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JSW STEEL LIMITED1.3 MTPA Integrated Steel Plant at

Pottaneri, Salem, Tamilnadu Pre-feasibility Report

PRE FEASIBILITY REPORT 2015 MECON Limited. All rights reserved

Page 1 of 51

CONTENTS

Chapter - 1 Executive Summary

Chapter - 2 Introduction

Chapter - 3 Project Description

Chapter - 4 Site Analysis

Chapter - 5 Planning Brief

Chapter - 6 Proposed Infrastructure

Chapter - 7 Rehabilitation and Re-settlement (R & R) Plan

Chapter - 8 Project Schedule and Cost Estimates

Chapter - 9 Analysis of Proposal




Page 2 of 51

LIST OF FIGURES

Figure No. Description

Fig. 2.1 Production Capacity of JSW Salem Works

Fig. 3.1 Location Map of Project Site

Fig. 3.2 Satellite Map of Project Site

Fig. 4.1 Road Connectivity Map of Salem

Fig. 4.2 Wind rose of Sep. to Dec. 2014 at Plant Site

Fig. 6.1 Overall layout of the proposed 1.3 MTPA ISP




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LIST OF TABLES

Table No. Description

Table 1.1 Proposed Configuration for 1.3 MTPA

Table 3.1 Proposed Changes in the Configuration of the Facilities and Products

Table 3.2 List of Raw Material Requirement

Table 3.3 Quantity of Solid Waste present and after Expansion

Table 4.1 Monthly Rainfall (mm) and Humidity

Table 5.1 Villages Falling within 10 km Radius from the Project Site

Table 8.1 Cost of Pollution Control and Monitoring Measures




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CHAPTER - 1

EXECUTIVE SUMMARY

M/s. JSW Steel Limited, Salem works is a part of JSW group, leading

manufacturer of alloy steels to meet the requirement of auto mobile sectors and

engineering applications. The plant is located at M.Kallipatti and Pottaneri

Village of Mettur taluk, Salem district, Tamilnadu state. JSW Steel, Salem

works is planning to expand the existing capacity from 1 to 1.3 MTPA. In this

regard, M/s. JSW Steel Ltd is planned to approach MoEF and obtain

environmental clearance from the ministry for the proposal of plant expansion.

To enhance the capacity from 1 to 1.3 MTPA, the following units namely

additional sinter plant of 90 m2, Blast furnace 1 & 2 will be enhanced, Energy

Optimization Furnace 1 will be enhanced, new bloom caster will be installed by

enhancing the capacity of BRM from 0.4 MTPA to 0.48 MTPA and Blooming

mill from 0.36 to 0.48 MTPA respectively. Installation of new annealing furnace

of 0.06 MT, additional oxygen plant of 250 TPD and additional 30 MW power

plant are also planned.

The existing land area is 586.09 acres. This land will be utilized for the

expansion of the plant.

The name plate capacity of the plant is 1 MTPA Integrated steel plant. The

Proposed configuration for 1.3 MTPA plant is as shown in Table 1.1.




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Table 1.1

Proposed configuration for 1.3 MTPA

Manufacturing Facilities Existing Capacity

Proposed Expansion

Total Capacity

after Expansion

1.0 Coke Oven Plant -1 (Non – Recovery

Type ) 0.50 0.5

2.0 Sinter Plant – 1 (20 Square Meter) 0.175 0.0 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)

7.1 Ladle Furnace – 2 (65 T)

7.2 Ladle Furnace - 3 common VD (65 T)

7.3 Ladle Furnace - 4 (65 T)

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 Annealed Steel unit 0.00 0.06 0.06 11.0 peeled and ground 0.00 0.04 0.04 12.0. Air Separation Plant 1 – 150 Ton/Day 12.1 Air Separation Plant 2 – 390 Ton/Day 12.2 Air Separation Plant 3 – 250 Ton/Day 13.0 Captive Power Plant 1 (7 MW) 13.1 Captive Power Plant 2 (2 x 30 MW) 13.2 Captive Power Plant 3 (1 x 30)




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1.1 Sinter Plant:

Presently, plant is operating two sinter plants with machine size 20 sq. m and

90 sq. m respectively. An additional sinter plant of 90 sq. m has been

envisaged with a productivity of 1.45 t/m2/hr for expansion, to cater to the

existing two no. blast furnaces after the capacity augmentation with the total

capacity of 2.12 MTPA. After commissioning and stabilization of sinter plant-

3, sinter plant-1 will be decommissioned.

1.2 Blast furnace

The plant is presently operating with two blast furnaces with capacities of 402

cum and 550 cum respectively. It is proposed to augment the capacities of

both the furnaces to 650 cum each, by replacing the existing refractory lining

with the superior quality refractories of lower thickness.

1.3 Steel making shop

The steel melting shop is having two numbers of Energy Optimizing

Furnaces (EOF), out of which one will be augmented to higher capacity and

thereby ensuring increase in operating capacity of steel melting shop from

0.86 MT to 1.3 MT.

Existing secondary steel refining is having four LRF and two vacuum

degaussing units. Three LRFs are having capacity of 65 T each where as

LRF1 is of 45 Ton which will be augmented to 65 Tons.

1.4 Continuous Casting Machine (CCM)

Existing casters plant comprising of each three stand billet and bloom caster.

In expansion additional bloom caster is envisaged, so as to increase the




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operating capacity from 1.0 to 1.3 MTPA.

1.5 Bar and Rod mill

Bar and Rod Mill is a semi automated rolling mill having a capacity of 4 lakh

tone per annum. The mill is designed to roll wide range of mild steel and alloy

steel products. Steel billets of size 160 mm x 160 mm x 7m & variety of

grades are charged into the reheating furnace. Rolled in three high reversible

mill, continuous mill of eighteen stand supplemented by Kocks block to have

bar and flat product, additional NTM machine for coil. Mill is having the

capacity of 0.4 MTPA which will be augmented to 0.48 MTPA by incorporating

two sliding stand/six continuous stand in place of trio in expansion.

