PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/online/... · pre-feasibility...

PRE-FEASIBILITY REPORT

ON

MODERNISATION OF EXISTING STAINLESS STEEL PLANT BY INSTALLATION OF NEW 148 m2 SINTER PLANT AND 680 m3 BLAST

FURNACE ALONG WITH ASSOCIATED FACILITIES AT KALINGA NAGAR INDUSTRIAL

COMPLEX JAJPUR, ODISHA

FOR

JINDAL STAINLESS LIMITED

MARCH 2020

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report

TABLE OF CONTENTS

Page

- i -

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

1.1 Identification of the Project and Project Proponent .............. 1-1 1.2 Brief Description of Nature of the Project............................ 1-2 1.3 Employment Generation (Direct and Indirect) due to the

Project ............................................................................ 1-2 1.4 Location with Co-ordinates ............................................... 1-2 1.5 Size or Magnitude of Operation.......................................... 1-2 1.6 Project Description with Process Details ............................. 1-3 1.6.1 Blast Furnace ............................................................... 1-3 1.6.2 Sinter Plant .................................................................. 1-5 1.7 Raw Material ................................................................... 1-6 1.8 Availability of Water and Power ......................................... 1-7 1.8.1 Water ........................................................................... 1-7 1.8.2 Power ........................................................................... 1-7 1.9 Waste Generation and Management ................................... 1-7 1.9.1 Waste Water Management .............................................. 1-7 1.9.2 Solid Waste Management ............................................... 1-7 1.10 Land Form, Land Use and Land Ownership ........................ 1-7 1.11 Existing Land Use of Project site........................................ 1-8 1.12 Drinking Water Management ............................................. 1-8 1.13 R&R................................................................................ 1-8 1.14 Schedule ......................................................................... 1-8 1.15 Capital Cost Estimate ....................................................... 1-8 1.16 Financial and Social Benefits of the Project ........................ 1-9

2 - INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION ...............................................................2-1

2.1 Identification of the Project and Project Proponent .............. 2-1 2.1.1 Project.......................................................................... 2-1 2.1.2 Project Proponent .......................................................... 2-1 2.2 Brief Description of Nature of the Project............................ 2-2 2.3 Need for the Project and Its Importance to the Country

and/ or Region................................................................. 2-3 2.4 Demand-Supply Gap ........................................................ 2-3 2.5 Imports vs. Indigenous production..................................... 2-3 2.6 Export Possibility ............................................................. 2-4 2.7 Domestic/ Export Markets ................................................ 2-4 2.8 Employment Generation (Direct and Indirect) due to the

Project ............................................................................ 2-4


TABLE OF CONTENTS (Continued)

Page

- ii -

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

3.1 Type of Project including interlinked and interdependent projects, if any ................................................................. 3-1

3.2 Location with Co-ordinates ............................................... 3-1 3.3 Details of Alternate Sites and the Basis of Selecting the

Proposed Site................................................................... 3-3 3.4 Size or Magnitude of Operation.......................................... 3-4 3.5 Project Description with Process Details ............................. 3-4 3.5.1 Blast Furnace ............................................................... 3-4 3.5.2 Sinter Plant .................................................................. 3-9 3.5.3 Auxiliary Facilities........................................................3-11 3.6 Raw Material ..................................................................3-11 3.7 Resource Optimization/Recycle & Reuse envisaged in the

project ...........................................................................3-12 3.8 Availability of Water and Power ........................................3-12 3.8.1 Water ..........................................................................3-12 3.8.2 Power ..........................................................................3-12 3.9 Waste Generation and Management ..................................3-13 3.9.1 Waste Water Management .............................................3-13 3.9.2 Solid Waste Management ..............................................3-13 3.10 Schematic representations of the feasibility drawing

which give information of EIA purpose ..............................3-13

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

4.1 Connectivity .................................................................... 4-1 4.2 Land Form, Land Use and Land Ownership ........................ 4-1 4.3 Topography ..................................................................... 4-2 4.4 Existing Land Use of Project site........................................ 4-2 4.5 Existing Infrastructure ..................................................... 4-2 4.6 Soil Classification ............................................................ 4-2 4.7 Climatic Conditions.......................................................... 4-4 4.8 Social Infrastructure Available .......................................... 4-4

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

5.1 Planning Concept ............................................................. 5-1 5.2 Population Projection ....................................................... 5-1 5.3 Land use planning ........................................................... 5-1 5.4 Assessment of Infrastructure Demand................................ 5-2 5.5 Amenities/Facilities ......................................................... 5-2

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

6.1 Industrial Area (Processing Area) ....................................... 6-1


TABLE OF CONTENTS (Continued)

Page

- iii -

6.2 Residential Area (Non Processing Area)............................... 6-1 6.3 Greenbelt ........................................................................ 6-1 6.4 Social Infrastructure ........................................................ 6-2 6.5 Connectivity .................................................................... 6-2 6.6 Drinking Water Management ............................................. 6-3 6.7 Industrial Waste Management ........................................... 6-3 6.8 Solid Waste Management .................................................. 6-3 6.9 Power Requirement and Supply/Source.............................. 6-3

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

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

8.1 Schedule ......................................................................... 8-1 8.2 Capital Cost Estimate ....................................................... 8-2

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

9.1 Financial and Social Benefits of the Project ........................... 1

TABLES

Table 1-1 - Main Technical and Economical Indices ............................ 1-3 Table 1-2 - Basic Design and Operating Parameter ............................. 1-5 Table 1-3 - Raw Materials for SP & BF............................................... 1-6 Table 3-1 - Main Technical and Economical Indices ............................ 3-6 Table 3-2 - Blast Furnace Production Capacity................................... 3-8 Table 3-3 - Basic Design and Operating Parameter ............................. 3-9 Table 3-4 - Raw Materials for SP & BF..............................................3-11

