FORM-I

FOR CAPACITY ADDITION OF INTEGRATED STEEL PLANT FROM 5.0 MTPA TO 10.0 MTPA AND CAPTIVE POWER PLANT FROM 300 MW TO 600 MW AT JSW ISPAT STEEL LIMITED, NEAR GEETAPURAM, DOLVI VILLAGE, PEN TALUKA, RAIGAD DISTRICT, MAHARASHTRA

Submitted to:

Ministry of Environment and Forests

New Delhi

ISPATSTEELLIMITED

DOLVIWORKS

Submitted by:

JSW ISPAT STEEL LTD., DOLVI WORKS

DOLVI VILLAGE, PEN TALUK, RAIGAD DISTRICT MAHARASHTRA

APPLICATION FOR PRIOR ENVIRONMENTAL CLEARANCE (FORM-1) (I) BASIC INFORMATION Name of the Project/s Capacity Addition of Integrated Steel Plant from 5.0 Mtpa To 10.0 Mtpa and Captive Power Plant from 300 MW To 600 MW at JSW ISPAT Steel Ltd., Dolvi Works, Dolvi Village, Raigad District, Maharashtra. 3 (a) Capacity Addition of Integrated Steel Plant from 5.0 Mtpa To 10.0 Mtpa and Captive Power Plant from 300 MW To 600 MW. Expansion Expansion of 3.0 MTPA Steel Plant to 5.0 MTPA and 300 MW Captive Power Plant under implementation. Category A No No The proposed plant facility is located in existing plant premises at Geetapuram, Dolvi Village, Pen Taluka, Raigad District, Maharashtra State. The site falls between Longitude - 730000 - 730500 E Latitude - 183900 - 184500 N The location of the site and study area map are given in Figure-1 & Figure-2, respectively. Plot/Survey /Khasra No. Village Tehsil District State Nearest railway station /airport along with distance in kms. Land comprises Dolvi, Jui Bapuji & khar Karavi Villages. Dolvi Pen Raigad Maharashtra Pen is the nearest railway station at about 8 km (aerial distance) on the Konkan Railway line connecting Mumbai-Mangalore along the west

S. No. in the schedule Proposed capacity / area / length / tonnage to be handled / command area / lease area / number of wells to be drilled New / Expansion / Modernization Existing Capacity / Area etc. Category of Project i.e. A or B Does it attract the general condition? If yes, please specify. Does it attract the specific condition? If yes, please specify. Location

coast of India. The nearest airport is Mumbai (national and international) located about 80 km in the north direction from the proposed project site. Nearest Town, City, District Headquarters along with distance in kms. Village Panchayat, Zilla Parishad Municipal Corporation, Local body (complete postal address with telephone nos. Name of the applicant Registered Address Alibag 20 Km

Grampanchayat, Dolvi.

JSW ISPAT Steel Ltd., Dolvi Works JSW ISPAT Steel Limited, Dolvi Works Jindal Mansion, 5A, Dr. G. Deshmukh Marg, Mumbai 400 026 JSW ISPAT Steel Limited, Dolvi Works Geetapuram, Village Dolvi, Taluka Pen, District Raigad. Maharashtra - 402107. Shri. Murali B. Shenoy Head-Utility & Services JSW ISPAT Steel Limited, Dolvi Works Geetapuram, Village Dolvi, Taluka Pen, District Raigad. Maharashtra. 402 107 Murali.Shenoy@jswispat.in Phone no: 02143 277501 15 Fax No. : 02143 277542

Address for correspondence

Name Designation (Owner / Partner /CEO) Address

Pin Code E-mail Telephone No. Fax No. Details of Alternative Sites examined, if any. Location of these sites should be shown on a topo sheet. Interlinked Project Whether separate application of interlinked project has been submitted? If yes, date of submission If no, reason

Not Applicable No Not Applicable Not Applicable Not Applicable

Whether the proposal involves approval / clearance under: if Yes, details of the same and their status to be given. (a) Name of the Court (b) Case No. (c) Order/ directions of the Court, if any and its relevance with the proposal project.

Not Applicable

(II) ACTIVITY 1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sr. No. 1.1

Information/Checklist Confirmation Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

Yes/ No No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data The company has already a total of about 1200 acres of land in its possession for its existing operating integrated steel plant complex of 5.0 MTPA capacity. Some of the proposed additional capacities are proposed to be setup within the existing plant and some need relocated by acquiring additional 600 acres land. There will be clearance of existing land, vegetation wherever required. The proposed area is generally plain area with slight undulation. Some of the proposed facilities will be constructed within the existing industrial area and some require land to be acquired adjacent to the existing plant boundary. Detailed land survey, topographical surveys and soil testing / investigation studies have been carried out earlier for existing plant while the land which is to be acquired has neither been surveyed, nor topographical surveys or soil testing /investigation have been done. 5.0 MTPA Integrated Steel Plant and 300 MW Captive Power Plant and support infrastructure such as township, raw water reservoir and railway sidings

1.2

Clearance of existing land, vegetation and building?

No

1.3

Creation of new land uses

No

1.4

Pre-construction investigations e.g. houses, soil testing?

Yes bore

1.5

Construction works?

Yes

Sr. No.

Information/Checklist Confirmation

Yes/ No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data will be expanded / constructed. The proposed facilities are furnished at Para 1.0 of Annexure-I. There will not be any demolition works during the construction of the plant. Temporary construction offices will be set up during the construction stage, which will be removed later. Excavation works will be carried out for constructing the civil structures of the facilities. The project requires filling, leveling and piling works. Not applicable Not applicable Not applicable Not applicable The description of manufacturing process and process flow of plant is presented in Annexure-I. Storage facilities are planned for raw material and finished goods. The wastewater generated from the indirect cooling circuit would be routed through the cooling tower and pressure filter for recycling purpose. The wastewater generated from the coke ovens will be treated in a bio-oxidation plant to reduce the level of phenolic compounds, oil & grease and cyanide. The treated wastewater will be reused in the system. The wastewater of gas cleaning plants of blast furnace and steel melt shop containing suspended solids will be clarified in the wastewater treatment plant. The clarified water will be recycled to the waste gas cleaning units. Similarly, the wastewater coming out from the continuous casting machine will be treated to remove scale and oil and the treated water will be recycled after cooling.

1.6 1.7 1.8

Demolition Works? Temporary sites used for construction works or housing of construction workers? Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations Underground works including mining or tunnelling? Reclamation works? Dredging? Offshore structures? Production and manufacturing Process? Facilities for storage of goods or materials? Facilities for treatment or disposal of solid waste or liquid effluents?

No Yes Yes

1.9 1.10 1.11 1.12 1.13

No No No No Yes

1.14 1.15

Yes Yes

Sr. No.

Information/Checklist Confirmation

Yes/ No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data The plant sanitary waste water will be treated in sewage treatment plant and the treated water will be used for dust suppression and maintenance of plant green belt. It is proposed to create housing complex for employees / construction workers. Augmentation of port, facilities for receipt of materials and dispatch products. Augmentation of port, facilities for receipt of materials and dispatch products. Not envisaged road and rail additional raw of additional road and rail additional raw of additional

1.16 1.17

Facilities for long term housing of operational workers? New road, rail or sea traffic during construction or operation? New road, rail, air water or other transport infrastructure including new or altered routes and stations, ports, airports etc? Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements? New or diverted transmission lines or pipelines? Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers? Stream crossings? Abstraction or transfers of water from ground or surface waters?

No Yes

1.18

Yes

1.19

No

1.20 1.21

Yes No

It is proposed to relocate the existing MSDS to a new location. The plant drainage network will be planned and designed in line with the existing topography and systems. Not envisaged The total water requirement for the 10.0 MTPA steel plant, 600 MW power plant and township will be about 116 MLD. At present JSW ISPAT Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara and consent for 30 MLD has been obtained. Application is in progress for the balance amount. The plant drainage net work will be designed such that there are no significant alterations in the existing drainage network. Construction materials, mechanical and electrical materials will be sourced from different parts of the state and as well as various part of country through road, rail and sea network.

1.22 1.23

No No

1.24

Changes in water bodies or the land surface affecting drainage or run-off Transport of personnel or materials for construction, operation or decommissioning?

No

1.25

Yes

Sr. No. 1.26

Information/Checklist Confirmation Long-term dismantling decommissioning restoration works? or or

Yes/ No No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Not envisaged.

1.27

Ongoing activity during decommissioning which could have an impact on the environment? Influx of people to an area in either temporarily or permanently?

No

Not envisaged

1.28

Yes

1.29 1.30 1.31

Introduction of alien species? Loss of native species genetic diversity? Any other actions? or

No No No

The requirement of total manpower for proposed expansion project will be about 5,000. However, the proposed Integrated steel plant will additionally generate more than 15,000 indirect secondary and tertiary employment. Not envisaged Not envisaged -

2. Use of Natural resources for construction or operation of Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply). Sr. No. 2.1 2.2 Information/Checklist Confirmation Land specially undeveloped or agricultural land (ha) Water (expected source and competing users) Yes/ No Yes Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Additional 600 acres land is required for the proposed project. The total water requirement for the 10.0 MTPA steel plant, 600 MW power plant and township will be about 116 MLD. At present JSW ISPAT Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara and consent for 30 MLD has been obtained. Application is in progress for the balance amount. The additional raw material requirement for the proposed capacity expansion is given below: Iron Ore Fines/Conc. (For Pellet Plant) Iron ore fines (for sinter plant) 4,200,000 6,880,000

2.3

Minerals (MT)

Yes

Iron Ore Lumps Coking Coal (for coke oven) Non-coking coal for PCI Limestone (for sinter plant) Limestone (for pellet plant) Dolomite (for sinter plant) Quartzite Limestone (for SMS) Dolomite (for SMS) Ferro-Alloy (for SMS) Bentonite (For pellet plant) Clinkers (For Grinding unit) 2.4 Construction material stone, aggregates, and/ soil (expected source-MT) Yes

380,000 3,500,000 675,000 491,000 80,000 503,000 60,000 860,000 388,000 103,600 28,000 5,000,000

2.5 2.6

Forests and timber (sourceMT) Energy including electricity and fuels (source, competing users) Unit: fuel (MT), energy (MW)

No Yes

Cement 0.85 million tonnes Coarse aggregates 1.25 million cu.m. Fine aggregates 0.85 million cu.m Reinforcement steel 0.125 million tonnes Structural Steel 0.35 million tonnes No timber use is envisaged in the proposed expansion project. The total power requirement is proposed to be supplied from the captive power plant of 600 MW capacity. Some power would also be available from the top pressure recovery turbine generators of the blast furnace & CDQ. Any additional power requirement will be met from the local grid. Not envisaged

2.7

Any other natural resources (use appropriate standard units)

No

3.

Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health Information/Checklist Confirmation Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies) Yes/ No Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data In-built safety features of the plant and machinery would be made adequate in order to avoid hazardous events causing damage to the life and property.

Sr. No. 3.1

Sr. No. 3.2

Information/Checklist Confirmation Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases) Affect the welfare of people e.g. by changing living conditions? Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc Any other causes

Yes/ No No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Not envisaged

3.3

Yes

Standard of living of the population surrounding the proposed project area is likely to be further improved. Not envisaged

3.4

No

3.5

No

4. Sr. No. 4.1

Production of solid wastes during construction or operation or decommissioning (MT/month) Information/Checklist Confirmation Spoil, overburden wastes or mine Yes/ No Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data No major spoil or overburden will be generated at the project site during land development. However, the spoil or earthwork generated during construction will be reused for construction. All municipal solid waste generated from the sewage treatment plant will be used within the plant site for plantation as manure. The oil sludge from the oil storage area and oil & grease removed from the wastewater treatment plant will be sold to authorized users/recyclers approved by state pollution control board. Major solid waste generated from the industrial processes would include BF slag, gas cleaning plant sludge, ESP/bag filter dust, refractory debris, etc. All the solid waste described above would be recycled/used in a proper manner / sinter plant and the rejects would be dumped in a designated area. Not envisaged Process sludge generated from the plant will be used as raw material in sinter plant. The sewage sludge from the STP will be

4.2

Municipal waste (domestic and or commercial wastes) Hazardous wastes (as per hazardous waste management rule-s) Other wastes industrial process

Yes

4.3

Yes

4.4

Yes

4.5 4.6

Surplus product Sewage sludge sludge from treatment or other effluent

No Yes

Sr. No.

