appears that the fractured rock starts immediately and extends to the depth of

1.5m and the fresh rock strata 2 m below the ground level. From the

geotechnical map it is evident that three seismic zones have been identified at

Bellary district. There are three lineaments are also identified. All the lineaments

are occurring at Zone II of seismic activities. The existing plant is located in

seismic Zone II and without any lineament. From the map it also can be seen

that the plant is located on pediplain plateau residual hill with structural hill

ranges. The basement has crystalline, granite, charnockite .

4.6 HYDROLOGY

The entire study area forms a part of Tungabhadra basin, downstream

catchments. The study area is mainly drained by Kaniga nala and Nari nala and

finally these two nala became tributaries to Daroji kere. The overflow of Daroji

kere meets Tungabhadra at 25 Km towards North. Hagari and Chikka hagari are

other tributaries to Tungabhadra which are not falling in the study area. There

are 15 minor and 2 major tanks are in Santur taluk. Daroji is one major tank with

1790 acres of command area with maximum water holding capacity of 788.28

Mcft located at 5 km in the north. Another one is man made exclusively meant

for plant feed water located at south of the plant. High level lined Tungabhadra




4-5

irrigation canal is passing at about 8 km north of the plant site. The let out water

from Tungabhadra dam to Andhra Pradesh flows in this canal for 8 to 9 months

in a year with an average height of water column ranging from 2 to 3 meter. This

water head influences the groundwater in the down gradient and near the canal

to some extent till the groundwater head gets matched with running water head.

Nevertheless, this canal water is not used for any industrial purpose and it is

unaffected by proposed activities. Hence further detailed study about the canal

is not detailed in this report.

4.7 CLIMATIC CONDITIONS

The climate of the area is interior arid zone and the total rainfall ranges

from 331 to 626.7 mm. (Year 1998 to 2005). More than 80% of the rainfall

received during the months of July to September from South West monsoon and

the balance is equated in North East monsoon. The study region is

characterized by hot and dry summer with temperature raising above 47 0 C

during the month of May.



5-1

5 - PLANNING BRIEF

5.1 PLANNING CONCEPT

The proposed brown field expansion project would be sited near

Toranagallu, Sandur taluk, Ballari district. The total land area of the proposed

project would be about 450 acres within the overall land area available with JSW

Steel.

5.2 POPULATION

The JSW Steel limited comes under the Sandur taluk an iron ore mining

area, has a population of 2,22,782 with nearly 80% residing in the rural area as

per 2011 Census. Due to relatively less rainfall and irrigation facilities there has

been a shift of employment from agriculture to industrial. This has also been

triggered by the setting up of the large steel plant in the taluk, besides Sandur

being the iron ore area for mining activities. This trend is continuing with new

opportunities of employment and business due to the setting up of the steel

plant. The proposed project will keep this momentum going.

The proposed project as per applicable regulations would employ local

workers. However due to foreseen employment opportunities in the proposed

project and increase in ancillary economic activities, growth in migrant

population is anticipated during construction stages.

5.3 LAND USE PLANNING

The total area for steel plant would be about 7742.06 acres, consisting of

tentatively the following:

Built up facilities in terms of buildings, shops, yards etc :

Roads & railway corridors

Drainage channels

Water bodies

Green Cover

Others:

The total greenbelt, of about 2208 acres constitute nearly 30% of the

overall plant area. Further an area of 228 acres is being covered with water

bodies. Further it is intended to carry out plantation on another 500 acres of

land adjoining the steel plant belonging to the forest and defense departments.



5 - Planning Brief (cont’d)

5-2

The layout would also house canteen, administrative buildings, workshops,

laboratories, railway tracks, stores, in-plant roads, etc.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

The following infrastructure development in the area is being carried out to

support the growth of the steel plant and for its sustainable operation.

A network of seven Pipe conveyors of 86 Km from the mine iron areas to

the steel plant site is under construction at an estimate of Rs 1200 cr by

JSW Steel to reduce the number of trucks operating for transporting iron

ore. This is being carried out to reduce the fugitive emissions and as a

compliance to one of the condition of the earlier EC.