FIGURES

Fig. 3-1 - General Location of Site ..................................................... 3-2 Fig. 3-2 - Specefic Location of Site .................................................... 3-3 Fig. 3-3 - Schematic Diagram for purpose of EIA ...............................3-14 Fig. 4-1 - Topographic Map of the Steel Plant Site ............................. 4-3 Fig. 8-1 - Implementation Schedule For Preordering Activities ............ 8-1

DRAWINGS

Drg 11555-97A-000-ENV-0001 - Plant General Layout Drg 11555-97A-000-ENV-0002 - Process Flow Diagram


1-1

1 - EXECUTIVE SUMMARY

1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

M/s Jindal Stainless Limited (JSL) has proposed to

modernize their existing stainless steel plant by installation of a new 148

m2 Sinter plant and a Blast Furnace of 680 m3 capacity (reduced from

capacity of 180 m² Sinter Plant and 1600 m³ Blast Furnace as per EC

dated 1st November, 2007) along with their auxiliary facilities in existing

steel plant at Kalinga Nagar Industrial Complex (KNIC) in Jajpur District

of Odisha to replace the use of scrap with hot metal in existing EAF.

However, there will not be any increase in overall plant

production capacity w.r.t crude steel and saleable steel. No additional

land would be required for the proposed project.

Jindal Stainless is one of the largest stainless steel

conglomerates in India. It was founded by Shri O.P Jindal in 1970. It

ranks amongst the top ten stainless steel conglomerates in the world.

Jindal Stainless Group has an annual crude steel capacity of 1.9 MTPA

and the group has an annual turnover of US $ 3.2 billion (as on

March'19). The group consists of five companies.

JSL is one of the largest integrated manufacturers of

stainless steel in India with existing capacity of

0.8 MTPA and received EC for capacity expansion of crude steel from

1.1 MTPA to 2.2 MTPA and cold rolling mill from 0.8 MTPA to 1.6 MTPA.

For more details, visit the website https://www.jslstainless.com/.

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 1 - Executive Summary (cont’d)

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1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed Brownfield project would fall under Category

‘A’ of item 3(a) “Metallurgical Industries (ferrous & non-ferrous)” of the

Schedule to the EIA Notification 2006 and amendments thereof.

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

It is estimated that about 500 to 600 casual/contractor

workers will be required during construction phase. Subsequently in the

operation phase, approximately 97 personnel would be directly employed

(57 executives and 40 non executives) and 258 personnel would be

indirectly employed.

1.4 LOCATION WITH CO-ORDINATES

The proposed sinter plant and blast furnace along with their

auxiliary facilities would be installed in the existing Steel plant of JSL at

KNIC, Danagadi near Duburi in Jajpur district of Odisha state. No

additional land is required for the proposed project. The project site is

located within 20º56’23” to 20º58’10” North latitude and 86º01’53” to

86º03’43” East longitude.

1.5 SIZE OR MAGNITUDE OF OPERATION

The proposed project would include production of the

following for captive use of JSL:

Sinter .. 1.34 MTPA

Hot metal .. 0.84 MTPA

Gran Shot/Pig casting .. 0.15 MTPA


1-3

1.6 PROJECT DESCRIPTION WITH PROCESS DETAILS

1.6.1 Blast Furnace

One no. of 680 m³ BF is proposed with annual operating

days of 350 days（8400h) and output of 0.84 MTPA hot metal for steel

making.

Product Mix: Major product and by-product are the hot

metal for steel making, BF gas and slag.

Out Put of Hot Metal .. 840,140 TPA

Normal output of BF gas .. 17×104 Nm3/h

Maximum output of BF gas .. 19×104 Nm3/h.

TABLE 1-1 - MAIN TECHNICAL AND ECONOMICAL INDICES

Sl. No. Description Unit Index Remarks

1 Working volume of Blast Furnace

m³ 680 --

2 Nos. of Blast Furnace -- 1 -- 3 Annual working days D 350 -- 4 Agglomerate rate % 80 Sinter ore 80%,

Lump ore 20% 5 Comprehensive grade of

charged ore to BF % > 56.5

--

6 PCI rate Kg/THM 150 -- 7 Top Pressure Bar (g) 1.5 Equipment capacity:

0.2 8 Furnace Top Temperature OC 120 - 250 -- 9 Hot Blast temp OC 1250 Preheating by

combustion air 10 Average daily production TPD 2400 11 Maximum daily

production

TPD 2600

12 Gas generating volume 104 Nm³/h 17 Max. 19

The blast furnace is envisaged to operate with sized iron ore,

sinter, coke, coal dust, fluxes and additives. The furnace will produce

840,140 TPA of gross hot metal. Coke will be supplied from existing

recovery type coke oven battery complex. The Blast Furnace will be


1-4

provided with coal dust injection facility to reduce the requirement of

coke. It will also be supplied with humidified and oxygen enriched air

blast. The hot metal produced will be generally sent to the steel melting

shop. Surplus hot metal will be converted in Gran Shot/pig. The

liquid slag will be granulated at the cast house slag granulation unit.

The BF top gas will be cleaned in the dust catcher and gas cleaning

system and distributed for further consumption to the stoves, runner

drying, Reheating furnaces in Mills, sinter plant etc. the balance BF gas

will be utilized for generation of power in existing 13 MW WHRB Power

Plant.

Gas Cleaning System: BF produces raw gas as a by-product

of the iron making process. The raw gas has a calorific value, which

allows it to be used as fuel. However BFG must be suitably cleaned prior

to further use. The gas cleaning plant consists of dry gas cleaning

system through bag filters, which has an advantage of elimination of

effluent treatment plant and no slurry is generated. The dry dust is

recycled back to Sinter plant. The clean gas is supplied to various users.