Information/Checklist Confirmation

Yes/ No

4.7

Construction wastes

or

demolition

Yes

4.8 4.9 4.10 4.11

Redundant equipment

machinery

or

No No No No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data used within the plant premises as organic manure. Small quantity of metallic scrap waste expected and the same will be used as melting scrap in steel making. Construction material will be used internally for filling and leveling of the sites within the plant site area. Not envisaged Not envisaged Not envisaged Not envisaged

Contaminated soils or other materials Agricultural wastes Other solid wastes

5. Sr. No 5.1

Release of pollutants or any hazardous, toxic or noxious substances to air (kg/hr) Information/ Checklist Confirmation Emissions from combustion of fossil fuels from stationary or mobile sources Yes/ No Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data The captive power plant is proposed to use Multi fuel gases having relatively low sulphur content. A stack of adequate height will be provided which may be single or two nos. depending upon the design and detailed engineering. The steam generators would be provided with low NOx burners and hence the emissions of the Oxides of Nitrogen from the steam generator would be minimum. The associated traffic with respect to the steel plant complex would generate carbon monoxide and Oxides of Nitrogen. From Pellet Plant, Sinter Plant, Coke Oven Plant, Blast Furnace, Direct Reduction Plant, Calcining Plant, Slab Caster Shop, BOF caster, LF & RH-Degasser Shop and Rolling Mills, SO2, NOx, dust, TSP, CO2, PAH, VOCs, heat and dust will be generated. The principal air pollution control system for pellet plant, sinter plant, DR Plant would be dedusting and waste gas cleaning systems separately.

5.2

Emission from processes

production

Yes

Sr. No

Information/ Checklist Confirmation

Yes/ No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data The coke oven gas generated in the coke ovens after by-product recovery would be utilized as supplementary fuel for proposed steel plant complex. The top gas coming from the blast furnace would be cleaned by taking the gas through BF gas cleaning device for separation of particulate before the clean gas is recovered for meeting in-plant energy demand. The stock house and cast house areas would be provided with proper DE/FE systems complete with ESPs and stacks. The LD gas generated in the SMS shop would be subjected to cleaning before it is used as plant supplementary fuel. There would be proper FE systems to capture any secondary fumes generated during hot metal and liquid steel transfer points. Dust emissions from calcining plant would be controlled by bag filters. The re-heating furnaces would generate particulates, SO2, NOx and CO. The combustion system would incorporate low NOx burner system and controlled combustion. Fugitive dust will be generated from the material handling activities. Dust suppression or dust extraction systems with bag filters along with water sprinklers will be provided to prevent the fugitive dust emissions. Further, the development of Greenbelt would prevent the fugitive dust emissions. Fugitive Dust. Dust emissions from raw material handling and construction materials are envisaged. Suitable dust suppression and dust extraction methods will be followed. There is no possibility of any odour generation as there are no organic solvents / processes involved. There is a possibility of odour from sewage; however, this can be reduced by maintaining good ventilation conditions. Not envisaged

5.3

Emissions from materials handling including storage or transport

Yes

5.4 5.5

Emissions from construction activities including plant and equipment Dust or odours from handling of materials including construction materials, sewage and waste

Yes Yes

5.6

Emissions from incineration of waste

No

10

Sr. No 5.7

Information/ Checklist Confirmation Emissions from burning of waste in open air (e.g. slash materials, construction debris) Emissions sources from any other

Yes/ No No

Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Not envisaged

5.8

No

Not envisaged

6. Sr. No. 6.1

Generation of Noise and vibration, and emissions of Light and heat Information/Checklist Confirmation From operation of equipment e.g. engines, ventilation plant, crushers From industrial processes or similar Yes/ No Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Noise will be generated from Sinter plant, Blast furnace, Rolling mills, continuous caster and Oxygen plant which will not be allowed to exceed 85 dB (A). Blast furnace, pellet plant, sinter plant, DR Plant, Rolling mills, continuous casting machines and Oxygen plant are likely to generate noise The expected noise level will not be allowed to exceed 85 dBA or proper noise protection systems will be used whenever required. There will be no adverse effect on the ambient Noise. Waste heat recovery unit is proposed for the proposed Sinter Plant and CDQ & Waste heat boiler is proposed for the Coke Oven Plant, so that no heat shall be wasted. Yes. This will be in the range of about 65-80 dB(A). Regular maintenance of the equipment will help in reducing these noise levels. Some noise <85 dB (A) will be generated. The noise levels are expected to be in the range of about 70-75 dB(A). Not envisaged Not envisaged

6.2

Yes

6.3

From construction demolition

or

Yes

6.4 6.5 6.6 6.7

From blasting or piling From construction or operational traffic From lighting or cooling systems From any other sources

Yes Yes No No

11

7.

Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal wasters or the sea Information/Checklist Confirmation From handling, storage, use or spillage of hazardous materials From discharge of sewage or other effluents to water or the land (expected mode and place of discharge) Yes/ No No Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Not envisaged.

Sr. No. 7.1

7.2

No

The sewage water will be treated and used for greenbelt development within the premises. Out side discharge is not envisaged. The wastewater from the plant units will be treated at the individual source of generation and re-used or re-cycled into the processes. There will not be any external discharge of wastewater. There is no discharge of wastewater outside the plant. Not envisaged Not envisaged

7.3

By deposition of pollutants emitted to air into the land or into water From any other sources Is there a risk of long term build up of pollutants in the environment from these sources?

No

7.4 7.5

No No

8. Sr. No. 8.1

Risk of accidents during construction or operation of the project, which could affect human health or the environment Information/Checklist Confirmation From explosions, spillages, fires etc and from storage, handling, use or production of hazardous substances From any other causes Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, slides, could burst etc) Yes/ No Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data There is a possibility of oil spillages and fires from the storages. However, suitable risk assessment will be carried out and disaster management plan will be in place. Not envisaged The area is generally flat land. There is no record of occurrence of floods, land slides, cloud bursts etc. The proposed project site falls in Zone-IV as per IS-1893 (Part-I):2002.

8.2 8.3

No No

12

9.

Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality Information/Checklist Confirmation Lead to development of supporting, facilities, ancillary development or development stimulated by the project which could have impact on the environment Supporting infrastructure (roads, power supply, waste or waste water treatment, etc) Housing development Extractive industries Supply industries Other Lead to after use of the site, which could have an impact on the environment Set a precedent developments for later Yes/ No Yes Details thereof (with approximate quantities/ rates, wherever possible) with source of information data Existing and ancillary facilities will improve.

Sr. No. 9.1

Yes

Existing infrastructure facilities will be expanded / extended to take care of the project. New facilities about 10 km North of plant, away from pre-dominant wind direction. The proposed facilities are captive to JSW ISPAT Steel Ltd., Dolvi Works. Existing supply chain will improve --The proposed project will have impact on environment. However, these impacts will be contained by adopting suitable mitigation measures. Ancillary industries will be developed as a consequence. The industry is not located in a critical zone. There are not many major industries operating in this region. Hence, no major effects are envisaged.

Yes No Yes

9.2

Yes

9.3 9.4

Yes Yes

Have cumulative effects due to proximity to other existing or planned projects with similar effects

(III) Environmental Sensitivity Sr. No. 1 Areas Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value Name / Identity No Aerial distance (within 15 km) Proposed project location boundary There are no ecological, landscapes, cultural or other related sensitive areas in 15 km radius.

13

Sr. No. 2

Areas Areas which are important or sensitive of ecological reasons wetlands, water courses or other water bodies, coastal zone, biospheres, mountains, forests Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

Name / Identity Yes

Aerial distance (within 15 km) Proposed project location boundary There are no national parks, sanctuaries in 15-km radius from proposed project site. Two rivers are within 15km radius from proposed project site. 1. Amba river 0.8 km, W 2. Bhogeswar river 7.8-km, N Four reserve forests exist in 15 Km radius area as listed below: RF near Kharkhara village (1- km, E) RF near Katkariwadi village (5.3km, NE) RF near Turmal village (4.6-km, E) RF near Katvira village(5.1- km, SW) RF near Dhavte village(8.5-km NE) Detailed floral and fauna studies will be conducted and details will be incorporated in EIA report. Amba river 0.8 km, W Bhogeswar river 7.8-km, N Nil Not applicable

Yes

4 5 6

Inland, coastal, marine underground waters State, national boundaries

or

Yes No No

7 8 9

Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas Defence installations Densely populated or built-up area Areas occupied by sensitive man made land uses (hospitals, schools, places of worship, community facilities) Areas containing important, high quality or scarce resources (ground water resource, surface resources, forestry, agriculture, fisheries, tourism, minerals) Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)

No Yes Yes

Nil within 10-km radius Pen Taluka is 6.9-km from the plant site. Pen Taluka has all the facilities such as primary schools, middle schools, high schools, hospitals health centers, public health sub centers, dispensaries and places of worship. No scarce resources are present in 15km radius

10

No

11

No

This is not a listed or critically polluted area.

14

Sr. No.

Areas

Name / Identity No

Aerial distance (within 15 km) Proposed project location boundary

12

Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

The proposed project site falls in zoneIV as per IS-1893 (Part-I): 2002. No land slides / flooding is envisaged in project area.

(IV) Proposed Terms of Reference for EIA Studies Annexure II.

I hereby given undertaking that the data and information given in the application and enclosure are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be rejected and Clearance give, if any to be the project will be revoked at our risk and cost. Date: 03rd December 2012 Place: Dolvi

Murali B. Shenoy Head Utility & Services JSW ISPAT Steel Limited Geetapuram, Village Dolvi, Taluka Pen, District Raigad Maharashtra 402107.

15

FIGURE -1 LOCATION MAP

Plant Site

16

FIGURE -2 STUDY AREA MAP

73 0' Kalve Sonkhar Bhalpada Tukaramwadi Kanebachapada Kalesri Mothe vadhav Borze Kane Johe Tambatshet

73 5'

Mumbai 98km

Hamrapur Varedi Sapoli

Shinole

Vadhav Narvel Benavle 18 45' Masad Khurd

Div

Khar Sapoli

Chinchghar

Vashi

Navgharwadi

Ramraj Antora Tarankhop Antora PEN

Kaproli Patnoli Dherankhar Dhondapada Umbarde Shirki

RF

18 45' Khalapur

Masad Khurd Masad Budruk Borve

Pipalpada

Shahapur Dhakta Shahapur

Pimpalpada Vashinaka Maleghar Uchede Kandepada Kandale Indranagar Wave Navegaon Kashmire Rode Ramwadi Vadgaon

27.8km Bh Dhavte Ambeghar og es hw ar R Borgaon .

