JSW SALEM WORKS · JSW Salem works presently, operating a steel plant with the name plate capacity of 1 MTPA. The demand for special alloy steel was growing at the rate of 15% a year

JSW SALEM WORKS

EXECUTIVE SUMMARY for

Expansion of Special Alloy Steel plant from 1 to 1.3 MTPA & Captive power plant from 67 to 97

MW at Mecheri, Mettur Taluk, Salem District - TamilnaduSalem District - Tamilnadu

MECON LIMITED

(A Govt of India Enterprise)(A Govt. of India Enterprise)

BANGALOREMEC/Q76L/01/S2/R0 November 2015

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*Construction of new BF of 650 m3 or modifying the present BF from 402 to 650 m3.

Manufacturing Facilities Existing Capacity (MTPA)

Proposed Expansion

(MTPA)

Total Capacity

after Expansion

(MTPA) 1.0 Coke Oven Plant -1 (Non – Recovery

Type ) 0.50 - 0.5

2.0 Sinter Plant – 1 (20 Square Meter) 0.175 - 0 2.1 Sinter Plant – 2 (90 Square Meter) 1.06 - 1.06 2.2 Sinter Plant – 3 (90 Square Meter) - 1.06 1.06 4.0 Blast Furnace – 1 (402 to 650 Cubic

Meter)* 0.367 0.316 0.683

4.0 Blast Furnace – 2 (550 to 650 Cubic Meter) 0.578 0.105 0.683

5.0 Energy Optimising Furnace – 1 (45 T to 65 T) 0.41 0.23 0.64

5.1 Energy Optimising Furnace – 2 (65 T) 0.62 - 0.62 7.0 Ladle Furnace - 1 with Common VD

(45 T to 65 T) 45T/heat 20 T/heat 65 T/heat

7.1 Ladle Furnace – 2 (65 T) 65 T/heat - 65 T/heat

7.2 Ladle Furnace - 3 common VD (65 T) 65 T/heat - 65 T/heat

7.3 Ladle Furnace - 4 (65 T) 65 T/heat - 65 T/heat

8.0 Continuous Casting Machine - 1 0.35 - 0.35 8.1 Continuous Casting Machine - 2 0.5 - 0.5 8.2 Continuous Casting Machine - 3 - 0.45 0.45 9.0 Bar & Rod Mill Augmentation 0.4 0.08 0.48 9.1 Blooming Mill Augmentation 0.36 0.12 0.48 10.0 Pickling and Annealing Steel unit - 0.06 0.06 11.0 Peeled and ground - 0.04 0.04 12.0. Air Separation Plant 1 – 150 Ton/Day 150

T/day - 150 T/day

12.1 Air Separation Plant 2 – 390 Ton/Day 390 T/day - 390 T/day

12.2 Air Separation Plant 3 – 250 Ton/Day - 250 T/day 250 T/day 13.0 Captive Power Plant 1 (7 MW) 7 MW - 7 MW 13.1 Captive Power Plant 2 (2 x 30 MW) 2X30

MW - 2X30 MW

13.2 Captive Power Plant 3 (1 x 30) - 30 MW 30 MW

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JSW Steel Limited Pottaneri Village, Salem Dist., Tamil Nadu

EIA/EMP Report for Proposed Capacity Expansion of 1 to 1.3 MTPA Integrated Steel Plant

Executive Summary

© 2015 MECON Limited. All rights reserved

E - 1

Executive Summary PROJECT NAME AND LOCATION JSW Salem works presently, operating a steel plant with the name plate capacity of 1 MTPA. The demand for special alloy steel was growing at the rate of 15% a year. In order to tap the potential market in special alloys, it planned to enhance the capacity of special alloy steel from 1 to 1.3 MTPA and expansion of power plant capacity from 67 to 97 MW. The proposed expansion of JSW, Salem works is located at M.Kallipatti & Pottaneri Village, Mecheri panchayat, Mettur Taluk, Salem District of Tamil Nadu state. The nearest town Mecheri is located at a distance of 3 km in NE direction from the project site.

The site lies in seismic zone-II as per seismic zone mapping of India. There is no capable fault within the study area.

The site is well connected by road (SH 20) and rail and Mecheri road railway siding is existing at the back of present plant. PRODUCTS AND CAPACITIES The existing plant is possessing EC issued by MoEF for 1 MTPA vide their letter number F. No. J-11011/281/2006-IA.II (I) dt. 2nd January, 2007. The details of major technological unit’s capacity for existing and proposed expansion are given below:



Executive Summary


E - 2

*Construction of new BF of 650 m3 or modifying the present BF from 402 to 650 m3.