The normal gas composition % by volume as follows:

Pulverized Coal Injection System: The system will

comprise of coal storage, raw coal handling, drying unit and pulverizer,

conveying facility, coal dust collection unit, storage bunker and

pulverized coal injection system.

Gran shot/Pig Casting machine: For casting the hot metal

into cold pigs two numbers of Gran Shot/Pig casting machine of capacity

1,800 TPD each has been envisaged for the BF. The machine will be

equipped with lime milk spray system, water spray for pigs/shots

cooling, etc. The pigs/shots will be discharged into the pig storage yard

and thereafter handled by a magnet gantry crane. Each machine will be


1-5

provided with hoists at the discharge end and lime milk preparation

building. An under slung crane has been envisaged in the pouring end

for maintenance and shot disposal.

1.6.2 Sinter Plant

To satisfy the requirement of 680 m³ Blast Furnace annual

outputs of 0.84 MT towards sinter production capacity, JSL planning to

set up 1 x 148 m² sintering machine. The annual output of qualified/net

sinter is 1.34 MT. The operating parameters of the Sinter Plant are

indicated in Table 1-2.

TABLE 1-2 - BASIC DESIGN AND OPERATING PARAMETER

Sl. No. Description Unit Value 1 Number of Sintering Machine Set 1 2 Effective area of sintering machine m2 148 3 Productivity (rated) T/m2/h 1.37 4 Availability of sintering machine % 90.4 5 Annual working regime days/annum 340 6 Annual sinter production MTPA 1.34 7 Quality of sinter

7.1 Grade TFe 54~55% 7.2 Basicity CaO/SiO2 1.8~2.1 7.3 Sized of the finished sinter mm 5-50 7.4 Temperature 0C <120 7.5 Drum index (+6.35) % 74 8 Dust content in exhaust gas at stack mg/Nm3 Below 50

Dry type electrostatic precipitators of total 1,250,000 m3/h

capacity at 160 OC - 250 OC shall be envisaged for de-dusting of waste

gases before entering the main exhausters. The unit will have high

efficiency to ensure less than 50 mg/Nm3 of dust in the outgoing gases

from the stack. Double cone dust valves and drag link chain conveyors

will be provided for discharge of dust from ESP hoppers. The dust from

ESP will be moistened in a moistening drum and will be recycled in the

sintering process. The waste gases coming out of the exhauster will be


1-6

let out to the atmosphere through a RCC stack of height 100 m

after de-dusting in ESP.

The main exhaust fan unit is envisaged for suction of air

through sinter mix bed on the sintering machine. The capacity of

exhauster is 18,000 m³/min at 160 OC and 1,600 mm WC suction at fan

inlet. The exhauster will be housed in a separate building. Adequate

handling facilities shall be provided in the main exhaust fan unit. The

suitable dedusting system has been envisaged at dust generation points

in the sinter plant complex.

1.7 RAW MATERIAL

The raw material required for the existing project is given in

Table 1-3.

TABLE 1-3 - RAW MATERIALS FOR SP & BF

Sl. No. Raw Material

Quantity, MTPA

Source Mode of Transportation

1 Coke 0.34 From JCL In plant 2 PCI coal 0.13 Import Rail/Road 3 Coke Breeze 0.06 From JCL In plant 4 Lump iron ore 0.26 Barbil/Joda/open market Rail/Road 5 Iron ore fines 0.99 Barbil/Joda/open market Rail/Road 6 Lime stone 0.04 - In plant 7 Dolomite 0.006 Jharkhand/ Chattisgarh Rail/Road 8 Pyroxenite 0.006 Sukinda Rail/Road 9 Quartz 0.014 Andhra Pradesh/

Chattishgarh Rail/Road


1-7

1.8 AVAILABILITY OF WATER AND POWER

1.8.1 Water

The estimated raw water requirement for the proposed

project is around 144 m3/hr (SP - 28 m3/hr and BF - 116 m3/hr). This

requirement will be met by existing source of water i.e. Brahmani river

and internal recycling.

1.8.2 Power

The estimated total average load of power requirement of the

proposed project is envisaged as 31 MW.

1.9 WASTE GENERATION AND MANAGEMENT

1.9.1 Waste Water Management

Waste waters from the various units i.e. Cooling Tower blow-

down, Boiler blow-down and part of the blow-down from the BF Circuit

would be utilised for slag granulation. Balance blow-down from the Blast

Furnace Circuit will be used in the Pig Casting Machine. Hence, the

proposed project is planned on “Zero Liquid Discharge” concept.

1.9.2 Solid Waste Management

The main solid waste generated in the proposed project

would be BF slag which will be granulated and sold to the cement

manufacturers. Other solid wastes like ESP/Bag Filter dust, refractory

debris, flue dust of existing steel plant etc. generated would be reused in

the sinter plant.

1.10 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed project will be installed within the complex of

existing Steel plant, hence the entire land belongs to JSL and the present

status of the land is industrial land. The proposed site primarily consists

of barren land.


1-8

1.11 EXISTING LAND USE OF PROJECT SITE

Approx 18.12 Ha of land would be required for the proposed

project. The proposed site primarily consists of barren land & bushes

and the present status of the land is industrial land as designated by

IDCO, Bhubaneswar.

1.12 DRINKING WATER MANAGEMENT

The total water requirement for drinking & sanitation would

be 1 KLD which is proposed to be drawn from the existing plant water

system.

1.13 R&R

The proposed project does not require additional land and

would be housed within the available plant boundary. Hence, there

would not be displacement of any human settlement. Hence there are no

issues relating to ‘Rehabilitation and Resettlement’.

