PRE-FEASIBILITY REPORT€¦ · INTEGRATED STEEL PLANT WITH CAPTIVE JETTY OF 52 MTPA HANDLING...

PRE-FEASIBILITY REPORT

ON

SETTING UP OF GREENFIELD 13.2 MTPA INTEGRATED STEEL PLANT WITH CAPTIVE JETTY OF 52 MTPA HANDLING CAPACITY

AND 30 MTPA IRON ORE GRINDING & DESLIMING FACILITIES

FOR

JSW UTKAL STEEL LIMITED

AUGUST 2018

JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty

and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report

TABLE OF CONTENTS

Page

- i -

1 - EXECUTIVE SUMMARY ................................................... 1-1

1.1 Iron Ore Grinding & Desliming Plant and Slurry Pipeline ..... 1-2 1.2 Integrated Steel Plant ......................................................... 1-3 1.3 Captive Jetty ...................................................................... 1-4

2 - INTRODUCTION OF THE PROJECT .................................. 2-1

2.1 Identification of the Project and Project Proponent ............... 2-1 2.1.1 Brief Description of the Nature of the Project .................... 2-3 2.2 Need for the Project and Its Importance to the Country ........ 2-4 2.3 Demand-Supply Gap, Imports vs. Indigenous

production, Export possibility & Domestic/ Export Markets ............................................................................. 2-5

2.4 Employment Generation (Direct and Indirect) due to the project ............................................................................... 2-8

3 - PROJECT DESCRIPTION ................................................. 3-1

3.1 Type of Project ................................................................... 3-1 3.2 Location ............................................................................ 3-1 3.3 Details of alternate sites considered and the basis of

selecting the proposed site .................................................. 3-3 3.3.1 Site location - Iron Ore Grinding and Desliming Plant ....... 3-3 3.3.2 Site location - Integrated Steel Plant and Captive Jetty ..... 3-5 3.4 Size or Magnitude of Operation ........................................... 3-9 3.5 Layout ............................................................................... 3-9 3.6 Project Description with Process Details .............................. 3-9 3.6.1 Mineral grinding and desliming ........................................ 3-9 3.6.2 Slurry Pipeline Project ................................................... 3-14 3.6.3 Integrated Steel Plant .................................................... 3-17 3.6.4 Slurry Receiving and Filtration Facilities ........................ 3-19 3.6.5 Pellet Plant ................................................................... 3-20 3.6.6 Coke Oven and By-Product Plant .................................... 3-22 3.6.7 Tar Processing and Benzol Refining Plant ....................... 3-26 3.6.8 Benzol Refining Process ................................................. 3-29 3.6.9 Sinter Plant................................................................... 3-30 3.6.10 Blast Furnace ............................................................... 3-32 3.6.11 Directly Reduced Iron (DRI) Plant ................................... 3-34 3.6.12 Steelmelt Shop .............................................................. 3-35 3.6.13 Lime Calcining Plant...................................................... 3-40 3.6.14 Rolling Mills .................................................................. 3-40 3.6.15 Cement Grinding Unit .................................................... 3-46



TABLE OF CONTENTS (Continued)

Page

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3.6.16 Captive Power Plant ....................................................... 3-46 3.6.17 Raw Materials for ISP & Mineral Grinding and

Desliming Plants ........................................................... 3-46 3.6.18 Captive Jetty ................................................................. 3-50 3.7 Resource Optimization/Recycle & Reuse envisaged in the

project ............................................................................. 3-69 3.8 Availability of Water and Power ......................................... 3-70 3.8.1 Water ............................................................................ 3-70 3.8.2 Power ........................................................................... 3-73 3.9 Waste Generation and Management................................... 3-76 3.9.1 Wastewater generation and management ........................ 3-76 3.9.2 Solid Waste Management ............................................... 3-78 3.9.3 Air Pollution .................................................................. 3-79 3.10 Schematic representations of the feasibility drawing

which give information of EIA purpose .............................. 3-84

4 - SITE ANALYSIS .............................................................. 4-1

4.1 Connectivity ....................................................................... 4-1 4.1.1 Iron Ore grinding and desliming plant .............................. 4-1 4.1.2 Integrated Steel Plant and Captive Jetty ........................... 4-1 4.2 Land Form, Land Use and Land Ownership ......................... 4-2 4.2.1 Iron Ore Grinding and Desliming Units ............................. 4-2 4.2.2 Integrated Steel Plant ...................................................... 4-3 4.2.3 Captive Jetty ................................................................... 4-3 4.3 Topography ........................................................................ 4-3 4.3.1 Iron Ore grinding and de-sliming Plant ............................. 4-3 4.3.2 Integrated Steel Plant and Captive Jetty ........................... 4-5 4.4 Soil.................................................................................... 4-6 4.4.1 Iron Ore grinding and desliming Units .............................. 4-6 4.4.2 Integrated Steel Plant and Captive Jetty ........................... 4-6 4.5 Climatic Conditions ............................................................ 4-6 4.5.1 Iron Ore grinding and desliming Units .............................. 4-6 4.5.2 Integrated Steel Plant and Captive Jetty ........................... 4-6 4.6 Social Infrastructure Available ............................................ 4-7 4.6.1 Iron Ore Grinding and Desliming Units ............................. 4-7 4.6.2 Integrated Steel Plant and Captive Jetty ........................... 4-8

5 - PLANNING BRIEF ........................................................... 5-1

5.1 Planning Concept ............................................................... 5-1 5.2 Population Projection ......................................................... 5-1 5.2.1 Mineral Grinding and Desliming ....................................... 5-1 5.2.2 ISP ................................................................................. 5-1 5.3 Land use planning.............................................................. 5-2




Page

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5.3.1 Iron ore grinding and desliming units ............................... 5-2 5.3.2 Integrated Steel Plant and Captive Jetty ........................... 5-2 5.4 Assessment of Infrastructure Demand ................................. 5-4 5.4.1 Iron ore grinding and desliming units ............................... 5-4 5.4.2 Integrated Steel Plant and Captive Jetty ........................... 5-4

6 - PROPOSED INFRASTRUCTURE ....................................... 6-1

6.1 Industrial Area (Processing Area) ........................................ 6-1 6.1.1 Iron ore grinding and desliming units ............................... 6-1 6.1.2 Integrated Steel Plant and Captive Jetty ........................... 6-1 6.2 Residential Area ................................................................. 6-3 6.3 Greenbelt ........................................................................... 6-3 6.4 Proposed Physical and Social Infrastructure ........................ 6-5 6.4.1 Iron ore grinding and desliming units ............................... 6-5 6.4.2 Integrated Steel Plant and Captive Jetty ........................... 6-6 6.5 Drinking Water Management and Sewage System ................. 6-6 6.5.1 Iron ore Grinding and De-sliming units ............................ 6-6 6.5.2 Integrated Steel Plant ...................................................... 6-6 6.5.3 Captive Jetty ................................................................... 6-7 6.6 Industrial Waste Management ............................................. 6-7 6.7 Solid Waste Management .................................................... 6-7 6.8 Power Requirement and Supply/Source ............................... 6-7

7 - REHABILITATION AND RESETTLEMENT .......................... 7-1

7.1 Iron Ore Grinding and Desliming Units ............................... 7-1 7.2 Integrated Steel Plant and Captive Jetty .............................. 7-1

8 - IMPLEMENTATION SCHEDULE AND COST ESTIMATE ....... 8-1

8.1 Implementation Schedule ................................................... 8-1 8.1.1 Iron Ore grinding and de-sliming units ............................. 8-1 8.1.2 Integrated Steel Plant ...................................................... 8-1 8.1.3 Captive Jetty ................................................................... 8-1 8.2 Capital Cost Estimate ......................................................... 8-2 8.2.1 Plant Cost ....................................................................... 8-2 8.2.2 Margin Money for Working Capital ................................... 8-3 8.2.3 Preliminary and Pre-operative Expenses ........................... 8-3 8.2.4 Interest during Construction ............................................ 8-3 8.2.5 Ore Grinding & Desliming Units plus Slurry Pipeline

Project and the Integrated Steel Plant ............................... 8-4 8.2.6 Captive Jetty ................................................................... 8-6




Page

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9 - ANALYSIS OF PROPOSAL................................................ 9-1

9.1 Financial Benefits of the Project .......................................... 9-1 9.2 Social Benefits ................................................................... 9-1

TABLES

Table 2-1 - Forecasted capacity and demand of steel by 2030-31 .......... 2-6 Table 2-2 - Major Market Segments - 2030 .......................................... 2-8 Table 3-1 - Evaluation of the sites based on multiple criteria ............... 3-4 Table 3-2 - Evaluation of the sites based on multiple criteria ............... 3-6 Table 3-3 - Evaluation of the sites based on multiple criteria ............... 3-8 Table 3-4 - Central terminal facility and pipeline system at joda......... 3-17 Table 3-5 - Major plant units and facilites ......................................... 3-18 Table 3-6 - Design Basis of Pellet Plants ........................................... 3-21 Table 3-7 - Typical Analyses of Raw Materials for Pellet Production .... 3-21 Table 3-8 - Basic design parameters of coke oven .............................. 3-23 Table 3-9 - Coal Blend Quality .......................................................... 3-23 Table 3-10 - Coke Quality ................................................................. 3-24 Table 3-11 - Major Units of coke oven ............................................... 3-24 Table 3-12 - Production from coke oven (Dry basis) ........................... 3-25 Table 3-13 - Products from Tar Distillation & Benzol Refining Plant ... 3-26 Table 3-14 - Design Basis of Sinter Plants ......................................... 3-30 Table 3-15 - Typical Analyses of Raw Materials for Sinter

production .............................................................. 3-31 Table 3-16 - Design Basis of Blast Furnace ....................................... 3-32 Table 3-17 - Typical Raw Materials Analysis (Dry Basis) ..................... 3-33 Table 3-18 - Estimated Annual requirements of Major Raw

Materials ................................................................ 3-49 Table 3-19 - Projected Traffic for the Captive Jetty ............................ 3-50 Table 3-20 - assumed Ship sizes for various products ........................ 3-51 Table 3-21 - Ship Calls ..................................................................... 3-52 Table 3-22 - Average Ship size and number of trips ........................... 3-54 Table 3-23 - Number of berths and unloading rate for each

commodity .............................................................. 3-55 Table 3-24 - Number of berths and the unloader capacity .................. 3-56 Table 3-25 - Width calculations for approach channel ........................ 3-57 Table 3-26 - Joda Unitwise requirement of Water ............................... 3-70 Table 3-27 - Captive Jetty - requirement of Water .............................. 3-71 Table 3-28 - ISP Unitwise requirement of Water ................................. 3-72 Table 3-29 - Estimated electricity load for the proposed jetty ............. 3-73 Table 3-30 - Power Requirement ....................................................... 3-75 Table 3-31 - Solid Waste Generation from the ISP .............................. 3-79




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Table 8-1 - Estimated Capital Cost for the Grinding & Desliming Plants at Joda and Slurry Pipeline from Joda to ISP near Paradeep ..................................................... 8-4

Table 8-2 - Estimated capital cost for the ISP ...................................... 8-5 Table 8-3 - Estimated Capital Cost for the Captive Jetty ...................... 8-6

FIGURES

Fig. 3-1 - Glimpse of the project sites (ISP with captive Jetty) ............... 3-3 Fig. 3-2 - Iron ore grinding and Desliming Units .................................. 3-3 Fig. 3-3 - Locations of the three sites .................................................. 3-7 Fig. 3-4 - The Route of Slurry Pipeline System ................................... 3-15 Fig. 3-5 - Channel depth components ................................................ 3-60 Fig. 3-6 - Section of the Breakwater .................................................. 3-64 Fig. 3-7 - Schematic Diagram ........................................................... 3-85 Fig. 4-1 - Map showing road and railway connectivity .......................... 4-2 Fig. 4-2 - Topographic Features of grinding and desliming plant

site at joda ............................................................... 4-4 Fig. 4-3 - Topographic Features of Integrated Steel Plant and

Captive Jetty site near Paradeep ................................ 4-5 Fig. 8-1 - Implementation Schedule .................................................... 8-1 Fig. 8-2 - Implementation Schedule .................................................... 8-1



1-1

1 - EXECUTIVE SUMMARY

JSW Utkal Steel Ltd. (JUSL), a wholly owned subsidiary of

JSW Steel Ltd., intends to set up 13.2 MTPA Integrated Steel Plant (ISP)

with captive jetty in Jagatsinghpur district and 30.0 MTPA Iron Ore

Grinding & Desliming Plant in Keonjhar district, Odisha with an

objective to expand its operation in Odisha.

Odisha, with its significant iron ore reserve and long

coastline offers an ideal location for setting up a steel plant. Geographic

proximity to potential coal mines in Jharkhand provides additional

logistics advantage for steel manufacturing. The iron ore belt of Odisha

is well connected by highways, which provides suitable infrastructure to

transport the iron slurry through slurry pipeline, considered to be the

most environment friendly and economic mode of conveying iron ore.

JUSL has proposed to set up a Greenfield ISP to produce

13.2 MTPA crude steel along with captive power plant (CPP) of 900 MW

capacity and cement grinding & mixing unit of 10.0 MTPA in

Jagatsinghpur district, near Paradeep in Odisha. JUSL also intends to

set up 30.0 MTPA iron ore grinding & de-sliming plant near Joda in

Keonjhar district of Odisha and iron ore slurry pipeline of approximate

length of 312 km from Joda to the ISP site near Paradeep to transport

the iron ore slurry. This slurry would be dewatered in the steel plant for

production of pellet. The pellet thus produced would be used as burden

in the blast furnaces of the proposed steel plant as well as transferred to

other units of JSW Steel Ltd. across India.



1 - Executive Summary (cont’d)

1-2

The ISP would be served by a Captive jetty of handling

capacity of 52.0 MTPA, to be located adjacent to the steel plant near the

mouth of Jatadharmohan River Creek. The captive jetty would cater to

the import and export requirements of the ISP helping it reduce the

infrastructure cost for the production of steel.

High Level Clearance Authority (HLCA), Government of

Odisha (GoO) has in-principle approved JSW's proposal in its meeting

dated 02.06.2017 held under Chairmanship of Hon’ble Chief Minister

for setting up the of ISP Greenfield Project with an investment of about

Rs. 65,000 crore. The approval for establishment of the Captive Jetty is

awaited.

The following section presents a brief outline of the

Pre-Feasibility Report (PFR) for the proposed plan for setting up of the

aforementioned proposed projects.

1.1 IRON ORE GRINDING & DESLIMING PLANT AND SLURRY

PIPELINE

Project Profile Iron ore grinding & desliming plant .. 30.00 MTPA Iron Ore Slurry pipeline (312 km) .. 30.00 MTPA

Products Processed Iron ore concentrate slurry .. 30.00 MTPA

Location Govardhanpur village near Joda in Keonjhar District, Odisha.

Major Facilities with Production capacity

- 2 Nos. Module of grinding & desliming facilities to produce 20.00 MTPA iron ore concentrate

- 1 No. module of grinding facility to produce 10.00 MTPA iron ore concentrate

- Pumping system for conveying 30.00 MTPA iron ore slurry via 312 km pipeline from Joda to the ISP site near Paradeep

Water consumption

2,940 m3/hr (15.5 MGD)

Water source Baitarani river

Power source & requirement

Annual energy consumption - 712 X 106 kWh, sourced from JSW Energy / grid power supply system (OPTCL)

Land details Abt. 391.93 acres (out of which 130.53 acre forest land), including about 120 acre for dry disposal of slime. About 47% of 391.93 acres already registered leased land

Employment generation

Construction phase - Around 700 workers, Operation phase - Approximately 175-200 direct employment

Implementation Schedule

45 months from ‘Go-ahead’ date

Capital Cost Around INR 4,243 Crore




1-3

1.2 INTEGRATED STEEL PLANT

Project Profile Crude Steel .. 13.20 MTPA Pellet Plant .. 32.00 MTPA Cement (Grinding & Mixing) .. 10.00 MTPA Captive power .. 900 MW

Products for Sale Pellet .. 14.81 MTPA DRI .. 0.38 MTPA

Hot Rolled Coils .. 3.63 MTPA Plates .. 1.18 MTPA Cold rolled products .. 3.98 MTPA (Cold rolled annealed & galvanized coil, colour coated coil) Tinplate .. 0.45 MTPA Silicon Steel .. 0.50 MTPA Long Products .. 2.80 MTPA (Rebar, Wire Rod, Medium sections)

Location Within Ersama Tehsil, near Paradeep of Jagatsinghpur District, Odisha.

Major Facilities

with Production capacity

Slurry dewatering system 30.0 MTPA

Coke oven 6.0 MTPA

Sinter plant 6.0 MTPA

Pellet plant 32.0 MTPA

DRI 1.2 MTPA

Blast furnace 13.5 MTPA Steelmaking Shop (SMS) 13.49 MTPA

Caster Shop 13.2 MTPA

Flat Products 9.74 MTPA

Long Products 2.8 MTPA

Calcining Plant 1.1 MTPA

Cement Plant 10.0 MTPA

Captive Power Plant 900 MW

Air Separation Plant 12,600 TPD TPD Tar processing plant 300,000 TPA

Benzol Refining Plant 100,000 TPA

Major Raw

Materials

Coking coal, Iron ore (lump, concentrate & fines), PCI coal,

Limestone, Dolomite, Clinker, Steam coal

Water consumption

9,200 m3/hr (48.58 MGD)

Water Source Jobra barrage of Mahanadi river


Annual energy consumption - 10,914 X 106 kWh, sourced from captive generating units & State Power Grid

Land details 2,980 acres (100% Government land)


Construction phase - Around 12,000-15,000 casual and contract workers

Operation phase - Approximately 12,000 direct employment



Capital Cost Around INR 65,000 crore




1-4

1.3 CAPTIVE JETTY

Project Profile Captive Jetty (Handling capacity) .. 52.00 MTPA

Location Mouth of Jatadharmohan River creek in Jagatsinghpur district, Odisha

Major Facilities - 10 Nos. Berths/Jetties - Material handling equipments including conveyers, stacker

reclaimers,etc - Breakwater

Water source & requirement

87.5 cu m/hr from the total water allocated to the ISP


Peak demand - 9.5 MW/10,000 KVA, sourced from OSEB

Land details Abt. 180 acres (100% Govt. land)


Construction phase - Around 1,000 workers, Operation phase - Approximately 350 direct employment



Capital Cost Around INR 2,104 crore

With regard to social infrastructure, the proposed projects

would emphasize on development & strengthening of shared physical

infrastructure comprising of roads, railway linkages, potable water

facilities and cyclone shelters. Additionally, focus would lie on

strengthening of scholastic education and vocational training.

Thus the projects in Odisha would employ around 16,000

workers in the construction phase and generate around 12,500 direct

employment opportunities in the operational phase. The projects are

expected to be completed within 84 months from ‘Go-ahead’ date.



2-1

2 - INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

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

total crude steel production of around 101.0 MTPA (Million Tons per

Annum) in the 2016-17. Indian economy is rapidly growing with

enormous focus on infrastructure and construction sector, promoting

further growth of steel industry.

JSW Steel Ltd. (JSW) currently produces about 18.0 MTPA

steel in their plants in Karnataka, Tamil Nadu & Maharashtra and are

scaling up the existing plants as well as new projects to attain a level of

40.0 MTPA by 2030. Globally, JSW owns a plate and pipe mill in the US,

and also mining assets in the US, Chile and Mozambique. JSW have

integrated cutting-edge technology, innovation, R&D with sustainability

and community initiatives in their journey of development.

JUSL is a wholly owned subsidiary of JSW Steel Ltd.,

established with an objective to expand its operation in Odisha. This

State has significant iron ore reserve and long coastline offers an ideal

location for setting up a steel plant. Geographic proximity to potential

coal mines in Jharkhand provides additional logistics advantage for steel

manufacturing. The iron ore belt of Odisha is well connected by

highways, which provides suitable infrastructure to transport the iron

slurry through slurry pipeline, considered to be the most environment

friendly and economic mode of conveying iron ore.



2 - Introduction of the Project (cont’d)

2-2

JUSL has proposed to set up an ISP to produce 13.2 MTPA

crude steel along with Captive Power Plant CPP of 900 MW capacity and

Cement grinding & mixing unit of 10.0 MTPA in Jagatsinghpur District,

near Paradeep in Odisha.

JUSL also intends to set up iron ore grinding & de-sliming

plant near Joda in Keonjhar district) of Odisha and 30.0 MTPA iron ore

slurry pipeline from Joda to the ISP site near Paradeep to transport the

iron ore slurry. This slurry would be dewatered in the steel plant for

production of pellet. The pellet produced would be used as burden in the

Blast Furnaces of the proposed steel plant as well as transferred to other

units of JSW Steel Ltd. across India.

The ISP would be served by a captive jetty of handling

capacity of 52.0 MTPA, to be set up adjacent to the steel plant near the

mouth of Jatadharmohan River Creek alongside the creek water front.

The captive jetty would cater to the import and export requirements of

the ISP helping it reduce the infrastructure & logistics cost for the

production of steel. However the units like cement grinding and mixing,

captive jetty and tar & benzol refining units will be built and operated by

the group verticals.




2-3

2.1.1 Brief Description of the Nature of the Project

The brief profile of the projects is as follows:

Iron ore grinding & desliming plant .. 30.00 MTPA

Iron Ore Slurry pipeline (312 km) .. 30.00 MTPA

Integrated Steel Plant with cement plant and CPP

- Crude Steel .. 13.20 MTPA - Pellet Plant .. 32.00 MTPA

- Cement (Grinding & Mixing) .. 10.00 MTPA

- Captive power .. 900 MW

Captive Jetty (Handling capacity) .. 52.00 MTPA

Saleable products

Pellet .. 14.81 MTPA

DRI .. 0.38 MTPA

Hot Rolled Coils .. 3.63 MTPA

Plates .. 1.18 MTPA

Cold rolled products .. 3.98 MTPA (Cold rolled annealed & galvanized coil, colour coated coil)

Tinplate .. 0.45 MTPA

Silicon Steel .. 0.50 MTPA

Long Products .. 2.80 MTPA (Rebar, Wire Rod, Medium sections)

The proposed production of crude steel and subsequent

rolling would be accomplished via blast furnace (BF)-basic oxygen

furnace (BOF)-caster route, followed by hot & cold rolling and further

value addition by galvanizing, colour coating, annealing, tin plating and

production of silicon steel. Long products such as bar, wire rods and

medium sections would also be produced.

The ISP would fall under category A, Section 3 (a), mineral

grinding & desliming facilities under Category A, Section 2 (b) & captive

jetty under Category A, Section 7 (e) of EIA Notification September 2006

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

1st December 2009. The slurry pipeline of length about 312 km from

Joda to the steel plant site near Paradeep is not passing through any

ecologically sensitive area.




2-4

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY

In 2016-17, production of crude steel was about 101.0 MTPA

with a growth of approximately 10.5% over 2015. India’s per capita steel

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

The Government of India has set pragmatic target of achieving per capita

steel consumption of 158 kg by 2030-31 requiring a crude steel

production of 255 MT and capacity of 300 MT.

Indian economy is rapidly growing with key focus on

infrastructure and construction sector. Several initiatives mainly,

affordable housing, expansion of railway networks, development of

domestic shipbuilding industry, opening up of defense sector for private

participation, and the anticipated growth in the automobile sector, are

expected to create significant demand for steel in the country.

Major factors which carry the potential of raising the per

capita steel consumption in the country are listed below:

i) Infrastructure improvement initiatives, such as ‘Smart

Cities project’, 'Housing for All by 2022', ‘Atal Mission for Rejuvenation and Urban Transformation (AMRUT)’,

ii) Manufacturing growth driven by Make-in-India initiative,

iii) Encouraging use of Made in India steel for various projects and levying of anti-dumping duties on certain steel products from Brazil, Russia, China, Korea and Indonesia.

iv) National Mineral Development Corporation expected to increase the iron ore production favoring steel production

v) Emergence of the rural market for steel buoyed by projects like MGNREGS, development of ‘Rurban Clusters’ under the Shyama Prasad Mukherjee Rurban Mission, Pradhan Mantri Gram Sadak Yojana, among others.




2-5

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

achieve expected demand of 300 MT and per capita consumption of

160 kg of finished steel by 2030-31, steel demand would need to grow at

a CAGR of around 7-7.5 per cent during the period against a CAGR of

3.5 per cent - 4 per cent over the last 5 years. This would mean that

capacity additions planned by most of the major steel players need to

come on stream in next few years.

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

added steel-CRGO, special steel, and alloys and focuses on pelletisation

and installation of slurry pipelines and conveyors with an emphasis on

BF/BOF technology.

NSP 2017 also promotes the establishment of steel plants

along the coast under the aegis of Sagarmala project would be

undertaken based on the idea of importing scarce raw materials and

exporting steel products.