1.6 Blooming mill

Blooming Mill is designed to produce heavy Rounds, Round Cornered

Square (RCS) in the range of 55 to 240 mm as finished product having a

capacity of 0.36 MTPA. The raw material input to the mill is from Bloom caster

of sizes 250 x 250 mm and 340 x 400 mm. Blooms are reheated in reheating

furnace and rolled in two high reversible mill. The intermediate product is

rolled in continuous 8 stand HV mill and required sizes are cut in hot saw. The

products are dispatched in dispatch area. The present capacity of 0.36 MTPA

is augmented to 0.48 MTPA in expansion by installing additional 2 stands.

1.7 Oxygen plant

Existing plant is having two units of 150 TPD and 390 TPD. In expansion

additional pressure swing absorber oxygen plant of a capacity of 250 TPD is

envisaged to cater Oxygen enrichment in blast furnace and oxygen

requirement of steel.




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1.8 Power plant

Existing captive power plant comprises of;

1 x 7 MW using BF gas fired boiler

1 x 30 MW using WHR Boilers of COP sensible heat and BF gas

1 x 30 MW using WHR Boilers of COF and supported AFBC boiler.

In expansion, additional 1 X 30 MW using the WHR boilers of COP and BF

gas is planned.

The requirement of 210 MW for 1.3 MTPA is met with the above captive

generation and the grid support of 40 MW from TANGEDCO




Page 9 of 51

CHAPTER - 2

INTRODUCTION

2.1 GENERAL

JSW Steel is India’s leading integrated steel producer with a present capacity

of 14.3 MTPA. By maintaining exemplary operational efficiencies, the other

activity like JSW Energy has grown ten-fold in just three years while, JSW

Cement creates the building blocks of India with its environmental benign

product. JSW Infrastructure is contributing to the nation’s development by

providing world class services to various entrepreneur through state-of-the-art

ports, terminals, shipyards and other facilities.

JSW group practices transparent in businesses, strong corporate governance

and their dedicated employees have contributed to make every endeavor a

great success. Expansions, up-gradations and technological innovations are

in built capacity of JSW and focused on individual growth of the company that

which has placed India in the business of steel on the global map.

JSW Group has committed to create more smiles at every step of the

business journey. JSW Foundation, the group’s CSR and sustainability arm,

is in constant pursuit of making life better for communities with its various

initiatives in the fields of health, education, livelihood and sports along with art

and culture.

The course of the impact on environment has changed as a result of pollution

control measures adopted in JSW industries, lush green townships and

cheerful employees with spirited growth. JSW group is proud to be house of

excellence that creates opportunities for every Indian and leads to the

creation of sustainable, dynamic and developed nation.




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While consistently adding values to its business, JSW is well aware to its

responsibility, towards environment by implementing best practices in its

business operations and contribution to society through various social

endeavors.

M/s. JSW Salem works, one of the leading special steel industry in south

India located at M.Kallipatti & Pottanneri village, Mettur taluk, Salem district,

Tamil Nadu, is planning for expansion of existing integrated steel plant from

1.0 to 1.3 MTPA. M/s. JSW limited had obtained environmental clearance for

1.0 MTPA vide letter no. J-11011/281/2006-IA.II (I) dt. 2nd Jan. 2007, from the

MoEF.

2.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

JSW, Salem works, which is India’s one of the largest Integrated Special

Steel plant located in Tamilnadu, Salem with designed capacity of 1 MTPA.

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Page 12 of 51

consumption of 500 to 700 kg in developed countries like Japan, European

countries, South Korea, USA etc. The developing countries like Brazil,

Mexico, and China have per capital consumption of about 110 kg to 150 kg

and the World average is about 150 kg which is also very high when

compared to Indian per capita consumption. Hence, there is a large scope in

India to improve the per capita consumption and thereby need arise to

increase the production of steel.

Automobile sector is growing rapidly in International market and India is

considered as one of the global manufacturers in this sector. Every year

India's GDP growth is adding on considerably to the automobile sector.

Reputed automobile manufactures like Nissan, Hyundai, BMW, Suzuki,

Honda, Chevrolet and Renault are expanding their activities in Indian market

every year. Recent and past southern part of India has witnessed massive

investments in automobile industries. Further, to enable manufacturing

processes, energy demand is also in raising trend and hence investment in

power sector is also inevitable.

At present, JSW Salem works is partially catering to the existing automobile

market and is ranked No.1 in special steel sector in India. In order to bridge

the demand and supply of special steel. JSW Salem works is planning for

expansion from 1 to 1.3 MTPA. Hence, the expansion project is considered

as important and required to bridge the gap between demand and supply in

special steel market.

2.5 EMPLOYMENT GENERATION

During construction phase of an integrated steel plant, there will be an ample

employment opportunities (direct) for local/outside populace during

construction work. There are other benefits, too. Important amongst them is




Page 13 of 51

the growth of allied steel industries around the plant engaged in supplying

equipments etc. to steel plant creates job opportunities (indirectly), and

contributes significant economic growth of that area. The living conditions

and welfare of people will improve by social welfare schemes which will be

implemented with the project commencement.




Page 14 of 51

CHAPTER - 3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

M/s. JSW Salem works, is an alloy steel plant with the name plate capacity of

1MTPA for which it has obtained consent to operate from state pollution control

board. In view of market demand JSW Salem works is going for capacity

addition from 1 to 1.3 MTPA. The configuration of existing integrated steel

plant which has obtained environmental clearance and proposed expansion

programme are shown in Table 3.1.

Table 3.1 Proposed changes in the configuration of the facilities and products

Manufacturing Facilities Existing Capacity

Proposed Expansion

Total Capacity

after Expansion

1.0 Coke Oven Plant -1 (Non – Recovery

Type ) 0.50 0.5

2.0 Sinter Plant – 1 (20 Square Meter) 0.175 0.0 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)

7.1 Ladle Furnace – 2 (65 T)

7.2 Ladle Furnace - 3 common VD (65 T)




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3.2 LOCATION of JSW PROJECT SITE

The project site of about 586.09 acres is located at M.Kailipatti & Pottenari

village of Mettur taluk in Salem district of Tamilnadu state. The proposed project

site is about 35 km from the Salem town. The latitude and longitude of the

estimated centre point of the project site is as follows:

Latitude: 11o 48’ 16”N to 11o 49’ 2”N Longitude: 77o 54’ 17”E to 77o 55’ 43”E

Map showing the general location, satellite view of project site is shown in Fig.