1.14 SCHEDULE

The project is envisaged to be implemented within a period of

twenty four (24) months from the receipt of EC. Pre-ordering activities

are envisaged to be completed within 6 months from the date of receipt

of EC.

1.15 CAPITAL COST ESTIMATE

The capital cost of the project is estimated at

Rs. 805 cr. including IDC of Rs. 70 cr.


1-9

1.16 FINANCIAL AND SOCIAL BENEFITS OF THE PROJECT

The proposed project of installation of Sinter plant and Blast

Furnace would

i) generate local direct & indirect employment opportunities and improve local income

ii) improve and build road network in the adjoining

villages iii) strengthen school buildings with playgrounds iv) provide the drinking water facilities v) promote diversification in skill set amongst young

adults vi) provide & conduct the free eye & health check up

programmes vii) further improve social awareness programme such as

sanitation and hygiene viii) augment the development of ancillary small-medium

scale industries, trade & commercial establishments and local entrepreneurship

ix) contribute to the Central and State Govt. revenue

through road tax, income by registration of trucks & trailers, income tax, corporate tax, GST etc

The peripheral development activities that would be

undertaken by the proposed project under Corporate Environment

Responsibility (CER) will focus on marginal communities and attempt to

bring forward an overall social development with emphasis in the areas

of education, training, health and social & physical infrastructure.


2-1

2 - INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 Project

M/s Jindal Stainless Limited (JSL) has proposed to

modernize their existing stainless steel plant by installation of a new 148

m2 Sinter plant and a Blast Furnace of 680 m3 capacity (reduced from

capacity of 180 m² Sinter Plant and 1600 m³ Blast Furnace as per EC

dated 1st November, 2007) along with their auxiliary facilities in existing

steel plant at Kalinga Nagar Industrial Complex (KNIC) in Jajpur District

of Odisha to replace the use of scrap with hot metal in existing EAF.

However, there will not be any increase in overall plant

production capacity w.r.t crude steel and saleable steel. No additional

land would be required for the proposed project.

2.1.2 Project Proponent

Jindal Stainless is one of the largest stainless steel

conglomerates in India. It was founded by Shri O.P Jindal in 1970. It

ranks amongst the top ten stainless steel conglomerates in the world.

Jindal Stainless Group has an annual crude steel capacity of 1.9 MTPA

and the group has an annual turnover of US $ 3.2 billion (as on

March'19). The group consists of following five companies :

i) Jindal Stainless Corp Mgt Services Pvt. Ltd.

ii) Jindal Stainless Ltd.

iii) Jindal Stainless (Hisar) Ltd.

iv) Jindal Coke Ltd.

v) Jindal United Steel Ltd.

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 2 - Introduction of the Project/Background Information (cont’d)

2-2

Jindal Stainless Limited (JSL) is one of the largest integrated

manufacturers of stainless steel in India with existing capacity of

0.8 MTPA and received EC for capacity expansion of crude steel from

1.1 MTPA to 2.2 MTPA and cold rolling mill from 0.8 MTPA to 1.6 MTPA

vide letter no J-11011/281/2007-IA II(I) dated 18th September, 2019. A

leader and a name synonymous with Enterprise, Excellence and Success,

the company’s ethos mirrors most characteristics similar to the metal it

produces; Akin to stainless steel Jindal Stainless Limited is innovative

and versatile in its thought process; strong and unrelenting in its

operations. For more details, visit the website

https://www.jslstainless.com/.

Associate Vice President (Env) of JSL is the responsible

authority for this EIA Report. The contact information is given below:

Shri Tushar Kanti Misra

Associate Vice President (Env),

Jindal Stainless Limited

Jajpur – 755026 (Odisha)

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

JSL has proposed to modernize their existing steel plant by

installation of a new 148 m2 Sinter plant and a Blast Furnace of 680 m3

capacity (reduced from capacity of 180 m² Sinter Plant and 1600 m³

Blast Furnace as per EC dated 1st November, 2007) along with their

auxiliary facilities in existing steel plant at KNIC in Jajpur District of

Odisha to replace the scrap with hot metal in existing EAF.

The proposed Brownfield project would fall under Category

‘A’ of item 3(a) “Metallurgical Industries (ferrous & non-ferrous)” of the

Schedule to the EIA Notification 2006 and amendments thereof.


2-3

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/ OR REGION

JSL intends to replace the scrap with hot metal in the

existing EAF to maximize the utilization of heat energy. This will also

reduce the dependency of availability of scrap and facilitate in producing

the consistent quality of product. This project would also generate

employment and other benefits which would be discussed in Section 9.1.

2.4 DEMAND-SUPPLY GAP

According to Steel Minister of India, India's shortage of

domestic scrap supply in the April 2017-March 2018 was at 6.85 MT

which will increase to 9.11 MT in 2021-22. The country imported

5.42 MT of steel scrap in 2017-18 compared with 5.71 MT in 2016-17.

Total demand for scrap in the April 2019-March 2020 is expected at

48.1 MT, while domestic supply is expected to reach 40.19 MT. Major

scrap suppliers to India are the UAE, the US, UK and South Africa

(source: https://www.argusmedia.com/en/news/1825052-indias-

domestic-steel-scrap-shortage-to-deepen).

The proposed project is the replacement of scrap with hot

metal in existing EAF. Replacement of scrap with hot metal would

maximize the utilization of heat energy. In addition, this will increase the

productivity, reduce the power consumption, reduce the electrode

consumption and increase the quality of steel.

2.5 IMPORTS VS. INDIGENOUS PRODUCTION

The proposed project is the replacement of scrap with hot

metal in existing EAF. Hence, this will replace import of scrap resulting

in lowering the dependency on Interaction supplies, savings for

foreign exchequer and would promote Make in India with utilization of

domestic raw material in Iron & Steel making process.