Bori Shinganvat Kolve Vadkhal

Sutarpada Lebhi Khidki KOPAR Chari Kurkundi Kamalpada Ghasvadkhar Divlang Shahabaj Bhanghar Pezari Dadaji Talanikar Valvade Ambepur Vagholi Nagjhari 18 40' Vadvali Navenagar Sukatrie Medhekhar Poinad Bhakhwadi Dehankoni

Katkariwadi

R. ba Am

Virani RESERVED FOREST

Dharamtar

PLANT

Dolvi

RESERVED FOREST
Kharkaravi Gadab Turmal Khapachiwadi

Bandhanwadi

Ambeghar

Bangalwadi RESERVED FOREST

Tadmalwadi Patharmal Jirne Dhombi Takachiwadi Mounepale Kherpale Shekatmal

Chaphegani 18 40'

Tadvagle Kathodipada Kharoshi

Kachali Katkorwadi Pitkari Shirgaon Katvira Kusambale Ratalpada Vaghvira Katvaripada Hemnagar Chikhali RESERVED FOREST

RESERVED FOREST Bakeghar

Talashet Kolghar Thakurwadi

Kharjul

DevaliRESERVED FOREST Anandnagar Kalad Pedkyawadi Karanjatep Brahmanwadi Kasu Khadakwadi Pandapur

Burdi

Ruishet Bhomoli Chaura

Navakar Kurdus Bidbav Dattawadipada Ananwadi Sambri Bidwagale Aveti 73 5' Mahabalewsaram 133.7km

Sutwadi Ruishet 73 0'

LEGEND

Plant Site Road Railway Line

Settlements Forest Boundary Nadi/Nala/Water Body

17

ANNEXURE-I INTEGRATED STEEL PLANT PROCESS DESCRIPTION 1.0 Introduction The project envisages capacity addition of Integrated Steel Plant from 5.0 MTPA to 10.0 MTPA and Captive Power Plant from 300 MW to 600 MW at Dolvi. The plant will be equipped with coke oven complex, pellet plant, sinter plant, blast furnace, Direct Reduction Plant, BOF converter, ladle furnace, RHDegasser, continuous casting facility, hot rolling mill, cold rolling mill, lime & dolo calcinations plant, oxygen plant, grinding unit & township for the production of value added products. Supporting facilities up to production of finished products will also be set up in the plant based on the state-of-the-art technology. All technological facilities required at each processing step to achieve good quantity rolled products are given below: S. No. Facilities Unit Total capacity at 5 MTPA (EC Received) 2.0 (by augmenting) 4.0 2.0 2.8 + 3.2 2.0 + 1.6 5.2 (By Augmenting the existing facilities) 2x200 T + 1x205 T 1x200 T + 1x205 T MTPA 3.5 (by augmenting) 2 x 1 strand 1.5 0.6 Additional units from 5 MTPA to 10 MTPA 2.0 4.0 2.5 8.0 4.5 Total capacity at 10 MTPA

1 2 3 4 5 6

DRI (Gas based Mega Module) Pellet Plant Coke oven with By- Product Plant & CDQ Sinter Plant Blast Furnace with Pig /Granshot Casting & TRT SMS (CONARC)

MTPA MTPA MTPA MTPA MTPA MTPA

4.0 8.0 4.5 14.0 8.1 5.2

7 8 9 10

SMS BOF Ladle Furnace VD/VOD/RH-Degasser CSP (HRC Coil) Thin Castercum- Hot Strip Finishing Train Conventional Slab Caster Plate Mill Galvanizing Line (Cold Rolled Steel Strips, Hot Dip Zinc Coated Full Hard) Electrical Steel CRGO Line Tin Plate Line Color Coating Plant Lime & Dolo Plant

MTPA

6.0 2 X 280/300 T 2 X 280/300 T -

6.0 2x200 T + 1x205 T + 2x280/300 T 1x200 T + 1x205T + 2x280/300 T 3.5

11 12 13

MTPA MTPA MTPA

2 x 2 strand -

Total 6 strands 1.5 0.6

14 15 16 17

MTPA MTPA MTPA TPD

0.4 0.4 0.5 1800

1800

0.4 0.4 0.5 3600

18

18 19 20 21 22

23

Oxygen Plant Captive Power Plant (Gas Based) Hot Rolling Mill with Shearing & Slitting line Slag & Clinker Grinding Unit CRM (Hot Rolled Skin Pass + Cold Rolled Full Hard Coil + Hot Rolled Pickled & Oiled Coil) Township

TPD MW MTPA MTPA MTPA

4100 300 1.0

3500 300 6.0 10.0 1.5

7600 600 6.0 10.0 2.5

Facilities required outside the plant boundary like sourcing of iron ore, coking and non-coking coal will also be taken up along with township etc. 2.0 Coke Oven Batteries Coke is one of the prime requirements for production of hot metal through blast furnace route. The coke supplies heat to the blast furnace for smelting purpose and also acts as reducing agent inside the furnace for reduction of iron oxides to metallic iron. Both active hot carbon of coke as well as reducing gas, generated in the furnace, by burning of coke, take part in reduction reaction. A number of technologies have been developed for reduction of coke requirement in blast furnaces resulting in cost effectiveness viz injection of auxiliary fuels like non-coking coal/tar/natural gas through tuyeres, etc. Considering the level of technological development in the coke making area and total requirement of blast furnace coke in the blast furnace, installation of recovery type coke oven batteries have been envisaged. The gross coke generated in the coke ovens will be screened. BF coke and nut coke will be sent to the blast furnace and coke fines/ coke breeze generated in the plant will be utilized in the sinter plant. The coke making technology would include pre-carbonization and post carbonization technologies like selective crushing of coal, stamp charging and high capacity ovens. 4 x 65 nos. batteries of 5.5 m tall Coke Oven having capacity of 2.5 MTPA has been envisaged for the capacity addition from 5.0 to 10.0 Mtpa. 3.0 Sinter Plant The sinter plant will be equipped with the following major facilities: Base blending for input materials Flux and fuel crushing facilities Lime dozing facility Mixing and nodulising unit Sintering machine equipped with sinter strand, ignition furnace, wind boxes, suction fan, dust cleaning unit, etc. Sinter coolers Sinter screening and transportation facilities Capacity of the sinter plant has been estimated based on use of about 8085% sinter in the burden of blast furnaces, which shall be obtained from the twin (2) modules of sintering machine of 4.0 MTPA capacity each.

19

4.0

Pellet Plant The Pelletization process involves reduction of moisture in the iron ore to less than 1%, grinding to 45 micron size, feed preparation by adding binders and moisture, green pelletization and induration (heat hardening). It is proposed to install a Pellet Plant capable of producing upto 4.0 Mtpa of pellets. This Pellet Plant will produce DRI grade pellets to be used in the sponge iron plant and balance pellets will be used in the BF.

5.0

Blast Furnace Hot metal production using blast furnace process has been envisaged for the proposed project, as the process is most established and competitive iron making technology till date. A number of technological improvements have taken place in blast furnace which have resulted in higher production, less coke consumption, most energy efficient, long campaign life, etc. State-ofthe-art blast furnace equipped with the following major facilities has been envisaged for the proposed plant: Covered stock house with automatic conveyor charging facilities Bell less top charging equipment High top pressure operation (2.5 kg/cm2 top pressure) and matching gascleaning plant. Stoves for generation of high hot blast temperature (1250C blast temperature). Coal dust injection facilities (150 kg/thm) Oxygen enrichment of blast. Cast house slag granulation plant. (The slag would be grinded in slag grinding unit) Top gas recovery Turbine Level- III automation and control system, etc. Hot metal produced from the blast furnace will be transported to the steel melting shop using torpedo ladles/open top ladles. Considering the daily requirement of hot metal in the steel melting shop for production of liquid steel, which is sufficient to produce about 4.5 Mtpa hot metal, 1 (one) blast furnace of 4.5 Mtpa capacity have been envisaged for the proposed project. Slag generated from the blast furnaces will be granulated in the cast house slag granulation plant. The granulated slag will be processed in the grinding units.

6.0

Pig Casting Machine The mismatched / off grade hot metal is proposed to be handled in a pig casting machine or a energy efficient hot metal noduliser unit. The PCM will consist of the following units / facilities. - PCM proper - Lime preparation unit - Settling tank and pump house - Pouring end and discharge end sprocket - Centralised grease lubrication system - PCM control room and sub-station. - Pig storage yard with magnet crane. These will be of adequate capacity for production of pig iron/nodulised iron.

20

7.0

Direct Reduction Plant One Mega Module Direct Reduction (DR) Plant based on the natural gas/coke oven gas/LD gas/Mixed gas with average gross production capacity of 2.0 Mt/yr has been envisaged.

8.0 8.1

Steel making and Secondary Refining Hot Metal Desulphurisation Two (2) twin hot metal desulphurisation stations of 280/300 t ladle capacity have been envisaged to bring down the sulphur content in hot metal received from blast furnaces. Desulphurisation of hot metal will be carried out in the hot metal charging ladles of steelmelting shop prior to charging into BOFs. Hot metal from blast furnace to steelmelting shop will be received by torpedo ladles/open ladles. Hot metal will be pretreated in desulphurisation stations before being used for steelmaking. The desulphurisation facilities will be based on lance injection process. Desulphurisation facilities are planned in hot metal receipt-cum-charging bay. Calcium carbide and magnesium based reagents will be used for desulphurisation of hot metal. Nitrogen will be used as the carrier gas during injection.

8.2

Steel Making Basic oxygen furnace technology for production of liquid steel has been envisaged for the proposed project. This process till date dominates the steel production scenario of high capacity integrated steel plant worldwide mainly due to its energy efficiency. As such, external energy in terms of either electrical power or solid/liquid/gaseous fuel is not required for process. However, requirement of electricity and gaseous fuel are mainly for driving of electrical equipment, ladle heating, etc. Most of the other steel making process like electric arc furnace/Induction furnace process consumes high amount of electrical energy. However, oxygen with high purity is required for conversion of hot metal to liquid steel and scrap/iron ore/DRI is required as coolant in BOF process. A significant amount of medium calorific value (2000 kCal/Nm3) gas is generated during carbon refining reaction period of steel making which will be separated in the gas cleaning plant using suppressed combustion system. Hot metal will be pre-treated before charging into the converter. For capacity addition from 5.0 to 10.0 Mtpa capacity, a new converter shop has been envisaged which has been designed to handle about 6.0 Mtpa hot metal, 4.5 Mtpa hot metal from proposed new Blast Furnace-2 and 1.5 Mtpa hot metal from existing Blast Furnace-1. Considering the requirement of liquid steel for subsequent process requirements, chemical composition of input materials, quality of liquid steel to be produced, sequence of casting of liquid steel into slabs, oxygen blowing rate etc., two (2) number of converters of capacity 280/300 t each have been envisaged for the proposed project.

8.3

Ladle Furnace (LF) With a view to achieve improved homogeneity and productivity of the primary unit and serving as a buffer between the Converter and the caster, ladle

21

furnace is the ideal secondary refining unit. The correction and homogenization of steel composition and temperature, desulphurisation and recarburisation, etc. can be efficiently carried out in a LF. Two (2) nos. LF of adequate size has been envisaged for the proposed project. The LF will also be equipped with argon purging facilities. 8.4 RH-Degasser In order to produce value-added products subject to market requirements, RH are essential as secondary refining units. The processes assure liquid steel of high purity, low level of inclusions and good homogeneity with respect to temperature and chemistry. These processes help attainment of very low levels of gases and inclusions and provide controlled alloying and mixing to produce a great variety of alloys. These processes also allow improvement in plant productivity (through sharing of refining load) and yield, in addition to ensuring good quality. Two (2) RH-Degasser units of matching size 280/300 t have been envisaged for production of value-added steels. The RH-TOP unit will be used for production of various steel grades and for special applications. 9.0 Slab Caster To produce hot rolled plates, slab casters have been proposed. The technology of continuous casting of steel into slabs has been fully mastered today for any grade of steel. This technology has become well established through extensive mechanisation and control of various operating parameters. The continuous casting process has gained worldwide acceptance, mainly because of high yield, good product quality and good economics of operation. In order to cast 6.0 MTPA liquid steel into Flat products, slab casters have been envisaged for the proposed project. Considering market requirements, two double strand casters capable of producing slabs of 950-2150 mm width and 220/250 mm thickness have been envisaged. However this could be revised to cater to the future market requirements. 10.0 10.1 Finishing Mill Hot Rolling Mill The continuous cast slabs from the slab caster are fed to a reheating furnace. The first part of the furnace serves as a heating zone while the second part as holding zone for the continuous cast slabs. The slabs are heated to achieve homogenous temperature over their enter length. The slabs are then passed through a descaler where high-pressure water is sprayed simultaneously on top and bottom surfaces to remove the scale. The cleaned slab is then rolled in the rolling mill comprising of roughing mill and continuous finishing mill train to the desired thickness. The rolled strip is then cooled to the desired coiling temperature by the laminar cooling water spray system on the runout roller table. The hot rolled strip is then coiled on the downcoiler. The hot rolled coil is transported by a coil conveyor system to the coil storage yard. The hot rolled coils are delivered by the coil conveyor system to the coil

22

yards where they are stored for further despatch. Based on the product-mix, one hot rolling mill of 6.0 Mtpa capacity has been proposed for the project. 10.2 Cold Rolling Mill Hot strips produced in the Hot rolling mill will be processed in the Cold rolling Mill. EC had been obtained at 5 Mtpa stage for CRM of 1.0 Mtpa capacity. It is now proposed to apply for amending the capacity to 2.5 Mtpa. This large size would be more energy efficient. 11.0 Captive Power Plant To meet the requirement of power for the proposed plant, a captive power plant of capacity 1 x 300 MW has been envisaged based on the excess fuel gases. 12.0 Lime & Dolo Plant The limestone and raw dolomite from storage bunkers will be fed to the screen by belt conveyor and undersize lime stone and dolomite will be screened out and stored in another bunker which is meant to store the undersize material. The undersize limestone and raw dolomite will be stored for onward disposal to other consuming units. Screened materials of Oversize will be fed to shaft kilns. Limestone and raw dolomite will be calcined at temperature of 9501150C. The lime and calcined dolomite from the kilns will be discharged to two different conveyors which are placed below the kilns. The lime and calcined dolomite will then be fed to single deck screen to separate out undersize material. The undersize lime and dolomite material will be stored in two separate bunkers. The sized lime and calcined dolomite of Oversize will be stored in bunkers. Lime and calcined dolomite of Oversize will be conveyed to SMS through belt conveyor and undersize lime will be transported through trucks/cement tanker to other consuming units. 3 Nos. x 600 TPD capacity Lime and Dolo Calcination Plant have been envisaged for the proposed. 13.0 Oxygen Plant Oxygen, nitrogen and argon will be produced by air separation process based on low pressure cryogenic cycle and double column rectification system. The unit will be able to produce gaseous as well as liquid products. Gaseous products from the oxygen plant will be distributed through pipeline network system consisting of pressure regulating and metering station to various consumers. Oxygen will be required for oxygen enrichment in the blast furnace, secondary refining in VD, cutting of slabs in continuous casting plant, and for general purpose use in various units of the steel plant. Nitrogen will be mainly required as carrier gas in coal dust injection system, bell less top equipment for blast furnace, purging in GCP of BF and also for occasional purging of fuel gas pipelines and equipment.