3.1 and Fig. 3.2.

7.3 Ladle Furnace - 4 (65 T)

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 Annealed Steel unit 0.00 0.06 0.06 11.0 peeled and ground 0.00 0.04 0.04 12.0. Air Separation Plant 1 – 150 Ton/Day 12.1 Air Separation Plant 2 – 390 Ton/Day 12.2 Air Separation Plant 3 – 250 Ton/Day 13.0 Captive Power Plant 1 (7 MW) 13.1 Captive Power Plant 2 (2 x 30 MW) 13.2 Captive Power Plant 3 (1 x 30)




Page 16 of 51

Fig. 3.1 Location map of project site




Page 17 of 51

Fig. 3.2 Satellite Map of Project site

3.3 SITE SELECTION BASIS

The land is already available for expansion of the project. The main features of

site including environmental considerations make the site suitable for the

proposed expansion are given below:

Existing plant & land with JSW and thus no R&R issues.

Logistic support like availability of raw material, water and power.

Suitable topography for construction of facilities.




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Good accessibility through road and rail.

Safe from site flooding possibility.

Suitable seismic zone.

No major storage facilities for inflammable and explosive materials.

No archeologically important heritage monuments are located within 10 km radius.

No declared biodiversity parks/sanctuaries are in the surroundings of site.

3.4 SIZE AND MAGNITUDE OF OPERATION

Total available land along with the existing plant is spread over 586.09 acres

of land and the proposed expansion would be carried out in the existing plant

locations. The magnitude of expansion from 1.0 to 1.3 MTPA.

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

Major Units

The following major technological units have been planned for the proposed

expansion and their capacities are indicated in Table 3.1.

(i) Sinter Plant

Sintering is an agglomeration process which converts the iron ore fines into

porous mass to make them as feed material for blast furnace iron making.

Sinter plant with 1.06 MTPA production capacity is planned with a sinter

machine of 90 sq. m size in expansion with necessary accessories like flux

and fuel crushing plant, circular cooler, mixing drums, product screening

facility, waste gas system, etc.

The sinter plant will consist of the following main technological units.




Page 19 of 51

Fuel and flux crushing unit

Flux screening unit

Storage and Proportioning unit

Primary mixing room

Secondary mixing room

Sintering and cooling unit

Waste gas dedusting unit

Main exhaust fan unit

Cold sinter screening unit

Plant dedusting units

The coke breeze generated in coke oven plant and blast furnace will be

recycled in sinter plant as solid fuel for sintering. The recycled material from

gas cleaning plant of blast furnace is also utilized. Flux materials like

limestone and dolomite will be crushed to <3 mm size in crushing plant and

stored in the proportioning bins. The coke breeze will be crushed to fines in

the range of 0 – 3 mm size using roll crushers and stored in proportioning

bins. All the raw materials will be mixed into a homogeneous mixer and

nodulised in mixing drums before charging onto sinter machine. Mixed gas

will be used as the fuel in ignition furnace in the sinter machine. Sintering will

take place in the machine and the hot sinter will be discharged to the circular

cooling machine. The cooled sinter will be screened to separate the fines <5

mm from the product sinter. The screened product will be dispatched to blast

furnace.

(ii) Blast furnace

The blast furnace is a vertical counter-current heat exchanger as well as a

chemical reactor in which burden material charged from the top descend




Page 20 of 51

downward and the gasses generated at the tuyere level ascend upward.

The inside profile of the furnace from top to bottom is termed furnace throat,

shaft, belly, bosh and hearth. The throat is the top part of the furnace and

includes the installation necessary for charging coke and burden materials

and drawing off the top gasses. The top gas is routed from the furnace

top to the gas purifiers and then to the consumption zones. The profile of

the furnace widens in the shaft that follows. The widening of the furnace

chamber from top to bottom is necessary to avoid hanging and scaffolding

of the burden in the blast furnace when the raw material expands during

heating. The height of the shaft is about 3/5 of the total height of the

furnace. The shaft is followed by the belly and bosh. The profile again

narrows in the bosh, as this is the part of the furnace, where the stock

column starts to melt the hearth is the lower cylindrical part of the furnace

where the fluid slag and the hot metal accumulate. Arranged in the upper

part of the hearth are water-cooled tuyeres made of copper. The hot air for

combustion is injected through these into the blast furnace. Hot metal is

tapped through the tap hole, which is opened by power driven drills into a

train of ladles kept below the runner of the cast house. Slag comes along

with the metal and is skimmed off with the help of skimmer plate towards

slag runner and is granulated and collected in the slag granulation plant. The

tap hole is tightly sealed with a mud gun after tapping process is complete.

Raw material (ore, sinter, coke) are screened before being charged into the

blast furnace through conveyors or skip. Air for combustion in the blast

furnace is blown from turbo blowers which is preheated in hot blast stoves to

temperatures around 1200°C, which is then blown through tuyeres.

In to the blast furnace. Each blast furnace is equipped with minimum three

stoves which operate alternatively. Preheating of air helps in reducing fuel




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consumption in the furnace.

The useful volume of the proposed BF’s shall be 650 m3 X 2 No’s with total

production of 1.3 MTPA gross hot metal and after considering handling

losses the net hot metal available for steel making shall be 1366000 TPA.

The feed charge to BF shall consist of 75% sinter, 25% pellet or lump ore.

(iii) Steel making shop

The Energy Optimizing Furnace (EOF) operates as a batch melting process

producing batches of molten steel known "heats". The EOF furnace

operating cycle is called the tap-to-tap cycle and is made up of the

following operations:

Furnace charging.