The concept of the proposed project is aligned with the

current progress plan of the country.

2.3 DEMAND-SUPPLY GAP, IMPORTS VS. INDIGENOUS PRODUCTION, EXPORT POSSIBILITY & DOMESTIC/

EXPORT MARKETS

Total national consumption of finished steel was 83.5 MT in

FY16. Driven by rising infrastructure development, growing demand for

automotives and lower per capita consumption compared to international

average, steel consumption is expected to reach 104 MT by the end of

2017. World Steel Association (WSA) has projected a growth of Indian

steel consumption of 7.1% at 94.91 MT in 2018, one of the highest

growing among the global steel producers.

The projected demand and capacity as per NSP 2017 would

be is as shown in Table 2-1.




2-6

TABLE 2-1 - FORECASTED CAPACITY AND DEMAND OF STEEL BY 2030-31

Sl. No. Parameters

Projections (2030-31), MT

1 Total crude steel capacity 300

2 Total crude steel demand/production 255

3 Total finished steel demand/production 230

4 Per capita finished steel consumption, kg 158

Source : NSP 2017 The import vs. export of steel for the last few years is presented

below:

Industry Steel Industry: Import vs Export, MT

Total

Finished

Steel

2013-14 2014-15 2015-16 2016-17 2017-18

5.45 5.99 9.32 5.59 11.71 4.08 7.23 8.24 7.482 9.62

Source : Joint Plant Committee Website : Ministry of Steel

From the above table it can be seen that over the last few

years, the gap between imports and exports have gradually declined due

to various factors like increase in minimum import price &

implementation of a more stringent anti-dumping policy and there has

been a net export of steel in the last financial year. The National Steel

Policy (NSP) 2017 aims to increase export of steel and reduce import by

2030-31. As of March 2017, the capacity utilisation of steel producers is

set to increase with strong export demand and signs of revival in

domestic sales.

Steel products find application in multifaceted sectors

mainly dominated by areas of infrastructure & transport. Among the

many drivers of demand, the following are having maximum influence in

triggering consumption of finished steel products like bars & rods,

structural and plates:




2-7

Product/Category Application

Bars & Rods

Infrastructure - House Building

Fasteners & Wires

Bright Bars

Industry

Structural Infrastructure - High-rises

Industrial Construction

Plates

Infrastructure - Bridges

Railways - Wagons, Coaches, Tankers

Industrial Construction

Defense Production

Energy - Boilers, Pressure Vessels, Penstocks

HR Products

Tube making industry

Railways - Wagon & Coach

Automobiles

Industrial Machinery

CR Products

White goods - Refrigerators, Air-conditioners

Automobiles

Silos & Containers

Precision Tubes

Furniture

Galvanized, Coated,

Tin Plate, Silicon

Steel (NGO)

Automobiles

Consumer durables

Food Industries

Electrical Appliances & machine

Construction

Packaging & Furniture

The NSP 2017 provides an overview of the segmental

composition of the projected Indian market for the year 2030-31 with

quantitative estimates of the likely demand and their associated growth

rates adopted for the study. A summary of the leading segments of the

domestic market is furnished in the Table 2-2.




2-8

TABLE 2-2 - MAJOR MARKET SEGMENTS - 2030

Market Segments

Demand

(Million Tons) % Share

Infrastructure (Project Construction)

90 39%

Construction

(Real Estate & Buildings) 45 20%

Engineering & Fabrication 43 19%

Energy 11 5%

Automotive 10 4%

Sub-total (Major Segments) 199 87%

Other Segments (Railways, Ship Building,

Defense, Gas Pipelines,

Packaging etc.)

31 13%

Total 230 100%

Source: NSP 2017

Barring project construction, other ‘heavy-weight’ or steel

intensive market segments like building construction, engineering and

fabrication etc. need not necessarily grow at rates faster than those of

the other comparatively less steel intensive segments. The segments like

automotives, defense production, ship building, and gas pipelines hold

out lot of promise for the future of steel demand with near double digit

annual growths.

2.4 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

In the construction & operation phases of the proposed

projects, both direct & indirect deployment of local work force would be

facilitated.




2-9

For the proposed mineral grinding & desliming plant to be

located in Gobardhandpur (Joda Block), it is estimated that around

700 contract workers would be required, during the phase of

construction. Consequently, in the operation phase approximately

175-200 direct personnel would be employed. In this phase, in addition

to direct employment, under the scope of indirect employment

opportunities 250-300 workers would be engaged.

In addition, for the jetty construction around 1,000 people

both semi-skilled and skilled people would be deployed. In the operation

phase, around 350 permanent employees and around 750 contract

employees would be required for the functioning of the jetty.

With respect to the proposed Integrated Steel Plant, i t is estimated

that there would be a requirement of around 12,000 to

15,000 casual and contract workers, during the phase of construction.

Subsequently in the operation phase, approximately 12,000 employees

would be directly employed. However, there will be indirect employment

of about 45,000 employees.



3-1

3 - PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed greenfield project would comprise the

following:

i) 30.0 MTPA Iron Ore concentrate by grinding and de-

sliming at Joda ii) 30.0 MTPA Slurry pipeline of 312 km from Joda to ISP iii) ISP of 13.2 MTPA crude steel capacity via

BF-BOF route and other associated facilities including:

a) Captive generation of 900 MW of power based on by-product fuel gases & coal (dual firing)

b) Grinding & mixing unit to produce 10.0 MTPA slag/fly ash cement

c) Air separation plant of 12,600 TPD total capacity

d) Tar and Benzol processing plant of 300,000 TPA capacity

iv) A captive jetty of handling capacity 52.0 MTPA

3.2 LOCATION

The proposed Iron Ore grinding & grinding & desliming units

would be located near Joda in Keonjhar district of Odisha. The

geographical location of the project site at Joda (near Govardhanpur

village) lies within 22003’27” to 22004’42” North latitude and 85027’24” to

85028’25” East longitude.

The proposed ISP with captive jetty site is located on the

north western bank of Jatadharmohan River Creek, within the

jurisdiction of Ersama Tehsil of Jagatsinghpur district of Orissa. The

site lies on the western bank of Jatadharmohan River Creek and is about



3 - Project Description (cont’d)

3-2

12 km south of Paradeep Port. The geographical location of the ISP with

captive jetty lies within 20011’ to 20013’ North latitude and 86030’ to

86035’ East longitude.

There are two small rivers between the Mahanadi and the

Devi, called the Patakund and the Jatadharmohan. These two small

streams between the larger rivers to the north and the south cater to

their small basins. Jatadharmohan River discharges in to a creek, where

the proposed Jetty would be located. A glimpse of the project sites,

mineral grinding & desliming plant, ISP with captive jetty is shown in

Fig. 3-1 and Fig 3-2 respectively.

FIG. 3-1 - IRON ORE GRINDING AND DESLIMING UNITS




3-3

FIG. 3-2 - GLIMPSE OF THE PROJECT SITES (ISP WITH CAPTIVE JETTY)

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE

3.3.1 Site location - Iron Ore Grinding and Desliming Plant

As mentioned earlier, the proposed Iron Ore grinding and

desliming unit with slurry pumping station would be located near Joda

to transport 30.0 MTPA iron ore slurry to the ISP located near Paradeep

in Jagatsinghpur district of Odisha. The following factors were

considered in selecting the above mentioned location:

i) Proximity to the iron ore mines with abundant reserve ii) Quality of iron ore available in these mines are in

conformity to the requirement ii) Availability of adequate land and other infrastructure

including water and power




3-4

In order to set up Iron ore grinding & de-sliming plant, three

potential sites have weighed against few critical factors for selection of

the most suitable site. The evaluation of the site for grinding and

de-sliming unit is presented in Table 3-1.

TABLE 3-1 - EVALUATION OF THE SITES FOR GRINDING & DE-SLIMING UNIT BASED ON MULTIPLE CRITERIA

Parameters

Site 1

Kasia (Bhadrasahi)

Site 2

Gobardhanpur (Joda)

Site 3

Basudevpur- Champua Road

Tahasil/District Barbil - Keonjhar Barbil - Keonjhar Champua - Keonjhar

Distance from nearest village

Village - Serenda - 0.2 km

Village - Gobardhanpur - 1 km

Kodagadia - 1.1 km

Distance from the NH & SH

NH-520 - 2 km NH-520 - 1 km NH-520 - 2.5 km

Distance from nearest

Railway station

Barbil - 10 km

Deojhar - 1km

Parjanpur - 5 km

Nearest town Barbil - 1 km Joda - 10 km Palashponga -2.5 km

Land Availability for

plant and machinery About 120 Ac. About 200 Ac. About 50 Ac.

Whether homestead involved

Yes Nil Yes

Nearby Mines (Working

& Upcoming)

WM- 08 Nos. WM- 10 Nos. Nil

UCM - 6 Nos. UCM - 6 Nos. Nil

Proximity to ecological sensitive zone

None within 10 km None within 10 km None within 10 km

Nearest Power Source for Construction power

Available in 5 km Available within 2 km Available in 12.5 km

Proximity to mines Within 01-10 km Within 5-10 km 20-25 km away

Nearest water intake

point

Around 23 km from

Baitarni river as from Karo not permitted

Around 8 km

(Batarani river)

Around 5 km

(Baitarani)

Proximity to nearest tailing storage area

15 - 20 km 3.5 km 15-20 km

Availability of IDCO land

Not Available Available Not Available

Forest area About 100 acres Nil About 50 acres

Forest area type Protected & Village

Forest -

Village & Protected Forest

Whether under Mining lease area

Yes No No

Whether Mineral bearing area

Yes No No

Conclusion Not Suitable

Most Suitable as it is non mineral bearing

area, non forest area and

proximity to source of raw materials, water,

power and suitable from logistics point of view.

Not suitable




3-5

3.3.2 Site location - Integrated Steel Plant and Captive Jetty

A site selection study for the ISP had been carried out at

three possible locations. The following major factors have been

considered while evaluating the sites for selecting the most suitable

options:

i) Availability of adequate land for installation of the units.

ii) Availability of suitable infrastructure in terms of

connectivity, water and power. iii) Proximity of the sites for setting up of captive jetty for

incoming and outgoing materials. iv) Availability of iron ore and coal due to proximity to the

mineral belts of Odisha & Jharkhand.

The analysis of various criteria for selecting the most

suitable location is presented in Table 3-2.




3-6

TABLE 3-2 - EVALUATION OF THE SITES FOR ISP BASED ON MULTIPLE CRITERIA

Criteria Site 1 - Dhamra with

captive jetty

Site 2 - Kalinganager

with Captive Jetty at Paradeep

Site 3 - Paradeep with

captive jetty

Availability of

Land

Adequate (abt. 3500 acre)

land not available for 13.2 MTPA ISP with captive jetty

Adequate (abt. 3500 acre)

land not available for 13.2 MTPA ISP

Required land available

in possesion of Government

Site features Location in vicinity of the coast, low lying and

inundation prone specially during monsson, proximity to Gahirmatha marine Sanctuary

Location away from the coastline & Industrial

zone,

Location in vicinity of the coast, Low lying

non agricultural waste land

Infrastructure Adequate land for setting

up of captive jetty not available. Lack of infrastructure like

rail & road network to adequately serve new ISP. Present infrastructure

adequate only for Dhamra Port

- Distance to nearest

port (Paradeep) is abt 145 km. Location of feasible site for setting up captive jetty is

100-150 km away - Kalinganager is an

industrial area having

over 5 Nos ISP with over 12 MTPA combined Capacity. The load on the

existing infrastructure is very high and expansion of existing

infrastructure is not feasible

- Adequate land

available for setting up captive jetty adjacent to the ISP thus minimizing the

logistic cost - Govt. of Odisha is

developing Corridor

from Haridaspur-Paradip and the potential for utilization of existing

infrastructure and expansion of the same is high

Handling/storage area requirement

Common storage yard for ISP & captive jetty due to contiguous location

Additional requirement of land for raw material/finished

product handling and storage at jetty

Common storage yard for ISP & captive jetty due to contiguous

location

Raw material source & linkage

Possible source of major raw materials (Iron ore & Coal) is Odisha &

Jharkhand for which adequate linkage available

Possible source of major raw materials (Iron ore & Coal) is Odisha &

Jharkhand for which adequate linkage available

Possible source of major raw materials (Iron ore & Coal) is

Odisha & Jharkhand for which adequate linkage available

Conclusion Not Suitable due to inadequate land

availability and proximity to ecologically sensitive area

Not Suitable due to inadequate land

availability, limited scope for infrastructure development and higher logistics cost.

Most suitable due to availability of adequate

land area, contiguity with the jetty and potential for infrastructure

development.




3-7

High Level Clearance Authority (HLCA), Government of

Odisha (GoO) has in-principle approved JSW's proposal in its meeting

dated 02.06.2017 held under Chairmanship of Hon’ble Chief Minister

for setting up the of ISP Greenfield Project with an investment of about

Rs. 65,000 Crore. The 77th State Level Single Window Clearance

Authority (SLSWCA) Govt of Odisha, has in principle approved JSW’s

proposal for setting up of captive jetty in the District of Jagatsinghpur

with an investment of Rs 2103 Crore wide its letter No COM-PORT-

CORSP-0004-2018/3539/Com, Bhubaneswar dated 8 th August 2018.

The most important consideration for choosing a site for a

jetty is its proximity to the proposed Industry. As already mentioned

earlier, the jetty is primarily being developed for handling of the Captive

cargo of the ISP including the 900 MW power plant and the cement-

grinding unit.

Three locations were evaluated for site selection for setting

up of the jetty. The location of the three sites is presented in Fig. 3-3.

The evaluation of the sites based on multiple criteria is presented in

Table 3-3.

FIG. 3-3 - LOCATIONS OF THE THREE SITES




3-8

TABLE 3-3 - EVALUATION OF THE SITES FOR CAPTIVE JETTY BASED ON MULTIPLE CRITERIA

Criteria Site 1 Site 2 Site 3

Location South of the Paradip Port by about 7 km, fronted with a well-

developed beach.

Seaward side of the Jatadharmohan River creek, on a stable sand

spit River.

Mouth of Jatadharmohan creek, along the riverfront, adjacent to the proposed ISP

Depths

available

12 km approach channel available

meeting 20m depth requirement

12 km approach channel available meeting 20m

depth requirement

14 km approach channel available meeting 20 m depth

requirement

Sedimentation Breakwater of jettys to

have large-scale sediment accumulation on the southern side and

erosion on the northern side of the coast

Breakwater of jettys to

have large-scale sediment accumulation on the southern side and erosion on the

northern side of the coast

Due to no obstruction to the flow

regime, the sedimentation of littoral drift is minimal

Protection from

Waves

To be done through reclamation of dredged material and protected by adequate

breakwater

To be done through reclamation of dredged material and protected by adequate breakwater

Location advantage in protection from direct waves except during cyclonic surges, to be prevented by design of unique berth

location. Breakwater protection may not be required except for providing tranquility near the entrance of the jetty

Sub Soil Sandy along with rock- Dredging

difficult and expensive

Mostly sandy-Dredging less difficult and

expensive

Mostly sandy-Dredging less difficult and expensive

Back up Land land to be created by reclamation between the breakwater

protections

land to be created by reclamation between the breakwater protections

located fronting on an existing land mass designated for setting up the ISP

Connectivity - Connectivity to the

existing road/rail network available

- About 5 km from proposed ISP

- Connectivity to the

existing road/rail network available

- Linkage would require constructon of bridge

over the Jatadharmohan River

- Connectivity to the existing

road/rail network available - Advantageous in terms of

proximity to the proposed ISP

Environmental Concerns

- No habitation, vegetation,

agriculture - Far from

Gahirmatha sanctuary

- Impact on the environment due to changes in coastal morphology due to

erosion & accretion

- No habitation, vegetation, agriculture

- Far from Gahirmatha sanctuary

- Impact on the environment due to

changes in coastal morphology due to erosion & accretion

- No habitation, vegetation, agriculture

- Far from Gahirmatha sanctuary

- Less Impact on the environment due to location

on the mouth of the creek, away from the shoreline

Cost Higher cost due to

large scale dredging, creation of breakwater

Higher cost due to large

scale dredging, creation of breakwater

Lesser cost since breakwater

required only for creation of tranquil zone




3-9

Site 3, at mouth of Jatadharmohan river Creek was found

suitable due to its proximity to the proposed ISP, location inside the

mouth of river (creek) away from the shoreline and other suitable

factors indicated above.

3.4 SIZE OR MAGNITUDE OF OPERATION

The proposed project would include production of 30.0 MTPA

Iron Ore slurry along with laying of slurry transport pipeline of total

length of about 312 km for transportation of the slurry from Joda to the

ISP at Paradeep. The ISP would produce 13.2 MTPA crude steel and

about 11.95 MTPA saleable flat and long rolled products along with 32

MTPA pellets, 900 MW of captive power & 10.0 MTPA cement (grinding &

mixing facilities). The project would also consist of setting up of a captive

jetty of handling capacity of 52.0 MTPA to cater to import of raw

materials & export of finished products.

3.5 LAYOUT

The plant general layout of the proposed grinding and

desliming plant near Joda is shown in Drg. No JSWUSL/OD/0003. The

plant general layout of the proposed ISP is shown in Drg. No.

JSWUSL/OD/0001 & the layout of the captive is jetty shown in Drg. No.

JSWUSL/OD/0002.

3.6 PROJECT DESCRIPTION WITH PROCESS DETAILS

3.6.1 Mineral grinding and desliming

Keeping in view the availability of desired quality of iron ore

to feed the proposed pellet plant at ISP, JSW plans to install 30.0 MTPA

grinding and desliming plant near Joda, and slurry pipeline for

transportation of iron ore concentrate from Joda site to the proposed ISP

site near Paradeep in Jagatsinghpur district of Odisha.




3-10

The plant would be installed in three modules, each module

having a capacity to produce 10.0 MTPA of pellet feed concentrate.

Module-1 and Module-2 would have grinding and desliming facilities and

Module-3 would have grinding facilities only. The modules would be

designed to treat iron ore fines of size (-)10 mm with grades ranging from

62 to 63 per cent Fe. The plant is envisaged to produce pellet feed

concentrate ranging from 63 to 64 per cent Fe. The brief description of the

processes is presented below:

Grinding and Desliming Plants (Module-1 and Module-2):

The iron ore fines of (-)10 mm size procured from different mines would

be reclaimed from the stockpile within the plant boundary to be treated

in two modules of grinding and desliming plants, each module

comprising of two circuits of capacity 5.20 MTPA (dry basis) each. The

iron ore fines in each circuit would be de-slimed in set of primary screw

scrubbers to separate 150 microns (µm) ultrafines in the feed material

and the de-slimed product (sands) of size (-)10(+)0.150 mm would be fed

to a vibrating screen for separation of 1 mm particles. The oversize of

the vibrating screen of size (+)1 mm would be ground to (-)1 mm in a

primary ball mill. The ground product would be treated in secondary

screw scrubbers for separation of 150 microns (µm) particles obtained as

overflow of the screw scrubbers. The overflow material from the screw

scrubbers of size (-)150 microns would be pumped to the concentrate

thickener and the sands obtained would be treated in the vibrating

screen for separation of 1 mm particles.

The undersize of the vibrating screen of size (-)1 mm would

be pumped to the regrinding circuit comprising of hydrocyclones and

derrick stack sizer screens to scalp out the (-)0.1 mm fractions in the

undersize product. The oversize of the stack sizer screens at (+)0.1 mm

would be fed to a regrind ball mill for final grinding to (-)0.1 mm. The




3-11

regrinding ball mill would be working in close circuit with the

hydrocyclones and derrick screens. The overflow of the hydrocyclones

(d80 = 0.1 mm) and the underflow of the derrick screens would be treated

in a concentrate thickener for recovery of usable water.

The (-)150 µm ultrafines obtained as overflow from the

primary screw scrubbers of each circuit, would be deslimed at 45 µm in a

desliming hydrocyclone to obtain a concentrate as underflow which

would subsequently be fed to a concentrate thickener by gravity. The

slimes of size (-)45 µm obtained as overflow from the desliming

hydrocyclones would be treated in an attrition scrubber for surface

conditioning via an intermediate thickener. Surface conditioning of

slimes is required for effective magnetic separation. The conditioned

slimes from the attrition scrubber, after treatment in a linear screen for

removal of any foreign material, would be upgraded in wet high intensity

magnetic separator (WHIMS) to produce the concentrate of desired

quality.

A medium intensity magnetic separator (MIMS) would be

provided before the WHIMS to separate any magnetic material from the

slimes which would otherwise result in choking of the matrix of the

WHIMS leading to its inefficient operation.

The composite concentrate obtained from the regrinding

circuit, underflow from the desliming cyclone, magnetic obtained from

MIMS and WHIMS and overflow of the secondary screw scrubbers would

be treated in a high rate thickener to increase the pulp density and to

make the concentrate amenable for slurry transportation through long

distance pipeline.




3-12

The tails (non-mags) obtained from the WHIMS would be

partially dewatered in a high rate thickener followed by final dewatering

in a paste thickener. The paste thickener would be located inside the

plant boundary and the paste at high solid concentration (around 70 per

cent solids by weight) would be stored in the slime storage area. The

clarified water obtained as overflow from the concentrate thickener,

intermediate thickener and paste thickener would be collected in a tank

and pumped back to the plant as process water.

The block flow diagram showing mass and metallurgical

balance and equipment flow sheet for the grinding and desliming plant is

presented in Drg. No. 11466-97B-000-ENV-0002.

Grinding Plant (Module-3): The iron ore fines of (-)10 mm

size procured from different mines would be reclaimed from the stockpile

within the plant boundary to be treated in a grinding plant, comprising

of two circuits of capacity 5 MTPA (dry basis) each. The iron ore fines in

each circuit would be de-slimed in screw scrubbers to separate

150 microns (µm) ultrafines in the feed and the de-slimed product of

(-)10(+)0.150 mm size would be fed to a vibrating screen for separation of

1 mm particles. The oversize of the vibrating screen of size (+)1 mm

would be ground to (-)1 mm in a primary ball mill. The ground product

would be treated in secondary screw scrubbers for separation of

150 microns (µm) particles obtained as overflow of the screw scrubbers.

The overflow material from the screw scrubbers of size (-)150 microns

would be pumped to the concentrate thickener and the sands obtained

would be treated in the vibrating screen for separation of 1 mm particles.

The undersize of the vibrating screen of size (-)1 mm would

be pumped to the regrinding circuit comprising of hydrocyclones and

derrick stack sizer screens to scalp out the (-)0.1 mm fractions in the

undersize product. The oversize of the stack sizer screens at (+)0.1 mm




3-13

would be fed to a regrind ball mill for final grinding to (-)0.1 mm. The

regrinding ball mill would be working in close circuit with the

hydrocyclones and derrick screens. The overflow of the hydrocyclones

(d80 = 0.1 mm), underflow of the derrick screens and the overflow of the

screw scrubbers at (-)150 µm would be treated in a concentrate thickener

to increase the pulp density and to make the feed amenable for slurry

transportation through pipeline.

The block flow diagram showing mass and metallurgical

balance for Module-3 is presented in Drg. No. 11466-97B-000-ENV-0003.

Plant feed & product: The grinding and desliming plants

(module-1 and module-2) and the grinding plant (module-3) is envisaged

to be fed with iron ore fines of size (-)10 mm. The typical chemical

composition of iron ore fines have been considered as follows:

Plant Feed Fe SiO2 Al2O3

Iron ore fines, % 62 to 63 3 to 3.5 3 to 3.2

The physical characteristics of the iron ore fines considered

for designing the plant and associated facilities are as given below:

Top size, mm .. 10 Specific gravity of solids .. 4.6 Bulk density, tons/cu m .. 2.6 Bond Work Index, kWh/ton .. 12 Angle of repose, degree .. 35 Moisture content, % .. 8 The plant is required to produce 30 MTPA of pellet feed

concentrate of the following desired quality:

Fe, % SiO2, % Al2O3, % LOI, %

63.0 to 64.0 2.5 to 3 2.5 to 2.7 3 to 4




3-14

Major equipment and facilities: The grinding and

desliming plant Module-1 and Module-2) wouldcomprise of four sections

namely:

i) Primary grinding section consisting of storage bins, belt feeders, belt conveyors, primary screw scrubbers, vibrating screens, primary ball mills and secondary screw scrubbers

ii) Desliming section consisting of desliming

hydrocyclones, intermediate thickener (high rate), attrition scrubber, linear screen, MIMS and WHIMS

iii) Regrinding section consisting of regrind ball mills, close circuit hydrocyclones and derrick stack sizer screens

iv) Dewatering and slimes disposal section consisting of concentrate thickeners (high rate), slime thickener (high rate) and slime thickener (paste)

The grinding plant (Module-3) would comprise of three

sections namely:

i) Primary grinding section consisting of storage bins, belt feeders, belt conveyors, primary screw scrubbers, vibrating screens, primary ball mills and secondary screw scrubbers

ii) Regrinding section consisting of regrind ball mills,

close circuit hydrocyclones and derrick stack sizer screens

iii) Dewatering section consisting of concentrate

thickeners (high rate)

3.6.2 Slurry Pipeline Project

As granulometry of the pellet feed is in very fine range (likely

d75 44 µm, d97 150 µm and d100 210 µm), pipeline offers an alternative

option for transportation of the same in slurry form using a pipeline in

lieu of railway transport. In this case, the ore would be ground to the




3-15

desired size at Joda, then slurried to requisite density, pumped along NH

and other state highways, dewatered using pressure filters at ISP near

Paradeep. The filter cake wouldthen be delivered directly to the proposed

pellet plant of ISP and/or feed stockpile.