23

Argon will be required for shrouding in the tundish, mould in the continuous casting plant and stirring in ladle. Argon will also be required for laboratory purpose. Oxygen Plant of capacity 3500 tpd has been envisaged for the proposed project. Flow sheet of the production process is shown in Figure-3. 14.0 Township The township is to serve a large steel plant of 10 Mtpa capacity and CPP of 600 MW capacity and may have up to 7065 dwellings of various categories in about 150 Acres of land. The new township shall be constructed to take care of the accommodation facilities of the employees. Area for the township has been identified near Pen but the specific details are yet to be finalized. Township details are given below: DOLVI TOWNSHIP AREA CALCULATION Area (sq. Ft)/ house 4000 2500 1700 1200 600 350 No. of Total houses Area No. of per (sq. Ft) storeys floor 60000 1 1 125000 1 1 850000 3 2 1800000 7 4 1800000 7 4 700000 7 4 5335000 Total houses No. of Area Req per blds. (sq. ft) bldg Required 1 15 60000 1 50 125000 6 83 283333 28 54 257143 28 107 257143 28 71 100000 1082619

Type 1 2 3 4 5 6 Total

BHK 5 4 3 2 1 1

Nos. 15 50 500 1500 3000 2000 7065

7 Total 8 Total

Area of roads/parking area in between houses, etc - 3 times more area than blgs. Area Area for GH / schools / gardens / play grounds/ water pond / temple / parkings / shopping centres/hospital etc

3247857 4330476 2178930 6509406 604743 149 150 sq. ft sq. m acres acres

TOTAL say

Raw water shall be treated in the plant and pumped to the township for their water requirement. Sanitary faecal sewage will be collected from the ablution blocks through pipeline and the same will be connected to a sewage treatment plant. The effluent from sewage treatment plant will be utilized for the development and maintenance of greenery. Details of the Sewage Treatment Plant are given below: Sewage treatment Plant provide only preliminary and primary treatment, and tertiary treatment is rare.

24

1. Preliminary treatment: This is the mechanical removal of coarse and fine solid material. The sewage passes through screens, which trap pieces of wood, rags, wire, etc. 2. Primary treatment: The sewage then flows slowly through grit tanks, where particles of sand or grit settle out. Fine particles still remain suspended in the sewage, so it is passed to large primary sedimentation tanks where most of the remaining particles settle out to form a sludge. Primary treatment removes about 6070% of suspended solids. The liquid leaving the primary sedimentation tanks still contains very fine solids and dissolved matter, so secondary treatment is usually required. 3. Secondary treatment: This is a biological process, involving the oxidation of dissolved organic material by micro-organisms to decompose the organic compounds, a process similar to that taking place in rivers, the soil, or filter beds in water treatment works. The process is speeded up by increasing the amount of oxygen available, which can be done by two possible methods: Filter beds:, Activated sludge:. Secondary treatment in addition to primary treatment removes about 7090% of the BOD in the sewage, so the effluent is usually sufficiently purified. 4. Tertiary treatment: Primary and secondary treatment remove only 20 40% of the phosphorus and nitrogen, and about half of the toxic compounds. If it is necessary to reduce plant nutrients or toxic compounds beyond these levels tertiary treatment is required, but this is very expensive and not commonly used. Various types of tertiary treatment exists, e.g. nutrient stripping, disinfection by UV light or filter membranes.

25

FIGURE -3 PROCESS-CUM-MATERIAL FLOW SHEET

26

ANNEXURE-II PROPOSED TERMS OF REFERENCE Project Implementation: A detailed description of all the additional elements of the project from 5.0 to 10.0 Mtpa stage during the pre-construction, construction and operational phases will be prepared. The elements analyzed will include the infrastructures of the project including: drainage features, roads, waste collection, disposal and management and utility requirements. Analysis and assessment of designs to ensure environmental soundness, sustainability and regulatory compliance of the designs will be studied and incorporated in the draft and final EIA Report. Field Assessments: Field assessments of the physical, ecological, and socioeconomic aspects of the site and associated environs will be conducted during winter season. These assessments will be used to determine the potential impacts, if any, of the proposed project. A photographic survey of the proposed site and the nearby environs has been conducted. The survey included a photo-inventory of the physical and biological features of the site and environs, and the areas are viewed with respect to the suitability of the proposed facility. The assessments included: Physical: Meteorology, air quality, geology, topography, soils, groundwater/surface water hydrology quality, hazard vulnerability, noise levels, land use, water use and solid waste management. Ecological: Terrestrial and aquatic communities; presence of rare, threatened and endangered species. Socioeconomic: Demography, regional setting, location assessment, and land uses. The technical scope of work for carrying out the baseline monitoring would be as given below. The baseline monitoring will be carried out in 10-km radius study area around the proposed project site for three months representing the winter season. Sr. No. 1 Attributes Ambient Air Quality Scope of Work 4 Locations - 2 days/week for 13 weeks (3 months) PM-2.5, SPM, RPM, SO2, NOx, and CO will be monitored as per CPCB guidelines. Design of ambient air quality sampling network with regard to topography, population, sensitive locations, emission sources, background

27

Sr. No.

Attributes

Scope of Work concentrations and possible impact zones, through application of screening air quality models for assessing the maximum GLC zones prior to start of baseline study. 1 Location - 90 days Wind speed, direction, temperature, humidity, cloud cover and rainfall will be monitored. This is further supported by the meteorological data for the area of interest from the nearest meteorological observatory and Trend analysis of micrometeorological data generated at the site. 9 Locations- (Surface and Ground water samples) Once during the EIA study Parameters as per IS-10500, IS:2296 and EPA Act as applicable . The survey also include estimation of water balance and assessment of impacts on regional water demand and availability of fresh water due to drawl of water for plant, recommendations on water conservation and rain water harvesting measures based on past experience on similar projects; and identification of suitable location and methodology for disposal of waste water form all sources. 6 Locations once during EIA study. Parameters related to afforestation, nutrients, pollutants etc. will be carried out. 8 Locations (Residential, Commercial and Sensitive areas) once during EIA study. Readings will be taken for 24-hr duration at each location Land use as per the district census handbooks as well as with the help of satellite imagery will be presented in 10-km radius study area. Characterization of all the solid wastes generated from the plant operations and its disposal including impacts due to disposal. Socio-economic and health aspects are covered for 10-km radius study area based on the Census documents and NIC database. Flora and fauna will be studied in 10-km radius study area. These studies will be based on primary as well as secondary sources. The survey also includes assessment of the species diversity, density, abundance etc. in the study area and formulation of ecological indexes, assessment of likely changes on flora and fauna due to the project related activities, suggestions

Meteorological data

Water Quality

4 5

Soil Quality Noise Levels

6 7 8 9

Land use Solid waste Socio-Economic Demography Ecological (Terrestrial Aquatic) and

studies and

28

Sr. No.

Attributes

Scope of Work for conservation and protection of flora and fauna in the study area and suggestions for development of new conservation areas locally.

10

Traffic Study

11

Aesthetic/Cultural Aspects

Traffic at important points on the approach roads will be surveyed for the existing total daily traffic, peak hour traffic and traffic composition. Assessment of the change in traffic composition and volumes and suggestions for improvement of traffic flow around the project site and around will be studied Identification of all historical/ archeological sites/monuments in the study area.

Detailed qualitative assessments of the physical, ecological, and socioeconomic conditions associated with the site in the Draft and Final Report. Legislation and Regulatory Considerations Government policies, legislation and regulations relevant to the proposal will be identified. Local plans and policies will also be evaluated. Project characteristics will be analyzed to ensure compliance with these policies, legislation and regulations. Appropriate recommendations will be provided to ensure regulatory compliance. The legislation relevant to the project will be summarized and presented in the EIA Reports. Environmental Impact Assessment The guidelines suggested and international practices will be reviewed to determine the adverse impacts and critical areas. There are various qualitative as well as quantitative methods of conducting EIA studies, each having its own merits and demerits. We intend to use the best logical tool to assess the impact of the project. The baseline data generated from above studies will be analyzed and compared with applicable standards for each environmental attribute, so that the critical environmental areas and also attributes of concern will be identified. The short term and long-term impacts particularly on sensitive targets such as endangered species, plants and historically important monuments will be identified. The Environmental Impact Assessment of proposed project will be done on above basis to determine the environmental acceptability of this proposed project in absence of control measures and after implementation of the mitigation measures, including worst impact. A qualitative and quantitative assessment of pollution aspects of proposed project (air and dust, wastewater, noise pollution, wastewater discharges etc.) will also be done to identify the adequacy of the proposed control measures as well as the likely impact on existing critical areas. Mitigation measures to reduce adverse impacts will be suggested.

29

Air Impacts: Emission Inventory will be carried out in an area of 10-km around the project site. A computer based internationally recognized mathematical air quality model (ISC-ST3) will be used to predict the concentration of SO2, NOx and SPM due to the operation of the proposed project. The model would also take into account other sources of pollution and topographical features of the area. The emission of relevant pollutant (SO2, NOx and SPM) from nearby sources shall be used in the model for more accurate estimate of air quality. The results will be presented for short term (24 hourly) concentrations over a radius of 10-km around the plant site. The dispersion model results will be included in the report using isopleths or other graphical methods, over laying a land use map of the surrounding area. The predicted air quality will be compared with existing regulations and mitigative measures, if any, will be identified. The long term and short term impact at all the monitoring locations shall also be estimated. Noise Impacts: Sources of noise and its impact on the environment would be clearly brought out. The noise level at varying distances for multi-sources will be predicted using suitable model. A comparison of measured noise (Leq) at monitoring locations to that of predicted noise levels (Leq) would be made and mitigatory measures required, if any, will be recommended to conform to regulatory ambient air noise standards. We propose to estimate increase in noise levels over the baseline conditions in different zones like industrial, residential and sensitive areas like hospitals, wild life habitation etc. The potential noise level exposure will be determined and evaluated for acceptable limits of exposure. Environment Management Plan For each potential negative impact identified, recommendations will be presented for avoidance, minimization or mitigation of impacts along with costs associated with potential mitigation. An EIA/EMP, based on three months baseline study, will be prepared for the project. The EMP will address the following: Identify and summarize all anticipated significant adverse environmental impacts; Identify and summarize all mitigation measures, including the type of impact to which it relates and the conditions under which it is required; Define a set of policies and objectives for environmental performance and continual enhancement of performance; Recommend monitoring measures including the parameters to monitored, methods to be used, sampling locations, frequency of measurements, detection limits and definition of thresholds that will signal the need for corrective actions; Recommend monitoring and reporting procedures; Recommend capacity development and training requirements for implementation of EMP;

30

Recommend organizational structure for effective implementation of the EMP; and Draw up an implementation and cost schedule for EMP.