Melting.

Refining.

De-slagging.

Tapping.

Furnace turn-around.

Modern operations aim for a tap-to-tap time of less than 40 minutes.

EOF shall be equipped with atmospheric injectors, tuyers & supersonic

lancers. Hot metal from the blast furnace is poured through launders. Oxygen

lances for refining of the liquid bath.

The present EOF- 1 is of capacity 1x45 T/heat and EOF 2 is of capacity

1x65 T/heat. EOF-1 will be augmented to 65 T/heat size in expansion. This




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will be capable of producing 1260000 TPA of liquid steel. The metallic feed

to EOF shall consist of 85% Hot metal and up to 15% solid charges

depending on the availability of scrap.

The liquid steel produced from EOF & LD Converter shall be subjected to

secondary metallurgy operation in ladle furnace with vacuum degassing.

. (iv) Ladle Refining Furnace (LRF)

Secondary steel treatment in the LRF provides the production of steel with

high precision as for chemical composition and temperature, allows

desulphuration of metal to be brought up to the specified parameters, the

amount of nonmetallic inclusions to be reduced and it also serves as the

accumulating and damping facility between a melting unit and steel casting

units. Since this is an alloy steel unit, the secondary additions are carried out

in this LRF unit to have the required chemical composition. Thus refined steel

from LRF is subjected to Vacuum degassing in the common VD unit for 2

LRF. It provides high degree of degassing, de-oxidation, desulphuration,

decarburization and nonmetallic inclusions removal. LRF + VD units are

equipped with argon lancing or if necessary, with oxygen blowing.

Required vacuum is created with the aid of VD boilers.

The liquid steel after secondary metallurgy operation shall be sent to

continuous casting machine. A brief description of CCM is as given below:

(v) Continuous Casting Machine (CCM)

During continuous casting, the liquid steel passes from the pouring ladle,

with the exclusion of air, via a tundish with an adjustable discharge device




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into the short, water-cooled copper mould. The shape of the mould defines

the shape of the steel. Before casting, the bottom of the mould is sealed with

a so-called dummy bar. As soon as the bath reaches its intended steel level,

the mould starts to oscillate vertically in order to prevent the strand adhering

to its walls. The red hot strand, solidified at the surface zones, is drawn

from the mould, first with the aid of a dummy bar, and later by driving rolls.

Because of its liquid core, the strand must be carefully sprayed and cooled

down with water. Rolls on all sides must also support it until it has

completely solidified. This prevents the still thin rim zone from disintegrating.

Once it has completely solidified, the strand can be divided by mobile cutting

torches or shears. Intensive cooling leads to a homogeneous solidification

microstructure with favorable technological properties. High casting speeds

are achievable nowadays; depending on dimensions and the number of

strands that cast simultaneously, speeds of about 0.6 to 3.5 m/min are

possible for slabs.

The exist ing CCM shop consists of a billet caster & Bloom caster which

produces billets & blooms. In expansion, it is planned to install bloom caster

3 to reach the capacity of 1.3 MTPA.

(vi) Bar mill

Bar and Rod mill is a semi automated rolling mill having a capacity of 0.48

MTPA. The mill is designed to roll wide range of mild steel and alloy steel

products. Steel billets of size 160 mm x 160 mm x 7m & variety of grades are

charged on to the charging grid and fed into the re-heating furnace to heat it

to a maximum of 1250 deg C. After attaining the required temperature these

hot billets are discharged from the furnace and fed into a three high mill

(TRIO) for further reduction to 104 mm x 112 mm. Billet reduced at TRIO will




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be sent to continuous mill (Train 1, 2 & 3) for further reduction to get the

required finishing size at the Kocks Block. Bars/flats, leaving the Kocks

Block/Continuous mill are divided by a dividing shear located after the

continuous mill, fed into the cooling bed and further cut into 500 T cold shear.

Finished product are bundled in the bundling station and stacked in the yard

in respective location. In case of coil production for sizes less than 16 mm,

bars leaving the Kocks Block are finished at NTM and they are wound in coil

shape by the Laying Head which is guided by a pinch roll. The bottom end of

the pipe revolves rapidly and forms the rod into rings that overlap in

spenserian form on to the stelmor conveyor where it can control the cooling

rate of the coil with the help of blowers. The coils are carried through the

conveyor and the coils are loaded to the ‘C’ hook conveyor by means of Coil

Transfer car and they are cooled to ambient temperature after passing

through a conveyor consisting of 100 no’s of ‘C’ hooks. These coils are

Inspected, end trimmed, compacted, bound/strapped and unloaded from the

conveyor. Coils are then stacked at the stacking yard at the designated

places. In case of coil production for sizes more than 16 mm, the finished bar

from Kocks travel through water boxes 1 & 2, then it is fed through pinch roll

to the Garret Coiler. These hot coils are handled with the help of a plate

conveyor.

(vii) Blooming mill

Blooming mill is designed to produce heavy rounds, Round Cornered Square

(RCS) in the range of 55 to 240 mm as finished product having a capacity of

0.36 MTPA. The raw material input to the mill is from Bloom caster of sizes i)

250 x 250 mm ii) 340 x 400 mm. It consists of reheating furnace of 100 T

capacity of BF gas fired with roller table to feed into two high reversible mill.

The Intermediate size from two high reversible mill is fed into 8 stands




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horizontal and vertical mill for further reduction to required sizes. The

products are transferred to hot saw roller table where it is cut into sizes and

fed into cooling bed. The end product after cooled is inspected in automatic

inspection line, Bundled and stored in stacking area for dispatch. In addition

to above another two strands shall be installed and capacity shall be

increased from 0.36 to 0.48 MTPA.

(viii) Oxygen plant

Oxygen (99.6% purity) will be consumed in blast furnace for oxygen

enrichment of blast and oxygen (99.6% purity) will also be consumed in the

steelmaking shop for blowing in the EOF, LD Converter and LRF for steel

making, in the continuous casting plant to meet the cutting needs and also

to meet the general purpose requirement of various shops of the steel

plant. Argon will be required for rinsing in ladles and also to maintain inert

atmosphere in the mould/tundish. Nitrogen will be required for purging of

gas pipelines, blast furnace top charging equipment, etc.