The route of the slurry pipeline system to transport iron ore

concentrate of 30.0 MTPA from pumping facility located at Joda to ISP

site located at Jagatsinghpur is shown in blue in Fig. 3-4.

FIG. 3-4 - THE ROUTE OF SLURRY PIPELINE SYSTEM




3-16

Design Basis: The pipeline system comprising of all the sub-

systems would be designed on the following basis:

Throughput to the system, tons/hr (normal) .. 3,750

Slurry concentration, % w/w .. 63

Number of working days per year .. 330

Working hours per day in three shift operation .. 24

Based on the above, the annual operating hours work out to

about 8,000 hours and the volume of slurry transported amounts to

about 3,067 m3/hr at 63% solids by weight.

Slurry Pipeline terminal facility at Joda: The thickened slurry

obtained as underflow from the concentrate thickeners would be stored

in eight numbers of slurry holding tanks, each with a capacity of

5,630 cu m. Each tank would be equipped with agitators to keep the

solids in suspension.

The slurry from the holding tanks would be transported to

ISP site at Jagatsinghpur by piston-diaphragm pumps (six working + one

standby).

A valve station would be provided at mid section of pipeline

system with provision of ceramic chokes to avoid any slack flow during

slurry transportation. No intermediate booster pump station has been

envisaged. The pipeline would be complete with Pressure Monitoring

Station (PMS) at an interval of every 30 -40 km, valve stations and

SCADA system. The details of central terminal facility and pipe line

system as envisaged for Joda is described in Table 3-4.




3-17

TABLE 3-4 - CENTRAL TERMINAL FACILITY AND PIPELINE SYSTEM AT JODA

Parameter Joda pipeline system

Volume of slurry transported

(at 63% solids w/w), m3/hr

3067

Total number of tanks, nos 8

Total retention time, hrs 14

Tank volume, m3 (live / total) 5,630 / 6,500

Tank dimension 21.5 m dia x 18 m height

Slurry holding tank agitator, Nos.

8

Mainline pump Charge pump

Type of pump Piston diaphragm Centrifugal

Number of pumps

6 working + 1 standby

1 working + 1 standby

Pump capacity, m3/hr 600 3,100

Slurry pipeline distance, km 312

Pipeline diameter (main), inch 32

Pipe material API 5L Steel Gr. x 70

Pipe wall thickness, mm 12.7-22.224

Liner material No liner

Wear allowance, mills 9 (for first 20 km) and 7.5 (for 21 km onwards)

3.6.3 Integrated Steel Plant

The plant would be designed for a capacity of 13.2 MTPA

crude steel, which, would be cast into long as well as flat products

namely bars, wire rods, sections, plates, hot, cold rolled coils,

galvanized, annealed steel, colour coated, silicon steel etc. for sale.

The proposed production of liquid steel and subsequent

rolling would be accomplished via Blast Furnace (BF)-Basic Oxygen

Furnace (BOF)-Caster route, followed by hot & cold rolling for production

of flat & long products.




3-18

The facilities at the production stage of 13.2 MTPA crude

steel are shown in Table 3-5.

TABLE 3-5 - MAJOR PLANT UNITS AND FACILITES

Sl. No.

Unit Facility Production,

MTPA

1 Slurry dewatering system

Thickener, Filtration (pressure filter) with water recovery system

30.0

2 Coke oven 8 x 62 ovens block, 6.25 m tall stamp charged, CDQ 6.0

3 Sinter plant 1 x 500 m sq. 5.775

4 Pellet plant 4 x 8.0 MTPA Grinding Unit – 180 TPH

32.0

5 DRI 1 x 1.2 MTPA 1.2

6 Blast furnace 3 x 5,350 cum 13.5

7 Steelmaking Shop (SMS)

SMS-1 3 x 350 t BOF 3 x 350 t LF

2 x 350 t RH

SMS-2 2 x 180 t BOF 2 x 180 t LF

1 X 180 t RH

13.49

8 Caster Shop Slab Caster - 3 x 2 strand Billet Caster - 1 x 8 strand

Billet/Bloom Caster - 1 x 6 strand

13.2

9 Flat Product Mills Plate Mill - 1 x 1.5 MTPA

Hot Strip Mill - 2 x 5.5 MTPA Tinplate Coil - 2 X 0.25 MTPA Silicon Steel - 2 X 0.25 MTPA

Cold Rolling Mill - 2 x 2.3 MTPA - Pickling line tandem cold mill(PLTCM)-2x2.3 MTPA - Continuous Annealing Line (CAL) - 2x1.0 MTPA - Continuous Galvanizing Line CGL - 4x0.5 MTPA

- Colour coating Line CCL - 4x0.25 MTPA

9.74

10 Long Product Mill Rebar mill - 1 x 1.2 MTPA Wire Rod Mill - 1 x 0.6 MTPA Medium Section Mill - 1.0 MTPA

2.8

11 Calcining Plant 6 x 600 TPD Lime Calcining Plant 1 x 600 TPD Dolo Calcining Plant

0.97 0.13

12 Cement Plant Grinding, mixing of slag, clinker & fly ash 10.0

13 Captive Power Plant By-product gas and coal based

3 x 300 MW

900 MW

14 Air Separation Plant 6 x 2,100 TPD 12,600 TPD

15 Tar processing plant Distillation units for producing Carbon Black Oil,

Anthracene Oil, Naphthalene, Wash Oil and Pitch

300,000 TPA

16 Benzol Refining Plant

Distillation units for producing BTX and other value added products

100,000 TPA

The production facilities would be adequately supported by

necessary auxiliary facilities such as raw materials unloading and

storage, proportioning of raw materials, electric power receiving and

distribution stations, various utility facilities, water treatment and

distribution system, etc.




3-19

The preliminary process flow sheet is shown in Drg. NO.

11467- 97A-000-PRG-0001. The following write-up lays down details of

the various process units.

3.6.4 Slurry Receiving and Filtration Facilities

The facilities are proposed to be set up at ISP, Jagatsinghpur

end for receiving and filtration of 30.0 MTPA iron concentrate slurry

round the year obtained from Joda pumping station via the slurry

pipeline.

For determination of the capacity of the filtration unit, the

following assumptions have been made:

Annual handling of concentrate, million tons (solids) .. 30

Number of working days per year .. 330

Number of working hours in three shift operation .. 24

Based on the above assumptions, the effective annual

working hours come out to be about 8,000. Accordingly, the average

hourly throughput rate to the slurry receiving and filtration unit is

estimated at about 3,788 tph.

Iron concentrate slurry would be received from Joda central

pumping station. The physical characteristics of the received slurry

would be as follows:

Percent solids in slurry, % .. 63 Specific gravity of the slurry .. 2.0 to 2.2

The filtration facility would produce dewatered iron ore

concentrate averaging 9 to 9.5 per cent moisture.




3-20

Process Concept: The incoming slurry would have specific

gravity in the range of 2 to 2.2. The incoming slurry would be transferred

either directly to slurry holding tanks, in case of specific gravity >2 or via

high rate thickener, in case of specific gravity <2 based on the density

meter reading at the pellet plant site. If the reading is <2, the incoming

slurry would be transferred to a high rate thickener for thickening of the

same to achieve the desired specific gravity. After achieving desired

specific gravity thickener underflow would be pumped back to the slurry

holding tanks.

The iron ore concentrate slurry with 63 per cent solids (w/w)

stored in the slurry holding tanks would be dewatered using pressure

filters to obtain the final product, the residual moisture in the filter cake

not exceeding 9 to 9.5 per cent. This concentrate cake would be conveyed

to pellet plant and/or to a ground stockpile through appropriate

conveyor system.

The water recovered from the pressure filters as well as the

thickener would be received in a clarified water reservoir, would be

utilised in the proposed integrated steel plant after commissioning of all

facilities.

The major equipment and facilities proposed to be provided

are:

a) Slurry holding tanks with agitator b) High rate thickener c) Filtration unit 3.6.5 Pellet Plant

It is envisaged that four pellet plants each of 8.0 MTPA

capacity would be installed. Pellet would constitute about 70 per cent of

the blast furnace burden. DRI plant would require about 1,450 kg of




3-21

charge pellet per ton of hot DRI produced. Pellet requirement in both DRI

plant and blast furnaces would be met from these pellet plants. Surplus

pellet would be used in other plants of JSW or sold.

Design basis: The design basis considered for pellet plant is

given in Table 3-6.

TABLE 3-6 - DESIGN BASIS OF PELLET PLANTS

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

pellet production are given in Table 3-7.

TABLE 3-7 - TYPICAL ANALYSES OF RAW MATERIALS FOR PELLET

PRODUCTION

Fe SiO2 Al2O3 CaO MgO LOI

% % % % % %

Iron ore concentrate 63.0-64.0 3.5-4.0 2.5-3.0 - - 3.0-4.0

Limestone - 4.0-5.0 1.5-1.7 47.0-48.0 2.5-2.8 41.0

Dolomite - 1.1-1.5 0.5 28.0-30.0 19.0-20.0 45.0

Lime - 2.50 2.00 83.0 3.2 4.00

Quartz fines - 97.0 1.0 - - -

Flue dust 37.00 6.50 4.20 3.60 1.10 38.00

Coke breeze 0.50 6.75 3.50 - - 86.50

The indicative chemical analysis of pellet produced would be

as follows:

Fe, % .. 62.55-62.57 CaO/SiO2 ratio .. 0.85-0.95

Al2O3, % .. 2.85-2.95 MgO, % .. 0.95-1.05

Item Value

Number of units, Nos. 4

Gross pellet from each unit, tpy 8,000,000

Screening loss, %

- at BF stock house 2

Operating days/year 350




3-22

Envisaged physical and metallurgical properties of pellet


Size range .. 8-18 mm Compressive strength .. 250 kg/pellet Tumbling index +6.3 mm .. 92% -500 micron .. 6% It is suggested that attainment of the above properties

should be ensured by adopting appropriate process parameters

established through necessary test work before implementation of the

project.

The pellet plant would comprise following facilities: i) Storage, handling & grinding of iron ore fines ii) Storage, handling and preparation of coal, dolomite

and bentonite iii) Proportioning and mixing iv) Balling, induration and cooling v) Product screening vi) Product pellet storage vii) Auxiliary facilities like fuel storage, laboratory, etc. viii) Electrostatic precipitator (ESP) ix) Cranes, hoists and elevator x) Plant electrics

xi) Instrumentation and Level- 1 xii) Plant communication system xiii) Utility system xiv) Air-conditioning and ventilation system xv) Fire fighting system

3.6.6 Coke Oven and By-Product Plant

By-product recovery type stamp charged (SC) coke ovens of

6.25 m height have been considered for the proposed coke oven plant

having necessary pollution control measures. 8 x 62 Nos. of ovens with

annual coke making capacity of 6,000,000 tons have been envisaged to

cater to the requirement of blast furnaces.




3-23

Gross coke production, tpy .. 6,000,000

Charge coke requirement in blast furnaces, tpy

.. 4,860,000

Surplus coke, tpy .. 488,700

Coke Breeze, tpy .. 621,300

CDQ Breeze, tpy .. 30,000 The basic design parameters of the coke oven battery are

given in Table 3-8.

TABLE 3-8 - BASIC DESIGN PARAMETERS OF COKE OVEN

Oven Dimension (cold), m

- Height .. 6.175

- Width .. 0.540

- Length .. 17

Useful Volume, cu m .. 45.6

Bulk Density, ton/cu m .. 1

Coking time, hrs .. 24.8

The proposed coke oven plant envisages use of low ash

imported coking coal in the coal blend. The degree of crushing would be

about 90 per cent below 3.15 mm.

The quality of coal blend envisaged for the proposed coke

oven plant is given in Table 3-9.

TABLE 3-9 - COAL BLEND QUALITY

Proximate analysis (dry basis)

- Ash .. 9-10 %

- Volatile matter .. 23-25 %

- Fixed carbon .. By difference

- Total sulphur .. 0.6 % (max.)

Mean reflectance (Ro) .. 1.05-1.10




3-24

The quality of coke envisaged is given in Table 3-10.

TABLE 3-10 - COKE QUALITY

Analysis (dry basis)

- Ash .. 11.5-12.5%

- Volatile matter .. 1.0 % (max.)

- Sulphur .. 0.7% (max.)

- Moisture .. 0.5 % (max.)

MICUM indices

- M40 .. 82 (min.)

- M10 .. 5.5-6.0

CSR .. 62-64

CRI .. 25 (max.)

The analyses of coal and coke are tentative and subject to

changes based on finalised coal sources and quality.

Major Facilities:

Coke oven battery: The major units of the coke oven batteries

are given in Table 3-11.

TABLE 3-11 - MAJOR UNITS OF COKE OVEN

Coke oven block .. 8

Total number of ovens in each battery .. 62

Oven machines ..

- Stamping charging-cum-pusher car .. 4

- Coke transfer car .. 4

- Gas transfer car .. 4

- Coke quenching car .. 2

- Coke bucket car .. 8W+2S

Coke dry quenching (CDQ) unit .. 4

Stand by wet quenching station .. 2

Coke breeze pond .. 2

Chimney .. 4

Coal charging & Pushing emission control (PEC) .. 2

On main charging system with HPLA .. 2 sets




3-25

The production of coke from the plant would be as shown in

Table 3-12.

TABLE 3-12 - PRODUCTION FROM COKE OVEN (DRY BASIS)

Hard coke (25 to 80 mm), tons/yr .. 5,100,000

Nut coke (10 to 25 mm), tons/yr .. 390,000

Coke breeze (0 to 10 mm), tons/yr .. 480,000

CDQ dust(Less than 1mm), tons/yr .. 30,000

Coke dry quenching: Coke cooling facility would be provided

to cool the red hot coke from oven at 1,000 - 1,050 OC to about 180 - 200

OC. in coke dry cooling plant with facilities to recover the available

energy in hot coke. Coke dry quenching (CDQ) plant would operate for

340-345 days. Two wet quenching stations are envisaged as stand-by for

operation when CDQ is not in operation.

Major facilities for CDQ are given below:

Cooling chamber .. 4 Nos. Design capacity (Normal), t/h .. 190

By-product plant: The by-product plant would be designed to

handle crude coke oven gas make of 310,000 N cu m per hour. The by-

product plant would be designed to process and clean crude coke oven

gas with respect of tar, ammonia, hydrogen sulphide and naphthalene.

In order to get compliance with prevailing environmental norms with

respect to SOx and NOx, plant is envisaged with desulphurisation and low

NOx burner.

The major units of by-product plant for cleaning of coke oven

gas to the required degree, and for recovery of crude tar and sulphur

would be the following:

i) Primary gas cooler and tar liquor separation section, ii) Electrostatic tar precipitator,




3-26

iii) Coke oven gas exhauster, iv) Desulphurisation and sulphur recovery unit, v) Ammonia scrubbing, stripping and destruction unit, vi) Naphthalene scrubbing and oil regeneration unit, vii) Dry type gas holder and flare stack, viii) Biological oxidation and dephenolisation plant,

Maximum slippages of tar vapours, naphthalene, ammonia

and hydrogen sulphide in the clean coke oven gas would be 10, 150, 30

and 200 mg per N cum respectively. Clean coke oven gas with calorific

value of about 4,200 Kcal/N cu m would be made available for

distribution at the takeover point after the by-product plant.

3.6.7 Tar Processing and Benzol Refining Plant

The recovered crude tar & crude benzol would be further

refined to produce additional value added products in Tar distillation

Plant of capacity 0.3 MTPA and Benzol Refining Plant of capacity

0.1 MTPA. The various products generated would be as shown in

Table 3-13.

TABLE 3-13 - PRODUCTS FROM TAR DISTILLATION & BENZOL REFINING PLANT

Tar Distillation products, TPA Benzol refining plant, MTPA

DNO 1,100 N G Benzene 43,900 Napthalene 8,100 N G Toluene 7,600 Pitch 72,900 Xylene 1,100 PCM

164,700 Solvent oil 1,100 Creosote 5,400 Still bottom Oil 4,300 Anthracene Oil 5,400 Road Tar 12,200 Wash Oil 300

Coal Tar Distillation Process:

Process Description: The various components present in the

coal tar would be separated by distillation process. Coal tar after

preheating and de-hydration would be fed to fractionating column in




3-27

which various fractions e.g. Light Oil, Middle fraction Oil, Anthracene

Oil, Phenol Oil, Wash Oil, Creosote Oil, Pitch-creosote Mixture etc. would

be separated depending on product mix.

Oils - Light oil, Phenol oil & Anthracene oil production: The top

fraction contains phenol oil, the middle fractions contain Naphthalene oil

along with phenol oil & wash oil and the bottom product contains

Anthracene oil and Creosote oil.

Binder Grade Pitch production: For production of Coal Tar

Pitch (Binder Grade), first soft pitch would be generated from the pitch-

creosote mixture at the bottom of fractionating column. The produced

soft pitch would be converted into modified pitch in modified pitch

section which also can be sold as product.

High QI (Quinoline Insolubles) pitch would be blended with

modified pitch to produce Binder pitch. A pitch melting system would be

used for melting of High QI pitch.

Carbon Black Oil (CBO) production: For the production of

Carbon Black Oil, soft pitch would be blended with Anthracene Oil

produced in distillation process.

Refined Naphthalene production: Vapors containing crude

naphthalene oil generated in distillation process would be continuously

cooled in condensers and collected by gravity into receivers. The

collected and cooled mixture would be transferred to refined naphthalene

section. In refined naphthalene section crude naphthalene would be

enriched and purified using crystallizer. The refined naphthalene would

be solidified using flakers.




3-28

Major Facilities: The following major facilities are proposed

for the Tar Distillation Plant:

i) Crude Tar Storage Tank ii) De-hydration Column iii) Fractionating Column iv) Light oil tank v) Middle Oil Tank (Caustic addition Tank) vi) Phenol oil tank vii) Wash Oil tank viii) Pitch-Creosote Mixture tank ix) Creosote oil tank x) Anthracene oil tank xi) Carbon black oil tank xii) Caustic soda tank xiii) Sodium phenolate tank xiv) Soft Pitch tank xv) Modified pitch tank xvi) Decanter xvii) Crystallizer xviii) Centrifuge xix) Cylinder press/flaker xx) Naphthalene storage & bagging unit xxi) Pitch melter xxii) Pitch reactor xxiii) Binder pitch shaping unit xxiv) Binder pitch bagging & storage unit xxv) Heat exchangers xxvi) Condensers xxvii) Pumps xxviii) Loading stations.

Tentative Product-Mix: The following chemicals would be

envisaged for recovery inside the proposed tar distillation plant. The

product-mix may undergo changes depending on market scenario.

i) Binder Grade Pitch ii) Naphthalene iii) Anthracene Oil iv) Phenol v) Light Oil vi) Pitch-Creosote Mixture vii) Creosote Oil viii) Wash Oil ix) Carbon Black Oil




3-29

3.6.8 Benzol Refining Process

Process Description:

Cleaning of Crude Benzol: The crude benzol would be washed

to remove the unsaturates. In the acid/alkali process, the crude benzol

would be washed with concentrated sulphuric acid to remove most of the

unsaturated compounds (chiefly mono olefins). This would be discharged

from the bottom of the wash tank as sludge acid, which is a misxture of

unused acid, entrained light oil and resins.

Cleaned benzol would be removed from the top of the tank

and passed to a neutralizer, where it would be first washed with dilute

solution of sodium hydroxide for removing any acid trace and later with

water. The cleaned crude benzol would be moved to the storage tank for

distillation. It wouldtake approximately one shift to carry out the

washing. The yield of cleaned crude benzol would be 94% to 96% of the

feed.

The crude benzol would be fractionally distilled in a

fractionating column for the final products. Indirect steam heated batch

stills would be used for obtaining Bezene, Tolune, Xylene and Solvent

Naphtha of various standard grades.

The residue from the batch still as well as the sludge from

acid alkali process can be used as fuel.

Major Facilities:

i) Fractionating columns ii) Crude benzol tank iii) Sulphuric acid tank iv) Acid wash tank v) Alkali wash tank vi) Alkali storage tank vii) Cleaned crude benzol tank viii) Product tanks ix) Heat exchangers x) Pumps xi) Loading station




3-30

Tentative Product-Mix: The following chemicals are

envisaged for recovery inside the proposed tar distillation plant.

i) Benzene ii) Toluene iii) Xylene iv) Solvent Oil v) Bottom Oil

3.6.9 Sinter Plant

Sinter would constitute around 25 per cent of the ferrous

burden to the blast furnaces. To meet the requirement of charge sinter

one sinter plant of around 500 sq m would be installed.

The design basis considered for the sinter plant is given in

Table 3-14.

TABLE 3-14 - DESIGN BASIS OF SINTER PLANTS

Item Quantity

Product sinter, tons/year .. 5,775,000

Charge sinter, tons/year .. 4,909,000

Screening loss at BF stock house, % .. 15

Operating days/year .. 330

Daily product sinter, tons/day .. 17,500

No. of strand .. 1

Approx. suction area, sq m .. 500

Product sinter size, mm .. 5-50

Temperature of sinter at cooler discharge, OC

.. 100

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

sinter production are given in Table 3-15.




3-31

TABLE 3-15 - TYPICAL ANALYSES OF RAW MATERIALS FOR SINTER PRODUCTION

Fe SiO2 Al2O3 CaO MgO LOI

% % % % % %

Iron ore fines 61.0-63.0 3.5-4.0 2.5-3.0 - - 3.0-4.0

Limestone - 4.0-5.0 1.5-1.7 47.0-48.0 2.5-2.8 41.0

Dolomite - 1.1-1.5 0.5 28.0-30.0 19.0-20.0 45.0

Lime - 2.50 2.00 83.0 3.2 4.00

Quartz fines - 97.0 1.0 - - -

Flue dust 37.00 6.50 4.20 3.60 1.10 38.00

Mill scale 69.50 1.23 1.22 0.68 0.25 5.00

Coke breeze 0.50 6.75 3.50 - - 86.50

The indicative chemical analysis of sinter produced would be

as follows:

Fe, % .. 55.2-55.8 CaO/SiO2 ratio .. 2.15 Al2O3, % .. 2.8-3.0 MgO, % .. 2.05-2.15 Envisaged physical and metallurgical properties of sinter


ISO tumbler index (+6.3 mm) .. 76% (min) Reducibility index .. 65% (min)

RDI (-3.15 mm) .. 28% (max) Sinter size range .. 5 to 50 mm Sinter mean size .. 18 mm

It is suggested that attainment of the above properties

should be ensured by adopting appropriate process parameters

established through necessary test work before implementation of the

project.

The sinter plant would comprise following facilities:

i) Proportioning system ii) Flux and fuel crushing iii) Lime grinding and conveying




3-32

iv) Mixing and nodulizing system v) Sinter machine section vi) Sinter cooler with WHRB vii) Sinter stabilizing section viii) Sinter storage and despatch ix) Waste gas system x) ESP xi) Cranes, hoists and elevator xii) Plant electrics xiii) Instrumentation and Level- 1 xiv) Plant communication system xv) Utility system xvi) Air-conditioning and ventilation system xvii) Fire fighting system

3.6.10 Blast Furnace

Requirement of hot metal for Steel Melt Shop would be

around 13.5 MTPA. Three Nos. of blast furnaces, each of useful volume

(U.V) 5,350 cu m has been envisaged to cater to the hot metal

requirement.

The blast furnace would incorporate all the modern

technological features. The design basis of blast furnace is given in

Table 3-16.

TABLE 3-16 - DESIGN BASIS OF BLAST FURNACE

Item Quantity

No. of furnaces 3

Volume, cu m (approx.) 3 x 5,350 (U.V)

Operating days 350

Burden:

Sinter, % 25

Pellet, % 70

Lump Ore, % 5

O2 enrichment, % 12

Coke rate (including nut), kg/thm 360

Coal rate, kg/thm 200

Slag rate, kg/thm 280

Coke ash, % 12.5

Si in metal, % 0.6 to 0.8




3-33

The major raw materials for blast furnace comprise iron ore,

sinter, pellet, additives and coke. Pulverised coal would be injected

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

of raw materials envisaged is given in Table 3-17.