Environmental Monitoring An environmental monitoring and management plan will be developed for the sensitive elements of the environment that may require monitoring during construction and operations of the facility. Recommendations will be made on the institutional arrangements that will be necessary to ensure effective monitoring and management. A detailed management and monitoring program will be developed to reduce the effects of potential negative environmental impacts. Risk Assessment and Disaster Management Plan Risk Assessment studies comprising sub-activities such as hazard identification, assessment and quantification of risk for suggesting risk mitigation measures based on Maximum Credible Accident (MCA) Analysis to be carried out for the proposed project. Preparation of the Risk Assessment Report will be followed by Disaster Management Plan (DMP) and Emergency Preparedness Plan (EPP) based on the quantitative Risk Assessment of the proposed activity and associated infrastructure for the project. Occupational Health and Safety We will review the existing system of safety management and occupational health surveillance system in the plant and recommend for further appropriate measures in view of the proposed expansion facilities.

31

32

D AREA HELIPA

ATE NG MAI

PR OP OS ED

RA IL W

AY

SI DI NG

STRIP MILL

Y DAR

U BO

UN

BO

R M H S

AREA
IR O

Y AR ND

W L AL

HOT

LF & VD
LCP-3

PLATE MILL

GA GOA

TE

TW

TW

TW

DR PLANT-2

FIN FAN COOLERS

FIN FAN COOLERS

BT3

S
R I V E R

IN

LA N T

OXYGEN PLANT
-1
FU RN AC E

A M B A

IR O ON R E

POWER PLANT 1x53.5 MW

BL AS T

C O C KI O N A G L

FL

U X

H. R. JHONSON PLANT AREA

B A M SE IX

HOT STRIP MILL BLAST FURNACE

COLD ROLLING MILLS

PELLET PLANT-2
P SI N LA T N ER T -2

SMS

LIME PLANT

SINTER PLANT-3

COKE OVEN PLANT-3

POWER PLANT

HARSCO

CEMENT PLANT

MSDS

ISPATSTEELLTD.

CapacityAdditionofIntegratedSteelPlantfrom 5.0MTPAto10.0MTPAand CaptivePowerPlantfrom300MWto600MW

Dolvi,Maharashtra

ProjectReport

TechnoProjectsManagementLtd.
Mumbai
December2012

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
CONTENTS
Chapter No. Title Page Nos. From 01 02 03 04 05 06 07 08 09 Introduction Market Analysis & Product Mix Major Technological Facilities Raw Materials Requirements Proposed Site Services, Utilities & Manpower Requirement Environmental Management Project Implementation Block Capital Cost 1-1 2-1 3-1 4-1 5-1 6-1 7-1 8-1 9-1 To 1-4 2-6 3-10 4-4 5-6 6-4 7-4 8-1 9-1

LIST OF DRAWINGS
Sl. No. 1. 2. 3. 4. 5. 6. Description Location Map Regional Map Road Linkage Process-cum-Material Flow Sheet General Layout Implementation Schedule Drawing No. JSW/DW/PR/001 JSW/DW/PR/002 JSW/DW/PR/003 JSW/DW/PR/004 JSW/DW/PR/005 JSW/DW/PR/006

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
01 01.01 INTRODUCTION Preamble Steel being a basic commodity for all industrial activities, quantum of its consumption is considered as an index of industrial prosperity. Since independence, there has been a substantial growth in the steel sector in India from 1.5 Mtpa in 1950-51 to about 71.3 Mtpa finished steel at present. The per capita steel consumption continues to remain at a level of about 59 kg only, compared to about >250 kg in the developed countries and about 50 250 kg in some of the developing countries. Further with nearly 20% of the world population, Indias consumption is only of the order of 4% of the world steel production. The National Steel Policy 2005 had envisaged steel production to reach 110 million tonnes by 2019-20. However, based on the assessment of the current ongoing projects, both in greenfield and brownfield, the Working Group on Steel for the 12th Plan has projected that the crude steel capacity in the country is likely to be 140 Mt by 2016-17 and has the potential to reach 149 Mt if all requirements are adequately met. India is world's fourth largest crude steel producer in 2011-12 with 71.3 million tonnes (Mt) in 2011-12 and is expected to become the second largest producer of crude steel in the world by 2015-16. JSW ISPAT Steel Ltd. is a 3.0 Mtpa Steel plant at Dolvi, Maharashtra based on BF-DR-CONARC-CSP process route. It also has cold rolling, galvanizing, colour coating plant, galvalume and
1-1

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
pipe & tube plant at Kalmeshwar, Nagpur in the state of Maharashtra. JSW ISPAT Steel Ltd., Dolvi Works has applied for and received the Environmental clearance for expansion of the integrated steel plant from 3.0 to 5.0 Mtpa and 300 MW captive power plant. JSW ISPAT Steel Ltd., Dolvi Works is again proposing to add some more units to take the capacity of the plant to 10.0 Mtpa at Dolvi. The proposed capacity enhancement has been envisaged keeping in view the projected demand of steel in domestic market. The total capital investment in the proposed project will be around Rs. 17,000 crores. The additional capacity can be produced with minor additions of land, water, power etc. by using large equipment and state of the art technology. The proposed investment will further boost the socio-economic profile of the region and will open up additional employment opportunities for the local people in the region. This Project Report is based on proven production technology, market demand, site suitability with respect to environmental norms, available infrastructure and economic viability of the project. 01.02 Existing & Additional expansion Facilities JSW ISPAT Steel Ltd., Dolvi Works has the existing capacity of 3.0 Mtpa and has Environmental clearance for 3.0 to 5.0 Mtpa expansion. It is proposed to further addition of some plant units which take the final plant capacity to 10.0 Mtpa.

1-2

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Details of facilities envisaged at 5 and 10 Mtpa Stages Details of facilities at 5.0 Mtpa stage and the proposed expansion from 5.0 to 10.0 Mtpa to attain 10.0 Mtpa are shown in Table 01.01. Table - 01.01 Facilities at 5.0 Mtpa stage and the proposed expansion from 5.0 to 10.0 Mtpa S. No. Facilities Unit Total capacity at 5 MTPA (EC Received) 2.0 (by augmenting) 4.0 2.0 2.8 + 3.2 2.0 + 1.6 Additional units from 5 MTPA to 10 MTPA 2.0 4.0 2.5 8.0 4.5 Total capacity at 10 MTPA

1 2 3 4 5 6 7 8 9 10

DRI (Gas based Mega Module) Pellet Plant Coke oven with By- Product Plant & CDQ Sinter Plant Blast Furnace with Pig /Granshot Casting & TRT SMS (CONARC) SMS BOF Ladle Furnace VD/VOD/RH-Degasser CSP (HRC Coil) Thin Castercum- Hot Strip Finishing Train Conventional Slab Caster Plate Mill Galvanizing Line (Cold Rolled Steel Strips, Hot Dip Zinc Coated Full Hard) Electrical Steel CRGO Line Tin Plate Line Color Coating Plant

MTPA MTPA MTPA MTPA MTPA MTPA MTPA

4.0 8.0 4.5 14.0 8.1 5.2 6.0 2x200 T + 1x205 T + 2x280/300 T 1x200 T + 1x205T + 2x280/300 T 3.5

5.2 (By Augmenting the existing facilities) 6.0 2x200 T + 1x205 T 2 X 280/300 T 1x200 T + 1x205 T 2 X 280/300 T -

MTPA

3.5 (by augmenting) 2 x 1 strand 1.5 0.6

11 12 13

MTPA MTPA MTPA

2 x 2 strand -

Total 6 strands 1.5 0.6

14 15 16

MTPA MTPA MTPA

0.4 0.4 0.5

0.4 0.4 0.5

1-3

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
17 18 19 20 21 22 Lime & Dolo Plant Oxygen Plant Captive Power Plant (Gas Based) Hot Rolling Mill with Shearing & Slitting line Slag & Clinker Grinding Unit CRM (Hot Rolled Skin Pass + Cold Rolled Full Hard Coil + Hot Rolled Pickled & Oiled Coil) Township TPD TPD MW MTPA MTPA MTPA 1800 4100 300 1.0 1800 3500 300 6.0 10.0 1.5 3600 7600 600 6.0 10.0 2.5

23

1-4

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
02 02.01 MARKET ANALYSIS AND PRODUCT MIX General JSW ISPAT Steel Ltd., Dolvi Works, envisages capacity addition of integrated steel plant to reach final capacity of 10.0 Mtpa. In order to arrive at a reasonable product-mix for the plant, a quick desk study based on the secondary data has been carried out and derived in the following paragraphs. 02.02 Global Steel Scenario World steel industry experienced growth during the previous years followed by a period of downturn. The fall in demand is attributed to the global downturn. All the major steel-producing countries and regions showed growth in 2011. The America, Asia & Oceania had higher growth rates while Europe and the CIS recorded relatively lower growth. However, Africa & Middle East showed negative growth in 2011. World crude steel production during 2011 was reported as 1,518 Million tonnes (Mt), 6.23% increase on the annual 2010 total of 1,429 Million tonnes. Annual production for Asia was 974.9 Mt of crude steel in 2011, an increase of 8.57% compared to 2010. World trade in finished steel, expressed as a percentage of world steel consumption is generally about 40 percent. Accordingly, it may be expected that total trade in finished steel will be of the order of 450 Million tonnes annually, of which flat products may constitute upto 60 percent i.e. about 270 Million tonnes and long products may constitute about 180 Million tonnes.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
02.03 02.03.01 Indian Steel Scenario Production The finished steel production in India has grown from a mere 1 Mt in 1951 to 13.2 Mt in 1990-91 and further increased to 74 Mt in 2011-12. During the first two decades of the planned economic development, i.e. 1950 to 1960-61 and 1960-61 to 1970-71, the average annual growth rate of steel production has been about 8%. However, this growth rate could not be maintained in the following two decades. During 1970-71 to 1980-81, the average annual growth rate in finished steel production came down to 5.2% and picked up marginally to 5.6% during 1980-81 to 199091. However, average annual growth during 1990-91 to 2000-01 has been encouraging to the level of 8%. The production of finished steel grew by 16.52 percent, from 44.54 Mt in 2005-06 to 49.39 Mt in 2006-07. The finished steel production for the 200809 registered a growth of 0.6% over 2007-08. Based on the assessment of the current ongoing projects, both in greenfield and brownfield, the Working Group on Steel for the 12th Plan has projected that the crude steel capacity in the country is likely to be 120 Mt by 2020. 02.03.02 Demand Domestic Demand Generally, a developing economy undertakes large number of infrastructure projects, which are necessary for building of the nation and ensuring economic growth. China is a leading example of the economic growth through phenomenal development of infrastructure.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
The Indian economy grew at 6.5% in 2011-12, down from 8.4% in 2010-11. The GDP growth in 2011-12 was the lowest in the past nine years. Global crisis, geopolitical disturbances and weather extremities contributed to the domestic economic slowdown. The industrial sector growth slowed to 3.4% in 2011-12 against 7.2% in 201011 and was primarily responsible for the slowdown of Indias economic progression. Present low per capita consumption in India is expected to drive demand for steel, which is likely to grow @ 7.5% per annum as per Ministry of Steel, Government of India projections, as detailed in the National Steel Policy 2005. Export demand Though India started steel production in 1911, steel exports from India began only in 1964. Exports in the first five years were India again mainly due to recession in the domestic Iron and Steel market. Once domestic demand revived, exports declined. started exporting steel only in 1975 touching a figure of 1 Mt of pig iron and 1.4 Mt of steel in 1976-77. Thereafter, exports again declined to pick up only in 1991-92 to 0.39 Mt. In 1995-96, exports of semi-finished and finished steel products were 1.77 Mt while in 2003-04 exports reached 5.2 Mt. During 2004-05, exports of these products have declined to 4.4 Mt. The exports have increased by 8.9 per cent in 2006-07 over 2005-06 to touch 4.9 Mt. Exports have declined in the year 2007-08 by 6.1 per cent to 4.6 Mt from 8.9 per cent in 2006-07. Imports of semi finished and finished steel products mainly HR plates, HR coils/sheets and CR coils/sheets by India have been in the range of 1.1 Mt and 2 Mt, during the last ten years.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report