Oxygen, nitrogen and argon will be produced by air separation process

based on low pressure cryogenic cycle and double column rectification

system. Oxygen shall be supplied with internal compression with process

liquid pumps and nitrogen either internal or external compression.

In expansion existing capacity of Air Separation Plant (ASP) is augmented

with 250 TPD Pressure Swing Absorber/cryogenic plant.




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(ix) Power plant

The present captive power generation units are as below

i) 1 x 30 MW – 30 MW (AFBC) coal based power plant

ii) 1 x 30 MW – 30 MW BFG and WHR Boilers

iii) 1 x 7.5 MW – BFG and FO based

In the proposed power generation plan, additional 1 x 30 MW generation unit

will be installed which will be based on BFG and WHR Boiler from expansion.

03.06 RAW MATERIAL REQUIREMENT

The raw material required for the proposed project along with the source is

listed in Table 3.2.

Table 3.2 List of raw material requirement

Sl. NO. Raw material

Quantity MMT/Year Source

1 Iron ore fines

1.378

Indigenous/Imported

2 Iron ore pellets 0.5 Indigenous source

3 Lump ore 0.821 Indigenous/Imported

4 Coking coal 0.637 Imported

5 Non coking coal (PCI) 0.407 Imported/

7 Power plant coal 0.198 Indigenous/Imported

8 Coke breeze for SP 0.023 Imported

9 Limestone

0.102 Imported/indigenous

10 Dolomite

0.148 indigenous




Page 27 of 51

Sl. NO. Raw material

Quantity MMT/Year Source

11 Quartzite

0.0224 indigenous

12 Dunite

0.021 indigenous

13 Lime powder

0.095 Imported/indigenous

14 Mill scale

0.095 Indigenous

15 Purchase coke

0.2 Imported

03.07 BRIEF OUTLINES FOR RESOURCE UTILIZATION

Existing plant is having the rain water harvesting pond to store the 8000 KL of

water.

03.08 AVAILABILITY OF WATER AND ITS SOURCE, ENERGY REQUIREMENT WITH SOURCE

(i) Water Existing water drawl agreement from PWD source is 5 MGD. The present

requirement is about 3.17 MGD including steel plant and captive power plant

of 67 MW. Total fresh water requirement after expansion requirement is

about 4 . 4 M G D . The present storage capacity is about 20 days. After

expansion, including the additional storage will be for the captive consumption

for 12 days.)

(ii) Energy

Gas from the BF, will be used in sinter plant, VD boiler and reheating furnaces

in the mills. Excess gas would be used in the captive power plant.




Page 28 of 51

03.09 QUANTITY OF WASTE GENERATED (LIQUID AND

SOLID) AND SCHEME OF MANAGEMENT

(i) Wastewater generation

Wastewater generated in individual steel production facilities. It is

recommended that each of the production units will be designed to utilize

less amount of water and recycle the water to the maximum by cascading

use of water. There will be blow downs from each of the systems. It is

suggested that the blow down water be collected centrally and treated to

make the water usable in less critical applications like slag quenching,

green belt development etc.

All efforts will be made to re-use and re-circulate the water and to maintain

zero effluent discharge. The following schemes are proposed for

wastewater management comprising, treatment, recycling a n d disposal

systems.

(ii) Gas cleaning plant wastewater

The blast furnace gas cleaning scheme will be of the conventional

venturi type which have become the bench mark for similar application.

The effluent coming out of the wet scrubber will be contaminated with

high concentration of suspended solids. The slurry will b e clarified in the

clarifier, to recover clarified water for recycling into the wet gas scrubber

after cooling in the cooling tower. The sludge settled in the clarifier will be

pumped to the existing sinter plant as a feed material for making sinter. It

is suggested that the blow down water from the cooling water circuits will

be used as make-up water in the gas cleaning re-circulation systems.




Page 29 of 51

(iii) Treatment of billet caster effluent and mill effluents

This effluent will be contaminated mainly with suspended solids and traces of

oil. The effluent from the mill will be collected first in scale pit which is a large

settling basin to separate out the floating oil and settable iron scales. The

cleaned water is passed through sand filters to remove finer particles, and

then the water is recycled in the process. The backwash from the filters is sent

to the settling tank for removal of particulates. The settled sludge is sent to

sinter plant for agglomeration. It is planned that the blow down water from the

cooling water circuits will be used as make-up in direct contact re- circulation

systems.

(iv) Treatment of power plant effluent

The power plant effluent will be the backwash of DM water plant. This

effluent will be relatively free from solids and oil and thus the effluent will

be treated in a neutralizing pit for pH correction only. The neutralized

effluent will be stored in the treated effluent lagoon for reuse along with

cooling tower blow down in the direct cooling system.

(v) Use of cooling tower blow downs

It is noted, that the re circulating water in cooling towers gets contaminated

with the dust in the atmosphere, necessitating blow down. It is

recommended that all cooling towers to be provided with side stream

pressure filters to reduce the volume of blow down. The cooling

towers are designed to operate at high cycles of concentrations (>8) to

conserve water. Further, cooling tower blow downs of indirect cooling




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water system shall be used for slag quenching, as make up to direct

contaminated cooling water circuits and surplus if any, will be stored in

the treated wastewater lagoon for in- plant use.

The major solid waste expected to be generated from the various facilities

of integrated steel plant are provided in Table 3 - 13.