TABLE 3-17 - TYPICAL RAW MATERIALS ANALYSIS (DRY BASIS)

Fe SiO2 Al2O3 CaO MgO

% % % % %

Sinter 55.2-55.8 4.5-4.6 2.8-3.0 9.7-9.9 2.05-2.15

Pellet 62.55-62.57 3.47-3.49 2.85-2.95 3.8-4.0 0.95-1.05

Sized ore 63.0-64.0 3.0-3.5 1.8-2.0 - -

Quartzite - 97.0 1.0 - -

Limestone - 4.0-5.0 1.5-1.7 47.0-48.0 2.5-2.8

Dolomite - 1.1-1.5 0.5 28.0-30.0 19.0-20.0

Ash Moisture CSR CRI % % % %

Coke .. 12.5 0.5 62 25 (min) (max)

Analysis of Coal for PCI (Dry Basis) is as follows:

Ash, % .. 9 - 10 Fixed carbon, %) .. 68 - 70 Volatile matter, % .. 18 - 20

The hot metal quality is envisaged to be as follows:

Si, % .. 0.6 - 0.8 S, % .. 0.04 - 0.06 P, % .. 0.1 - 0.15

The plant comprises following facilities:

i) BF proper ii) Cast house iii) Slag granulation plant iv) Hot blast stoves v) Gas cleaning plant vi) Stock house and charging system vii) Hot metal handling system viii) Cranes and hoists




3-34

ix) Coal dust injection system x) Hot metal granulation and ladle repair shop xi) Stockhouse & Casthouse de-dusting system xii) Air blowing system xiii) Plant electrics xiv) Instrumentation, automation and control system xv) Communication system xvi) Water system xvii) Utility system xviii) Fire fighting system xix) Air conditioning and ventilation system The granulated BF slag would be used for manufacture of

cement in the captive cement manufacturing unit.

3.6.11 Directly Reduced Iron (DRI) Plant

The pellet would be used to produce directly reduced iron

using coke oven gas (COG) as the reductant. About 1.73 MTPA of pellets

would be used as raw material, producing about 1.2 MTPA DRI. The DRI

would be fed to the steelmaking shops as a coolant. However, the surplus

DRI would be used in other plants of JSW.

COG based DRI Plant of capacity 1.2 MTPA would have

following design consideration:

Feed material : Acid grade iron oxide pellet (64.8% Fe) Reductant : Clean COG with BTX less than 32 g/N cu m

and tar less than 0.05 g/N cu m Production rate : 150 tons per hour Annual availability : 8000 hrs Product : Cold DRI/Hot briquetted iron (HBI) Major consumer : BOFs at steelmelt shops; balance to be sold Product quality : Metallisation - 93% Total iron - 87% Carbon - 1.5% Sp. Consumption : Iron ore pellet - 1.41 t/t DRI COG - 2.3 G Cal/t DRI Power - 150 kWh/t DRI Water - 2 cu m/t DRI Oxygen - 70 N cu m/t DRI




3-35

The major facilities of the proposed plant are given below:

i) Oxide feed charging system. ii) Thermal reactor system (including COG metering

station, compressors, heat exchangers and thermal reactors).

iii) Reduction furnace. iv) CO2 removal system. v) Gas compressors and mist eliminator. vi) Top gas waste heat boilers. vii) Gas handling and DRI handling facilities. viii) Cold DRI silos. ix) Hot briquetting machine. x) Water, utility, electrics, Instrumentation, automation

and communication systems.

3.6.12 Steelmelt Shop

SMS-1

A break-down of the average tap-to-tap time of converters,

indicating the duration of various activities, is given in Table below.

Activity Time

min.

Charging of scrap .. 2 Charging of hot metal .. 5

Oxygen blowing .. 16

Deslagging & sampling .. 5

Reblow .. 2

Steel tapping .. 6 Slag off .. 3

Vessel inspection .. 2

Slag splashing .. 2

Unforeseen delays .. 2

Tap-to-tap time .. 45




3-36

On the basis of the annual liquid steel requirement and the

average tap-to-tap time indicated in the above table, computation of the

nominal converter heat size is presented in the table below:

Production of liquid steel, MTPA .. 10.5

Converter operation, days/year .. 365

No. of converters installed .. 3

Liquid steel production per day, tons .. 28,800 Considering converter availability and

utilization, No. of converters operating .. 2.6

Liquid steel production per day .. 11,000

per operating converter, tons

Average tap-to-tap time, min. .. 45

No. of heats/day/converter .. 32 Liquid steel required per heat, tons .. 344

Selected heat size, tons liquid steel .. 350

SMS-2

A break-down of the average tap-to-tap time of converters,

indicating the duration of various activities, is given in table below.

Activity Time min.

Charging of scrap .. 2 Charging of hot metal .. 5 Oxygen blowing .. 16 Deslagging & sampling .. 5

Reblow .. 2 Steel tapping .. 6 Slag off .. 3 Vessel inspection .. 2 Slag splashing .. 2 Unforeseen delays .. 2

Tap-to-tap time .. 45




3-37

On the basis of the annual liquid steel requirement and the

average tap-to-tap time indicated above, computation of the nominal

converter heat size is presented in the table below.

Production of liquid steel, MTPA .. 2.99

Converter operation, days/year .. 365

No. of converters installed .. 2

Liquid steel production per day, tons .. 8,200 Considering converter availability and

utilization, No. of converters operating .. 1.6

(Low utilization based on availability of casters)

Liquid steel production per day .. 5,125

per operating converter, tons

Average tap-to-tap time, min. .. 45 No. of heats/day/converter .. 32

Liquid steel required per heat, tons .. 160

Considering JSW’s present operating

experience in other plants,

Selected heat size, tons liquid steel .. 180

Production capacity of casters in SMS 1: The production

capacity of continuous casting machines have been estimated at

10.5 million tons considering the following operational parameters as

given in table below.

3 x 2-strand Slab Caster

Parameter Value

Heat size, ton 350

No. of strand 2 Average throughput, tons/min. 7.65

Average casting time, min. 46

No. of heats in sequence 32

Preparation time, min. 50

Sequence time, min. 1,522 No. of sequence/day/Caster 0.95

Possible no. of heats/day/caster 30

Caster availability, days 330

No. of heat cast per year/Caster 9,900

Production capability, mtpy/Caster 3.5

No. of caster 3 Production capability of casting shop, mtpy 10.5




3-38

Production capacity of casters in SMS 2 : The estimated

production capacities of continuous casting machines are furnished in

Tables below.

Long product - 1 x 6 strand billet cum bloom caster

Description Parameter

Heat size, ton 180

Throughput considered, tons/min. 3.2 Average casting time, min. 56

No. of heats in sequence 8

Preparation time, min. 48

Sequence time, min. 496

No. of sequence/day 2.90 Possible no. of heats/day/caster 23


No of heat cast per year 7240

Production capability per year per caster

(MTPY of liquid steel)

1.30

No. of caster 1

Production capability of billet cum bloom cum

beam-blank caster, MTPY

1.30

Long product - 1 x 8 strand billet caster

Parameter Value

Heat size, ton 180

Reference section size, mm 160 x 160 No. of strand considered for calculation 7

Average casting speed, m/min 3.0

Throughput, tons/min. 3.71

Average casting time, min. 49

No. of heats in sequence 12 Preparation time, min. 40

Sequence time, min. 628

No. of sequence/day 2.30

Possible no. of heats/day/caster 27


No of heat cast per year 8,910 Production capability per year per caster (MTPY

of liquid steel)

1.60

No. of caster 1

Production capability of billet caster, MTPY 1.60




3-39

Charge mix: The proposed charge mix for the converters

would be as shown below:

Specific Consumption kg/ton LS

Hot metal and gran-shot .. 993 Scrap .. 61 DRI .. 61

In addition to scrap/gran-shot/DRI, sized iron ore/

briquetted mill scale would also be used as coolant.

Yields: The yields in liquid steel production and casting

have been considered as follows:

% Metallic input to liquid steel .. 90.0 (180 ton BOF) .. 90.5 (350 ton BOF) Liquid steel to billets .. 97.5 Liquid steel to slab .. 98.0

The major facilities proposed to be installed in the steelmelt

shop are as below.

SMS-1

Scrap handling facilities Hot metal handling facilities 3 x 370 ton twin hot metal desulphurization & associated

facilities 3 x 350 ton converter and associated facilities BOF gas cleaning plant Secondary emission control system Flux handling facilities Liquid steel handling facilities Slag handling facilities 3 x 350 ton inert gas rinsing station 3 x 350 ton ladle furnaces 2 x 350 ton RH-OB degasser unit 3 x 2 strand slab caster Auto scarfing facilities for slabs




3-40

SMS-2

Scrap handling facilities Hot metal handling facilities 2 x 190 ton twin hot metal desulphurization & associated

facilities 2 x 180 ton converter and associated facilities

BOF gas cleaning plant Secondary emission control system Flux handling facilities Liquid steel handling facilities Slag handling facilities 2 x 180 ton inert gas rinsing station 2 x 180 ton ladle furnaces 1 x 180 ton RH-OB degasser unit 1 x 8 strand billet caster 1 x 6 strand billet cum bloom caster

3.6.13 Lime Calcining Plant

At 13.2 MTPA production stage of crude steel, it is envisaged

that six lime Calcining plant and one dolomite calcining plant of 600 TPD

would be installed to produce calcined lime and dolo, sufficient to cater

to the demand of calcined lime/dolo of the steelmelt shops.

3.6.14 Rolling Mills

The following mills would be installed with production

capacities as follows:

Mills No. and capacity

Hot Strip Mill (HSM) .. 2 x 5.5 MTPA

Plate Mill (PM) .. 1 x 1.5 MTPA

Rebar mill (RBM) .. 1 x 1.2 MTPA

Wire rod mill (WRM) .. 1 x 0.6 MTPA

Medium Section Mill (MSM) .. 1 x 1.0 MTPA Cold Rolling Complex .. 2 x 2.3 MTPA

Tinning mills .. 2 x 0.25 MTPA

Electrical steel mills .. 2 x 0.25 MTPA




3-41

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

for a production of 5,500,000 tons/year of HR coils.

Input: Cast slab would be used as input for the hot strip mill. Width, mm .. 800 - 2,100 Thickness, mm .. 230 Length, mm .. 11,000 Unit weight (max), kg .. 40,000 Finished product: The HR coil size would be as follows:

Width, mm .. 800 - 2,050 Thickness, mm .. 1.2 - 25.0 Coil weight (max), ton .. 40 Mill yield, % .. 98 Each hot strip mill would comprise of the following facilities:

i) Walking beam type reheating furnaces ii) Primary hydraulic descaler iii) One 2-Hi roughing stand with attached edger iv) One 4-Hi roughing stand with attached edger v) Crop shear vi) Secondary hydraulic descaler vii) Seven 4-Hi finishing stands viii) Run-out roller table

ix) Laminar cooling system x) Down coilers xi) Walking beam coil conveyor system

Plate Mill (PM): The plate mill would be designed for a

production of 1,500,000 tons/year of plates.

Input Material:

Slab Thickness .. 150 - 300 mm Width .. 1,500 - 2,600 mm Length .. 2,600 - 4,800 mm

Finished Product:




3-42

Thickness .. 5 mm - 100 mm Width .. 1,500 mm - 4,800 mm Max Length .. 6000 - 24.000 mm Max plate weight .. 30 tons

Yield .. 92% The plate mill would consist of the following major

equipment/facilities:

i) Slab Reheating Furnaces ii) Descaling System iii) Mill Stand iv) Accelerated Cooling v) Hot Plate Leveller vi) Cooling Bed vii) Heavy Plate Production Facility viii) Inspection bed ix) Crop shear x) Double Side Trimming Shear xi) Slitting shear xii) Dividing Shear xiii) Cold Plate Leveller xiv) Pile transfer xv) Heat treatment facilities

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

production of 1,200,000 tons/year.

Input: Continuously cast billets of following size would be

used as input to the rebar mill:

Section, mm .. 150 x 150 Length, mm .. 12,000

Finished product: Output from rebar mill would be as

follows:

Size .. 8-40 mm dia. rebars Cut to length .. 6-12 m Mill yield, % .. 97




3-43

The mill would comprise of the following major facilities:

i) Billet Charging grids ii) Walking beam type reheating furnace iii) Roughing train and intermediate train iv) Shears v) No twist blocks

vi) Water boxes and troughs vii) Cooling beds with high speed entry equipment viii) Cold shear ix) Chain transfer x) Bundle strapping machines xi) Bundle unloading stations

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

designed for production of 600,000 tons/year.

Input: Continuously cast billets of following size would be

used as input to the WRM:

Section, mm .. 150 x 150 Length, mm .. 12000 Finished product:

Size .. 5.5-20 mm dia

Mill yield, % .. 97

The mill would comprise of the following major facilities:

i) Charging grids ii) Walking beam type reheating furnace iii) Descaler iv) Single strand high speed roughing mill v) Double strand intermediate mill train vi) Shears vii) Pre-finishing mills viii) Wire rod blocks ix) Reducing and sizing blocks x) Water boxes and troughs xi) Laying heads and pinch rolls xii) Air cooling conveyors xiii) Reform station with ring distribution xiv) Coil conveyor




3-44

Medium Section Mill (MSM): The medium section mill would

be designed for production of 1.0 MTPA of structural sections.

Input: Cast bloom of following sizes would be used as input

for the mill.

Size, mm .. 390 x 320 380 x 280

Length, mm .. 6,000 & 9,000

Finished product: The finished product would be sold in

following sizes:

Bundle weight .. 10 ton (max) Cut to length … 6-12 m Mill yield, % .. 95

The mill would comprise of the following major facilities: i) Charging grid ii) Walking beam type reheating furnace iii) Descaler iv) Breakdown stand

v) Universal rougher vi) Edger vii) Universal finishing stand viii) Shear/hot saw ix) Cooling bed x) Straightener xi) Cold saw xii) Inspection table xiii) Automatic piler xi) Weighing device xv) Collecting table

Cold Rolling Complex: Two identical cold rolling mill

complex would be installed to produce cold rolled annealed, galvanized




3-45

and color coated coils. Each complex would comprise of the following

process units:

i) One Pickling line coupled with tandem cold mill (PLTCM) of 2.3 MTPA capacity

ii) One continuous annealing line (CAL) of 1.0 MTPA capacity

iii) Two continuous galvanizing line (CGL) of 0.5 MTPA capacity each

iv) Two color coating line (CCL) of 0.25 MTPA capacity each

v) Recoiling lines (RCL) as required vi) Acid Regeneration Plant (ARP) Tinning Mills: Two identical tinning complexes would be

installed. Each complex would be designed for a production of 0.25

MTPA of tinplates and would include the following process units:

i) Pickling line ii) Reversing cold rolling mill iii) Electrolytic cleaning line iv) Annealing furnace v) Temper mill vi) Coil preparation line vii) Electrolytic tinning line

Electrical Steel Mills: Two identical electrical steel

complexes would be installed. Each complex would be designed for a

production of 0.25 MTPA of electrical steels and would include the

following process units:

i) Coil preparation Line ii) Annealing and pickling line iii) Reversing cold rolling mill iv) Decarburisation & coating facility v) Box annealing facility vi) Carlite line and thermal flattening facility vii) Tandem annealing line viii) Slitting line ix) Coil packaging line




3-46

3.6.15 Cement Grinding Unit

It is proposed to install cement grinding, mixing and bagging

units to utilize the granulated blast furnace slag produced at the

iron-making unit as well as the fly ash generated at the captive

power plant of the ISP. Ground granulated blast furnace slag

would be mixed with clinker and gypsum, sourced from outside and

fly ash sourced from the captive power plant of the integrated

steel plant to produce Portland slag cement. In addition to the same, fly

ash from the captive power plant would also be mixed with clinker to

produce Pozzolona Portland cement.

In order to utilize the entire amount of granulated

blast furnace slag available from the iron-making unit of the

integrated steel plant, the net production capacity of the Portland

slag cement unit would be 7.5 MTPA. In order to utilize the entire

amount of fly ash generated in the captive power plant, Pozzolona

Portland cement unit would be installed in addition to the Portland

slag cement unit. The capacity of the Pozzolona Portland cement unit

would be 2.5 MTPA and the total capacity of cement production would be

10.0 MTPA.

3.6.16 Captive Power Plant

The proposed project has been envisioned to produce around

900 MW of power, based on available by-product fuel gases and steam

coal. The configuration of the power plant would be 3 x 300 MW. In

addition, 221 MW power would be produced from CDQ of Coke ovens and

TRT of BF.

3.6.17 Raw Materials for ISP & Mineral Grinding and Desliming Plants

Iron ore grinding & desliming plant: The total iron ore

fines requirement for production of 30 MTPA concentrate thus works out




3-47

to around 30.80 MTPA (on dry basis). Iron ore concentrate would be

dispatched from Joda plant for onward transportation to ISP through

slurry pipeline.

In Keonjhar & Sundargarh there are about 58 iron ore

merchant mines, having a total iron ore production capacity of about 121

million ton per annum. The present production level is much lower than

the total quantity of reserves, hence it is assumed that adequate iron ore

reserve is available locally for the proposed project.

Besides local sources, other possible sources of iron ore

include:

i) Vicinity to Jharkhand which has large iron ore

reserve ii) Potential availability of iron ore from Odisha from

auction of new mines to be possibly scheduled across 2018-19

iii) Mining lease of about 20 iron ore mines in Odisha is

scheduled to expire in 2020 for which auction process would likely start in 2019

iv) Odisha Govt has also planned to augment iron ore

production to 200 MTPA by 2020-21, suggesting the availability of additional iron ore in the market.

Considering above facts it can be inferred that enough iron

ore available in Odisha to meet the annual requirement of about

30.8 MTPA.

The iron ore would be transported to raw material handling

system of the plant by rail, pipe conveyor and road. Transportation

through rail & pipe conveyor would be maximized (>60%) and rest by

road to minimize air pollution. Suitable raw material yards would be




3-48

established to stock raw material in stockpile. One twin boom stacker

(TBS) and two Nos. of single boom stacker of 4,000 tph each are

envisaged to build the stockpile. The materials would be reclaimed from

the stockpile through 2 Nos of wheel-on-boom reclaimer (WBR) of

capacity 2,650 tph for onward transportation to the hopper in grinding

and de-sliming plant through tripper conveyor for continuous feeding

considering 24 hours of operation. Eight nos. of vibrating screens with

capacity of 1,000 tph and two nos. of vibrating screens of capacity

400 tph for handling material of cone crusher (capacity - 400 tph) have

been considered.

Integrated Steel Plant: The estimated annual requirements

of major raw materials for the integrated steel plant are presented in

Table 3-18.




3-49

TABLE 3-18 - ESTIMATED ANNUAL REQUIREMENTS OF MAJOR RAW MATERIALS

Sl. No.

Major Raw materials

Estimated Quantity, tons Likely source Mode of transport

1 Coking Coal and Pet Coke

7,831,900

International market Sea

2 Anthracite 192,000 International market Sea

3 Iron ore

(Lump)

1,187,900 Procured from the Joda-

Barbil and Koira mines region, Odisha

Rail (50%)/

Road(50%)

4 Iron ore concentrate

30,000,000 Captive Iron ore grinding & desliming plant, Joda

Slurry Pipeline

5 Iron ore fines 4,695,300 Procured from the Joda-Barbil and Koira mines region, Odisha

Rail

6 PCI coal 2,700,000 International market Sea

7 Limestone 4,934,500 BF grade - Purchased from mines in Bagalkot area, Karnataka /Central India (Jukehi-Katni-Niwar area) SMS grade- Imported from Middle-East Countries (UAE & Oman)

Sea (55%)/Rail (35%)/Road (10%)

8 Dolomite 2,350,100 International market/Domestic

Sea(15%)/Rail(70%)/ Road(15%)

9 Steam coal 2,700,000 Procured from Mahanadi Coalfields Limited

(MCL) and South Eastern Coalfields Limited (SECL)

Rail

10 Bentonite 320,000 International market Sea

11 Quartzite 270,000 International market/Domestic

Sea(10%)/Rail(50%)/ Road(40%)

12 Clinker 5,116,000 International

market/Domestic

Sea

13 Gypsum 232,000 Domestic Rail (50%)/Road(50%)

Captive Jetty: The captive jetty would cater to the logistical

demand of the raw material and the finished product of the ISP,

including the cement and captive power plant.




3-50

3.6.18 Captive Jetty

Traffic Projections: The raw material requirement of the

proposed ISP and mineral grinding & de-sliming plants has already been

described in the preceding sections. The raw material & finished

products expected to be handled at the jetty is depicted in Table 3-19.

TABLE 3-19 - PROJECTED TRAFFIC FOR THE CAPTIVE JETTY

Sl. No. Raw material Estimated handling capacity, MTPA

1 Coking Coal 8.84

2 Anthracite 0.32

3 PCI Coal 2.84

4 Steam Coal 4.50

5 Lime stone (SMS) 2.40

6 Dolomite (SMS) 0.40

7 Bentonite 0.30

8 Clinker 5.30

9 Quartzite 0.03

Total (Incoming) 24.93

1 Finished Steel1 6.00

2 Pellet/Iron Ore Concentrate 15.00

3 Cement2 6.00

Total (Outgoing) 27.00

Grand Total 51.93

1 - 50% of the steel is considered as coastal cargo 2 - 60% of the Cement is considered as coastal cargo and 40% for local market

Functional Planning of Jetty Facilities:

Conceptual Planning: The following inter-connected factors

have been considered for planning of the jetty:

i) Ships Sizes expected at the Jetty based on characteristics and quantum of cargoes to be handled

ii) Number of Ship Calls

iii) Handling Capacity and Number of Berths

iv) Channel alignment and dimensions

v) Land Area Requirements

vi) Ships’ operational areas




3-51

Each of the above considerations is itself dependent on a

number of factors, some of which are outside the control of jetty

planners or operators. The above parameters are discussed in the

following paragraphs to enable evolving the layout of the proposed jetty.

Ships Sizes Expected at the Jetty: This jetty is essentially

built to cater to the demands of the ISP consisting of the 13.2 MTPA steel

plant, 900 MW power plant using dual fuel and the 10.0 MTPA cement

grinding unit. There are basically 3 types of cargo to be handled at the

jetty, i) Coal, to be imported from Indonesia/South Africa/Australia,

ii) Limestone, from an Indian and/or Middle East locations and

iii) Finished Steel products, transported through coastal shipping.

Raw materials/Finished Products would be handled in a mix

of Handymax, Panamax and cape size vessels. The ship sizes together

with their main dimensions considered for planning purposes for this

report is given in Table 3-20.

TABLE 3-20 - ASSUMED SHIP SIZES FOR VARIOUS PRODUCTS

Cargo Vessel Design vessel Dimensions (m)

Size (DWT) Length Beam Draft

Coal 180,000 290 45 17.5 Lime Stone 75,000/45,000 230/212 33.0/32.5 13.5/12.0 IBRM 180,000 290 45 17.5

Steel Products 45,000 212 32.5 12.0

Lime Stone 45,000 212 28.2 11.5

Coastal Shipping (Cement)

10,000-25,000 165 24.2 8.5

Number of Ship Calls: For calculating the number of ship-

calls, it is envisaged that ‘full shiploads’ would be the average shipment

for all commodities. The distribution of ship sizes is to be considered to

assess the number of ship calls that would occur for each commodity,

between the possible maximum size governing the Ocean trade and the

minimum size of vessel likely to be utilised.




3-52

The number of ship calls, for each type of ship corresponding

to the respective cargo for the development of the ISP, is given in

Table 3-21.

The envisaged project cargo can be handled in a single berth

nearer to the entrance which would be taken up for construction first.