2-4

2.6 EXPORT POSSIBILITY

Products from Sinter Plant and Blast Furnace of the

proposed project are purely for captive use of JSL, hence, export

possibilities for the proposed project has not been envisaged. However,

the final product i.e. Stainless steel is being exported.

2.7 DOMESTIC/ EXPORT MARKETS

There is no proposal to sell the sinter and hot metal as the

production is purely for captive use of JSL.

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

During the construction & operation phases of the proposed

projects, both direct & indirect workers would be required.

It is estimated that about 500 to 600 casual/contractor

workers will be required during construction phase. Subsequently in the

operation phase, approximately 97 personnel would be directly employed

(57 executives and 40 non executives) and 258 personnel would be

indirectly employed.


3-1

3 - PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY

The proposed project is envisaged for installation of a new

Sinter plant and Blast furnace along with their auxiliary facilities in the

existing Steel complex at Odisha to meet the hot metal requirement in

existing EAF for replacement of scrap. However, there will not be any

increase in overall plant production capacity w.r.t. crude steel and

saleable steel.

3.2 LOCATION WITH CO-ORDINATES

The proposed sinter plant and blast furnace along with their

auxiliary facilities would be installed in the existing Steel plant of JSL at

KNIC, Danagadi near Duburi in Jajpur district of Odisha state. No

additional land is required for the proposed project. The project site is

located within 20º56’23” to 20º58’10” North latitude and 86º01’53” to

86º03’43” East longitude. General location of the project site is shown in

Fig. 3-1. Specific location of the project along with the coordinates of the

corner points is shown in Fig. 3-2. Project site layout is shown in Drg.

11555-97A-000-ENV-0001.

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 3 - Project Description (cont’d)

3-2

FIG. 3-1 - GENERAL LOCATION OF SITE


3-3

FIG. 3-2 - SPECEFIC LOCATION OF SITE

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

The area within the existing works boundary of JSL would be

able to accommodate the new sinter plant and blast furnace. Hence, no

additional land would be required for the proposed project and no

alternative sites have been considered for the proposed project. The

existing site has also the following advantages:

i) Availability of adequate land for installation of sinter plant and blast furnace along with their auxiliary facilities


3-4

ii) Availability of suitable infrastructure in terms of connectivity, availability of water & power

iii) Suitability of the land from topographical and

geological considerations. iv) Availability of skilled labour force v) The site does not require any Rehabilitation &

Resettlement (R&R) issues

3.4 SIZE OR MAGNITUDE OF OPERATION

The proposed project would include production of the

following for captive use of JSL:

Sinter .. 1.34 MTPA

Hot metal .. 0.84 MTPA

Gran Shot/Pig casting .. 0.15 MTPA

Process Flow Diagram is shown in Drg. 11555-97A-000-ENV-0002.

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

3.5.1 Blast Furnace

One no. of 680 m³ BF is proposed with annual operating

days of 350 days（8400h) and output of 0.84 MTPA hot metal for steel

making.

Product Mix: Major product and by-product are the hot

metal for steel making, BF gas and slag.

Out Put of Hot Metal .. 840,140 TPA

Normal output of BF gas .. 17×104 Nm3/h

Maximum output of BF gas .. 19×104 Nm3/h.


3-5

Main Technical feature and level of equipment:

1. Technique for long BF campaign: dumpy BF profile and optimized refractory configuration. 2. BF proper: fully-covered cooling stave; bosh, belly and proper upper area use SG iron cooling stave with dual industrial cooling water pipelines, and furnace bottom is water-cooled. 3. Energy friendly for BF: higher blast temperature –oxygen enrichment& PCI.

4. The stock house system 5. BF charging is by belt conveyors.

6. The top charging is by BLT.

7. The BF is equipped with 1 no. of tapping hole without slag hole. The main iron runner is hot-metal storage type with air-cooling facility. It dopts fully-hydraulic mud gun and fully hydraulic tapping machine.

8. The cast house is a flat platform without sand-filled level, which is featured in less investment, good-looking and practical.

9. Granulating process: Open filter bed type, Featured by high quality of granulation and environment-friendliness.

10. Three Nos. of improved top-combustion HBS, which is

featured in less investment, air and gas preheating, 1200OC of hot blast temp which is helpful for longer service life.

11. The BF Gas Cleaning Plant is under fully dry-type process.

12. The energy from BF gas pressure and temperature shall be recycled.

13. The design of automation control system shall be in principle of EIC. The process control for major BF process production line shall be by Level 2 automation system.


3-6

TABLE 3-1 - MAIN TECHNICAL AND ECONOMICAL INDICES

Sl. No. Description Unit Index Remarks

1 Working volume of Blast Furnace

m³ 680 --

2 Nos. of Blast Furnace -- 1 -- 3 Annual working days D 350 -- 4 Agglomerate rate % 80 Sinter ore 80%,

Lump ore 20% 5 Comprehensive grade of

charged ore to BF % > 56.5

--

6 PCI rate Kg/THM 150 -- 7 Top Pressure Bar (g) 1.5 Equipment capacity:

0.2 8 Furnace Top Temperature OC 120 - 250 -- 9 Hot Blast temp OC 1250 Preheating by

combustion air 10 Average daily production TPD 2400 11 Maximum daily

production

TPD 2600

12 Gas generating volume 104 Nm³/h 17 Max. 19

The blast furnace is envisaged to operate with sized iron ore,

sinter, coke, coal dust, fluxes and additives. The furnace will produce

840,140 TPA of gross hot metal. Coke will be supplied from existing

recovery type coke oven battery complex. The Blast Furnace will be

provided with coal dust injection facility to reduce the requirement of

coke. It will also be supplied with humidified and oxygen enriched air

blast. The hot metal produced will be generally sent to the steel melting

shop. Surplus hot metal will be converted in Gran Shot/pig. The

liquid slag will be granulated at the cast house slag granulation unit.