Manufacturing Facilities Existing Capacity (MTPA)

Proposed Expansion

(MTPA)

Total Capacity

after Expansion

(MTPA) 1.0 Coke Oven Plant -1 (Non – Recovery

Type ) 0.50 - 0.5

2.0 Sinter Plant – 1 (20 Square Meter) 0.175 - 0 2.1 Sinter Plant – 2 (90 Square Meter) 1.06 - 1.06 2.2 Sinter Plant – 3 (90 Square Meter) - 1.06 1.06 4.0 Blast Furnace – 1 (402 to 650 Cubic

Meter)* 0.367 0.316 0.683

4.0 Blast Furnace – 2 (550 to 650 Cubic Meter) 0.578 0.105 0.683

5.0 Energy Optimising Furnace – 1 (45 T to 65 T) 0.41 0.23 0.64

5.1 Energy Optimising Furnace – 2 (65 T) 0.62 - 0.62 7.0 Ladle Furnace - 1 with Common VD

(45 T to 65 T) 45T/heat 20 T/heat 65 T/heat

7.1 Ladle Furnace – 2 (65 T) 65 T/heat - 65 T/heat

7.2 Ladle Furnace - 3 common VD (65 T) 65 T/heat - 65 T/heat

7.3 Ladle Furnace - 4 (65 T) 65 T/heat - 65 T/heat

8.0 Continuous Casting Machine - 1 0.35 - 0.35 8.1 Continuous Casting Machine - 2 0.5 - 0.5 8.2 Continuous Casting Machine - 3 - 0.45 0.45 9.0 Bar & Rod Mill Augmentation 0.4 0.08 0.48 9.1 Blooming Mill Augmentation 0.36 0.12 0.48 10.0 Pickling and Annealing Steel unit - 0.06 0.06 11.0 Peeled and ground - 0.04 0.04 12.0. Air Separation Plant 1 – 150 Ton/Day 150

T/day - 150 T/day

12.1 Air Separation Plant 2 – 390 Ton/Day 390 T/day - 390 T/day

12.2 Air Separation Plant 3 – 250 Ton/Day - 250 T/day 250 T/day 13.0 Captive Power Plant 1 (7 MW) 7 MW - 7 MW 13.1 Captive Power Plant 2 (2 x 30 MW) 2X30

MW - 2X30 MW

13.2 Captive Power Plant 3 (1 x 30) - 30 MW 30 MW



Executive Summary


E - 3

LAND REQUIREMENT The total area of the existing plant is 586.09 acres, in which the existing facilities have occupied about 350 acres. The proposed expansion facilities will be occupying about 29 acres. The total plantation area is 194 acres i.e. 33% of the total area available. The land is under the possession of JSW categorized under industrial land. No eco sensitive zones or reserve forests exist within 5 km. However, Solappadi, Gonur and Vanavasi RF are falling at a distance of 9 km and 7 km respectively. There are no industries with 10 km radius. RAW MATERIAL REQUIREMENT

The raw material required for the proposed capacity expansion along with the source is listed in table below:

Sl. NO. Raw material

Present Quantity

MMT/Year

Post Exp. Quantity

MMT/Year Source

1 Iron ore fines

0.845

1.47 Indigenous/Imported

2 Iron ore pellets NA 0.5 Indigenous source 3 Lump ore 0.806 0.705 Indigenous/Imported 4 Coking coal 0.585 0.585 Imported

5 Non coking coal for COP 0.147 0.147 Imported

6 Non coking coal for PCI 0.147 0.215 Imported

7 Power plant coal 0.172 0.172 Indigenous/Imported

8 Coke breeze for SP 0.023 0.023 In house

9 Limestone 0.08 0.135 Imported/indigenous

10 Dolomite 0.091 0.147 Indigenous

11 Quartzite 0.030 0.039 Indigenous

12 Dunite 0.030 0.039 Indigenous

13 Lime powder 0.0585 0.0945 Imported/indigenous

14 Mill scale 0.097 0.158 Indigenous



Executive Summary


E - 4

Sl. NO. Raw material

Present Quantity

MMT/Year

Post Exp. Quantity

MMT/Year Source

15 Purchase coke 0 0.156 Imported

16 Anthracite 0.039 0.095 Imported

WATER REQUIREMENT An agreement already exists between PWD and JSW to utilize 5 MGD of raw water from downstream of river Cauvery. Presently, about 3.17 MGD of raw water is utilized through an intake facilities located at downstream of Mettur dam which meets the 1 MTPA capacity of steel plant and captive power plant of 67 MW. The estimated fresh water requirement after expansion will be to the tune of about 4.4 MGD. A raw water storage reservoir is located within the JSW premises which will be meeting the total requirement of water for 12 days after expansion. POWER REQUIREMENT

BF gas will be used in sinter plant, VD boiler and reheating furnaces in the mills. Excess gas is being used in the captive power plant. The average power demand of the plant after expansion is estimated to be about 90 MW. It is expected that the power to the tune of 97 MW will be generated from the steel plant facilities after expansion. It is proposed to meet the entire energy requirement from the captive source taking the support of state electricity grid for stability. Provision will be made to sell out the surplus power if any, through the grid. FUEL REQUIREMENT Additional fuel requirement including coal for power plant is not expected. The surplus gas generated due to expansion and surplus power generated from waste heat recovery boilers are being used to meet in house power requirement.