TABLE 3-21 - SHIP CALLS

Total throughput

(MTPA)

Distributed throughput Assumed Vessel size

(DWT)

No. of Ships calls

Total throughput

achieved % Throughput (MTPA)

COAL

16.5 75 12.38 180000 69 12375000

25 4.12 80000 52 4152000

121 16500000

LIME STONE, DOLOMITE & QUARTZITE

2.83 60 1.7 75000 23 1698000

40 1.13 45000 26 1132000

49 2830000

IBRM

15.00 75 11.25 180000 63 11340000

25 3.75 80000 47 3760000

110 15100000

STEEL PRODUCTS

6.0 50 3.00 45000 67 3015000

50 3.00 25000 120 3000000

187 6015000

BENTONITE

0.3 50 0.15 75000 2 150000

50 0.15 45000 4 180000

6 330000

CEMENT

6.00 50 3.00 45000 67 3015000

50 3.00 25000 120 3000000

187 6015000

CLINKER

5.30 50 2.65 45000 59 2655000

50 2.65 25000 106 2650000

165 5305000




3-53

Handling Capacity and Number of Berths : Berth occupancy is

considered in relation to acceptable waiting time and such provision

covers the following occurrences:

i) Expected pattern of arrival - whether random,

scheduled or some other pattern ii) Occurrence of reduced depth of water at berth - caused

by tidal restrictions and other berthing restrictions. iii) Cargo handling restrictions at berth iv) Cargo handling rates achievable and ship’s time at

berth. v) Incidence of weather conditions which delay ship

berthing and departure. vi) Downtime of handling equipment due to wind

conditions/ mechanical failures. vii) Reduction in number of hours of work per day and

incident holidays viii) Handling equipment reliability factors

Berth occupancy is usually considered acceptable for a

single berth when this figure lies between 45% and 60%. In support of

this stipulation, a calculation is made for various cargoes proposed to be

handled at this jetty. A major consideration to validate this calculation

would have to be the ship arrivals, i.e. whether it is right to regard

arrivals as purely random (most unlikely) or whether it can be

considered fully planned and programmed (also most unlikely if ships

are coming from afar) or whether some intermediate condition could be

said to apply.

Assuming that ship arrivals are scheduled, but, within this

scheduling there creeps a degree of error due to delays at loading ports,

bad weather and other mishaps etc. which requires an arrival date

tolerance of +3 days, it is estimated that on a 50 % berth utilisation,

about 40% of the ships would be delayed in obtaining berths and that

the average waiting time would be of the order of 7 to 8 hours; which is

considered to be an acceptable condition.




3-54

Based on these considerations, average ship size and

number of ship trips have been calculated and presented in Table 3-22.

TABLE 3-22 - AVERAGE SHIP SIZE AND NUMBER OF TRIPS

Commodity

Average Ship

Size*, DWT

Throughput Million tons/yr.

(No. of ships)

Coal 136,500 16.5 (121)

Lime Stone 57,000 2.83 (49)

IBRM 155,000 15.10 (110)

Steel Products 35,000 6.01 (187)

Bentonite 38,000 0.33 (6)

Cement 35,000 6.01(187)

Clinker 26,000 5.30(165)

Note: Average ship size has been taken as the weighted average based

on the cargo handled and the ship distribution.

The above table is estimated on the primary assumption that

all operations including navigation, maneuvering, berthing and de-

berthing are proposed to be carried out 24 hours per day.

The dry bulk commodities like Coal, and Limestone could

conceivably be handled at the same berth. Coal traffic would require one

separate berth from the beginning as would the limestone and out bound

IBRM. There would be 2 cape size berths corresponding to average ship

size of 150,000 DWT or more and 2 Panamax berths for handling

Bentonite, Gypsum and Limestone. The other berths for Steel products,

Cement and other cargos with an average vessel size around 30,000-

35,000 DWT would be handled in berths designated for handymax

vessels.

There would be separate berths for Coal, Limestone, IBRM,

Cement/Clinker, Steel Products and 1 extra berth for the jetty crafts in

the first phase of development. In the final stage of development there

would be clearly designated Cape Size, Panamax and handymax berths

so that the dredging and other associated activities could be optimized.




3-55

The rated capacity of unloading and number of berths for

each commodity namely Coal, Lime stone, IBRM, Steel Products,

Bentonite and Cement is given in Table 3-23.

TABLE 3-23 - NUMBER OF BERTHS AND UNLOADING RATE FOR EACH COMMODITY

Berth/

De-berth

Hatch

movement

Average

Parcel Size

Annual Through-

put

No of

Ship

trips

Efficiency

Factor

Rated

capacity

Occupancy

Factor

Number of

Berths

3 0.9 136,500 16.5 121 0.60 5000.00 0.65 1.2

3 0.9 57,000 2.83 49 0.60 5000.00 0.36 1

3 0.9 155,000 15.10 110 0.60 6500.00 0.62 1

3 0.9 35,000 6.01 187 0.60 1200.00 0.64 2

3 0.9 38,000 0.33 6 0.60 4000.00 0.04 1

3 0.9 35,000 6.01 187 0.60 1200.00 0.64 2

3 0.9 26,000 5.30 165 0.60 2000.00 0.54 1

Total Ship Calls per annum 825 Total No. of Berths 10.00

Coal, with an annual throughput of 16.5 million tons, would

be transported in either Panamax or Cape Size vessels. The calculations

assumes the 330 days working in a year with 20 hours per day working.

For the coal and Lime Stone 2 unloaders with a 2,500 TPH rates capacity

would be deployed on each berth. For the IBRM berth, two unloaders of

3,250 TPH rated capacity would be required. For the steel products and

Cements, special handling is doctrine with mobile harbour cranes and

pneumatic loaders respectively. The quay length for the berths would be

3,400 m.

Additional berths for the jetty crafts also could be accounted

in the later years of the first development, so that the optimisation of the

capital expenses are achieves. Table 3-24, summarizes the findings

including the unloader capacity.




3-56

TABLE 3-24 - NUMBER OF BERTHS AND THE UNLOADER CAPACITY

Cargo No. berths Cap. Berth/tph

Coal 1.3 2 x 2,500

Lime Stone 1.0 2 x 2,500

IBRM 1.0 2 x 3,250

Steel Products 2.3 2 x 600

Bentonite 1.0 -

Cement 2.3 3 x 400

Clinker 1 2 x 1,000

Channel Alignment and Dimensions: The alignment of the

approach channel should generally be such that the entry and exit of

vessels to and from the jetty are possible with the maximum possible

ease. This requires that the approach channel should be aligned to the

most frequent direction of waves, so that rolling and yawing of the

vessel, while transiting the channel, are a minimum.

However, as already mentioned, the proposed jetty has

limited option for the alignment of the channels, keeping the same

outside Paradip Port limits. There are very limited options for alignment

of the approach channel, which necessarily has to be heading the about

3000 N for obvious reasons of keeping the entrance of SW monsoon

waves in to the estuary.

The channel after about 5300 m would turn to be parallel

with the Paradip Port boundary. A bearing further north would enter or

come very close to the Paradip Port waters. Interestingly, this bearing is

very close to the bearing of the Paradip Port Approach Channel, which is

1200. It is also supported by the most prominent wave direction, i.e.,

SSE or 1570.The length of the channel is about 6 km to the 15 m

contour, and about 11 km to the 20 m contour. The alignment of the

channel is given in the admiralty chart in Drg No JSW/JETTY/AC/001A.




3-57

Width of Channel: The required width of any channel,

measured at bed level, is expressed in terms of the beam of the Design

Vessel. In accordance with BIS Code IS: 4651 (Part V) – 1980, the

channel width should be 3.3 to 5.0 times the beam of the Design Vessel

for one-way traffic. For two-way traffic, BIS recommends the channel

width to be 6.1 to 8.0 times the beam of the Design Vessel. These

numbers are the mandatory minimums to be adopted.

The Permanent International Association of Navigation

Congresses (PIANC) and the International Association of Ports and

Harbors (IAPH) have published a Guide for Design of Approach Channels,

in which the International Maritime Pilots Association has participated.

It has been proposed in this Guide that model studies are desirable.

However, a Concept Design method for Approach Channels has been

recommended as given in the Table 3-25.

The values adopted in the case of this Jetty channel are

shown in bold italics.

TABLE 3-25 - WIDTH CALCULATIONS FOR APPROACH CHANNEL

1. Basic Maneuvering Lane, WBM Maneuverability

- Good 1.3 B

- Moderate 1.5 B

- Poor 1.8 B

2. ADDITIONAL WIDTH Wi Vessel Speed

Outer channel exposed to open water

Inner channel protected

water

(a) Vessel speed (knots)

- fast > 12 0.1 B 0.1 B

- moderate > 8-12 0.0 0.0

- slow 5-8 0.0 0.0

(b) Prevailing cross wind (Knots)

- mild 15 (< Beaufort 4) all 0 0

- moderate > 15-33 fast 0.3 B -

(> Beaufort 4 - Beaufort 7) mod 0.4 B 0.4 B

slow 0.5 B 0.5 B

- severe> 33-48 fast 0.6 B -

(>Beaufort 7 - Beaufort 9) mod 0.8 B 0.8 B

slow 1.0 B 1.0 B




3-58

(c) Prevailing cross current (Knots)

- negligible < 0.2 all 0.0 0.0

- low 0.2 - 0.5 fast 0.1 B -

mod 0.2 B 0.1 B

slow 0.3 B 0.2 B

- moderate > 0.5 -1.5 fast 0.5 B -

mod 0.7 B 0.5 B

slow 1.0 B 0.8 B

- strong > 1.5 - 2.0 fast 0.7 B -

mod 1.0 B -

slow 1.3 B -

(d) Prevailing longitudinal current (knots)

- low < 1.5 all 0.0 0.0

- moderate > 1.5 – 3 fast 0.0 -

mod 0.1 B 0.1 B

slow 0.2 B 0.2 B

- strong > 3 fast 0.1 B -

mod 0.2 B 0.2 B

slow 0.4 B 0.4 B

(e) Significant wave height Hs and length (m)

- Hs < 1 < L all 0.0 0.0

fast 2.0 B

- 3>Hs > 1 and = L mod 1.0 B

slow 0.5 B

fast 3.0 B

- Hs > 3 and > L mod 2.2 B

slow 1.5 B

(f) Aids to Navigation

- excellent with shore traffic control

0 0

- good 0.1 B 0.1 B

- moderate with infrequent poor visibility

0.2 B 0.2 B

- moderate with frequent poor visibility

> 0.5 B > 0.5 B

(g) Bottom surface

- if depth > 1.5 T 0 0

- smooth and soft 0.1 B 0.1 B

- smooth or sloping and hard 0.1 B 0.1 B

- rough and hard 0.2 B 0.2 B

(h) Depth of waterway

- >1.5T (>1.5t for Inner Channel) 0 0.0 B

- 1.5T - 1.25T(<1.5T-1.15T for Inner Channel

0.1 B 0.2 B

- <1.25T (<1.5T for Inner Channel) 0.2 B 0.4 B




3-59

(i) Cargo hazard level

- low 0.0 0

- medium 0.5 B - 0.4 B

- high 1.0 B - 0.8 B

3. Width for bank clearance, (WBr or WBg)

Sloping channel edges and shoals Fast 0.7 B -

Moderate 0.5 B 0.5 B

Slow 0.3 B 0.3 B

Steep and hard embankments, structures

Fast 1.3 B -


Slow 0.5 B 0.5 B

4. Width for passing distance, Wp

Vessel Speed Fast 2.0 B -


Slow 1.2 B 1.0 B

Encounter traffic density

- light 0 0

- moderate 0.2 B 0.2 B

- heavy 0.5 B 0.4 B

Thus according to PIANC/IAPH, the width of a one-way

channel would be 5.1 times the beam of the Design Vessel. One-way

channel is contemplated initially (where largest vessel is Cape), that is,

5.1 x 45 = 230 m. For a two-way channel, it is proposed to widen the

channel to 6.9 B = 310 m.

Depth of Channel: The depth required a ship to navigate any

sector of a channel safely and efficiently depends principally on the

maximum draft and the climatic conditions obtaining at the time of

navigation. It is obvious that the depth of water must be adequate to

allow for the effects of heave, pitch, roll, and squat. Other factors such

as fresh water draft, errors in charting, or post-charting siltation and

dredging tolerances also need to be taken into account.

The additional depth of water required over and above the

ship’s maximum draft due to the combined effect of all these inter-

related factors is termed as Net Under-Keel-Clearance, which is required

to be 0.3 m for soft bottoms and 1.0 m for rocky bottoms. The channel

depth components are depicted in Fig. 3-5.




3-60

CHANNEL DEPTH COMPONENTS

FIG. 3-5 - CHANNEL DEPTH COMPONENTS

It is envisaged to deploy Cape Size vessels for Coal and

IBRM. In fact Cape Size vessel would commence operation from the very

beginning of operation when, the squat would be 0.65 m.

The other parameters which govern the depth of the channel

have been examined. Heave is the vertical up and down motion of the

vessel due to wave action. It is assumed here that the design wave height

shall be 3 m. Since the waves in nature are not symmetrical, the trough

being only one-third of the wave height below the mean water level, the

heave is taken as 1.0 m.

The pitch of the vessel is taken as 10, from similar studies of

ship maneuverings on real time, full bridge models. The vertical motion

is therefore 2.0 m.

S

afety

C

learance




3-61

Thus the depth of water in the channel has to be the draft

(17.5 m) plus the squat (0.65 m) plus heave (1 m) plus pitch (2 m), giving

a total of 21.15 m. Deducting 1.0 m for entry restricted to high water

neaps, the dredged depth would be 20.15 m. Adding a net under keel

clearance of 0.3 m and a dredging allowance of 0.25 m, the capital

dredging would be to 20.70 m below Chart Datum. The maintained depth

could however be reduced to 20 m CD, considering that ships can pass

through mud layers, on the concept of nautical depth. Therefore, a depth

of 20 m would be maintained from the beginning of jetty operation.

Design of Berths and Breakwater: For safe maneuvering and

operation of the vessels at the berth and efficient cargo handling,

protective structures are often necessary to create the desired level of

tranquility. Therefore, depending on the marine environmental

conditions, if the jetty is located on the coast the required tranquility can

be achieved with provision of breakwater(s) of suitable length.

Accordingly the main structural components can be summarized as;

1. Breakwater

2. Berths

3. Storage and foreshore facilities

Breakwaters: The breakwaters are subjected to dynamic

forces of waves and need to be safe against the maximum wave action

expected at the site. At the same time the design of the breakwater

should be optimized so as not to become too costly without sacrificing

safety. In general the life of the breakwaters structure is taken as 100

years. In order to make an optimal design the choice of the design wave

height is very important.




3-62

The site is affected by SW and NE monsoons and wind

predominantly blows from SSE. In addition the Bay of Bengal is affected

by about 1½ cyclone per year on an average.

Selection of design wave: The near shore wave model carried

out with the effects of storm surge; indicate that, the maximum wave

height at a water depth of 10 m is about 7.5 m. The breakwater is

located at about 7.0 m of water. With storm surge of 1.6 m the maximum

breaking wave height at MSL is 7.04 m.

Accordingly, the breakwater shall be designed for these

breaking waves. For the other portion of the water, which is located in

the shallower portion, lesser wave heights shall be applied.

Depending upon the location of the breakwater it is essential

to know whether the depth of water at the structure is able to sustain

the design wave height i.e., whether the wave height at the site is

controlled by water depth. A wave breaking at the structure would exert

maximum force on the structure whereas a non-breaking or broken wave

would produce lesser force. Theoretically, a wave with height H would

break in a water depth of 1.3 H. It has been a common practice to design

a structure located in a water depth where d 1.3 H for breaking waves,

if 'H' is equal to or less than the design wave height, assessed for the

site.

The Mean High Water Springs at Paradip is +1.3 m and High

of High Water is + 2.58 m C.D. As already mentioned earlier, the

maximum probable wave height, with a recurrence period of one year,

which may reach the Coastal band from SSE, would be 7.5 m. Thus, the

minimum water depth required for sustaining 7.5 m wave would be

1.3 x 7.5 = 9.75 m. In general statistically all the worst conditions

occurring simultaneously, is rare.




3-63

Therefore, it is considered safe enough to assume the design

wave conditions at MHWS +2.58 m for zero order damage

For Breakwater

i) Breaking wave at MHWS + 2.58 m

ii) No overtopping of waves at HHWL

Type of structure: Rubble mound structure has been

considered for breakwater construction. The details of the breakwater

section are decided on various considerations, such as method of

construction, whether crest level be such that no overtopping of waves

would take place, crest width requirements, necessity for lee side

reclamation or otherwise, bedding requirements and large size stones

which could be available from the quarries.

In the rubble mound section, use of stones in the armour

layer is always economical. However the required size (weight) may be

neither easily quarriable nor possible to be transported to the breakwater

site. In such a case, new blocks of recent origin like Accropod and Core-

loc may be used due to the specific advantage that these blocks can be

used in a single layer instead of in double layer as is the case with most

of the other blocks.

For the preliminary design of the breakwater the following

conditions were considered.

i) No overtopping for HHWL ii) Specific gravity of stones as 2.7 and for concrete 2.4 iii) Stones more than 5 ton are not available economically

from the available quarries iv) KD factor for stones ( is given as 2 in Shore

Protection Manual (SPM) Based on our experience KD = 3 is in order.

v) Construction level at + 6.5 m or higher.




3-64

Based on various considerations mentioned in the earlier

paragraphs, breakwater sections for various reaches for the south, west

and north breakwaters have been worked out. It may be noted that

armour stones are used for the entire west and north breakwaters. For

the south breakwater, stones are used in the armour up to zero contour

beyond which 6 tons Accropod are suggested in the trunk portion. For

the round heads, 11 tons Accropod have been proposed. It may also be

noted that wherever there is reclamation on the lee side of the

breakwater no heavier stones are required for protecting the core.

However a geofabric filter would have to be provided between the lee side

core slope and the reclamation fill to avoid leaching of fill material

through the voids in the breakwater. The above sections are designed

considering normal wave attack on the breakwater section. It may be

noted that the possibility exists for reducing the armour size after

obtaining the directions of waves at various reaches and carrying out

model studies for the stability of the breakwater. Fig. 3-6 depicts

sectional profile of the proposed breakwater.

FIG. 3-6 - SECTION OF THE BREAKWATER




3-65

Structure for Berthing Face: The type of structure adopted for

providing berthing facilities can be broadly divided into the following two

types:

1. Continuous Wharf Type Structure (Diaphragm wall)

2. Open Berth Structure

Continuous Wharf Type Structure is again of two types,

Diaphragm wall Type and Caisson Type.

The open berth structure mainly implies berthing structure

on piles. Due to their inherent nature of offering minimum resistance to

the existing flow regime and sediment movement, the piled structures

have very little or no impact on the coastal morphology.

Accordingly, for facilities proposed near Paradip, berths are

planned on Piles.

In order to maintain flexibility of operation the berths are

proposed to be constructed in a continuous manner. However, the length

requirement for a berth is shown below;

Vessel Capacity .. 150,000 DWT Overall length and beam .. 305 m x 42.5 m Length of Berth .. 325 m Width of Berth .. 39 m Distance between rails .. 20.0 m Forward clearance .. 2.5 m Conveyors .. 5.0 m Footpath and other facilities .. 5.0 m

Total .. 32.5 m say 33 m




3-66

As per IS:4651 (Part V)-1980, for long continuous wharf for

large ocean going vessels, the recommended length of the berthing area

should not be less than the length of the design vessel plus 10% subject

to a minimum of 15 m. However, from the operation point of view, it is

always preferable to have a continuous, wharf, so that, the loading and

unloading equipments could be shared between the berths. Therefore, a

continuous wharf would be most ideal. As per the calculations above

only 6 berths are required and the length of each berth would be around

325 m. However, there would be a continuous berthing face for

accommodating all the vessels. The total length of the berths are 2 cape

berths of 362.5 m long and balance 2 Panamax berths of 290 m long

each and 4 handymax berths of 265 m each, totalling to about 2,365 m.

Design Basis for the Berths and estate level: A highest high

water level of about 2.58 m including a storm surge of 1.6 m and a water

level of 5.10 m has been adopted. Allowing for locally generated waves

due to high wind of 1.3 m and 1 m free board the jetty top level is

assumed at + 6.5 m CD for the coastal Harbour. The top level of berth is

therefore kept at + 6.5 m CD. The existing ground level is at around +

4.0 m and the dredged bed level is -16.00 m CD, with a 1: 2 slope for the

finished slope of the dock basin up to the dredged level s, the width of

the Jetty head could be calculated as follows:

Top Level of jetty (and estate level) .. + 6.5 m Bottom level of skirt beam of berth .. + 5.0 m & the top level of skirt .. + 3.5 m Bed Level .. - 19.50 m With 1:2 slope up to bed layer Vertical distance .. 19.50 m Horizontal distance .. 39.00 m So width of the berth .. 39.00 m




3-67

Accordingly, the width of the berths is decided. It should be

noted that as indicated above, from the handling point of view only a

width 33 m is required. Therefore, the greater of the two, would be

adopted in the present case.

Material Handling Systems & Equipment: The broad concepts

on cargo handling systems are:

i) The jetty would work round the clock. ii) All ships are to be turned around in a maximum of

3 days (72 hours). As a matter of abundant caution the system capacities would enable the unloading/ loading the maximum size of ships of any particular cargo in about 48 hours’ time.

iii) Uni-flow of cargoes without any backtracking or contra-

flow at any stage. iv) Parallel flows of cargoes so that crossing of flows is

avoided. v) Protection of cargoes from climatic conditions, during

receipt, handling, transfer and storage e.g. cement and coal being conveyed with totally enclosed systems (which has also the benefit of protecting the environment),

covered areas limestone and steel etc. vi) Provision of facilities for weighing/measuring of cargoes

received and cargoes dispatched like belt scales, flow-meters, weighbridges, etc. for all commercial and accounting proposes at appropriate stages.

vii) With loose bulk materials like coal, etc., the in-jetty

storage capacity to be adequate for a minimum of 1 month cargo by the trade.

viii) Adequate storage capacity for each cargo so that there is

no simultaneous receipt as well as dispatch of materials from any individual storage area/stack.




3-68

ix) Separate access to each storage for cargo evacuation so that the outflow from each area would be smooth and unhindered.

x) Easy road access to all the operational areas, storages. xi) Minimising the rail network in the jetty while fully meeting

the rail evacuation requirements. xii) Central Co-ordination Control tower to monitor jetty

activities and house latest Meteorological facilities Coal: The jetty operations in coal handling are broadly

divided into the following sequential operations.

i) Unloading from ship and transfer to the wharf belt conveyor.

ii) Transfer through a belt chain to stack feed conveyor ii) Transfer to the stacker through a tripper iv) Stacking of coal by the stacker v) Reclaiming by the reclaimer and transfer to the out

loading conveyor vi) Transfer to the loader belt through a cross conveyor vii) Transfer to the loader through a tripper viii0 Transfer of the cargo to the Plant day bins of each

plant without any separate storage at the plant site.

Lime Stone: Open storage of limestone is proposed, with 4

stacks of 450 x 50 x 10 m and would be handled as ‘dry bulk cargo’ by

grab unloaders. Reclaimation would be done by bucket chain reclaimer.

The reclaimer and the subsequent belts would be wholly controlled for

delivery to the day bins of the plants directly.

Finished Steel Product: During initial stages, plates,

structural & construction materials and wires would be imported for the




3-69

Odisha plant and stored in the open, for which level yards shall be made.

This area would be used in the later stages for storing the steel products.

The unloading and loading for the loading for the imported

billets, plates, structural & construction materials and wire as well as

the steel products shall be carried out using Mobile harbour cranes, and

later replaced with fixed unloaders/loaders. The Conveying of these

materials shall be carried out using the FLT or tractor trailer. The

unloaders would directly unload on to the trailers.

3.7 RESOURCE OPTIMIZATION/RECYCLE & REUSE

ENVISAGED IN THE PROJECT

The Jetty would have minimum recycling of the

resources, since it mainly deals with the servicing of the Cargo,

stacking, reclaiming and then sending the same to the plant heads or to

the ship as the case may be. As it is not a manufacturing process no

recycling items is envisaged, except for fender rubber systems and

usable.

The steel plant would be designed with state-of-art

technology for optimum consumption of energy & other resources. By

product fuel gases would be reused within the plant as in-plant fuel and

also to produce power in the CPP. Coke oven gas would be used as

reductant to produce DRI. In addition, adopting a compact layout for the

Plant would enable to optimise the utilisation of land, which is another

critical resource. By utilising the fines and scrap generated during the

process within the plant for the production process, usage of raw

materials is optimised. Water consumption would also be optimised by

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

make-up in the network along with adoption of practices like dry type

GCP for BF & BOF gas. Solid byproducts would be reused to the extent




3-70

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

cement manufacturing unit.

3.8 AVAILABILITY OF WATER AND POWER

3.8.1 Water

Iron Ore Grinding and Desliming Unit: Water required for

the proposed iron ore grinding and desliming plant at Joda would be

drawn from Baitarani river at a distance of about 10 km from the

proposed site and stored in a raw water reservoir located outside the

plant boundary at Joda.

Raw water from above reservoir would be pumped to a

smaller reservoir within the plant premises. The requisite quantity of

water from the raw water reservoir would be drawn and treated in raw

water treatment plant. The make-up water generated would be stored in

make-up water reservoir at plant premises.

The requirement of make-up water would be about 2,940 cu

m/hr for Joda plant. The unit wise requirement of water is shown in

Table 3-26.

TABLE 3-26 - JODA UNITWISE REQUIREMENT OF WATER

Sl.