The BF top gas will be cleaned in the dust catcher and gas cleaning

system and distributed for further consumption to the stoves, runner

drying, Reheating furnaces in Mills, sinter plant etc. the balance BF gas

will be utilized for generation of power in existing 13 MW WHRB Power

Plant. Following facilities are envisaged in the project:


3-7

i) Raw material storage yard, stock house, fines handling and main blast furnace charging conveyor

ii) Blast furnace proper

iii) Cast house with tilting runners and dedusting system

iv) Stoves and waste gas chimney

v) Hot blast supply system including hot blast main, expansion joints, bustle main and tuyere stock assembly

vi) Dust catcher and dust discharge equipment

vii) Gas cleaning plant including water system and sludge tanks and flare stack system

viii) Cast house slag granulation plant with its water system Dry slag pit

ix) Water cooling system for blast furnace proper, blast furnace under hearth and stove valves

x) Stock house dedusting system, ventilation and air- conditioning system

xi) Ladle repair shop

xii) Gran shot/Pig casting machine

xiii) Railway tracks for transportation of hot metal and rolling stock, locomotives

xiv) Instrumentation, automation and process control system

xv) Blower house and cold blast supply system

xvi) Compressor and compressed air piping

xvii) Shop electrics and illumination

xviii) Hoisting and handling facilities

xix) Effluent, waste handling, drainage and sewerage

xx) Interplant and inter shop pipelines for steam, BF gas, compressed air and oxygen & Nitrogen

xxi) BF control room


3-8

TABLE 3-2 - BLAST FURNACE PRODUCTION CAPACITY

Sl. No. Name Quantity 1 Main product:

Hot Metal

840,140 TPA 2 By-product:

Granulated Slag BF Gas

268,845 TPA

17 x 104 Nm3/hr (avg) 19 x 104 Nm3/hr (max)

Molten slag will be granulated in the cast house slag

granulation plant under normal operation and 95% yield has been

assumed in the system. However, if slag granulation is not done due to

slag quality variation or non-availability of slag granulation plant, then

the slag will be discharged in the dry slag pits.

Gas Cleaning System: BF produces raw gas as a by-product

of the iron making process. The raw gas has a calorific value, which

allows it to be used as fuel. However BFG must be suitably cleaned prior

to further use. The gas cleaning plant consists of dry gas cleaning

system through bag filters, which has an advantage of elimination of

effluent treatment plant and no slurry is generated. The dry dust is

recycled back to Sinter plant. The clean gas is supplied to various users.

The normal gas composition % by volume as follows:

Pulverized Coal Injection System: The system will

comprise of coal storage, raw coal handling, drying unit and pulverizer,

conveying facility, coal dust collection unit, storage bunker and

pulverized coal injection system.

Gran shot/Pig Casting machine: For casting the hot metal

into cold pigs two numbers of Gran Shot/Pig casting machine of capacity

1,800 TPD each has been envisaged for the BF. The machine will be

equipped with lime milk spray system, water spray for pigs/shots

cooling, etc. The pigs/shots will be discharged into the pig storage yard


3-9

and thereafter handled by a magnet gantry crane. Each machine will be

provided with hoists at the discharge end and lime milk preparation

building. An under slung crane has been envisaged in the pouring end

for maintenance and shot disposal.

3.5.2 Sinter Plant

To satisfy the requirement of 680 m³ Blast Furnace annual

outputs of 0.84 MT towards sinter production capacity, JSL planning to

set up 1 x 148 m² sintering machine. The annual output of qualified/net

sinter is 1.34 MT. The operating parameters of the Sinter Plant are

indicated in Table 3-3.

TABLE 3-3 - BASIC DESIGN AND OPERATING PARAMETER

Sl. No. Description Unit Value 1 Number of Sintering Machine Set 1 2 Effective area of sintering machine m2 148 3 Productivity (rated) T/m2/h 1.37 4 Availability of sintering machine % 90.4 5 Annual working regime days/annum 340 6 Annual sinter production MTPA 1.34 7 Quality of sinter

7.1 Grade TFe 54~55% 7.2 Basicity CaO/SiO2 1.8~2.1 7.3 Sized of the finished sinter mm 5-50 7.4 Temperature 0C <120 7.5 Drum index (+6.35) % 74 8 Dust content in exhaust gas at stack mg/Nm3 Below 50

The following advanced features have been envisaged for the

proposed sinter plant complex.

i) Electronic weighing and proportioning system ii) Circular sinter cooler iii) Energy efficient ignition furnace


3-10

iv) Process gas and plant de-dusting system using high efficiency ESP’s

v) Process control and automation using PLC vi) Waste Heat Recovery System in Sinter Cooler to

generate steam.

The sinter plant complex envisaged receipt of crushed fuel &

flux, iron ore fines, BF returns fines flue dust and RMP and

proportioning unit. The sinter plant will consist of the following main

technological units:

i) Fuel and flux crushing unit ii) Flux screen unit iii) Proportioning unit iv) Primary mixing room v) Secondary mixing room vi) Sintering and cooling unit vii) Waste gas de-dusting unit viii) Main exhaust fan unit ix) Cold sinter screening unit x) Plant de-dusting units

The above units will be inter connected by conveyor

galleries and junction houses for conveying sinter mix, finished sinter,

hearth layer and sinter return fines.

Dry type electrostatic precipitators of total 1,250,000 m3/h

capacity at 160 OC - 250 OC shall be envisaged for de-dusting of waste

gases before entering the main exhausters. The unit will have high

efficiency to ensure less than 50 mg/Nm3 of dust in the outgoing gases

from the stack. Double cone dust valves and drag link chain conveyors

will be provided for discharge of dust from ESP hoppers. The dust from

ESP will be moistened in a moistening drum and will be recycled in the

sintering process. The waste gases coming out of the exhauster will be

let out to the atmosphere through a RCC stack of height 100 m

after de-dusting in ESP.