Table 3.3

Quantity of solid waste present and after expansion

Sl. No. Solid waste Nature of solid

t

Quantity (t/d)

Probable reuse

Blast furnace 1 Sinter BF return Sinter 178 Sinter plantSteel melting shop

1

Slag

Slag

732

Road making and 70kg/tonne of crude steel will be used

2 Flume dust from bag filter

dust 415 Sintering plant

Continuous casting machine

1 Scale and muck Scales 110 Sintering plant

2

Scrap

-

266

Within the steel plant- DRI

Rolling mills

1

Scrap

Scrap

103

Within the steel plant- DRI

2 Scale and muck Scale 8.5 Sintering plant




Page 31 of 51

3

Oil and grease traps

Oil and grease

0.3

To be sold to authorized vendor

4

Reheat furnace

Broken refractories

-

Land filling

Coke oven plant 1 Coke breeze Dust 465 coke oven

2 Dust from bag

filters Dust 31 Power plant/

coke oven

Captive power plant

1

Ash including fly ash

Dust

316

Cement and brick manufacturing

2 Bottom ash clinker 80 Road construction

Sl. No. Solid waste Nature of solid waste

Quantity (t/d)

Probable reuse

Lead acid batteries

Sold to authorised vendors

(vi) Solid waste management

About 90% of EOF slag will be used within the plant as road making and

ballast for railway track. BF slag will be granulated and it will be utilized in

captive cement plant.




Page 32 of 51

CHAPTER- 4

SITE ANALYSIS

4.1 CONNECTIVITY

The site is well connected by road and rail. The project site is located about

35 km South-West of Salem city. Mettur town is located at 12 km in SW

direction. NH 7 passing at 22 km away from plant site.

The nearest railway station is Salem at a distance of 35 km and nearest

airport is Bangalore at a distance of 200 km.

The road connectivity map of Salem is shown in Fig. 4.1.

Fig. 4.1 Road connectivity map of Salem




Page 33 of 51

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed project site is located within the existing facilities of JSW Steel

works Salem and the proposed area is plain land. The land earmarked for

expansion is neither vegetated nor having any buildings. Hence, site clearing

activities like clearing the vegetation or demolition exiting building are not

contemplated.

4.3 TOPOGRAPHY

The site is mostly flat. However the surrounding area is undulated with hills

and hillocks. The following reserve forests along with the directions with

respect to project site are observed in 15 km surrounding area.

i) Vanavasi Reserve Forest in SW

ii) Gonur and Solappadi reserved forest in NW

iii) Parigam reserved forest in N

iv) Ramasamy reserved forest in NE

v) Elattur reserved forest in ENE

No environmentally sensitive area is located nearby. The Stanley reservoir is

located in west direction. The important crops grown are paddy, groundnut,

fodder, sugarcane, maize, cholam, ragi, cumbu, cotton, and turmeric. The

main source of irrigation is from bore wells and dug wells.

4.4 EXISTING LAND USE PATTERN

The site is located in the interior part of Salem district, which is spread from

southwest to northeast and is situated on the eastern side of Tamilnadu state.

The district is 11° 14' and 12°53' north latitude and 77° 44' and 78° 50' east




Page 34 of 51

longitude. This district is bounded by Dharmapuri district on the north, Erode

district on the west, Namakal and Tiruchirapalli districts on the south, and

Perambalur and Villupuram districts on the east and the proposed project site

is not attracted by any other statutory act like CRZ. No national park, eco-

sensitive area are identified within 15 km radius study area.

4.5 EXISTING INFRASTRUCTURE

The site is well connected by road and rail. Presently the site is connected by

a metal road. The site is located at about 26 km from NH-7 which is passing

in eastern direction. The nearest railway station is Salem situated at about 35

km.

4.6 SOIL CLASSIFICATION

Site geology

Salem is located on the high grade Precambrian terrain of south India with a

network of shear zones of Neo to Early Proteorozoic age. The Salem-Attur

shear zone, an extension of Moyar-Bhavani shear zone passes through this

area. Charnockite, pyroxene granulite, magnetite quartzite, Khondalite, calc

granulite and younger granitoidare other rock units exposed in the area.

The district is endowed with rich mineral resources such as Magnesite,

Bauxite, Quartz, Felspar, Limestone, Soapstone, Dunite, Roughstone,

Granites. (Source-District website of Salem)




Page 35 of 51

Soil classification

The soils can be broadly classified into 6 major soils types viz., Red insitu,

Red Colluvial Soil, Black Soil, Brown Soil, Alluvial and Mixed Soil. Major part

of the district is covered by Red insitu and Red Colluvial soils. Block soils are

mostly seen in Salem, Attur, Omallur and sankari taluks. Brown Soil occupies

major portion of Yercaud and parts of Salem and Omallur taluks and the

Alluvial Soil is seen along the river courses in Omallur and Sankari taluks.

mixed soil is occurring only in Attur taluk. The proposed site is located on

black cotton soil.

4.7 Climatic data from secondary sources

The district receives the rain under the influence of both southwest and northeast

monsoons. The northeast monsoon chiefly contributes to the rainfall in the

district.

Rainfall data from six stations over the period 1901-2003 were utilized and a

perusal of the analysis shows that the normal annual rainfall over the district

varies from about 800 mm to 1600 mm. It is the minimum around Sankari (800

mm) in the southwestern part of the district. It gradually increases towards north,

northeast and east and attains a maximum around Yercaud (1594.3 mm) in the

northern part.

The district enjoys a tropical climate. The weather is pleasant during the period

From November to January. Mornings in general are more humid than the

afternoons, with the humidity exceeding 75% on an average. In the period June

to November the afternoon humidity exceeds 60% on an average. In the rest of

the year the afternoons are drier, the summer afternoons being the driest. The




Page 36 of 51

hot weather begins early in March, the highest temperature being reached in

April and May. Weather cools down progressively from about the middle of June

and by December, the mean daily maximum temperature drops to 30.2°C, while

the mean daily minimum drops to 19.2°C and 19.6°C in January in Salem and

Mettur Dam respectively. The Monthly rainfall (mm) & Humidity details are

provided below in Table 4.1.