No. Description

Make up

(m3/hr)

1 Process water for slurry preparation 2,100

2 Evaporation & Seepage Loss 150

3 Dust suppression 100

4 Drinking 10

5 Greenbelt maintenance 50

6 Moisture retained in slime 50

7 Miscellaneous (Batching & Flushing) 480

Total 2,940

Captive Jetty: The approximate water requirement is

estimated to be 87.5 cu m/hr. The water requirement for various

activities is shown in Table 3-27.




3-71

TABLE 3-27 - CAPTIVE JETTY - REQUIREMENT OF WATER

Description Quantity

Dust suppression .. 75 m3/hr

Bunkering .. 11.5 m3/hr

Sanitary and drinking .. 1.0 m3/hr

Total .. 87.5 m3/hr

Integrated Steel Plant: Jobra barrage of Mahanadi River

near Cuttack has been identified as the source of river water for the

proposed Steel Plant, in view of the salinity of the nearby rivers and

availability of water to cater to future expansion. It would be required to

lay 87 km long pipeline to bring water from Jobra barrage to the plant.

The total water requirement for the steel plant and captive

power plant would be approximately 12,415 m3/hr. However, about

1,500 m3/hr of water would be recovered from iron ore slurry & reused

for ISP. About 1,715 m3/hr of water would be recovered after treatment

from the effluent generated in ISP. So net requirement of makeup water

would be 9,200 m3/hr, which is proposed to be drawn from Jobra

barrage on Mahanadi River. It is also envisaged to provide for a water

reservoir to meet the requirement during the lean season with adequate

pumping capacity.




3-72

The unit wise requirement of water is shown in Table 3-28.

TABLE 3-28 - ISP UNITWISE REQUIREMENT OF WATER

Sl.

No. Consumers

Make-up water

cu m/hr

Soft water

cu m/hr

DM water

cu m/hr

Effluent

generation

1 Raw material handling 300

2 Sinter plant 60 5 10

3 Pellet plant 600 20 32

4 Coke oven 900 400 250

5 BF 1,395 120

6 HMDS1&2 10 4

7 BOF1 465 8 180 54

8 LF1 60 15 15

9 RH1 80 6 20

10 Slab caster 285 15 50

11 HSM 1,340 300

12 CRM complex 380 90 200

13 Tin plate 145 10 110

14 Silicon steel 100 30

15 Plate mill 250 56

16 DRI 380 20 100

17 BOF2 155 3 60 18

18 LF2 20 5 5

19 RH2 20 2 5

20 Billet and Billet/bloom caster 75 2 20

21 Rebar mill 90 22

22 WRM 65 15

23 MSM 85 22

24 Cement plant 150 36 18

25 Calcining plant 5 2

26 Air separation plant 900 225

27 CPP 2,200 120 300

28 Chilled water plant 250 62

29 Softening plant 260 15

30 DM plant 970 90

31 Drinking & sanitation 220 150

32 Other Miscellaneous 200

Total 12,415 2,200

Recovery from effluent treated in CETP for reuse

1,715

Recovery from dewatering iron ore slurry

1,500

Net Make-up Water Requirement 9,200

Evaporation Loss in CETP 50

Reject water to be discharged to sea 435




3-73

3.8.2 Power

Iron Ore grinding & desliming Units: The power

requirements for the proposed facilities at Joda would be met from JSW

Energy/grid power supply. The estimated overall power requirement for

the proposed facilities at Joda is given below.

Joda

Annual energy consumption, kWh x 106 712

15-min. maximum demand, MW 100

1-min. peak demand, MW 106 To meet any exigency during power failure, DG sets of

required capacity would be provided. For areas not provided with DG

sets, provision would be made for taking emergency lighting power

supply in the substations, control rooms, etc. from the control battery

banks, where provided, or from the portable emergency lighting units.

Captive Jetty: Power for the jetty is envisaged to be

purchased from OSEB at 66 kV, through overhead lines in duplicate

feeders up to the switch yard located within the jetty premises or tapped

from incoming feeder of ISP. The power distribution within the jetty

premises would be through underground cables laid in cable ducts or

tapped from incoming feeder of ISP. The power demand of the captive

jetty is presented Table 3-29.

TABLE 3-29 - ESTIMATED ELECTRICITY LOAD FOR THE PROPOSED

JETTY

Sl. No. Unit Total Demand, kW

1. Lime stone Handling 1,360

2. Coal Handling 4,400

3. Steel Products Handling 1,000

4. Fire Fighting and Water Supply 500

5. Lighting, Air-conditioner, Lifts etc. 2,500

6. Miscellaneous Loads 1,000

Total 12,960

The Peak Demand with a diversity factor of 0.7 9,500

With a PF if 0.95 10,000 KVA




3-74

Adequate numbers of DG sets are envisaged to provide power

to the jetty, in the case of power failure. These generators would meet

the emergency requirements and lighting load and not for cargo

handling.

Integrated Steel Plant: The estimated power requirements

of various plant units including utilities and auxiliary facilities for the

Plant is indicated below:

Annual energy consumption, kWh x 106 .. 10,914 Average demand, MW .. 1,350

The power requirement would be met from the following

sources:

i) State Grid power supply system at 220 kV

ii) Captive power Plant based on surplus By-Product Gas and steam coal

iii) TRT (Top Gas recovery from Blast Furnace)

iv) CDQ (Waste Heat from Coke Dry Quenching)

The power requirement of the integrated steel plant is

elaborated in the Table 3-30.




3-75

TABLE 3-30 - POWER REQUIREMENT

Plant Unit

Annual energy

requirement, kWhx106

Average Power

Demand, MW

Dewatering and Filtration unit 109.80 13.73

Coke oven with CDQ 480.00 54.79

Tar Distillation Plant 20.26 2.31

Benzol Refining Plant 13.15 1.50

Pellet Plant 1280.00 161.62

Sinter Plant 242.56 30.63

Gas based DRI plant 193.20 24.15

Blast furnace with Elec Blower 1755.00 208.93

BOF1 including HMDP 399.00 50.38

BOF2 including HMDP 113.62 14.35

LF1 315.0 39.77

LF2 89.7 11.33

RH1 12.60 1.59

RH2 1.79 0.23

Slab Caster 154.35 19.49

Billet/Bloom Caster 34.98 4.42

HSM 767.69 96.93

Plate Mill 153.79 20.21

Rebar Mill 115.20 14.41

Wire Rod Mill 81.00 10.23

Medium Section Mill 60.00 7.99

Cold Rolling Mill (PLTCM) 391.00 52.55

Continuous Annealing Line 117.00 15.73

Continuous Galvanising Line 143.33 19.26

Colour Coated Line 69.65 9.36

Silicon Steel 44.55 6.09

Tin plate Mill 47.83 6.53

RCL-1 1.74 0.22

RCL-2 0.93 0.12

Cement Plant 360.00 45.45

Calcination plant 66.37 8.38

ASP 1663.20 210.00

RMHS 286.06 32.65

Utility and Services 1011.75 115.50

Total plant requirement 10596.10 1310.82

Total with 3% loss 10913.98 1350.15

Total with 1.25 diversity factor 10913.98 1350.15




3-76

DG sets of adequate capacities are proposed for the plant

units as well as CPP auxiliaries to cater to the requirement of safe

shutdown and safety of personnel during total black-out condition when

power supplies to plant network from both the sources viz. grid and CPP

have failed.

3.9 WASTE GENERATION AND MANAGEMENT

3.9.1 Wastewater generation and management

Iron Ore grinding and desliming Units: There would be

generation of waste water due to slimes from the grinding & desliming

unit, floor washings and surface run-off from the dry ore stockpiles

during monsoons. The slimes before paste thickener would have about

30 % fine solids by weight. The slime would be taken to paste thickener

to recover water and the paste containing about 70% solid would be

stored in a slime storage area.

All the waste water streams would have only suspended

solids, whether it is slimes or floor washings or run-off from the

on-ground stockpiles. It is proposed to have separate clarifier exclusively

for treating floor washings and surface run-off from stockpiles. The

clarified water would be reused within the plant and the underflow would

be mixed with the slimes for disposal in the slime storage area. Effluent

in the form of Sewage would be treated in package type sewage treatment

plant (STP) and the treated sewage would be reused for dust suppression

& greenery development.

Captive Jetty: Wastewater generation from the jetty would

be in form of sanitary effluent and industrial effluent consisting of

washing of ships, washing different types of machines and devices as

well as water which are used for cooling the devices, etc. The sanitary

wastewater would be pumped into the sewer system in the jetty area

which would be reused for dust suppression & greenery development

after treatment.




3-77

There would be a STP/ETP set up for this purpose and the

treated water would be used for sprinkling or horticulture. The

sprinkling water would be in form of a fog hence substantial run off is

not expected in to the dumping pond. The collected water in the dump

pond would finally be treated in the STP/ETP and reused.

Integrated Steel Plant: Around 2,200 cu m/hr of effluent is

estimated to be generated from cooling towers blow down, sewage

treatment plant, BOD Plant, DM Water Plant, Soft water plant, CRM etc,

which would be treated in Central Effluent Treatment Plant (CETP) for

re-use in the plant. Reject water generated from CETP RO plant (about

435 cu m/hr) is proposed to be discharged into the sea. About 1,500 cu

m/hr of water would be recovered from the dewatering of iron ore slurry

which would be further treated in waste water treatment plant for

utilization within the steel plant. However, during interim period

(construction phase) recovered water from the iron ore slurry would be

discharged into the sea after meeting the discharge standards.

Effluent water would be treated to the desired extent in

suitable treatment facilities and recycled back to the process as

make-up, facilitating adequate re-use of water in the respective re-

circulating systems and economizing the make-up water requirement.

Part of the effluent would be re-used after primary treatment in CETP for

firefighting system, floor washing, toilet flushing, dust suppression and

horticulture. Sewage generated from toilet blocks etc would be collected

by means of suitable sewer system for treatment in Sewage Treatment

Plant (STP). Biological solid waste generated from STP would be used as

manure for development of greenery. Chemical sludge and salt would be

sent to near-by secured landfill site.




3-78

3.9.2 Solid Waste Management

Iron Ore grinding and desliming Units: The major solid

waste would be the slimes consisting of total non-magnetic fraction

obtained from the WHIMS. The slime would be partially dewatered in a

high rate thickener followed by final dewatering in a paste thickener. The

paste thickener would be located inside the plant boundary and the

paste at high solid concentration (around 70 per cent solids by weight)

would be discharged to the slime storage area. The clarified water

obtained as overflow from the concentrate thickener, intermediate

thickener and paste thickener would be collected in a tank and pumped

back to the plant for reuse. Around 120 acres of land has been

earmarked for dry disposal of slime generated from the proposed grinding

and desliming plants. The dry slime would be evacuated from time to

time and sold to potential users like cement/tiles/brick manufacturers

etc.

The slimes storage area of appropriate holding capacity,

lined with appropriate liner would be constructed for a lifetime of at least

20 years with gradual increase of embankment height.

Captive Jetty: In general, very less quantity of solid

waste is generated from the jetty activity. Solid waste of other

municipal origin shall be segregated into biodegradable and non-

biodegradable component. Non-biodegradable waste shall be disposed

of through the authorized vendors. Biodegradable waste shall be

composted onsite and shall be used as manure for horticulture.

Integrated Steel Plant: The estimated generation of major

solid wastes is shown in Table 3-31.




3-79

TABLE 3-31 - SOLID WASTE GENERATION FROM THE ISP

Solid wastes

Expected

generation Management Scheme

MTPA

BF Slag 3.8

Granulation in Slag granulation plant

and used in cement manufacturing in captive cement plant. A small quantity

would be used internally in the ISP

Steelmaking Slag 2.02

Recovery of metallics & non-metallics for

in-plant use. Balance utilized as railway

ballast, in construction aggregrate, after processing.

Flue Dusts 0.3 Reuse in Agglomeration

Mill Scales/Sludge 0.15 Reuse in agglomeration

Chrome & other Sludge 0.0015 Transferred to authorized agency

Fly Ash 0.94 Used to produce cement in the captive

cement plant.

Bottom Ash 0.24 Would be stored in ash pond and used

for road making

Besides the above, there would be other solid wastes like

clarifier sludges, ESP/Bag Filter dust, refractory debris etc. generated

from the proposed steel plant. These would be reused/recycled within

the plant to the extent possible and the balance would be transferred to

Authorised agencies for reuse/recovery of materials/disposal as per

prevailing regulations.

3.9.3 Air Pollution

Iron Ore grinding and desliming Units: The proposed iron

ore sizing & grinding & desliming plants near Joda would comprise of

three physical operations namely,

i) Receipt of crushed iron ore by conveyors and stockpiling

ii) Ore grinding & desliming by washing with water for separation of undesirable impurities present in ore

iii) Finally, transportation of beneficiated ore of different size fractions




3-80

The grinding and desliming process, being wet ore, would not

cause any air pollution as such except fugitive dust emissions in the

handling, sizing and stocking of dry ores.

Fugitive dust emissions arising from the handling and

stockpiling of dry iron ore would be arrested by compressed air based

water spraying (dry fogging) at several emission points. In addition,

there would be an arrangement for water sprinkling for the dry

stockpiles to abate wind borne dust emission.

The closed zone would be the sizing plant, which would be

housed in a separate building. Dry fogging (DF)/Dust Extraction (DE)

system would be adopted to control the fugitive dust emissions in the

closed zone. It is also envisaged to clean the nozzles at regular intervals

for effective utilization of DF system.

All the conveyors carrying sized materials would be of

covered type. The transfer points would be suitably designed to avoid

ingress of water. In addition, there would be provision of DF system at

the transfer points to arrest fugitive dust emissions.

Captive Jetty: Air emissions from the captive jetty would be

mainly fugitive dust emission from the stockpiles and during conveying

of materials. The fugitive emission would be controlled by water

sprinkling and dry fogging. In addition, there would be a row of wind

shields, that would be provided around the stockyards so that any

unlikely emission of dust could be arrested from spreading. The height of

the stock piles would be minimum 2 m less than that of the wind

shields.




3-81

Integrated Steel Plant: Various process operations would

generate particulate dusts, volatile organic carbons (VOCs), oxides of

sulphur and nitrogen and carbon dioxide to the environment. The

emission would be from the stacks as well as there would be fugitive

emission of dusts from open & closed areas.

Fugitive dust emissions generating from the handling and

stockpiling of raw material in open stockyards would be controlled by

water sprinkling at regular intervals. All closed zone working areas

such as raw materials handling zone, conveyor transfer points, dust

generation points at screen would be provided with dust extraction (DE)

systems/dry fogging (DF) at several emission points to control the

fugitive dust emissions. DE system shall consist of suction hood followed

by bag filter/ESP, ducts, extraction fans and stack of appropriate height.

Coke oven: Emissions from coke ovens would mainly result

from coal charging and coke pushing. Fugitive emissions may result

from various leakages from oven doors, charging lids, ascension pipe (AP)

covers etc. Charging emissions would be controlled by High Pressure

Liquor Aspiration (HPLA) injection in goose neck during charging.

Coking emissions would be controlled by efficient sealing of oven doors,

water sealing arrangement of AP cap etc. Land based fume extraction

system would be adopted for charging and pushing emission control.

The hot coke would be quenched by coke dry quenching (CDQ) with

recovery of sensible heat for steam generation.

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

recovery plant with recovery of tar, ammonia and sulphur to make it

suitable for use as plant fuel and as reductant in the DRI plant.

Sinter plant: The conventional air pollution systems like DE

systems of sinter stock house based on electrostatic precipitator (ESP)

and waste flue gas cleaning by ESP would be considered. The particulate




3-82

dust emission from the product sinter screening units would be

controlled by DE systems complete with duct, fabric filters and stack of

adequate height. Partial recirculation of waste gas would be adopted for

heat recovery and energy conservation measures. MEROS (Maximised

Emission Reduction of Sintering) Process for reduction of oxides of

sulphur, heavy metals and organic compounds would be installed.

Pellet Plant: Emissions from Pellet Plant would mainly be

from Induration Process, which are controlled by installation of ESP with

adequate height of chimneys.

Blast furnace: In addition to cleaning of BF gas in dry type

gas cleaning plant (GCP), the main sources of air pollution would be

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

DE systems complete with dust extraction hoods, ESP/ Bag Filter, ID fan

and stack of adequate height. Similarly, the cast house would have

separate fume collection system during taping of hot metal and slag,

equipped with bag filter/ESP for separation of particulates before venting

through a stack of appropriate height.

Heat recovery from stove waste gas shall be installed for

preheating of BF Gas and combustion air for stoves. In addition, energy

conservation would be carried out through installation of TRT and

pulverized coal injection.

Lime/Dolomite Calcining Plant: The emissions arising due

the fuel burning in lime calcining plant would be collected and taken

through a bag filter to separate out the lime/dolo fines. The lime/dolo

fines thus collected would be recycled to the sinter plant. The kilns in

the calcining plant and other dust generation areas would be provided

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

adequate height to clean the particulates.




3-83

BOF: Besides BOF gas cleaning in dry type GCP, which is

basically a process necessity, secondary emissions would be generated

mainly from charging and tapping operations. The secondary emissions

of the steelmelt shop would be controlled by APC comprising of doghouse

with collection hood, ID fan, bag filter and stack of appropriate height.

Ladle Furnace: The primary emissions of LF would be

collected by fume extraction (FE) devices. Dust laden fumes would be

indirectly cooled and cleaned through a bag filter for separation of

particulates and the clean gas would be vented into the atmosphere

through a tall stack of adequate height. The secondary emissions would

be controlled through canopy hood extraction, which would be integrated

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

tapping operations. The gas cleaning system would be complete with

water cooled duct, fume and gas cooler, bag house, ID fan and stack of

appropriate height.

Caster Area: The water required for cooling the hot cast

slabs and billets would generate hot fumes comprising mainly water

vapour, hot waste water and suspended particulates. The slab casting

area would be provided with adequate ventilation in order to have the

water vapour properly dispersed.

Rolling Mills: Clean by-product gases would be used in the

reheating furnaces as fuel. Burning of the gases would give rise to the

emissions of particulates, CO2 and NOx. NOx emissions would be

controlled by optimising the excess air supply and proper burner design.

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

which is fairly clean, would be vented through a stack of adequate

height. The acid pickling line of CRM would be provided with a scrubber

system for fume extraction (FE) along with acid regeneration plant (ARP).




3-84

For annealing/galvanizing/colour coating of Cold rolled (CR)

coils, it would be heated in the inline annealing furnaces prior to its

respective treatments. The waste produced due to burning of fuel would

be vent to the atmosphere through a stack of adequate height.

The non-annealed cold rolled coils would undergo hot dip

galvanisation in molten zinc baths followed by passivation. These

processes would generate vapours and fumes which would be controlled

by fume extraction systems.

Cement Grinding Unit: The cement grinding unit would

comprise of raw material storage, handling and feeding facilities and

finished product storage, handling and packing facilities. The main

sources of air pollution would be fugitive dust emissions from the raw

material and product handling units. The raw material and product

handling facilities would be equipped with dust extraction systems

comprising of bag filters.

Captive Power Plant: The surplus by-product fuels gases

and steam coal would be burnt in the boilers for generation of power.

Power would also be generated from CDQ & TRT. The flue gas thus

generated from the boiler would be vented through stack of appropriate

height. ESPs would be provided to capture the fly ash generated by the

coal fired burners.

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY

DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE

As per the Environment Impact Assessment (EIA)

notification dated 14th September 2006 and subsequent amendments,

this project falls under category A. It would be required to prepare

EIA/EMP report to obtain the Environmental Clearance (EC) for the

project from the MoEFCC. The schematic diagram given in Fig. 3-7

represents the steps required for EIA to obtain the EC.




3-85

FIG. 3-7 - SCHEMATIC DIAGRAM



4-1

4 - SITE ANALYSIS

4.1 CONNECTIVITY

4.1.1 Iron Ore grinding and desliming plant

National Highway (NH) 520 runs along South and North West

of Iron ore grinding & desliming units located near Joda at a distance of

about 2 km from the project sites.

The proposed unit near Joda is 10 km away from Joda town

and can be approachable from Joda by NH 520 and fair weather

Panchayat roads. The nearest Railway Station, Deojhar under SE

Railway is located at a distance of about 1 km.

The slurry would be pumped from Joda pumping facility

to the Pellet plant located within the Integrated steel plant near Paradeep

at Jagatsinghpur district via slurry pipeline having total length of

312 km.

4.1.2 Integrated Steel Plant and Captive Jetty

SH 12 connecting Cuttack and Paradeep is situated at the

northern side of the proposed project site. NH 53 connecting Chandikhol

& Paradeep is located along the eastern side of the site and the site

requires road linkage from the Highway NH-53. The site is connected by

roads, including National highways, to Bhubaneshwar/Cuttack and

Paradeep Port.

The nearest rail station is Paradeep & Siju. Railway

connectivity exists between Cuttack & Paradeep, Haridaspur & Paradeep

and Haridaspur & Siju. It would be required to set up railway linkage

from the nearest available railway line. The nearest airport is

Bhubaneswar at a distance of around 120 km by road. The nearest port



4 - Site Analysis (cont’d)

4-2

is at Paradeep, about 12 km from the plant site. However, the proposed

captive jetty would be used for its raw material receipts & transfer of

finished products.

A map showing road and railway connectivity is presented in

Fig. 4-1.

FIG. 4-1 - MAP SHOWING ROAD AND RAILWAY CONNECTIVITY

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

4.2.1 Iron Ore Grinding and Desliming Units

The proposed site for location of Iron ore grinding & de-

sliming would be located at Govardhanpur village near Joda in Keonjhar

district of Odisha. The land area required would be 391.93 acres, out of

which forest land is about 130.53 acres. About 47% of the total 391.93

acres is already registered as leased land.




4-3


The proposed site for setting up of the Greenfield ISP project

is located within the jurisdiction of Ersama Tehsil of Jagatsinghpur

District of Odisha. The geographical location of the project site lies

within 20011’ to 20013’ North latitude and 86030’ to 86035’ East

longitude.

Around 2,980 acres of land would be required for the

proposed ISP project. The proposed site primarily consists of forest land

and the rest is industrial land under the ownership of IDCO.

4.2.3 Captive Jetty

The proposed captive jetty, located adjacent to the ISP would

also lie within the jurisdiction of Ersama Tehsil of Jagatsinghpur District

of Odisha. The geographical location of the project site lies within 20011’

to 20013’ North latitude and 86030’ to 86035’ East longitude.

The land area of 180 acres would be required for the captive

jetty which primarily consists of industrial land under the ownership of

IDCO.

4.3 TOPOGRAPHY

4.3.1 Iron Ore grinding and de-sliming Plant

The Joda grinding and desliming unit is located in the

Baitarini river basin. The general elevation of the area is about 485 m

above MSL. The region lies between the hill ranges of Gandhamardan,

Thakurani and Kiriburu having undulated topography intercepted with

mountains and hills with altitudes ranging from 488 to 918 m above

MSL. The drainage pattern of the area is dendritic in nature. The River

Baitarini is the only drainage channel of the study area. Most of the

monsoon run-offs from the hills lead towards the Baitarini River

drainage system.




4-4

The topographic features may be seen from Survey of India

Topo Sheet Nos. 73F8, 73 F12, 73 G5 & 73 G9 for the grinding and

desliming plant located at Joda and is shown in Fig 4-2.

FIG. 4-2 - TOPOGRAPHIC FEATURES OF GRINDING AND DESLIMING PLANT SITE AT JODA




4-5


The project area and its surroundings (10 km from the plant

boundary) being a part of Mahanadi delta is a flat land with hardly a

relief. The general elevation varies from 1m to about 5 m above mean

sea level having a peak height of 10 m at the apex of Jatadharmohan

River Creek catchment. The landform elements of the southern part

include such coast line features as prograding barrier beach-sand

dune-sand spit-creek system separating the inland areas from open sea.

The northern part of the Jatadharmohan is a sandy flat with subdued

dune topography.

FIG. 4-3 - TOPOGRAPHIC FEATURES OF INTEGRATED STEEL PLANT AND CAPTIVE JETTY SITE NEAR PARADEEP




4-6

The topographic features of the study area may be seen from

Survey of India Topo Sheet OSM Nos. F45U7, F45U8, F45U11 and

F45U12. The Topographic map is shown in Fig 4-3.

4.4 SOIL

4.4.1 Iron Ore grinding and desliming Units

The soil in Joda, can be broadly categorized as lateritic type,

rich in iron and aluminum. The soil is broadly grouped into Ultisols

comprising mainly of lateritic soils and red and yellow soils and two

Alfisols comprising red sandy soils and red loamy soils.


The soil cover of the area mainly consists of silty sand. The

project site would be reclaimed using dredged sand to raise the level 1m

above the highest storm surge level.

4.5 CLIMATIC CONDITIONS

4.5.1 Iron Ore grinding and desliming Units

The regional climate of the Joda is located in humid tropical.