PROCESS DESCRIPTION

The steel plant expansion is planned to follow the current route which BF-EOF- SMS route. The plant will have SP, BF, Non recovery CO, GCP, EOF, CCM, bar & rod mill, blooming mills, pickling and annealing facilities ASP and CPP units. All stacks are equipped with air pollution units like bag filters, ESP dry and wet scrubbers to meet pollution control norms. Zero liquid discharge is practiced by the existing plant and the same will be continued after expansion. The most of the solid wastes generated from various units like raw material handling, BF and sludge generated from the GCP effluent are recycled back into sinter



Executive Summary


E - 5

plant. A portion of EOF and BF-GCP sludge is being used for cooling purpose. The balance is stored inside plant. MoU is exiting with universities to utilize the solid waste for paver blocks. The solid waste generated from power plant (coal ash) is utilized nearby cement industries. CAPITAL COST The estimated capital cost is about 1025 crores. And the project is scheduled to be completed in a period of 36 months.

BASELINE DATA GENERATION The baseline data w.r.t air, ground water, surface water soil, fauna & flora, noise and socio-economic studies were conducted during summer season that is March to May 2015. The pollutant like PM2.5, PM10, SOx, NOX, and CO as mentioned in the ToR has been monitored and the ranges are as follows; PM2.5 = 8.90 to 34.83 µg/m3. PM10 = 23.28 to 76.00 µg/m3. SOX = 1.21 to 9.50 µg/m3. NOX = 11.41 to 60.76 µg/m3. CO = 160 to 252 µg/m3.

The results are observed to be well within the stipulated norms. Samples of ground (8) and surface (4) water samples were collected once during monitoring season. The results indicate that most of parameters are within the recently prescribed norms of groundwater. The exceptions are total hardness, calcium and TDS. The reason could be attributable to mixing of surface water. The area is encountered by hard rock overlained by sedimentary rock which may contain calcium and magnesium and leads to increase in hardness. Whereas, the surface water parameters are meeting the norms. The soil samples were collected from five locations and they are suitable for green belt development. Results did not indicate any characteristic, which may adversely affect plant growth. The soil samples collected from agriculture and barren land indicate that the soil is in good condition and is not affected by any type of pollutant though there are some deviations from critical limits of micro-nutrients. No endangered species of fauna and flora are identified within the study area. The socio economic condition was studied by conducting equal sample allocation method on the nearby population and it appears to be good due exiting steel plant, silk waiving and dairy products.



Executive Summary


E - 6

No hazardous chemicals are handled in the process. However, for start–up of the plant HSD & FO are used. They are stored as per the OSID guidelines. A detailed risk assessment studies were carried for the storage tanks located at various places of within the plant boundary. The maximum thermal radiation 4 Kw/m2 sufficient to cause pain is occurring at a distance of 33 m for FO. The various safety system adopted to mitigate the risk to the employees are goggles, safety shoes, gum boots, ear plugs and helmets within the plant. No specific safety system is required since; the plant is not handling any hazardous chemicals. AIR IMPACTS The expansion leads to increase of back ground concentration of SPM, SOX and NOX and fugitive emissions. It is predicted that the max. Concentrations of these pollutants are occurring within the plant site. From the above predicted results it can be concluded that the pollutant concentrations are well within the norms stipulated by MoEF even after expansion. WATER IMPACTS Since zero discharge concepts are practiced no impact on water is expected. However, an increase of 1.23 MGD of water is expected due to expansion and the same will be met from the existing downstream facilities of Mettur dam constructed in Cauvery River. There is no withdrawal of groundwater and hence, ground water depletion is not anticipated. Further, groundwater pollution is also not anticipated since the raw material and product stock area is paved with impermeable layers.

CSR PLAN JSW management has spent about Rs. 455.04 lakhs from 2012 to till date for welfare activities of surrounding villages. The various activities involved are RO plants, school scholarships, Medical camps, Mission for vision, school toilets and benches, construction infrastructure facilities like toilets for villages, water shed management at several villages to improve the groundwater , Women empowerment schemes like tailoring etc. It has been planned to enhance the fund allotment progressively on CSR activities on year to year basis due to expansion.



Executive Summary


E - 7

OCCUPATIONAL HEALTH MEASURES JSW is following OSHAS norms for the welfare of their employees. Medical check-up are being conducted once in a year for their employees. These practices will be intensified after expansion. POST PROJECT MONITORING PLAN Since, it is an existing plant continuous monitoring for process stacks and ambient air, water and noise are being carried out to meet SPCB requirements. The compliance reports are being prepared and submitted to SPCB and MoEF-RO as compliance to environmental condition issued by concerned authorities regularly. The same practice will be continued for the proposed expansion project also.

Documents

JSW SALEM WORKS · JSW Salem works presently, operating a steel plant with the name plate capacity of 1 MTPA. The demand for special alloy steel was growing at the rate of 15% a year