3-11

The main exhaust fan unit is envisaged for suction of air

through sinter mix bed on the sintering machine. The capacity of

exhauster is 18,000 m³/min at 160 OC and 1,600 mm WC suction at fan

inlet. The exhauster will be housed in a separate building. Adequate

handling facilities shall be provided in the main exhaust fan unit. The

suitable dedusting system has been envisaged at dust generation points

in the sinter plant complex.

2.3.5 Laboratory

A well equipped laboratory for testing of raw materials, fuel,

products, & water Facilities for environment monitoring is also a part of

laboratory.

3.5.3 Auxiliary Facilities

Various services facilities like repair and maintenance shop,

central stores, administrative building, canteen, guesthouse, time office,

water supply & laboratory etc. are provided.

3.6 RAW MATERIAL

The raw material required for the existing project is given in

Table 3-4.

TABLE 3-4 - RAW MATERIALS FOR SP & BF

Sl. No. Raw Material

Quantity, MTPA

Source Mode of Transportation

1 Coke 0.34 From JCL In plant 2 PCI coal 0.13 Import Rail/Road 3 Coke Breeze 0.06 From JCL In plant 4 Lump iron ore 0.26 Barbil/Joda/open market Rail/Road 5 Iron ore fines 0.99 Barbil/Joda/open market Rail/Road 6 Lime stone 0.04 - In plant 7 Dolomite 0.006 Jharkhand/ Chattisgarh Rail/Road 8 Pyroxenite 0.006 Sukinda Rail/Road 9 Quartz 0.014 Andhra Pradesh/

Chattishgarh Rail/Road


3-12

3.7 RESOURCE OPTIMIZATION/RECYCLE & REUSE ENVISAGED IN THE PROJECT

The proposed plant would be designed with state-of-art

technology for optimum consumption of energy & other resources.

Replacement of scrap with hot metal would maximize the utilization of

heat energy. In addition, this will increase the plant productivity, reduce

power and electrode consumption and increase the quality of steel. Also,

adoption of compact layout for the Plant would enable to optimise the

utilisation of land, which is another critical resource. Water consumption

would also be optimised by recycle of treated water as plant make-up

water.

3.8 AVAILABILITY OF WATER AND POWER

3.8.1 Water

The estimated raw water requirement for the proposed

project is around 144 m3/hr (SP - 28 m3/hr and BF - 116 m3/hr). This

requirement will be met by existing source of water i.e. Brahmani river

and internal recycling.

3.8.2 Power

The tentative power requirement of the proposed system is given below:

Area Power requirement, MW Blast Furnace 16.5 Sinter Plant 9.5 Utilities 5

Total 31.0

The required power will be sourced from existing captive power plant.


3-13

3.9 WASTE GENERATION AND MANAGEMENT

3.9.1 Waste Water Management

Waste waters from the various units i.e. Cooling Tower blow-

down, Boiler blow-down and part of the blow-down from the BF Circuit

would be utilised for slag granulation. Balance blow-down from the Blast

Furnace Circuit will be used in the Pig Casting Machine. Hence, the

proposed project is planned on “Zero Liquid Discharge” concept.

3.9.2 Solid Waste Management

The main solid waste generated in the proposed project

would be BF slag which will be granulated and sold to the cement

manufacturers. Other solid wastes like ESP/Bag Filter dust, refractory

debris, flue dust of existing steel plant etc. generated would be reused in

the sinter plant.

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. 3-3

represents the purpose of EIA report.


3-14

FIG. 3-3 - SCHEMATIC DIAGRAM FOR PURPOSE OF EIA

Project Concept

Land requirement

Water requirement

Power requirement

Raw material requirement

TOR received from the concerned Authority

Baseline Data Generation for

Air, Water, Noise, Soil, Ecology and Sociology

Impact Assessment

Mitigation/Management Plan Suggested


4-1

4 - SITE ANALYSIS

4.1 CONNECTIVITY

The Plant is situated in Kalinga Nagar Industrial Complex

(KNIC), Jajpur in the state of Odisha. State Highway (SH-20) runs on the

northern side of the plant. East Coast railway line connecting Jakhpura

and Daitari stations runs parallel to the plant boundary on the eastern

side. Tata Steel and Visa Steel are located on the western and southern

part of the plant repectively. SH-20 connects the plant to Jajpur Road.

The site is also well connected by roads, including National highways, to

Bhubaneswar/Cuttack and Paradeep Port. NH-53 (old NH-200) runs

parallel to the site in western direction at an aerial distance of about

4.5 km. The Jajpur Keonjhar road railway station on Howrah-

Kharagpur- Bhubaneswar- Vishakhapatnam line is about 12 km towards

East of the project site. The nearest international airport is at

Bhubaneswar, about 110 km by road from the plant site. Paradeep port

and Dhamra Port are about 120 km and 140 km respectively by road

from the plant site.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP


existing Steel plant in KNIC, hence the entire land belongs to JSL and

the present status of the land is industrial land as designated by IDCO,

Bhubaneswar. The proposed site primarily consists of barren land &

bushes.

The total land required for proposed expansion is estimated

around 18.12 Ha within the existing plant premises of 452.61 Ha of JSL.

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 4 - Site Analysis (cont’d)

4-2

4.3 TOPOGRAPHY

The study area is characterized by moderately undulating

topography with presence of moderate to low lying hillocks and mounds

at places. The elevation of plain area is upto 120 m above mean sea level.