The annual average temperature and humidity of the region are 27°C and

70%. The average wind speed is around 5.5 kmph.


The regional climate is humid tropical. As per India

Meteorological Department, Pune (IMD), the lowest temperature recorded

was 120C as against highest temperature recorded was 41 0C in the

month of May. The relative humidity (RH) is uniformly high in the order

of 80% throughout the year except during the winters.

The wind blows predominantly from South West (SW) during

the period from March to September and for rest part of the year wind

generally blows from north and northeast directions. The study area is

prone to frequent depressions and storms and there are chances of

occurrence of cyclones.




4-7

4.6 SOCIAL INFRASTRUCTURE AVAILABLE

4.6.1 Iron Ore Grinding and Desliming Units

The proposed mineral grinding and desliming plant is located

in the village of Gobaradhanpur, in Joda Block in Keonjhar district of

Odisha. On the onset of the new millennium, this district, rich in iron

ore deposits, experienced unparalleled industrialization. With availability

of raw materials and cheap labour, investments have strengthened and

the local economy is predominantly based on large-scale steel producers

with its ore processing plants within the region.

Several secondary and tertiary educational institutes

characterize Keonjhar. The professional training is skewed towards

engineering, medical and commerce field.

Structured townships with adequate greenbelt, luxury hotels

and restaurants are available in the district. High traffic connecting

routes are wider and in good condition along with strong transport links.

However, Keonjhar, under Ministry of Panchayati Raj in

2006, had been enlisted as one of the most backward districts of the

country and is one of the 19 districts in Orissa currently receiving funds

from the Backward Regions Grant Fund Programmes (BRGF).

Government schemes like Madhu Babu Pension Yojana, Indira Awas

Yojna, Indira Gandhi National Old Age/Widow/Disability Pension

Scheme are operational.

According to the Census data of 2011, Schedule Caste (SC)

constitutes 11.6% while Schedule Tribe (ST) is 45.4% of total population

in the district. Some of the principal tribes are Bathudi, Bhuyan,

Bhumij, Gond, Ho and Juang. The tribal groups are engaged in

agricultural activities or are working as casual labourers in mining and




4-8

quarrying services. Assimilation of the tribal groups with mainstream

communities and continuance of their own ethnic and cultural identity is

a parallel social process witnessed in the area. Apart from Oriya

language, the indigenous population of the district speaks adivasi

language like the community of Bhunjiya.

Abundant but unpredictable distributions of rainfall result

in crop failures in the area. Around 80% of the rural workforce earns

their livelihood through a combination of practices that include

traditional agriculture, selling of fuel wood, collection of non-timber

forest products and wage earning. Only 6 % of the local population earns

their livelihood in the working mines of the district.


The proposed Integrated Steel Plant and Captive Jetty (12 km

south along the coast of Paradeep Port) falls under the district of

Jagatsinghpur. The district ranks first in the state in male literacy rate

with 88.96 percent and second in female literacy rate with 69.94 per cent

(Census 2011). Govt degree college, Govt womens college, three nos of

ITIs, three Nos of DAVs and one DPS and other convent schools exist in

and around Project site. In addition, there are around thirty junior

schools are also available for boosting education in the close vicinity of

the project site. However, few other colleges like Swami Vivekananda

Memorial (Autonomous) College, Jagatsinghpur; Adikabi Sarala Das

Mahavidyalaya, Tirtol; Sidha Baranga Junior College of Education and

Technology, Punanga; Keduapada Higher Secondary School ,

Gadibrahma Women’s College, Keduapada; Biju Patnaik (Junior) College,

Ashrampatna ; Swami Vivekananda Memorial (Junior) College,

Jagatsinghpur; Swagatika College of Science and Education in

Jagatsinghpur are prominent secondary and tertiary educational

institutes of the district.




4-9

Natural calamities like floods and cyclones are major

hindrance in the economic development of the area. The project area

indicates absence of skilled industrial work force. Production and allied

activities related to agriculture, dairy and animal husbandry is

prevalent. Ancestral income from fishery, betel vineyards and cashew

plantations is predominant. Additionally, small-scale trade and

household industry (bamboo products & fishnets), transport services,

non-agricultural labour engages a major portion of local population.

The prominent local industries are Paradeep Port Trust,

Essar Group, Paradeep Phosphates Limited, Skol Breweries Limited,

Hindustan Petroleum Corporation Limited (Oil Terminal) , JSW

Infrastructure, IFFCO and Indian Oil Corporation Limited.

Primary Health Centres (PHCs), Anganwadi Centres

(emphasizing on maternal health and childcare), Auxiliary Nursing

Mother (ANM) centres and local private clinics are operational in the

study area. Paradeep hospital managed by Paradeep Port Trust within

the project area is a prominent medical centre. Critical cases are referred

to hospitals in Cuttack.

Rural Development Programme and Rural Electrification

Scheme have reached several villages in the project influence area.

Under such schemes, interlink roads between villages and provision of

regular supply of electricity has been facilitated.



5-1

5 - PLANNING BRIEF

5.1 PLANNING CONCEPT

The proposed iron ore grinding & desliming plant would be

located near Joda in Keonjhar district of Odisha. The area requirement

would be about 391.93 acres for the plant facilities, railway siding, road

& pipeline corridor and dry disposal of slime.

The proposed ISP and captive jetty would be located near

Paradeep, Odisha. The total land area of the proposed project would be

about 3,160 acres spread across 7 villages in Jagatsinghpur district of

Odisha.

5.2 POPULATION PROJECTION

5.2.1 Mineral Grinding and Desliming

Radial coverage of 10 km from the proposed mineral

beneficiation plant site at Gobaradhanpur (in Joda block within Keonjhar

district) comprises of around seventy-two villages. The other core zone

villages are Beleipada & Bhagalpur. The total population as per 2001 and

2011 Census data was 52,555 and 63,877 respectively. The decadal

growth is around 21.54 %. Hence, the population projection of the area

for the year 2017 is projected to be around 72,130.

5.2.2 ISP

The Project Influence Area (PIA) of 10 km radial coverage

from the boundary of proposed ISP & Captive Jetty comprises of around

sixty-three villages. The core zone villages are Jatadhar, Dhinkia,

Noliasahi, Polanga, Bayanalkandha, Gobindapur and Nuagan. The total

population as per 2001 & 2011 Census data was 69,163 and 74,116

respectively. The decadal growth is around 7.16 %. Hence, the



5 - Planning Brief (cont’d)

5-2

population projection of the area for the year 2017 is projected to be

around 77,300.

The proposed project as per applicable regulations would

employ local workers. However due to foreseen employment opportunities

in the proposed project and increase in ancillary economic activities,

growth in migrant population is anticipated.

5.3 LAND USE PLANNING

5.3.1 Iron ore grinding and desliming units

The total land requirement for the proposed grinding and

grinding & de-sliming facilities as well as the raw material handling

facilities including other associated units have been estimated to

around 281.8 acres. Greenbelt would be developed to comply with the

statutory norms. Moreover, suitable site for disposal of slime would be

required in close proximity of the plant and the land requirement

of the slime storage area has been estimated to around 120

acres considering 15-20 years of plant operation.


The total area for steel plant would be about 2,980 acres,

consisting of government and private land. The area would house the

following facilities:

i) Raw material yard ii) Sinter plant iii) Pellet plant iv) Coke ovens v) DRI plant vi) Blast Furnace vii) SMS (Steel Melt Shop) with Casters viii) Lime/dolo Calcining plant ix) Oxygen Plant x) Water Facilities xi) Rolling Mills (Hot & Cold rolling) xii) Finishing facilities




5-3

xiii) Captive power generation units xiv) Cement Plant xv) Tar Distillation & benzol processing The total greenbelt, comprising of about 33% of total plant

area of about 984 acres, would be reserved in the layout. The layout

would also house canteen, administrative buildings, workshop, railway

tracks, stores, in-plant roads, etc.

The total area requirement for development of the jetty would

be about 180 acres and would include the following units:

i) Waterfront and Berth Back-up Area ii) Other areas including conveyor corridors, truck

terminals, common user facilities, buildings and for miscellaneous jetty activities

Greenbelt would be developed in the jetty area in conformity

with the statutory norms. The jetty area would also include essential

ship operational areas such as Navigational channel, turning

circle/Maneuvering area, Dock basin, berths and hauling out space.

In view of the location of the ISP & the captive Jetty near the

coastline and its proximity to Jatadharmohan river, the project would be

designed in compliance with the Coastal Regulation Zone (CRZ)

Notification 2011, and its subsequent amendments.

Demarcation of High Tide Line (HTL) and Low Tide Line (LTL)

would be carried out in Coastal Zone Management (CZM) Maps of scale

1:4,000 by a MoEFCC authorized agency. Setback & hazard lines for HTL

and LTL would be indicated In the CRZ report along with the

classification of different coastal zones as per the CRZ notification 2011

and its amendments. Approval for the CRZ map would be sought from




5-4

Odisha Coastal Zone Management Authority (OCZMA) for setting up the

project.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND


With regard to the proposed Mineral Grinding & desliming Plants

proposed to be located at Gobaradhanpur (Joda Block, following are the

specific demands related to social and physical infrastructure:

i) Support towards skill development facilities ii) Support towards free & compulsory quality primary

education and measures addressing school dropouts


With regard to the proposed Integrated Steel Plant and

Captive Jetty to be located in Jagatsinghpur District, following maybe

the specific requirements related to social and physical infrastructures,

which are likely to be taken up under the guidance and participation of

Govt. of Odisha.

i) Support towards development of road linkage from

major roads/distribution roads to the proposed site ii) Support towards development of railway linkage from

the nearest railway station to the proposed site

iii) Support towards availability of potable water facilities

in surrounding villages especially during natural calamities and dry seasons

iv) Support towards development of village evacuation

routes during natural calamities v) Support towards strengthening and upgradation of

cyclone shelters at Dhinkia, Nuagan and Gadkujang



6-1

6 - PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)


The present infrastructure has been elaborated in Chapter 4.

It is proposed to transport the iron ore slurry via pipeline which is

considered to be safe, environment friendly system that incurs

minimum handling loss, minimises foot-print and provides maximum

safety during transportation. NSP 2017 also encourages transportation

of iron ore fines to pelletisation units through slurry pipelines as it

reduces pollution and de-congests transportation infrastructure.

The iron ore slurry from Joda would be transported to the

pellet plant located within the ISP near Paradeep via slurry pipeline

having total length of about 312 km.


The existing infrastructure for the ISP & the captive jetty has

been discussed in Chapter-4.

It would be required to set up adequate infrastructure

facilities like navigational aids, bunkering, jetty craft, etc to support the

operation of the captive jetty. It is proposed to strengthen and widen the

existing MDR (Major District Road) connecting to NH55.

Navigational Aids would include buoys and beacons, transit

and clearing marks as well as signaling systems, radio aids and

communications, electronic systems, radar etc. which are installed on

land or in water for guidance to all ships for safe and regulated

navigation in the channels, anchorages, berths, docks etc. It is



6 - Proposed infrastructure (cont’d)

6-2

envisaged that navigation would be carried out throughout the year, by

day and night except during times of high wind speeds and low visibility,

and inadequate draft etc.

For the jetty and its approaches, the Uniform International

Lateral Buoyage System is envisaged. However, due to the mobile nature

of buoys, shore based marks would be used wherever possible either as

supplements to buoyage or by themselves. Other Jetty crafts would

include mooring boats, fire tenders, pilot launches and a mooring buoy.

State Highway (SH) 12 connecting Cuttack and Paradeep is

situated at the northern of the proposed project site. National Highway

(NH) 53 connecting Chandikhol & Paradeep is located along the eastern

side of the site and the site requires road linkage from the Highway

NH-53 and other major district roads. In addition, NH 55 connecting

Cuttack to Paradeep via Jagatsinghpur, Ersama and Nuagaon located on

the Eastern side of the project site.

The nearest rail station is Paradeep. Railway connectivity

exists between Cuttack and Paradeep and proposed Haridaspur &

Paradeep. It would be required to set up railway linkage from

Siju/Badabandh station.

The proposed communication systems would consider

telephone system, wireless communication system and loudspeaker

intercommunication (LSIC) system. As part of the Telephone system, an

EPABX based telephone exchange of suitable capacity is envisaged to

cater to the requirement of telephone facilities. Telephone exchange

gateway would be UPS powered or provided with battery back-up.




6-3

6.2 RESIDENTIAL AREA

Residential facilities have been considered for the projects. It

is envisaged to build townships for employees of Iron ore grinding &

desliming plant and integrated steel Plant & captive jetty.

The township would accommodate families of employees of

various hierarchies from the steel plant, captive power plant and captive

jetty. Types of buildings planned for housing would be apartment type

which is a cluster of dwelling units with common staircase and lobby.

The apartment blocks would be divided into several categories of dwelling

units of different covered areas. Number of dwelling units per floor would

be two numbers to avoid congestion in the common lobbies.

The township would be well planned and equipped with all

necessary amenities and services. The township would have the

infrastructure such as water supply, underground sewerage, electricity,

roads etc with easy maintenance provisions. Other amenities such as

school, community center, guest house, health center, hospital, shopping

complex, post office, bank, park, playground, Cyclone center etc would

also be provided. Treated water shall be supplied from the water

treatment plant and pumped to an elevated storage tank in the

township area.

6.3 GREENBELT

It is obligatory to develop dense greenbelt area in proposed

project plant as per CPCB guidelines. Green belt is proposed to be

developed in compliance with the regulatory norms. This would not only

prevent the fugitive dust emissions but also improve the peripheral

appearance of the plant from aesthetics point of view. Unpaved areas, if

any, within the plant boundary would be provided with grass/tree cover.




6-4

Depending on the type of soil suitable for growth, higher

survival rate in the region, large leaf index area, nativity of the species

and pollution load, following are the proposed species of trees which may

be planted as greenbelt at the iron ore grinding & desliming site at Joda:

1. Arjuna - Terminalia arjuna 2. Asna - Terminalia alata 3. Dharua - Anogeissus latofolia 4. Gambhar - Gmelina arborea 5. Jamun - Syzygium cuminiin 6. Karanjo - Pongamia pinnata 7. Kurum - Haldinia cordifolia 8. Kusum - Schleichera oleosa 9. Mahula - Madhuca indica 10. Neem - Azadirachta indica 11. Piasal - Pterocarpus marsupium 12. Sal - Shorea robusta 13. Sisoo - Dalbergia sisso 14. Teak - Tectona grandis

The following are the proposed species of trees which may be

planted as greenbelt for the ISP & captive jetty:

1. Neem - Azadirachta indica 2. Akashmone - Acacia auriculiformis 3. Chatim - Alstonia scholaris

4. Amaltas - Cassia fistula 5. Copper Pod - Peltophorum pterocarpum 6. Jungle Jalebi - Pithecellobium dulce 7. Kalajam - Syzygium cumini 8. Kassod - Cassia siamea 9. Jhau - Casuarina equisetifolia 10. Kadamba - Anthocephalus chinensis 11. Arjun - Terminalia arjuna 12. Indian Almond - Terminalia catappa 13. Debdaru - Polyalthia longifolia




6-5

6.4 PROPOSED PHYSICAL AND SOCIAL INFRASTRUCTURE

The generic proposed social and physical infrastructure

development activities in the project areas within the districts of

Jagatsingpur and Keonjhar are as follows:

i) Support towards availability of para teachers and

scholarships to primary schools in the local villages

ii) Support towards vocational training of young local adolescents (both boys and girls) to promote social and economic empowerment

iii) Financial support to local entrepreneurs in areas of fishery, animal husbandry, household industry, floriculture and cash crop plantations. Emphasis would be given to women and especially abled members of the local tribal community

iv) Support towards development of community halls with basic amenities, playground and toilets

v) Financial and community support to government initiatives relating to social forestry, sanitation and solid waste management measures

vi) Support towards setting up of Mobile Health units (MHUs) and financial and community support towards strengthening of existing primary health centers


The following proposed activities related to social

infrastructure are applicable for the iron ore grinding and desliming

plant:

i) Support towards skill development facilities ii) Extension of support towards strengthening of primary

and secondary schools with regard to provision of qualitative free & compulsory education




6-6


The proposed physical infrastructure in relation to

Integrated Steel Plant and Captive Jetty is as follows:

i) Support towards development of road linkage from NH-

53 to the ISP and from Paradeep to the captive jetty as per requirement

ii) Support towards development of new railway linkage from Siju/Badabandh Railway Station to the ISP

iii) Potable water facilities in surrounding villages especially during natural calamities and dry seasons

6.5 DRINKING WATER MANAGEMENT AND SEWAGE SYSTEM

6.5.1 Iron ore Grinding and De-sliming units

The drinking and sanitary water system would be provided to

meet the water requirement of the plant personnel and laboratory. The

requirement of drinking water would be 10 cu m/hr for the Joda plant.

The drinking water would be collected in an overhead storage tank from

which drinking water would be distributed to the various consumers.


The total water requirement for drinking & sanitation would

be 220 cu m/hr approximately, which is proposed to be drawn from the

plant water system and the total water requirement of the plant would be

sourced from Jobra barrage on Mahanadi River. The water would be

treated in a Raw Water Treatment Plant (RWTP) and the treated raw

water would be used for drinking purposes after necessary disinfection.

The plant and township would have a well connected

underground and above ground sewerage network system. The water

would be treated in a common sewage treatment plant and the treated

water would be used for maintenance of greenery, dust suppression etc.




6-7

6.5.3 Captive Jetty

There would be a requirement of 1 cu m/hr water for human

consumption and use which would be provided from the water system for

ISP. A closed loop grid system with necessary cross connections and

valve stations would be provided inside the jetty premises. Two outlet

points at each berth would be provided for supply of potable water to

ships. A pump house would be provided with necessary pumps and

controls to maintain water supply.

6.6 INDUSTRIAL WASTE MANAGEMENT

The proposed project would generate various types of wastes

including liquid effluents and solid wastes, which have been detailed in

Chapter-3.

6.7 SOLID WASTE MANAGEMENT

In general, very less quantity of solid waste is

generated from the jetty activity. Solid waste of other municipal origin

shall be segregated into biodegradable and non-biodegradable

component. Non-biodegradable waste shall be disposed of through the

authorized vendors. Biodegradable waste shall be composted onsite

and shall be used as manure for horticulture.

Major solid wastes produced in the grinding and desliming

units would be slimes along with floor washings and monsoon run-offs

from the stockpiles.

Major solid wastes produced in the ISP would be namely

blast furnace slag, steel slag and coal ash among others. The solid waste

management has been discussed in details in Chapter-3.

6.8 POWER REQUIREMENT AND SUPPLY/SOURCE

The estimated power requirements for the grinding &

desliming units, ISP and captive jetty have been indicated in Chapter-4.



7-1

7 - REHABILITATION AND RESETTLEMENT

The proposed jetty based steel plant project and the iron ore

grinding & de-sliming facilities entail the aspects of Land Acquisition,

Rehabilitation and Resettlement (LARR). Human settlements have been

identified. Hence baseline socio-economic survey would be separately

carried out for each project area, which would be utilized to develop the

Rehabilitation and Resettlement plan enlisting the actual impacted

number of households, number of displaced families and the applicable

categories of compensation. The process would be governed by the

applicable regulations.

7.1 IRON ORE GRINDING AND DESLIMING UNITS

The mineral grinding & de-sliming plants proposed to be

located in Govardhanpur village in Keonjhar district of Odisha and

envisages a total land requirement of 391.93 acres.

With regard to the iron ore grinding & desliming plants,

applicable regulations relate to District Mineral Foundations (DMFs) of

the state. Under Odisha District Mineral Foundation Rules, 2015 vide

notification No.7745/SM dated 18/08/2015 of the Department of Steel &

Mines, Government of Odisha, the workings of the foundations is

regulated.

7.2 INTEGRATED STEEL PLANT AND CAPTIVE JETTY

This Greenfield project with regard to Integrated Steel Plant

and Captive Jetty located near Paradeep (12 km south along the coast of

the Paradeep Port) envisages a total land requirement of 3,160 acres.



7 - Rehabilitation and Resettlement (cont’d)

7-2

The aforementioned proposed project would focus on issues

related to the affected communities in the project influence area. The

study area indicates traditional sources of livelihood amongst fishing

communities of Jatadharmohan River creek and in betel vineyards &

cashew plantations of the Jagatsinghpur district. The proposed project

may reflect social and economic loss relating to livelihood, contribution

to local markets and settlement. Appropriate mitigation measures would

be developed through transparent consultation with the affected

communities and authorities as per applicable regulations.



8-1

8 - IMPLEMENTATION SCHEDULE AND COST ESTIMATE

8.1 IMPLEMENTATION SCHEDULE

8.1.1 Iron Ore grinding and de-sliming units

The preliminary overall implementation schedule for

aforesaid iron ore grinding & desliming plant including slurry pipelines

indicating the time period required to complete the major activities like

engineering, procurement of equipment, construction/erection, testing of

facilities is shown in the form of a bar chart in Fig. 8-1. It is envisaged

that the iron ore grinding & desliming plant including slurry pipelines

would be completed in a timeline of 45 months from the ‘Go-ahead’ date.


The preliminary overall implementation schedule for

13.2 MTPA crude steel production with commissioning of various plant

facilities of the project is shown in the form of a bar chart in Fig 8-1

which is enclosed with the Report.

It is envisaged that the project would be completed within a

period of 84 months from the ‘Go-ahead’ date. It is considered that

construction work at site for various plant facilities of the project would

commence after Grant of EC from MoEFCC & CTE from OSPCB, and also

completion of major engineering works.

FIG. 8-1 - IMPLEMENTATION SCHEDULE

8.1.3 Captive Jetty

The construction of the captive jetty is envisaged to be

completed within a period of 30 months from date of issue of statutory

clearances. The construction schedule (Fig.8-2) prepared is enclosed

below.



8 - Implementation Schedule and Cost Estimate (cont’d)

8-2

ACTIVITY

YEAR

S.

No.MONTH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

1 DREDGING (Port area)

(Approach Channel)

2 BERTHS

3 BREAKWATER

4 OTHERS

Time

FIG. 8-2 - IMPLEMENTATION SCHEDULE OF CAPTIVE JETTY

8.2 CAPITAL COST ESTIMATE

The capital cost estimate of the project is presented under

the following heads:

a) Plant cost b) Margin money for working capital c) Pre-operative expenses d) Interest during construction

8.2.1 Plant Cost

The plant cost includes cost of land and its development,

infrastructure cost, civil work and structural steelwork, plant and

equipment, erection and commissioning. Provision for contingency,

design, engineering and administration during construction are included

in the plant cost.

Design, engineering and administration during

construction, project management and consultancy services: Cost

towards the same is estimated at 5 per cent on a normative basis on the

supply price of plant and equipment including civil work and structural

steelwork, land and land development and external facilities.




8-3

Contingency: A contingency provision is made at 5 per cent

on a normative basis of plant cost to cover the cost of unforeseen items.

This contingency provision does not provide for any forward escalation

and exchange rate variation.

8.2.2 Margin Money for Working Capital

Twenty-five per cent of the estimated working capital for the

first year of operation has been included in capital cost as margin money

for working capital.

8.2.3 Preliminary and Pre-operative Expenses

A provision is made for preliminary expenses towards initial

studies, capital issue and miscellaneous other expenses. A provision is

also made for pre-operative expenses and start-up expenses as up-front

fee payable on borrowing from financial institutions/bank.

8.2.4 Interest during Construction

Interest during construction has been calculated on gross of

Input Tax basis and based on the following assumptions:

a) Debt-equity ratio of 2:1 b) Ratio of Foreign Currency Loan to Rupee Term Loan is

1:1 c) Cost of debt for Foreign Currency Loan (pre-tax) at

4.8 per cent and Rupee Term Loan (pre-tax) at 9 per cent per year

d) Year-wise allocation of fund as per implementation

schedule e) Drawal of fund in the ratio of Debt: Equity.




8-4

8.2.5 Ore Grinding & Desliming Units plus Slurry Pipeline Project and the Integrated Steel Plant

Based on the above considerations, estimated capital cost of

iron ore grinding & desliming units and slurry pipeline project is given

below in Table 8-1.

TABLE 8-1 - ESTIMATED CAPITAL COST FOR THE GRINDING & DESLIMING PLANTS AT JODA AND SLURRY PIPELINE FROM JODA

TO ISP NEAR PARADEEP

Sl. No.

Description Total

Rs. crore

A. Plant Cost

1. Land and land development 309.5

2. Civil and structural steelwork 355.6

3. Plant and equipment as erected 3000.16

4. Infrastructure facilities 358.5

5. Design, Engineering and Administration during Construction 129.8

6. Contingency 192.1

Total(A) 4345.7

B. Other Costs

1. Margin money 115.5

2. Preliminary and pre-operative expenses 90.6

3. Interest during construction 257.4

Total(B) 463.6

C. Capital Cost (Gross of Input Tax)

4809.3

D. Input Tax Credit 566.1

E. Capital Cost (Net of Input Tax)

4243.2




8-5

The estimated capital cost for the integrated steel plant with

cement and captive power plant is worked out at about INR 65,000 crore

and detailed in Table 8-2.