In view of the above and anticipated higher emphasis on export of steel products in future as per National Steel Policy-2005 (26 Mt exports of steel products by 2020), export demand in the range of 10% to 15% of apparent consumption of various products and 150% for GP/GC sheets has been considered. Iron and steel industrys growth in India has been exceptional though there have been occasional downturns. National steel policy 2005 estimated domestic steel production to grow by 7.3% annually and consumption to grow by 6.9% and projected steel production of 110 million tonnes by the year 2019-20. However, in 2006-07 domestic steel production grew at the rate of 10.9% and consumption at 11.6%, accordingly, the estimates for production of steel was revised in 2008 and was projected at 180 million tonnes as target to be achieved by 2019-20. 02.03.03 Resultant GAPS/Surpluses Based on the demand and availability, future gaps and surpluses have been projected in Table-02.01: Table-02.01 Demand, Availability and Resultant Gaps/Surpluses Sl.No. Products 2006-07 Steel Products I Non Flat Products 1 Wire Rods Demand Availability 6040 4940 8840 4940 12970 4940 In (000 t) 2011-12 2016-17

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Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
- Gaps/Surpluses* 2 Light Merchant Products Demand Availability - Gaps/Surpluses* 3 Medium Merchant Products Demand Availability - Gaps/Surpluses* 4 Heavy Sections Demand Availability - Gaps/Surpluses* II Flat Products 5 HR Plates Demand Availability - Gaps/Surpluses* 6 HR Coils /Sheets Demand Availability - Gaps/Surpluses* 14400 12040 (-) 2360 23160 16180 (-) 6980 42525 16180 (-) 26345 3680 1350 (-) 2330 5175 2700 (-) 2475 6900 2700 (-) 4200 560 720 (+) 160 750 820 (+) 70 1000 820 (-) 180 2440 2115 (-) 325 3465 2115 (-) 1350 4910 2115 (-) 2795 9790 10150 (+) 360 14060 11900 (-) 2160 20220 11900 (-) 8320 - 1100 - 3900 - 8030

*Note: Demand and Gaps/Surpluses are including Export. From the above, the following conclusions can be drawn:

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
There is enough scope for creation of additional steel making capacity in the country to meet the growing domestic demand. There is enough opportunity for Indian Steel Producers to enter the growing world trade in steel. 02.04 Keeping in view the steel market trends, it is proposed to enhance the capacity to attain 10.0 Mtpa integrated steel plant at Dolvi. 02.05 The tentative product ranges would be : Flat products

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
03 03.01 MAJOR TECHNOLOGICAL FACILITIES General The project envisages capacity addition to attain the final capacity of integrated steel plant to 10.0 Mtpa at Dolvi. The plant will be equipped with coke oven complex, pellet plant, sinter plant, blast furnace, sponge iron plant, BOF, ladle furnace, RH-Degasser, continuous casting facility, hot rolled mill, cold rolling mill, captive power plant, lime & dolo plant, oxygen plant, grinding unit, raw material handling system, township and jetty expansion for the production of flat products. The General Layout is shown in the Drg. No. JSW/DW/PR/005. Supporting facilities up to production of finished products will also be set up in the plant based on the state-of-the-art technology. In this chapter, all major technological facilities required at each processing step of the plant are given (Table 03.01) below with brief description in subsequent paragraphs. Table 03.01 Processing Steps and Technological Facilities Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. Processing step Coke making Pelletization Sintering Iron making Steel making Secondary refining Continuous casting Finished Steel Technological facility Recovery Coke Ovens Pellet plant Sinter Plant Blast Furnace Direct Reduction Plant BOF Ladle Furnace RH-Degasser Slab Caster Hot Rolled Mill Cold Rolled Mill

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
9. 10. 11. 12. 13. Power generation Calcining Oxygen making Slag & Clinker Grinding Township Captive Power Plant Lime & Dolo Calcination Plant Oxygen Plant Slag & Clinker Grinding Unit Dwelling units

Facilities required outside the plant boundary like expansion of JSW ISPAT Dolvi jetty and RMHS facilities, sourcing of iron ore, coking and non-coking coal will also be taken up along with township etc. The process-cum-material flow sheet has been shown in the drawing no. JSW/DW/PR/004. 03.02 Coke Oven Batteries Coke is one of the prime requirements for production of hot metal through blast furnace route. Considering the level of technological development in the coke making area and total requirement of blast furnace coke in the blast furnace, installation of recovery type coke oven batteries have been envisaged. The complex is proposed to be equipped with four (4), stamp charged 5.5m tall coke oven batteries of 65 ovens each. The gross coke generated in the coke ovens will be screened. BF coke & nut coke will be sent to the blast furnace and coke fines/ coke breeze generated in the plant will be utilized in the sinter plant. The coke making technology would include pre-carbonization and post carbonization technologies like selective crushing of coal, stamp charging and high capacity ovens. Introduction of these technologies are required to reduce the hard coking coal requirement by blending with soft coking coal in coal
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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
blend to improve coke quality, to facilitate automation and pollution control and to maximize the use of semi-soft coking coal. 03.03 Pellet Plant The Pelletization process involves reduction of moisture in the iron ore to less than 1%, grinding to 45 micron size, feed preparation by adding binders and moisture, green pelletization and induration (heat hardening). It is proposed to install a Pellet Plant capable of producing upto 4.0 Mtpa of pellets. This Pellet Plant will produce DRI grade pellets to be used in the sponge iron plant and rest pellets will be used in the BF. 03.04 Sinter Plant Sintering is an agglomeration process in which iron ore fines are mixed with return materials, limestone, and finely sized fuel such as coke breeze. The return materials consist of mill scale from hot rolling operations and dust from steel melting shop and blast furnaces. The raw materials are mixed before they are placed on the traveling grate of the sinter machine. Near the head end of the grate, the surface of the raw materials is ignited by a gas fired ignition furnace located over the bed. As the mixture moves along the grate, air is drawn through the mixture at the wind boxes to enhance combustion and sinter (fuse) the fine particles. As the bed burns, carbon dioxide, cyanides, sulfur compounds, chlorides, fluorides and oil and grease are driven off with the gases. The sinter drops off the grate at the discharge end and is cooled (either by air or a water spray), crushed, and screened to maintain uniformity in the size of the sinter fed to blast furnaces.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Improperly sized sinter and fines from screening are returned for reprocessing. The advantages of agglomerated burden in the blast furnace is well established and almost all the high capacity blast furnaces world-wide are using agglomerated burden for most efficient furnace operation. The major advantages for use of sinter in blast furnace are as follows: Control of physical, chemical and high temperature properties of burden materials Avoid use of raw flux charging directly in the blast furnace Increase in productivity of the furnace Decrease in coke/fuel rate Longer life of furnace Production of desired grade of hot metal, etc. Apart from the above advantages, the iron ore fines generated in the mines during production of iron ore lumps are used in the sinter plant which avoids the problems related to disposal of fines in the iron ore mines. Moreover, metallurgical waste materials generated in different process steps shall be recycled in the sinter plant, which minimizes the dust pollution inside the plant boundary. The sinter plant is equipped with the following major facilities: Base blending for input materials Flux and fuel crushing facilities Lime dozing facility Mixing and nodulising unit Sintering machine equipped with sinter strand, ignition furnace, wind boxes, suction fan, dust cleaning unit, etc. Sinter Coolers
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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Sinter screening and transportation facilities

Capacity of the sinter plant has been estimated based on use of about 75-80% sinter in the burden of blast furnaces, which shall be obtained from the sintering machine of 8.0 Mtpa capacity. 03.05 Blast Furnace Hot metal production using blast furnace process has been envisaged for the proposed project, as the process is most established and competitive iron making technology till date. A number of technological improvements have taken place in blast furnace which has resulted in higher production, less coke consumption, most energy efficient, long campaign life, etc. State-of-the-art blast furnace equipped with the following major facilities has been envisaged for the proposed plant: Stock house with automatic conveyor charging facilities Bell less top charging equipment High top pressure operation (3.0 kg/cm2 top pressure) and matching gas-cleaning plant Stoves for generation of high hot blast temperature (1250oC blast temperature) Coal dust injection facilities (150 kg/t-hm) Oxygen enrichment of blast Cast house slag granulation plant Top Gas Recovery Turbine Cast house slag granulation plant. (The slag would be
grinded in slag grinding unit)

Level-III automation and control system, etc. Hot metal produced from the blast furnace will be transported to the steel melting shop using hot metal ladles.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Considering the daily requirement of hot metal in the steel melting shop for production of liquid steel, which is sufficient to produce about 4.5 Mtpa hot metal, 1 (one) blast furnace of 4.5 Mtpa capacity have been envisaged for the proposed project. Slag generated from the blast furnaces will be granulated in the cast house slag granulation plant. The granulated slag will be processed in the grinding units. 03.06 Direct Reduction (DR) Plant One Mega Module Direct Reduction (DR) Plant based on the Natural Gas/coke oven gas/LD gas/Mixed gas with average gross production capacity of 2.0 Mt/yr has been envisaged. 03.07 03.07.01 Steel making and Casting Facilities Steel Making Basic oxygen furnace technology for production of liquid steel has been envisaged for the proposed project. This process till date dominates the steel production scenario of high capacity integrated steel plant worldwide mainly due to its energy efficiency. As such, external energy in terms of either electrical power or solid/liquid/gaseous fuel is not required for process. However, requirement of electricity and gaseous fuel are mainly for driving of electrical equipment, ladle heating, etc. Most of the other furnaces like electric arc furnace/ induction furnace consumes high amount of electrical energy. However, oxygen with high purity is required for conversion of hot metal to liquid steel and scrap/iron ore/DRI is required as coolant in BOF process.
3

A significant amount of medium calorific value (2000

kcal/Nm ) gas is generated during carbon refining which is

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
separated in the gas cleaning plant. Hot metal will be pre-treated before charging into the converter. Considering the requirement of liquid steel for subsequent process steps, chemical composition of input materials, quality of liquid steel to be produced, sequence of casting of liquid steel into slabs, oxygen blowing rate etc., two (2) number of converters of capacity 280/300 t has been envisaged for the proposed project. 03.07.02 Ladle Furnace (L.F.) With a view to achieve improved homogeneity of the primary unit, ladle furnace is the ideal secondary refining unit. The correction and homogenization of steel composition and temperature, desulphurisation and recarburisation, etc. can be efficiently carried out in a L.F. Two (2) L.F. of size 280/300 t has therefore been envisaged for the proposed project. The LF will also be equipped with argon purging facilities. 03.07.03 RH-Degasser RH degasser are envisaged as secondary refining units. The

process assures liquid steel of high purity, low level of inclusions and good homogeneity with respect to temperature and chemistry. This process helps attainment of low levels of gases and inclusions and provides controlled alloying and mixing to produce variety of alloys. This process also allows improvement in plant productivity (through sharing of refining load) and yield. Two (2) RH-Degasser units of matching size 280/300 t has been envisaged for production of value-added steels. The RH-Degasser unit will be used for production of various steel grades and for special applications.