Setting up of a raw water pond over 600 acres’ area for storing water to

meet the requirements of the steel plants during the dry months for

stable operations.

4- lane National highway is under construction by NHAI connecting

Hospet to Gooty. This will lessen the fugitive emission during road

movement and assist in dispatch of steel products by Road.

A Daroji railway link for providing another outlet connection for the

Ballari side (to the east side of the plant) to move the raw material and

steel products.

Provision of safe potable water facilities in surrounding vil lages is being

implemented by JSW Steel along with other Government agencies.

seasons

Provision of safe piped potable water facilities to Sandur is being

executed by Government agencies.

A by pass along the road along Vaddu is planned to facilitate smooth

movement of traffic to avoid my railway cross overs currently existing in

the JSW land

Under the Karnataka Mining Environment Restoration Corporation a SPV

appointed by the Honorable Supreme court, several infrastructure

development works is being taken up in Sandur taluk, at an estimated

cost of over Rs 10,000 Cr in the next few years. These include:

Drinking water facilities



5 - Planning Brief (cont’d)

5-3

Provision of medical facilities in the project influence area with

special emphasis on primary health care through private Mobile

Health Units, Government Public Health Centers and medical camps

Industrial and Vocational training to local youth groups (both girls

& boys) for diversification of skills and enhancement of livelihood

Provision of social infrastructure like that of community toilets,

playgrounds, community halls with basic amenities

JSW STEEL Limited 18.0 MTPA CRUDE STEEL PRODUCTION


Fig 6-1&2 : Location of proposed expansion of crude steel capacity

6 - PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

The existing integrated steel plant of JSW Steel l imited is situated between

15o 10' - 15o 12' N latitude and 76o 38' - 76o 40'E longitude, near Toranagallu

village of Bellary district in the state of Karnataka. The site is located at 32 km

from Bellary, 33 km from Hospet and about 340 km from Bangalore by road.

Nearest railway station to the steel plant is Toranagallu. Broad gauge railway

lines between Guntakal and Hubli are passing through this station. The eastern

port of Chennai is 460 km and western port of Goa is 430 km. Mumbai is about

740 km on the North West. Location map is shown as Fig. 6-1

National Highway (NH) 67 connecting Ballari and Hubli is situated at the

northern part of the proposed project site. State Highway (SH) 40 connecting

Toranagallu & Sandur is located along the western side of the site and the road

connecting Antapur to NH-67 is on the eastern site of the plant site. The SER

line connecting Vijayawada to Hubli is situated on the northern side of the site.

The production facilities in the proposed expansion to 18 Mtpa will be located

within the existing plant area which is highlighted in Fig 6-2

6.2 RESIDENTIAL AREA

JSW Steel currently has at present five satellite townships (Vidyanagar,

VV nagar, Shankar hill town, Lake view) located along the periphery of the steel

plant with about 6200 dwellings. Another township Hill View township with 2600

dwellings is under construction. All these residential areas have amenities like

roads, electricity, drinking water, underground drainage, sewage treatment,

parks & gardens, security etc. Besides, due to the existence of the steel plant,

the surrounding villages have also been developed and are capable of handling

additional population as needed. Other amenities such as school, community

center, guest house, health center, hospital, shopping complex, post office,

bank, park, playground etc has also been provided in these townships.

Further, a township to accommodate 3500 construction workers is proposed to

take care of the housing needs of migrant population during construction

activities. The accommodation for the additional manpower for the proposed

expansion will be accommodated in these existing facilities. There will be no

temporary construction for accommodating the workers employed during

construction.



6 - Proposed Infrastructure (Cont’d)

6-2

The electrical power and treated water is provided from the existing steel plant.

Treated water is being supplied from the drinking water treatment plant

located within the steel plant.

6.3 GREENBELT

The steel plant is surrounded by lush greenery which besides arresting

pollution has helped in providing a serene environment for the surrounding

population. A total area of about 2500 acres has been developed both inside

and surrounding the steel plant area. Unpaved areas, if any, within the plant

boundary is also provided with grass/tree cover. The greenery development

beyond the “own area” is being carried out on the barren areas surrounding the

steel plant with the help of the local forest department.