Table 4.1

Monthly rainfall (mm) & Humidity

Climatic data from secondary sources Annual rainfall – 1185.4 mm Temperature

Winter – 15.60C to 32.10C Summer – 22.30C to 430C

Monsoon – 25.30C to 32.50C Post monsoon – 19.30C to 32.40C

Average wind speed – 6.4 km/hr

Name of the Station: Salem Year: 2010-2011

Months

Mean Maximum Mean Minimum Humidity %

Normal (2)

Actual(3)

Normal(4)

Actual(5)

8.30 hrs. (6)

17.30 hrs (7)

April 2010 36.9 39.1 25.1 26.8 67 38

May 36.8 37.7 25.5 25.8 72 45

June 34.9 34.2 24.4 24.6 78 54

July 33.4 32.5 23.6 23.4 80 58

August 33.2 31.9 23.4 23.3 83 61

September 33.1 32.0 23.3 23.2 82 63

October 31.9 32.9 22.8 23.3 81 61

November 30.5 29.1 21.2 22.1 89 75

December 30.1 28.3 19.6 20.6 84 64

Jan 2011 33.1 31.3 19.2 19.7 78 43

February 33.7 32.4 20.2 20.3 73 40

March 33.7 35.5 22.5 22.2 71 30

H W S M P

S

Humidity Winter – 46Summer – 4Monsoon – Post MonsoSource: IMD

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Page 37 of

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Page 38 of 51

4.8 Social infrastructure available

Population

The total population of Salem dist. As on 2001 is about 30.16 lakh and

Mechieri block constitute about 10.87 lakh. The population growth rate during

2001 – 2011 is about 15.44% of salem district. The density of the population

of Salem is i.e., 665/sq. km The literacy rate of Salem is about 72.86 % as per

2001 census.

The Salem district is well supported with social infrastructure facilities like

Hospital (10 No’s), Dispensaries (14 No’s), Primary health centers (75 No’s),

Health sub-centers (348 No’s) and other medical institutions (20 No’s).




Page 39 of 51

CHAPTER - 5

PLANNING BRIEF

5.1 Planning concept

The plant will be located interior part of Salem district in Tamilnadu. Already

M/s. JSW has installed a steel plant of capacity 1.0 MTPA in the proposed

project site. The proposed project is an expansion project.

5.2 Population projection

Project will be creating considerable employment opportunities for local

people during construction phase. During recruitment preference will be given

to local as per employment guideline of the State. However, priority will be

given to the nearby village people after testing their skills and abilities. The

villages falling in the study area of 10 km radius are shown in the Table 5.1.

Table 5.1 Villages falling within 10km radius from the project site

Sl. No. Name of the Village

1. Mecheri

2. Karappatti

3. Pudu Kuttappatti

4. Kuttappatti

5. Ervadi

6. Palakkaranur

7. Kanakkappatti

8. Nangavalli

9. Malamanur

10. Kuvundanur

11. Amarattanur




Page 40 of 51

12. Errappareddiyur

13. Malaiyanur

14. Kudiraikkaranur

15. Mallamooppampatti

16. Chinna Seeragapadi

Source: Census of India 2011

5.3 Land use planning

The proposed site is admeasuring about 586.09 acres. The proposed land

use is as follows:

Plant facilities – 42.9 acres

Material handling conveyors – 2.7 acres

Green belt – 29.7 acres

Miscellaneous (Settling tank, Rain water harvesting) – 1.5 acres

Open barren land for future use – 7.0 acres

Approach roads inside plant boundary – 6.2 acres

Seismology

The site is located in zone II of seismic zoning map of India as per IS 1893-

2012 which associated with low seismic potential The detailed geological and

seismological investigations revealed that the site is outside the range of

capable fault within 5 km from the project site. The design basis seismic

parameters are evaluated based on geological seismological information.

5.4 Assessment of infrastructure demand

The proposed plant will be located near to Mecheri village. The project site is

fenced with compound wall. Inside the plant all the required infrastructure like

internal roads, water supply, storm water drains are already developed and




Page 41 of 51

the same will be expanded further to meet the expansion requirement.

5.5 Amenities/facilities

The site is well connected by road and rail. Presently the site is connected by

a metal road from NH-7. The site will be made physically isolated from the

surroundings by rubble masonry wall on all sides. Other physical protection

measures (security) have also been adopted for the site.




Page 42 of 51

CHAPTER - 6

PROPOSED INFRASTRUCTURE

6.1 Industrial area (Processing area)- Plant Site

The layout already shown will be spread over the acquired land of 586.09

acres in Mecheri block. The following are the existing/proposed construction

within the plant site.

Coke oven

Sinter plant

Blast furnace

Energy optimization furnace

Laddle refining furnace & VD

Continuous casting machines

Rolling mills (Non flat)

Oxygen and calcining plant

Power plant

Fire Station

Other Facilities: This includes Sewage Treatment Plants (STP), Effluent

Treatment Plant (ETP), Raw Water Treatment Plant (RWTP), Rainwater

Harvesting Pond, First Aid Centre, Diesel Storage yard, Security towers,

Chemical storage yard, all roads and storm water drains etc.

Overall layout of the proposed 1.3 MTPA ISP is shown in Fig. 6.1.




Page 43 of 51

Fig. 6.1 Overall layout of the proposed 1.3 MTPA ISP




Page 44 of 51

6.2 Residential area- township site

Township is not being planned for the proposed project.

6.3 Green belt

Under plantation programme, green belt will be developed around the plant

boundary. About 33% of the total land (193.4 acres) is proposed for green

belt plantation during the initial five years. The species to be grown in the

areas should be dust tolerant and fast growing species so that a permanent

green belt is created.

The plants having following characteristics are chosen for plantation.

Ability to tolerate and remove air pollutants.

Ability to grow in the area.

Rapid rate of growth.

Evergreen habit

Large crown volume

Small leaves with smooth surface

Should not have adverse effects on soil chemistry and ground water.

Have aesthetic value.

All these traits are difficult to get in a single species. Therefore a combination

of several species with all these traits is sought while planning a plantation.

The plantation should be planted close to the source or close to the area to

be protected to optimize attenuation within physical limits.

The areas that need special attention under plantation development are:

Along plant boundary

Along the side of roads




Page 45 of 51

Around offices and other buildings

Stretches of open land at project site complex

The following species are having a better chance of survival in this region.