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Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
03.07.04 Slab Caster The product-mix envisages processing of approximately 6.0 Mt of liquid steel through conventional slab caster. Considering the capacity of the plant, conventional slab casting machine has been envisaged for the proposed plant. The slab caster will be equipped with the state-of-the-art facilities like electro-magnetic stirring, mould oscillation, shrouding of liquid metal with inert gas, online width control, etc. Considering market requirements, two double strand casters capable of producing slabs of 950-2150 mm width and 220/250 mm thickness have been envisaged. However this could be revised to cater to the future market requirements. 03.08 03.08.01 Finished Steel Hot Rolling Mill It is envisaged to process slabs through Hot Rolling Mill Finishing Train for the production of hot rolled coils / strips. This will have the ability to produce coils of thickness 1.6 to 8.0 mm and with 900 to 2000 mm width with a capacity of 6.0 Mtpa. 03.08.02 Cold Rolling Mill Hot strips produced in the hot rolling mill will be processed in the Cold rolling Mill. EC had been obtained at 5 Mtpa stage for CRM of 1.0 Mtpa capacity. It is now proposed to apply for amending the capacity to 2.5 Mtpa. This large size would be more energy efficient.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
03.09 Captive Power Plant To meet the requirement of power for the proposed plant, a captive power plant of capacity 1 x 300 MW has been envisaged based on the multi fuel gases. 03.10 Lime & Dolo Calcination Plant Calcined lime and dolo will be used in steelmaking shop of the steel plant. In order to meet the requirement of proposed expansion of integrated steel plant, 3 x 600 tpd lime & dolo calcination plant have been envisaged. 03.11 Oxygen Plant To meet the oxygen requirement of proposed expansion of integrated steel plant, oxygen plant of capacity 3,500 TPD has been envisaged. The oxygen plant will also meet the requirement of nitrogen and argon of different technological facilities envisaged in the proposed integrated steel plant. Table-03.02 Major Additional Plant Facilities and Their Capacities S. No. Facilities Unit Total capacity at 5 MTPA (EC Received) 2.0 (by augmenting) 4.0 2.0 2.8 + 3.2 2.0 + 1.6 Additional units from 5 MTPA to 10 MTPA 2.0 4.0 2.5 8.0 4.5 Total capacity at 10 MTPA

1 2 3 4 5 6 7

DRI (Gas based Mega Module) Pellet Plant Coke oven with By- Product Plant & CDQ Sinter Plant Blast Furnace with Pig /Granshot Casting & TRT SMS (CONARC) SMS BOF

MTPA MTPA MTPA MTPA MTPA MTPA MTPA

4.0 8.0 4.5 14.0 8.1 5.2 6.0

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5.2 (By Augmenting the existing facilities) 6.0

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
8 9 10 Ladle Furnace VD/VOD/RH-Degasser CSP (HRC Coil) Thin Castercum- Hot Strip Finishing Train Conventional Slab Caster Plate Mill Galvanizing Line (Cold Rolled Steel Strips, Hot Dip Zinc Coated Full Hard) Electrical Steel CRGO Line Tin Plate Line Color Coating Plant Lime & Dolo Plant Oxygen Plant Captive Power Plant (Gas Based) Hot Rolling Mill with Shearing & Slitting line Slag & Clinker Grinding Unit CRM (Hot Rolled Skin Pass + Cold Rolled Full Hard Coil + Hot Rolled Pickled & Oiled Coil) Township MTPA 2x200 T + 1x205 T 1x200 T + 1x205 T 3.5 (by augmenting) 1 x 2 strand 1.5 0.6 2 X 280/300 T 2 X 280/300 T 2x200 T + 1x205 T + 2x280/300 T 1x200 T + 1x205T + 2x280/300 T 3.5

11 12 13

MTPA MTPA MTPA

2 x 2 strand -

Total 6 strands 1.5 0.6

14 15 16 17 18 19 20 21 22

MTPA MTPA MTPA TPD TPD MW MTPA MTPA MTPA

0.4 0.4 0.5 1800 4100 300 1.0

1800 3500 300 6.0 10.0 1.5

0.4 0.4 0.5 3600 7600 600 6.0 10.0 2.5

23

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
04 04.01 RAW MATERIALS REQUIREMENTS General Raw materials availability is becoming critical due to the heavy demands made and the limited resources. Proper sourcing and appropriate beneficiation combined with logistics planning has become vital for the success of any plant operation. The other important criterion, concerned to raw materials, is the cost of transportation involved from mine site to plant site. Iron ore lumps, Iron ore fines, non-coking coal, coking coal, limestone, dolomite and quartzite are the major raw materials required for the plant. Keeping in view the plant location it is proposed to utilize the waterways for major transportation. For this purpose it is proposed to suitably extend the jetty. 04.02 Requirement of Raw Materials The additional annual (net and dry) requirements of various raw materials for capacity addition from 5.0 to 10.0 Mtpa are given in table 04.01. Table-04.01 Additional Annual Major Raw Material Requirement (net & dry basis): Sl. No. 1. 2. 3. 4. Raw material
Iron Ore Fines/Conc. (For Pellet Plant) Iron ore fines (for sinter plant) Iron Ore Lumps Coking Coal (for coke oven)

Quantity (tpa)
4,200,000 6,880,000 380,000 3,500,000

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Non-coking coal for PCI Limestone (for sinter plant) Limestone (for pellet plant) Dolomite (for sinter plant) Quartzite Limestone (for SMS) Dolomite (for SMS) Ferro-Alloy (for SMS) Bentonite (For pellet plant) Clinkers (For Grinding unit) 675,000 491,000 80,000 503,000 60,000 860,000 388,000 103,600 28,000 5,000,000

Estimated requirement of all raw materials have been briefly described in subsequent paragraphs. 04.02.01 Iron ore The estimated requirement of total Iron ore fines is 11.08 Mtpa on net and dry basis. Considering about 10% losses due to moisture, and 5% losses due to handling, the iron ore requirement works out to about 13.0 Mtpa. Iron ore lumps requirement is estimated to around 0.38 Mtpa in the Blast furnace. Considering about 10% losses due to moisture, and 5% losses due to handling, the iron ore lumps requirement works out to about 0.45 Mtpa in Blast Furnace. 04.02.02 Coal Generally, for coke making, metallurgical coal of different grades are used in blend. Availability of low ash coking coal of desired quality in this country is limited. Hence, it has been envisaged that requirement of metallurgical coal for the proposed steel plant will be met through imports. The possible sources of supply of

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
metallurgical coal are Australia and China, while Australia, Russia, South Africa and Indonesia are the possible sources of coal used for PCI coal for BF. 04.02.03 Coking coal The requirement of coking coal is about 3.5 Mtpa on Net and Dry basis. 100% Imported Coking Coal is proposed to be used in the coke oven complex. Considering moisture loss of 10%, handling loss of 5% the annual requirement is about 4.12 Mt. 04.02.04 Coal for PCI The PCI Coal requirement for the blast furnace is about 675,000 tpa on Net and Dry basis for pulverized coal injection through the tuyeres. Considering moisture loss of 10%, handling loss of 5% the annual requirement is about 0.79 Mt. The ash content of the injected coal is normally lower than that of the coke for the most efficient coal dust injection operation. Since very low ash content non-coking coal is not available in India, it will be met through imports. 04.02.05 Limestone Limestone will be required as flux material both for iron making and for steel making. In case of steel making, limestone will be calcined in a captive calcination plant and the calcined product, namely burnt lime, will be used in steel melt shop for production of liquid steel. The desirable chemical analysis of BF grade limestone is as follows:

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
SiO2 % 3.61 Al2O3 % 0.60 CaO % 50.74 MgO % 1.91

For quality reasons, sustained supply and cost effectiveness, some imported SMS grade limestone may also be used. High-grade low silica limestone is produced and traded by several countries namely Japan, Vietnam, Thailand, Middle-East etc. The typical analysis of imported limestone is as follows: SiO2 Al2O3 % % 0.43 0.20 CaO % 54.54 MgO % 0.91

Some of the Calcined Lime requirement will be fulfilled from the existing lime calcination plant. 04.02.06 Dolomite Dolomite will be required as flux material both for iron making and for steel making. In case of steel making, Dolomite will be calcined in a captive calcination plant and the calcined product, namely burnt dolo, will be used in steel melt shop for production of liquid steel. For quality reasons, sustained supply and cost effectiveness, some imported SMS grade limestone may also be used. 04.02.06 Quartzite It has been proposed to use quartzite in the blast furnace. It has been proposed to procure quartzite from local region. A typical analysis of quartzite from this area is as follows: SiO2 % 96.5 Al2O3 % 0.60

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
05 05.01 PROPOSED SITE Site Location The capacity addition of integrated steel plant to take the final capacity to 10.0 MTPA is proposed to be set up within the existing steel plant of JSW ISPAT Steel Ltd., Dolvi Works. The existing integrated steel plant is situated in Dolvi village of Raigad district in the state of Maharashtra. The site is at a distance of 100 km from Mumbai, and about 40 km from Panvel by Road. The location map and the regional map of the proposed site have been shown in the drawing no. JSW/DW/PR/001 and drawing no. JSW/DW/PR/002 respectively. The indicative coordinates of the proposed site are given below: Longitude - 730000 - 730500 E Latitude - 183900 - 184500 N 05.02 Area Requirement The company has already a total of 1200 acres of land in its possession for its existing integrated steel plant complex. The layout of its existing plant was prepared keeping in mind the area requirement for infrastructure, material handling facilities, different shops / units as required and also area for steel plant ancillaries and for future expansion within the acquired land. Some of the proposed additional capacity is proposed to be setup within the existing plant and some needs relocated by acquiring additional 600 acres of land. The area requirement for the proposed plant has been minimized since the infrastructure and auxiliary facilities are already existing.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Special attention has been made to provide connectivity to the existing facilities viz. utilities, raw material corridors, hot metal tracks, railway tracks, etc. It is proposed to procure additional 600 acres of land at plant site for the expansion from 5.0 to 10.0 Mtpa. 05.03 Logistics The raw material sources are already connected by rail/ road/waterways which will require to be further upgraded. It is proposed to built additional Jetty of suitable length and connect it with closed conveyors to the plant. 05.03.01 Road The National Highway NH-17 (Mumbai-Goa) passes on the east side of the plant. State Highway also passes on the north side of the plant. Mumbai city is located at about 100 km on the NorthWest side of the plant. The Road linkage of the proposed site is shown in Drg.No. JSW/DW/PR/003. 05.03.02 Railways The nearest railway station Pen is about 8 km from the plant site and is located in the east on the Konkan Railway Mumbai Mangalore main line. Rail linkage from plant site has to be strengthen to avoid the congestion if part of the finished products could be sent through railways. 05.03.03 Port Connectivity The Dolvi complex has a captive port located close to it on the Amba River, which opens into the Arabian Sea. This port can
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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
handle barges and mini-bulk carriers up to 4000 dry weight tonnage (DWT). Moreover, a jetty adjoining the complex is capable of handling cargo of up to 10 million tonnes per annum. Imported raw materials and finished products, to be exported, could be handled through these ports. It is proposed to increase the jetty length to handle the additional raw material that will handle upto 50 million tones per annum. 05.03.04 Air Connectivity The nearest Mumbai airport is 80 km away from site connected through major road. The proposed Navi Mumbai International airport is 40 km away from plant site. 05.04 Water The total water requirement for the 10.0 MTPA steel plant, 600 MW power plant and township will be about 116 MLD. At present JSW ISPAT Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara and consent for 30 MLD has been obtained. Application is in progress for the balance amount. 05.05 Power The total power requirement for the proposed capacity addition is proposed to be supplied from the captive power plant and the State electricity grid. Some power would also be available from the top pressure recovery turbine generators of the blast furnace and the Coke Dry Quenching Plant. Waste heat recovery from sinter cooler is also proposed.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Power supply for the proposed plant shall be made available from the 220 kV existing switchyard. It is proposed to relocate the existing switchyard and suitably augment it. 05.06 Township The new township shall be constructed to take care of the accommodation facilities of the employees. Area for the township has been identified near Pen/Plant but the specific details are yet to be finalized. The township is to serve a large steel plant of 10 Mtpa capacity and CPP of 600 MW capacity and may have up to 7065 dwellings of various categories in about 150 Acres of land. Township details are given below: DOLVI TOWNSHIP AREA CALCULATION No. of Area Total houses (sq. Ft)/ Area (sq. No. of per Nos. house Ft) storeys floor 15 4000 60000 1 1 50 2500 125000 1 1 500 1700 850000 3 2 1500 1200 1800000 7 4 3000 600 1800000 7 4 2000 350 700000 7 4 7065 5335000 Total houses No. of per blds. Area Req bldg Required (sq. ft) 1 15 60000 1 50 125000 6 83 283333 28 54 257143 28 107 257143 28 71 100000 1082619

Type 1 2 3 4 5 6 Total

BHK 5 4 3 2 1 1

7 Total 8 Total

Area of roads/parking area in between houses, etc - 3 times more area than blgs. Area Area for GH / schools / gardens / play grounds/ water pond / temple / parkings / shopping centres/hospital etc

3247857 4330476 2178930 6509406 sq. ft 604743 sq. m 149 acres 150 acres
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TOTAL say

JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Raw water shall be treated in the plant and pumped to the township for their water requirement. Sanitary faecal sewage will be collected from the ablution blocks through pipeline and the same will be connected to a sewage treatment plant. The effluent from sewage treatment plant will be utilized for the development and maintenance of greenery. Details of the Sewage Treatment Plant are given below: Sewage treatment Plant provides only preliminary and primary treatment, and tertiary treatment is rare. 1. Preliminary treatment: This is the mechanical removal of coarse and fine solid material. The sewage passes through screens, which trap pieces of wood, rags, wire, etc. 2. Primary treatment: The sewage then flows slowly through grit tanks, where particles of sand or grit settle out. Fine particles still remain suspended in the sewage, so it is passed to large primary sedimentation tanks where most of the remaining particles settle out to form sludge. Primary treatment removes about 6070% of suspended solids. The liquid leaving the primary sedimentation tanks still contains very fine solids and dissolved matter, so secondary treatment is usually required. 3. Secondary treatment: This is a biological process, involving the oxidation of dissolved organic material by micro-organisms to decompose the organic compounds, a process similar to that taking place in rivers, the soil, or filter beds in water treatment works. The process is speeded up by increasing the amount of oxygen available, which can be done by two possible methods: Filter beds Activated sludge

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
Secondary treatment in addition to primary treatment removes about 7090% of the BOD in the sewage, so the effluent is usually sufficiently purified. 4. Tertiary treatment: Primary and secondary treatment remove only 2040% of the phosphorus and nitrogen, and about half of the toxic compounds. If it is necessary to reduce plant nutrients or toxic compounds beyond these levels tertiary treatment is required, but this is very expensive and not commonly used. Various types of tertiary treatment exists, e.g. nutrient stripping, disinfection by UV light or filter membranes.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
06 06.01 SERVICES, UTILITIES & MANPOWER REQUIREMENT General Besides raw materials, other major requirements of the plant are water, power and fuel. Blast furnace, coke oven and LD gas generated in the plant combined with Natural gas will meet the demand of fuel of different consuming units. Multi fuel gases may be utilized for generation of power. The power demand of the plant will be met from the captive power plant and augmented thru the existing main receiving substation. 06.02 Power System The power requirement is proposed to be supplied from the captive power plant and the state electricity grid. Some power would also be available from the top pressure recovery turbine generators of the blast furnace and the CDQ. From the main receiving and step down station of the plant, power will be stepped down to 33 kV to feed to the various plant load centers. These load centers will have provision to step down further to 11 kV/6.6 kV and 415 V for distribution of power at required voltages. Necessary power compensation equipment and harmonic filters will be provided to take care of the fluctuating load of converter shop and continuous casters. For all 220 kV, 33 kV, 11 kV and 6.6 kV supplies, centralized supervision, monitoring and emergency control system will be adopted.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
06.03 Water System The total water requirement for the 10.0 MTPA steel plant, 600 MW power plant and township will be about 116 MLD. At present JSW ISPAT Steel Ltd., Dolvi Works has been allocated about 56.0 MLD water from Amba river, Nagothane, K.T.Bandhara and consent for 30 MLD has been obtained. Application is in progress for the balance amount. Raw water treatment plant will be installed for pretreatment of raw water and the clarified water will be pumped through MS pipeline to the proposed units. The different categories of water to be used in the recirculating system are: a) Demineralised (DM) water for closed recirculating cooling systems. b) Soft water for closed recirculating cooling systems. c) Indirect cooling water (ICW) for secondary cooling of the water-to-water heat exchangers of the closed cooling circuits. d) Direct cooling water (DCW) for gas cleaning circuits, slag granulation, open machinery cooling and scale flushing. e) Make-up water & service water for captive power plant. For conserving water, independent recirculating systems have been proposed along with cooling towers, pump houses and treatment units. Make-up water for different process units will be made available from main plant make-up water ring main and will be conveyed to

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
respective cold wells of various recirculating systems and storage reservoirs. In order to combat industrial pollution and to comply with guidelines laid down by the statutory authorities, suitable treatment units and neutralization pits will be provided to control water pollution in different water system units. Attempts will be made to achieve zero discharge as far as practicable by making use of bleed water from cooling tower and other effluent water for dust suppression. Waste water generated from different areas of plant will be treated to the desired extent and recycled in the recirculating system as far as possible, facilitating adequate reuse of water. Backwash water generated from different pressure filters will be treated in a treatment plant having sludge disposal facilities. The treated water will be reused in the direct cooling circuit. 06.04 Manpower Requirement The steel plant will not only require management and executive manpower but also, skilled, semi-skilled, unskilled and clerical manpower. However, a number of jobs like major repair and maintenance, cleaning, transportation and loading/unloading of bulk materials, etc. will be done by engaging out side agencies. Considering a labour productivity of 1,100 tonnes of finished steel per man-year, which is at par with international standard, the requirement of total manpower is about 5,000 including power plant. The above number covers the top management, middle and junior level executives and other supporting staff. The above manpower excludes the manpower required for outsourcing of repair and
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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
maintenance jobs of the entire plant and also does not cover the personnel for township, medical facilities, etc. The category wise break-up of manpower is indicated in table 06.01. Table 06.01 Category wise break-up of manpower Sl. No. 1. 2. 3. 4. 5. 6. Category Managerial Executive Skilled Semi-skilled Unskilled Clerical Total Requirement 180 400 1300 1600 1400 120 5,000

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
07 ENVIRONMENTAL MANAGEMENT The proposed units of steel plant would result in air, water and land pollution of varying nature and degree. This chapter briefly outlines the nature and sources of pollution and also suggests broad environmental protection measures to be adopted for limiting pollution within permissible levels. 07.01 Nature of Pollution The additional capacity would comprise various production facilities such as raw material yard, coke oven plant, sinter plant, blast furnace, Steel making & secondary refining, captive power plant, lime & dolo calcining plant, continuous casting, hot rolling mill and cold rolling mill. The inputs to the above facilities will comprise raw materials/in-process materials along with water, fuel and power. These would therefore lead to release of emissions to the air, generation of wastewater and solid wastes. The sources of pollution 07.01. Table-07.01 Sources and Nature of Pollution Facility/Department Raw material yard Sinter plant Pollutants released Fugitive dusts SO2, NOx, dust, heat, noise Heating in cooling water Coke Oven TSP, CO2, NOx, SO2, PAH, heat Type of pollution Air pollution Air pollution & Noise pollution Thermal pollution of water bodies at the outfall Air pollution from the proposed project and the types of environmental pollution likely to occur are summarized in Table-

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
TSP, VOC Oil & grease, phenol, cyanide Blast furnace Sponge Iron Plant Calcining plant Dust, SO2, NOx, heat, noise Dust, SO2, NOx, heat, noise Heat, dust, SO2 & NOx Work zone air pollution Water pollution Air pollution and Noise pollution Air pollution and Noise pollution Air pollution Work zone air pollution Steel Melt Shop Continuous caster Dust, NOx, heat Heat, particulate dust, SO2, NOx, noise Suspended scales, Traces of oil & grease Rolling Mills (HSM & CRM) Heat, particulate dust, SO2, NOx, noise Suspended scales, Traces of oil & grease Power Plant Heat, SO2 & NOx Work zone air pollution Air pollution and Noise pollution Water pollution Air pollution and Noise pollution Water pollution Air pollution Water pollution 07.02 Pollution Prevention and Control Measures In consideration of the above stated pollution potential of the integrated steel plant, suitable mitigation schemes are envisaged in order to control environmental pollution within the permissible norms and keep the environment fairly clean. 07.03 Design Targets The proposed pollution control measures would be designed on the basis of the following criteria:

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report

a.

Characteristics of treated Temperature shall not waste water to be exceed 5oC above ambient discharged to plant drain TSS < 100 mg/l Oil & grease < 10 mg/l BOD < 30 mg/l at 20oC for 5 days COD < 250 mg/l. Stack emissions TSP < 50 mg/N m3 Work zone dust level (8 hrs < 5 mg/m3 TWA) Work zone noise (Leq) 85 dB (A) (Time weighted average of 8 hrs)

b. c. d.

Routine environmental monitoring of stack emission, ambient air quality, work zone air quality, noise level and waste water receiving pond and surface water stream will have to be carried out. The monitored data would be recorded and necessary corrective measures implemented to ensure that design targets are maintained and avoid any non-compliance of Statutory Regulations. 07.04 Plant safety Plant safety measures would form an integral part of the environment protection plan of the proposed plant. Workers safety would be of highest degree of concern so as to avoid any form of personal injury or untoward accident. In-build safety features of the plant and machinery would be made adequate in order to avoid hazardous events causing damage to the life and property.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
07.05 Greenbelt and landscaping Adequate space would be created for gardening and tree plantations to dovetail with the existing greenbelts. This would prevent the fugitive dust emissions. Unpaved areas, if any, within the plant boundary would be provided with grass cover. This would not only act as lung space but would also improve the plant aesthetics.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
08 08.01 PROJECT IMPLEMENTATION General Implementation of capacity enhancement of an Integrated Steel Plant is a challenging task and calls for meticulous planning, scheduling and monitoring to realize the project goals in budgeted time frame. Dovetailing the new units with the existing ones is a great challenge. JSW has an enviable track record for project execution. A highly experienced team has been set up for the purpose through specifically defined responsibilities. 08.02 Schedule The implementation schedule for installation of the proposed Integrated Steel Plant is indicated in the form of bar chart in the drawing no. JSW/DW/PR/006. The overall schedule shows that from the date of start of the project (Zero date), the complete plant will be commissioned in 36 months. The schedule as presented is based upon conventional project implementation logics for Steel Plant, preliminary vendor information available and in-house experience. The schedule of 36 months has been conceived, considering the existing practices and delivery schedule of similar plants & equipment at Dolvi. 08.03 Zero Date The date of start of project activities has been assumed as zero date for installation of the proposed capacity addition at Dolvi.

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JSW ISPAT Steel Limited

Capacity Addition of ISP from 5.0 MTPA to Maharashtra 10.0 MTPA and CPP from 300 MW to 600 MW

Project Report
09 BLOCK CAPITAL COST The estimated block capital cost for the capacity addition to take the integrated steel plant capacity from 5.0 to 10.0 Mtpa is estimated as Rs. 17,000 crores.

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D AREA HELIPA

ATE NG MAI

PR OP OS ED

RA IL W

AY

SI DI NG

STRIP MILL

Y DAR

U BO

UN

BO

R M H S

AREA
IR O

Y AR ND

W L AL

HOT

LF & VD
LCP-3

PLATE MILL

GA GOA

TE

TW

TW

TW

DR PLANT-2

FIN FAN COOLERS

FIN FAN COOLERS

BT3

S
R I V E R

IN

LA N T

OXYGEN PLANT
-1
FU RN AC E

A M B A

IR O ON R E

POWER PLANT 1x53.5 MW

BL AS T

C O C KI O N A G L

FL

U X

H. R. JHONSON PLANT AREA

B A M SE IX

HOT STRIP MILL BLAST FURNACE

COLD ROLLING MILLS

PELLET PLANT-2
P SI N LA T N ER T -2

SMS

LIME PLANT

SINTER PLANT-3

COKE OVEN PLANT-3

POWER PLANT

HARSCO

CEMENT PLANT

MSDS

CAPACITY ADDITION OF ISP FROM 5.0 MTPA TO 10.0 MTPA AND CPP FROM 300 MW TO 600MW AT DOLVI, MAHARASHTRA PROJECT IMPLEMENTATION SCHEDULE
SL. NO. ACTIVITIES DURATION OF ACTIVITY 2 4 6 8 DURATION IN MONTHS 10 12 14 16 18 20 22 24 26 28 30 32 34 36

1 2 3 4 5 6 7 8 9 10 11

Project Approval Basic Engineering Detailed Engineering Tendering, Scrutiny and order placement Planning & construction of Infrastructure facilities Civil works Fabrication & Erection of Structures Delivery of Equipment Erection of Equipment Testing & Commissioning of Steel Plant Production to commence

0 Month 6 Months 29 Months 23 Months 15 Months 30 Months 24 Months 21 Months 20 Months 4 Months -

DRG. NO. JSW/DW/PR/006