The list of species of trees planted in and around JSWSL is given in Table- 6-1

6.4 PROPOSED SOCIAL INFRASTRUCTURE

JSW Steel over the years, though its CSR activities has provided support for the

overall socio-economic development the surrounding areas. It is estimated that

about two lakh population in the surrounding areas have been directly benefited

by JSW infrastructure development activities. To develop these infrastructure,

JSW has already invested around 120 crores. These include:

Rural Social Infrastructure including clean water, decent housing,

environmental sanitation, personal hygiene and adequate nutrition,

Coordination between multiple funding streams and agencies supporting the

surrounding areas.

Basic education to promote quality, dignity, self-respect, with a sense of

belonging as well as political integration.

Formal and informal education to promote rural productivity

Set up OP Jindal Centre, a multi-functional educational campus which

provides Vocational Training, Distance Education, Tamanna special school,

Rajiv Gandhi Institute of Steel Technology, Safety training center, Textile

training center, Sanitary Napkin production unit.

Model schools have been built in Vaddu, Bhujanganagar& Toranagallu. These

model schools each having 20 classrooms to kindle the spirit of education

among the children

Constructed 42 model School Toilets as a part of 'Swachh Bharat'

Two rural BPO center where local women are employed

In association with Akshaya Patra foundation, a midday meal scheme

benefitting about 30,000 children in 432 schools in the surrounding villages.

Developed parks in several vil lages and towns.

Built an Interpretation center at Daroji wildlife sanctuary.




6-3

Restoration of temples in and around Hampi.

Set up Jindal Sanjeevani Hospital, a multi-specialty hospital etc

It is intended to continue and expand these activities for the overall development

of the area.

6.5 CONNECTIVITY

JSW steel is well connected to other parts of the country by Road and Rail.

Toranagallu is now connected by air from Hyderabad and Bangalore.

6.6 DRINKING WATER MANAGEMENT AND SEWAGE SYSTEM

Over the years, JSW has built necessary infrastructure for providing drinking

water to the residents in the township and to surrounding villages. Currently,

about 15,000 m3/d of drinking water is being supplied to the steel plant and

township. This will be augmented to 20,000 m3/d in the proposed expansion.

The treated wastewater is being used for plantation and industrial purposes.

Further, Karnataka Government is proposing to provide drinking water to Sandur

taluk by laying a separate pipeline from the HLC canal. The work is in progress

and is expected to be completed by Dec 2019.

6.7 INDUSTRIAL WASTE MANAGEMENT

In the process of steel mal process and non-process wastes and effluents are

generated. These are discussed in detail in Chapter-3.

6.8 SOLID WASTE MANAGEMENT

The major solid wastes produced in the steel manufacture are blast furnace

slag, steel slag dust & sludge among others. The solid waste management has

been discussed in detail in Chapter-3.

6.9 POWER REQUIREMENT AND SUPPLY/SOURCE

JSW Steel has set up four captive power plants with a capacity to generate 830

MW of electricity. Besides about 110 MW of electrical power is being generated

from waste energy sources. Electrical power is also being imported from

JSWEL, a Group company which has an installed capacity of 860 MW.

The power requirement of the steel plant and township will be met from these

sources. There is no proposal to install any power plant under the proposed

expansion. The details of power requirement at 18 Mtpa is explained in detail in

Chapter-3

TABLE 6-1: LIST OF SPECIES OF PLANTS/SHRUBS PLANTED IN AND

AROUND JSWSL




6-4




6-5




6-6




6-7

JSW STEEL Limited 18.0 MTPA CRUDE STEEL PRODUCTION PRE-FEASIBILITY REPORT

Fig 6-1&2 : Location of proposed expansion of crude steel capacity



7-1

7-REHABILITATION & RESETTLEMENT

The proposed project is a brown field project with all the proposed facilities

coming up with in the existing land area of the existing integrated steel plant

complex.

The project entails use of existing water allocation, power generation

facilities with zero l iquid discharge. Further, all the solid wastes are proposed to

be recycle or sold.

In view of this, there are no R & R issues.