TABLE 8-2 - ESTIMATED CAPITAL COST FOR THE ISP

Sl. No. Description

Total (Rs in crore)

A. Plant Cost

Land and land development 4662.3

Civil and structural steelwork 903.6

Plant & Equipment as erected 56060.1

Infrastructure facilities -

Design, Engineering and Administration during Construction (DE&ADC)

174.6

Contingency 3090

Total (A)

67480.6

B. Other Costs

Margin money

129.8

Preliminary & Pre-operative expenses

442.4

Interest during construction (IDC)

6681.7

Total (B) 7253.9

C. Capital Cost (Gross of Input Tax) 74734.6

D. Input Tax Credit 9822.3

E. Capital Cost (Net of Input Tax) 64912.3




8-6

8.2.6 Captive Jetty

The project cost estimates is provided in Table 8-3.

TABLE 8-3 - ESTIMATED CAPITAL COST FOR THE CAPTIVE JETTY

Sl.

No. Particulars

Amount,

Crore

1.0 Land Development 10.00

2.0 Breakwater 125.28

3.0 Dredging 384.00

4.0 Civil works

4.1 Berths 525.00

4.2 Buildings 27.00

4.3 Water supply etc 25.00

4.4 Road (Internal) 100.00

4.6 Foundations for Equipments 20.00

Total Civil works 1216.28

4.7 Investigation, consultancy etc. 12.16

Grand Total Civil works 1228.44

5.0 Mechanical equipments

5.1 Mechnaical Unloader - Coal 110.00

5.2 Mechanical unloader - Lime Stone 110.00

5.3 Unloader (MHC) 80.00

5.5 Stacker Reclamier - Coal 90.00

5.6 Stacker Reclamier - Lime Stone 25.00

5.5 Conveyor for coal 21.00

5.6 Conveyor for Lime Stone 20.00

5.8 Work Shop Equipments 25.00

5.10 Tractor Trailor 12.00

5.11 Dust suprression Etc. 15.00

5.12 Navigation Aids 10.00

5.13 Spares for 2 years 25.90

5.14 Errection and commisioning 59.94

Grand Total Mechanical Equipments 603.84

6.0 Miscellaneous

6.1 Electricals 150.00

6.2 Power backup 50.00

6.3 Installation and comm. (Elct) 22.00

Grand Total Electricals 222.00

7.0 Contingencies @ 5% 41.30

8.0 Consultancy @ 1 % 8.26

Total Project Cost 2103.84



9-1

9 - ANALYSIS OF PROPOSAL

9.1 FINANCIAL BENEFITS OF THE PROJECT

The financial benefits accrued from the project would not

only profit the owners but also strengthen the economy of the state due

to earning from taxes and duties from the Plant. Installation of a

state-of-art steel plant with captive power plant, jetty and other facilities

would also add huge impetus to the growing economy of the state and

the country.

9.2 SOCIAL BENEFITS

The proposed Greenfield project would

i) Introduce their recognized social upliftment programmes in the project area for

a) Education of especially abled children b) Promotion of skill development

c) Provision of need based/merit based educational

scholarships

d) Redressal of issues of malnutrition

e) Initiation of watershed programme to enhance soil and

moisture conservation (in collaboration with ICRISAT, an UN accredited agency)

f) Promotion of women empowerment

g) Protection of environment and greenery development

h) Restoration of art

ii) Yield local direct and indirect employment opportunities in

the project influence area

iii) Promote the development of ancillary industries, medium-

small scale trade & commercial establishments, local

entrepreneurship and diversification in skill set

The peripheral development activities that would be

undertaken by the proposed project would focus on affected communities

in the project influence area. The project would bring forward an overall

community development with emphasis on the areas of education,

vocational training, health and social infrastructure.



i

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

ENABLING WORK

SLURY PIPELINE

GRINDING AND DE-

SLIMING PLANT

COKE OVEN

SINTER PLANT

PELLET PLANT

DRI PLANT

BLAST FURNACE

STEEL MELT SHOP

HOT STRIP SCHEDULE

REBAR MILL

MEDIUM / HEAVY

SECTION MILL

COLD ROLLING MILL

YEAR 6 YEAR 7Description

YEAR 1 YEAR 2 YEAR 3 YEAR 4 YEAR 5

PO TO MAIN PACKAGE / MAIN PROCESS

COMPLETION OF MAJOR ENGINEERING

COMPLETION OF MAJOR EQUIPMENT DELIVERY

COMPLETION OF CONS. WORK & COLD TRIAL

READINESS OF PRIORITY RMHS, POWER, WATER & UTILITIES

COMMISSIONING OF UNITS

Note : -It has been considered that after completion of major Engineering Work, Site Work will be started.

Fig. 8-1- IMPLEMENTATION SCHEDULE

4

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MRSS

WATER RESERVOIR

PUMPINGSTATION

WATER

CONV.

CONV.

ST-1

CONV.

CONV.

ST-2

CONV.WBR-1

JH

TBS-1

WBR-2

CONV.

CONV.

JH

JHCONV.

CONV.

CONV.

CONV.CONV.JH

JH

JH

JH

JH

JHSCREEN HOUSE

CRUSHERHOUSE

JH

JH

CONV.

CONV.

CONV.CONV.

CONV.

CONV.

E- 341528.906N- 2441440.325

E- 341007.723N- 2440313.658

RAW MATERIALS ENTRY GATE

CO

NV

. BC

-1

CO

NV

. BC

-2

CO

NV

. BC

-3

CO

NV

. BC

-4

CO

NV

. BC

-5

CO

NV

. BC

-6

PLANT BOUNDARY

1

2

3

4 4 6

8 9

10

11

12

13

14

15

1617

17

18

2223

24

21

6

6

ROAD

ROAD

ROAD

32

MRSS

WATER RESERVOIR

PUMPINGSTATION

WATER

CONV.

CONV.

ST-1

CONV.

CONV.

ST-2

CONV.WBR-1

JH

TBS-1

WBR-2

CONV.

CONV.

JH

JHCONV.

CONV.

CONV.

CONV.CONV.JH

JH

JH

JH

JH

JHSCREEN HOUSE

CRUSHERHOUSE

JH

JH

CONV.

CONV.

CONV.CONV.

CONV.

CONV.

E- 341528.906N- 2441440.325

E- 341007.723N- 2440313.658

E- 342179.773N- 2441043.247

E- 341615.023N- 2440430.956

RAW MATERIALS ENTRY GATE

CO

NV

. BC

-1

CO

NV

. BC

-2

CO

NV

. BC

-3

CO

NV

. BC

-4

CO

NV

. BC

-5

CO

NV

. BC

-6

PLANT BOUNDARY

1

2

3

4 4 6

8 9

10

11

12

13

PROPSED PIPELINE (CONCENTRATE)

14

15

1617

17

18

2223

24

21

6

6

ROAD

ROAD

ROAD

32

PLANT ENTRY GATE

PLANT BOUNDARY

21

25 26

27

2829

30 31

LBDS-1

21

1719 20

32E- 342237.053N- 2441566.075

(

D

o

u

b

le

C

ir

c

u

it

-

0

.

1

K

m

)

LEGENDSPROPOSED FACILITIES

SLURRY HOLDING TANKS

PUMP HOUSE FOR SLURRY TRANSPORTATIONCHEMICAL DOSING UNIT

EMERGENCY DUMP PONDWATER RESERVOIR

MAIN RECEIVING AND STEP DOWN SUB-STATION (MRSS)LOAD BLOCK DISTRIBUTION SUB-STATION (LBDS)

REPAIR AND MAINTENANCE SHOP

PLANT OFFICE

11

1 WEIGH BRIDGE

GROUND HOPPER AREA2

3 STOCK PILE AREA

4 GRINDING AND DESLIMING UNITGRINDING UNIT5

6 CONCENTRATE THICKENERS (HRT)

7 INTERMEDIATE THICKENERS (HRT)

8 TAILINGS THICKENER (HRT)

9 TAILINGS THICKENER (PASTE)

10 THICKENER OVERFLOW TANKS

12

13

14

15

16

17

18

19

CHEMICAL LAB AND QUALITY CONTROL CENTRE20

CAR PARKING21

SCREEN HOUSE22

CRUSHER HOUSE23

ADMINISTRATIVE BUILDING24

STORE25

AMBULANCE ROOM26

FIRST AID STATION27

CANTEEN28

SECURITY BARRACK29

CHECK POST30

GATE HOUSE/ TIME OFFICE31

ASSEMBLY POINT32

GREEN BELT AREA

IN PLANT ROADS

GENERAL LAYOUT PLAN OF IRON ORE GRINDING - BENEF ICIATION-SLURRY UNIT AT

GOBARDHANPUR, JODA, KEONJHAR , ODISHA AS PROPOSED BY JSW UTKAL STEEL LTD

JSW UTKAL STEEL LTDGENERAL LAYOUT PLAN OF IRON ORE GRINDING - BENEF ICIATION-SLURRY UNIT AT

GOBARDHANPUR, JODA, KEONJHAR , ODISHA AS PROPOSED BY JSW UTKAL STEEL LTD

Date : 08/08 /2018 R-01 Scale: 1: 50,000

Director,JSW UTKAL STEEL LTD

Submitted by

Drg No- JSWUSL/OD/0003 REV-01

GENERAL LAYOUT PLAN OF INTEGRATED STEEL PLANT &CAPTIVE JETTY AS PROPOSED BY JSW UTKAL STEEL LTD

JSW UTKAL STEEL LTDGENERAL LAYOUT PLAN OF INTEGRATED STEEL PLANT &CAPTIVE JETTY AS PROPOSED BY JSW UTKAL STEEL LTD

Purpose- 12 MTPA FINISHED STEEL

Date : 08/08 /2018 R-18 Scale: 1: 50,000

Director,JSW UTKAL STEEL LTD

Submitted by

32°

JETTY ACCESS

27

26

25

44

35

44

43

41

40

3

7

19

5+

1

6

38

17

16

15

23

22

20

8

13

12

4

10

11

42

18

24

2B

2A

48

49

50

34

51

39

47

9

21&

4A

7A

45

7

37

44

44

28

29

30

31

32

33

36

52

52

52

53

53

53

53

53

53

53

53

54

54

55

55

55

54

52

46


32°

APPVD

CHECKED

DRAWN

FOR :DATE

BY

BY

BY

SCALE -

LKC

JSW UTKAL STEEL LTDPLOT-3, FOREST PARK, BHUBANESWAR ODISHA

LAYOUT OF CAPTIVE JETTY

JSW UTKAL STEEL LTD

SNS

SPS

03.08.18

03.08.18

03.08.18

Port Craft

Maint,

Storage..etc Area

(50x50 m)

Cement Silo Each of 12000 Mt (250x90 M)

Covered Iron Ore / Pellet Storage

Cap=900000 Mt ( 05 cape Ship) 550x90 M

Covered Coal / Coke Storage Cap=360000

Mt ( 02 cape Ship) 550x90 M

Lime StorageDolomite Storage

Bentonite StoargeMisc Storage

Covered Shed Storage Cap=360000 Mt ( 05 Panamax) 550x90 M

Dump Pond

Work Shop Complex

45x45 M

Store

45x45 M

Canteen

Operator

Change

RoomAdmin

Room

Ele.

Installation

& Control

Room

Open Area for Marrine

Equipment & Furniture

200x106 M

Covered Clinker Storage Cap=360000 Mt

( 02 cape Ship) 550x90 M

Turning Basin

410 m Dia CD

(-)20.0 M

Turning Basin

630 m Dia CD

(-)20.0 M

North Bre

ak W

ater

South Break Water

310 M

Navigational Channel

Steel Product Storage ( Ex. ) 6

00x90 M

Steel Product Storage ( Ex. ) 6

00x90 M

Statutory Facility

Misc. Units

1280

2120

1712

130

130

130

344

BAY OF BENGAL

Description of Ship Nos Remarks

1 Import Cargo 24.38 Mt

Coastal/Export Cargo 27.00 Mt

Cape Size Vessels( 180000 DWD)

04 Nos

Panamax / Handimax 05 Nos

Port Craft 01 Nos

Cargo and Berth Details (Quay Length 3400 M)

Sl.

2

3

4

5

Berth L-375 M

Berth L-300 M

Berth L-300 M

Quay Length 3400 M


WHIMS

LEGEND:

ROM

BINS

SCREW SCRUBBER

SUMP & PUMP

TAILING HOLDING TANK

WET SCREEN

PRIMARY BALL MILL

SUMP & PUMP

SUMP & PUMP

CLASSIFYING CYCLONE

DERRICK SCREEN

REGRINDING BALL MILL

DESLIMING CYCLONE

CLASSIFYING CYCLONE

SUMP & PUMP

TO TAILING POND

INTERMEDIATE THICKENER

PROCESS WATER TANK

CONCENTRATE THICKENER

TO PROCESS

SLURRY HOLDING TANK

CIRCUIT - I

SLURRY TRANSPORTATION

10 MTPA

CONCENTRATE

5.20 MTPA FEED (NET & DRY BASIS)

5.78 MTPA FEED (GROSS BASIS)

CIRCUIT - II

5.20 MTPA FEED (NET & DRY BASIS)


TAILING THICKENER (PASTE)

RETURN WATER TANK

SCREW SCRUBBER

ATTRITION SCRUBBER

LINEAR SCREEN

MIMS

ROM

BINS

SCREW SCRUBBER

SUMP & PUMP

WET SCREEN

PRIMARY BALL MILL

SUMP & PUMP

SUMP & PUMP

CLASSIFYING CYCLONE

DERRICK SCREEN


DESLIMING CYCLONE

CLASSIFYING CYCLONE

SUMP & PUMP

SCREW SCRUBBER


ODISHA

CONSULTING ENGINEERS, KOLKATA

M. N. DASTUR & COMPANY (P) LTD

BLOCK FLOW DIAGRAM FOR

GRINDING AND DESLIMING PLANT

( MODULE-1 & MODULE-2)

11466-97B-000-ENV-0002 0

PRELIMINARY

2. GROSS QUANTITY INCLUDES 8% MOISTURE AND 2% HANDLING LOSS.

NOTE:-

1. THIS BLOCK FLOW DIAGRAM IS APPLICABLE FOR MODULE-1 &

MODULE-2 .


LEGEND:


PROCESS WATER TANK

SLURRY HOLDING TANKSSLURRY HOLDING TANKS

TO PROCESS

SLURRY TRANSPORTATION SLURRY TRANSPORTATION

BINS

SCREW SCRUBBER

SUMP & PUMP

WET SCREEN

PRIMARY BALL MILL

SUMP & PUMP

SUMP & PUMP

CLASSIFYING CYCLONE

DERRICK SCREEN


CLASSIFYING CYCLONE

SUMP & PUMP

(-) 10 mm FINES

STOCK PILE

CIRCUIT - I

5 MTPA FEED (NET & DRY BASIS)


CIRCUIT - II



SCREW SCRUBBER

BINS

SCREW SCRUBBER

SUMP & PUMP

WET SCREEN

PRIMARY BALL MILL

SUMP & PUMP

SUMP & PUMP

CLASSIFYING CYCLONE

DERRICK SCREEN


CLASSIFYING CYCLONE

SUMP & PUMP

(-) 10 mm FINES

STOCK PILE

CIRCUIT - I



SCREW SCRUBBER

PRELIMINARY


ODISHA



BLOCK FLOW DIAGRAM FOR GRINDING PLANT

( MODULE-3 )

11466-97B-000-ENV-0003 0

NOTE:-

1. THIS BLOCK FLOW DIAGRAM IS APPLICABLE FOR MODULE-3.

2. GROSS QUANTITY INCLUDES 8% MOISTURE AND 2% HANDLING LOSS.

13,500,000

HOT METAL

10,500,000

LIQUID STEEL

CO

KE

270,000

QU

AR

TZ

IT

E

2,700,000

4,914,000

PC

I

4,909,000

105,000

105,000

CA

LC

IN

ED

LIM

E

IR

ON

O

RE

FE

RR

O A

LLO

YS

SLAB CASTER

3 X 2-STRAND

PLATES

1,183,000

703,500

PLA

NT

R

ET

UR

N S

CR

AP

PLATE MILL

HO

T M

ET

AL

640,000

15,149,000

CH

AR

GE

P

ELLE

T

9,859,000

1,575,000

SLAG

CH

AR

GE

S

IN

TE

R

CA

LC

IN

ED

D

OLO

105,000

RE

TU

RN

S

IN

TE

R

866,000

MILL S

CA

LE

BO

F S

LA

G

FLU

E D

US

T

OR

E F

IN

ES

3,591,300

PE

LLE

T F

IN

ES

43,900

267,000

49,100

344,000

886,300

RETURN FINES TO SP

5,775,000

PRODUCT SINTER

1 X 500 SQM

SINTER PLANT

CO

KE

B

RE

EZ

E

319,100

310,500

DO

LO

MIT

E

618,500

LIM

E S

TO

NE

DR

I

640,500

LADLE FURNACE

3 X 350-TON

SECONDARY REFINING UNIT

10,500,000

SLAB

10,290,000

1 X 1.2 MTPY

1,697,000

PELLETLIME

2,400

DRI LUMP

798,000

TO SMS-1

640,500

TO SMS-2

182,000

242,800

LCP

6 X 600 TPD

LIME FINES

438,000

LIME STONE FINES

971,300

CALCINED LIME

LIME STONE

DOLOMITE

2,496,000

346,600

SMS-1

DOLO FINES

DOLOMITE FINES

CALCINED DOLO

134,900

60,800

33,700

RH DEGASSER

2 X 350-TON

PELLET PLANT

4 X 8.0 MTPY

AN

TR

AC

IT

E

LIM

ES

TO

NE

192,000

1,280,000

1,104,000

320,000

BE

NT

ON

IT

E

DO

LO

MIT

E

1,504,000

CO

KE

B

RE

EZ

E

288,000

32,000,000

(1 X 1.5 MTPY)

DCP

1 X 600 TPD

GROSS PELLET

IR

ON

O

RE

F

IN

ES

SCREEN

HOUSE

1,732,000

FOR DRI PLANT

PELLET FINES

TO SP

35,000

HBI FOR SALE

378,000

COG BASED DR PLANT

54,000

QU

AR

TZ

F

IN

ES

90,000

LIM

E F

IN

ES

F

RO

M C

P

33,700

BU

RN

T D

OLO

F

RO

M C

P

BF

STOCK HOUSE

15,456,000

GROSS PELLET

1,053,000

LU

MP

O

RE

HOT METAL

9,859,000

3 X

370 T

HM

DS

9,909,000

HO

T M

ET

AL

BOF SHOP

3 X 350-TON

LIME FINES

118,900

GR

AN

ULA

TIO

N

HO

T M

ET

AL

HO

T M

ET

AL

569,000

GR

AN

ULA

TE

D

770,000

HO

T M

ET

AL

731,500

HO

T M

ET

AL

GR

AN

UL

AT

ED

4,200,000

4,200,000

LIQUID STEEL

6,300,000

HRC

8,824,000

HOT STRIP MILL

(2 X 5.5 MTPY)

9,004,000

SLA

B T

O H

SM

COMPLEX

2 X 0.25 MTPY

HRC

520,000

PLTCM

2 X 2.3 MTPY

HRC

4,693,900

TINPLATE

PLATES

455,500

TIN

ACL

2 X 0.25 MTPY

CGL

4 X 0.5 MTPY

CAL

2 X 1.0 MTPY

4,600,000

500,000

SILICON STEEL

(CRNO)

2,100,0002,000,000

CCL

4 X 0.25 MTPY

995,000

1,000,000

2,047,500

COLOUR COATED COIL

RCL

2 X 0.25 MTPY

585,000

1,950,000

1,944,000

ANNEALLED COIL

579,000

1,365,000

RCL

1 X 0.25 MTPY

1,044,250

1,047,500

COLD ROLLED

GALVANIZED COIL

314,250

733,250

2,990,000

LIQUID STEEL

29,900

29,900

CA

LC

IN

ED

LIM

E

IR

ON

O

RE

FE

RR

O A

LLO

YS

BILLET CASTER

1 X 8-STRAND

200,300

PLA

NT

R

ET

UR

N S

CR

AP

MEDIUM SECTION MILL

HO

T M

ET

AL

182,600

2,807,000

448,500

SLAG

CA

LC

IN

ED

D

OLO

29,900

DR

I

182,000

LADLE FURNACE

2 X 180-TON

SECONDARY REFINING UNIT

2,990,000

BEAM BLANK

2,915,000

SMS-2

RH DEGASSER

1 X 180-TON

(1 X 1.0 MTPY)

BOF SHOP

2 X 180-TON

2,990,000

598,000

LIQUID STEEL

2,392,000

LIQUID STEEL

2,821,000

HO

T M

ET

AL

2 X

190 T

HM

DS

2,807,000

HO

T M

ET

AL

162,500

HO

T M

ET

AL

15,000

CALCINED LIME

BILLET/BLOOM/

1 X 6-STRAND

MEDIUM SECTION

2,806,000

WIRE ROD MILL

(1 X 0.6 MTPY)

REBAR MILL

(1 X 1.2 MTPY)

BILLETS

1,237,000

BILLETS

618,000

BLOOM

1,060,000

REBAR/ WIRE ROD/

(STAMP CHARGE)

BY-PRODUCT RECOVERY COKE OVENS

8 X 62 OVENS

PE

T C

OK

E

726,900

1,579,000

HA

RD

C

OK

IN

G C

OA

L

5,526,000

CO

KIN

G C

OA

L

SE

MIS

OF

T

COKE

SCREEN HOUSE

6,000,000

GR

OS

S C

OK

ES

TO

CK

H

OU

SE

5,055,000

12,000

SULPHUR

270,000

CRUDE TAR

30,000

CDQ DUST

52,500

CALCINED LIME

CO

KE

T

O

435,000

INTERPLANT TRANSFER

COKE FOR

10,500,000

LIQUID STEEL

LIQUID STEEL

3,610,000

HRC FOR SALE

4,100,000 500,000

1,286,000

GR

AN

ULA

TE

D

FINES

33,900

LIME

BEAM BLANK CASTER

BILLET / BLOOM/

3 X 5350 CUM

BLAST FURNACE

309,000

PELLET FINES TO SP

311,000

GRANULATION

SLAG

4,050,000

GRANULATED SLAG

3,848,000

PLANT

189,000

DO

LO

MIT

E

540,000

LIM

ES

TO

NE

72,000

BENZOLE

CRUDE

141,000

COKE BREEZE TO SP

480,000

COKE BREEZE TO SP & PP

1 X 0.3 MTPY

TAR DISTILLATION

PLANT

270,000

CRUDE TAR

1,100

DNO

8,100

NAPHTHALENE

72,900

PITCH

164,700

PCM

5,400

CREOSOTE

5,400

OIL

12,200

ROAD TAR

ANTHRACENE

300

WASH OIL

1 X 0.1 MTPY

BENZOLE REFINING

PLANT

43,900

N.G. BENZENE

7,600

N.G. TOLUENE

1,100

XYLENE

72,000

BENZOLE

CRUDE

14,812,000

PLANT TRANSFER/SALE

DRI FINES

24,000

PELLET FOR INTER

PELLET

150,000

FLY ASH

3,312,000

CLINKER

232,000

GYPSUM

PORTLAND

SLAG CEMENT

PLANT

7,500,000

IRON ORE FINES

3,591,300

IRON ORE FINES

31,104,000

495,000

1,732,000

PELLET FOR DRI PLANT

789,000

FLY ASH1,804,000

CLINKER

PORTLAND

POZZOLANA

CEMENT PLANT

2,500,000

PORTLAND

PROZZOLANA

CEMENT

CEMENT

(2 X 1.25 MTPY) (2 X 3.75 MTPY)

(10 MTPY)

SLAG

202,000

DRY PIT

PORTLAND

SLAG

CEMENT

30,000,000

IR

ON

O

RE

C

ON

C.


ODISHA



PLANT MATERIALS FLOWSHEET

11467-97A-000-PRG-0001 B

Steel Storage

Covered Storage Shed 1

Bitumen / Oil etc

Covered Storage Shed 2

Silo ComplexClinker Storage Shed

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PR

OD

UC

ED

B

Y A

N A

UT

OD

ES

K E

DU

CA

TIO

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L P

RO

DU

CT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PR

OD

UC

ED

B

Y A

N A

UT

OD

ES

K E

DU

CA

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SAMU_7408

Text Box

DRG NO. JSW/JETTY/AC/001A

Date post:	18-Oct-2020
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