Plantations are done at a spacing of 2 x 2 m. The expected rate of survival

will be around 75%. The efforts to improve the survival of the saplings and

their healthy growth will be taken up like watering, fencing, keeping watch and

ward and seeking guidance from the local Forest Dept.

6.4 Drinking water management (source and supply of water)

Total fresh water requirement is 5 MGD. The source of the raw water is down

stream of river Cauvery. Water supply will be from the main supply line of

about 16 km.

6.5 Sewerage system

All effluent will be treated to meet the statutory norms and reused in the plant

to ensure zero discharge.

About 3.3 m3/hr of treated sewage will be generated from STP, and the same

will be used for green belt development.

6.6 Solid waste management

SMS slag will be initially dumped suitably and then will be used for road/paver

block, making/ballast for railway track after granulation. BF slag will be utilized

in cement plant.




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6.7 Power requirement and supply/ source

The average power demand of the plant is estimated to be 90 MW. Power to

the tune of 97 MW will be generated.

It is proposed to meet the entire requirement of electric power from the

captive sources taking the support of state electricity grid for stability.

Provision will be made to sell the surplus power if any through the grid.




Page 47 of 51

CHAPTER - 7

REHABILITATION AND RESETTLEMENT

(R & R PLAN)

7.1 Rehabilitation and Resettlement (R & R) Plan

The project site of about 586.09 acres, which is located at Village M.Kallipatti

P.O, Pottaneri, Mecheri, Mettur-Taluk, Salem District, Tamilnadu state. The

plant site is already under the possession of JSW and no habitation exist in

the proposed plant site hence no R & R issues. The land area required for the

plant with associated common facilities with adequate screening distance

between the plant and the site boundary is available and hence land

acquisition or displacement of public is not envisaged. As a social

commitment from the company the R & R policy as mentioned in the earlier

EIA/EMP report is being followed.




Page 48 of 51

CHAPTER- 8

PROJECT SCHEDULE AND COST ESTIMATE

8.1 Project schedule

The construction work is expected to commence in year 2015 on obtaining

statutory clearance and commissioning of the plant to reach the ultimate

capacity is expected in 2016.

8.2 Cost Estimate

The cost envisaged for pollution control and monitoring measures like

ventilation, air conditioning, are included in the capital cost. Cost towards

environmental monitoring facilities is additionally included. In the analysis of

capital cost, recurring cost is also included to know the yearly expenditure.

Other features which forms an integral part of the plant design like stacks, ash

handling equipment are not included in the analysis. Hence, constructions of

STP and other environmental measures like collection pits are included in the

analysis.

The estimated capital cost of the project is about Rs. 800 crores. A good

fraction of this expenditure goes towards pollution control measures. Table 8.1

gives the breakup of the cost for various control measures.

In addition to those indicated in the table, there are a number of other

features, which forms an integral part of the plant design and

contribute to either save energy or to decrease the energy

consumption.




Page 49 of 51

Likewise, the costs of fire protection and physical protection measures

are not considered, although there may be secondary environmental

consequences due to fires or security lapses.

The estimates of recurring costs include only the revenue expenses for

operating the respective facilities. The salary of staff and capital

depreciation are not included.

Table 8.1 Cost of pollution control and monitoring measures

Item Capital cost

(Rs. in Crores)

Recurring Cost per annum

(Rs. in Crores) Environmental Pollution Control Air pollution Control Water Pollution Control

(ETP & STP) Solid Waste Management Noise pollution Occupational health

10 20

10 2 3

1 2 1

0.2 0.3

Environmental and Pollution Monitoring Environmental Survey and

Sampling Social corporate

responsibilities Green belt development

5

2

0.5

0.5

0.2

0.05 Green belt development 52.5 5.25




Page 50 of 51

CHAPTER - 9

ANALYSIS OF PROPOSAL

9.1 GENERAL

Development of industrial projects does not necessarily have adverse impact

on the environment. There is always an associated beneficial impact. The

proposed project will fulfill the demand of nation’s special steel. The major

benefits that can be anticipated are in terms of (i) employment for the locals,

both in the skilled and the semi skilled category, (ii) increased opportunities for

education, (iii) development of infrastructure such as schools, hospitals and

roads and (iv) growth of small scale industries. Impacts from these are

generally difficult to quantify in a precise manner. Since the proposed project is

an expansion project there will not be any negative impact instead there will be

an infrastructural development of the area which will benefit the people

livelihood.

9.2 EMPLOYMENT AND ECONOMIC BENEFITS

The plant will provide substantial job opportunities for the locals and persons

from Mecheri and Salem. People belonging to nearby villages are likely to be

engaged everyday for outsourced works as contract labour in the project

activities.

In total, it is expected that indirectely around 2000 people will get benefited due

to this project. However, this numbers will be reached over a period of time as

per the progress of project. Needless to mention that, during the construction

phase of about 1 year, more number of people will get employment.




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One can expect growth in the commercial activities commensurate with the

anticipated increase in population. Migration and urbanization of adjoining

areas also adds to the opportunities.

Transport and communication facilities will vastly improve. Besides the mass

transport by state run buses, availability of taxis and autos will grow

appreciably.

9.3 BENEFITS FROM WELFARE ACTIVITIES

As and when the proposed project is approved and the construction begins,

M/s. JSW would commit itself to spend Rs. 2.0 crores per annum for social

welfare projects. The amount would be spent for essential purposes like

Schools, medical aid, parks, shopping complex, training facility, supporting

water supply scheme to the nearby villages, roads and other amenities

.

9.4 RECOMMENDATION

The proposed project is likely to bring in additional benefits to the areas

surrounding the plant in terms of increase in the educational, health,

infrastructure and employment potential.

Like in any other project increase in the employment potential both direct as

well as through contractual labour would bring in additional income for the

people living around the project area.

Proposed project of JSW would also join and strengthen the ongoing social

welfare activities, contributing in terms of resource and manpower.

Documents

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