8-1

8 - IMPLEMENTATION SCHEDULE & COST ESTIMATE

8.1 IMPLEMENTATION SCHEDULE

The proposed project of installation of the 18 Mtpa steel plant is an

extension of the earlier proposed expansion of capacity from 10 MTPA to 16

MTPA. The expansion of crude steel capacity to 18 MTPA is expected to be

completed by March 2022, with commissioning of various plant facilities of the

project is shown in the form of a bar chart in Fig.8-1 which is attached.

It is envisaged that the project would be completed within a period of 44

months from the date of receipt of Environmental Clearance (EC) . It is

considered that construction work at site for various plant facilities of the project

would commence after Grant of EC from MoEFCC & CFE from KSPCB, and

also, completion of major engineering works .

8.2 CAPITAL COST ESTIMATE

The estimated capital cost for the plant & equipment worked out for all

the facilities are presented in Table 8-1. The expansion from 10 Mtpa to 16 Mtpa

was originally estimated at Rs 16000 Cr. Considering the changes in

configuration of the facilities, the proposed expansion from 13 Mtpa to 18 Mtpa

is expected to cost Rs 19621 Cr, out of which Rs 1055 Cr will be spent for

implementation for environment monitoring & control facilities as given in Table

8-2



8 - Implementation Schedule & Cost estimate (Cont’d)

8-2

TABLE 8-1 :COST ESTIMATES : 18.0 MTPA EXPANSION OF CRUDE STEEL AT VIJAYANAGAR

Sl. No.

Unit Total in Rs Crore

1 Blast Furnace No.5 1895

2 Pellet Plant No.3 (including Filtration facilities)

1212

3 Steel Melting Shop No. 3 & 4 2953

4 Hot Strip Mill No.3 2846

5 Cold Rolling mill 3 4800

6 Raw Material handling augmentation 470

7 Utility & Services 133

8 Energy management & MSDS. 594

9 Logistics 202

10 Daroji rail linkage 182

11 Infrastructure (including dismantling CO 1&2), Road and bridges.

145

12 Design, Engineering & Consultancy services for 18.0 MTPA

47

13 Salaries & Admin 1% 24

Basic Project Cost 15503

Taxes 7% 1085

Contingency 5% 775

Core Project Cost 17363

IDC 8 % 1389

Margin Money 5% 868

Total Project Cost 19621




8-3

TABLE 8-2 COST ESTIMATES : ENVIRONMENTAL CONTROL MEASURES AT 18.0 MTPA

Major Environment Control Facilities Total in Rs Crore

1. Dry GCP for higher capacity BOF converters 80

2. Enhanced capacity of earlier proposed environmental control facilities

280

3. Flue gas desulphurisation for CPP 3&4 350

4. Additional bag filter for ESPs of Sinter Plant 245

5. Environment control monitoring 20

6. Steel slag- Steam box technology in SMS-4 80

Total 1055




8-4



9-1

9 - ANALYSIS OF PROPOSAL

9.1 FINANCIAL BENEFITS OF THE PROJECT

The financial benefits accrued from the project would improve the

profitability of the promoter company, but also strengthen the economy of the

state due to revenues from taxes and duties derived from sale of value added

products. Installation additional facilities in terms of state-of-art steel plant

with captive power plant, add huge impetus to the growing economy of the

state and the country.

9.2 SOCIAL BENEFITS

The proposed brown field expansion in a relatively backward part of the

state of Karnataka would help in

- Further enhance local direct and indirect employment opportunities

in the project influence area

- promote the development of ancillary industries, medium-small scale

trade & commercial establishments, local entrepreneurship and

diversification in skill set

- generate local income, boost the local purchasing power and promote

an increase in land prices & rent

- contribute to the local economy and the state revenue

The peripheral development activities that would be undertaken by the

proposed project will focus on vulnerable communities in the project influence

area. The project would bring forward an overall socio-economic development

with emphasis in the areas of employment, education, training, health and

infrastructure.

Documents

EXPANSION OF JSW STEELenvironmentclearance.nic.in/writereaddata/Online/TOR/22...7 Cold Rolling Mill -3 of 2.3 MTPA capacity(New) 8 Larger capacity Lime and Dolo Calcining plants (f