The topographic features of the project area may be seen

from Survey of India OSM Sheet No. F45U1. The Topographic map is

shown in Fig 4-1. The study area is mainly drained by the river

Brahmani along with its tributaries. The river is having south-easterly

flow direction. The meandering of rivers gives rise to formation of ox-bow

lakes along their course. The drainage pattern is anastomosing and

braided in the alluvial plain while it is dendritic in nature near the

foothills. There are no streams or river passing through and no visible

drainage course spread in the existing plant premises.

4.4 EXISTING LAND USE OF PROJECT SITE

Approx 18.12 Ha of land would be required for the proposed

project. The proposed site primarily consists of barren land & bushes

and the present status of the land is industrial land as designated by

IDCO, Bhubaneswar.

4.5 EXISTING INFRASTRUCTURE


existing Steel plant which is already well connected by road & rail.

Existing water, power and land infrastructures are adequate for the

proposed expansion.

4.6 SOIL CLASSIFICATION

To assess the soil quality of study area, Physico-chemical

data on soil samples were collected from secondary data. The soil pH is

in the range of 6.9 to 7.4. Electrical conductivity ranged from 0.32 – 0.42


4-3

dS/cm. SAR value in the range of 4.41 to 4.82 indicate moderate level of

sodium present in the soil of the study area. The soil is very rich in iron

content.

FIG. 4-1 - TOPOGRAPHIC MAP OF THE STEEL PLANT SITE

210 00

860 00’ 860 05’

OSM No – F45N16

JSL Plant

200 55’

OSM No – F45O4

SH 20

NH 53

Brahmani River

OSM No – F45T13 OSM No – F45U1


4-4

4.7 CLIMATIC CONDITIONS

The study area lies in the humid tropical region. Climate of

the region is characterized by aggressive summer and a seasonal rainfall.

The summer season (March-May) is very hot and the temperature is in

the range of 45°C to 46 °C followed by South-west monsoon which starts

from the first week of June to the end of September. The annual rainfall

is about 1475 mm. The wind direction is predominantly from S and SW.

4.8 SOCIAL INFRASTRUCTURE AVAILABLE

i) The project area falls under ‘Kalinganagar Industrial Complex’. With the development of several large and medium scale industries, the study area has witnessed speedy development of infrastructure with regard to road linkages, black top roads, communication facilities, trade and commerce. The State Highway (SH-2) connects Jajpur and Talcher and the Expressway that runs from Daitari and Paradeep Port are in the study area

ii) The General Hospital in Jajpur Town is the main

health care centre in the study area, equipped with modern facilities. There are few villages having Primary Health Centres as well.

iii) Socio-economic infrastructure facilities like that of

schools (both primary & secondary), parks, banks, post offices and shopping centres are available in the study area.

iv) With regard to education, the district of Jajpur is

characterized by several educational and professional institutes namely B.B. High School, Dasarathpur High School, N.C.College, V.N. College, N.C College, Biraja Women’s College, Biraja Law College, B.S.College, Sukinda College and A.P.College etc.


5-1

5 - PLANNING BRIEF

5.1 PLANNING CONCEPT

The proposed project is the installation of sinter plant and

blast furnace along with their auxiliary facilities. The proposed project

would fall under Category ‘A’ of item 3(a) “Metallurgical Industries

(ferrous & non-ferrous)” of the Schedule to the EIA Notification 2006 and

amendments thereof. Following facilities have also been considered in

the proposed project:

� Augmentation of existing EAF material handling syatem to meet the requirement

� Augmentation of existing water and power supply

network

5.2 POPULATION PROJECTION

The total population of Study area (earlier EIA Report

November 2018) for the years 2001 and 2011 are 3,01,593 and 3,57,475

respectively. The computed decadal growth is that of 18.53 %. Hence the

projected population of study area as per the computed decadal growth

for the year 2020 is estimated at 417,100.

5.3 LAND USE PLANNING

The total steel plant area of undivided JSL is

502.02 hectares (1240 acre). The total area is divided among three Group

companies with areas given below:

JSL – 318.02 Ha (785.52 acre)

JUSL – 154.66 Ha (382.02 acre)

JCL – 29.34 Ha ( 72.46 acre)

Total – 502.02 Ha (1240.00 acre)

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 5 - Planning Brief (cont’d)

5-2

Now JUSL will surrender part of their allocated land

(332.43 acre) to JSL. Land area allocation after surrender will be as

follows:

JSL – 452.61 Ha (1117.95 acre)

JUSL – 20.07 Ha ( 49.59 acre)

JCL – 29.34 Ha ( 72.46 acre)

Total – 502.02 Ha (1240.00 acre)

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

i) Toilet facility will be provided at all new control rooms, pump houses, substations, offices and all manned units.

ii) Workers rest rooms with drinking water facility.

5.5 AMENITIES/FACILITIES

Workers will be provided with safety equipments, rest rooms,

drinking water and first aid facilities.


6-1

6 - PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The proposed Sinter plant and Blast furnace along with their

auxiliary facilities would be sited in the existing Steel plant of JSL at

Kalinga Nagar Industrial Complex in Odisha state. No additional land is

required for the present project.

The proposed project would be carried out within the existing

plant area (452.61 Ha) of JSL. 18.12 Ha of vacant land would be utilized

for the proposed plant.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No new residential facilities have been considered for the

proposed project. Only temporary rest shed has been provided for the

labour.

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.

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 steel plant site:

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 6 - Proposed Infrastructure (cont’d)

6-2

List of selected tree species for greenbelt development: 1. Amaltas - Cassia fistula 2. Cassia - Cassia siamea 3. Jamun - Syzygium cumini 4. Neem - Azadirachta indica 5. Siris - Albizzia lebbek 6. Sisoo - Dalbergia sisso

6.4 SOCIAL INFRASTRUCTURE

i) Support and augmentation of existing government initiatives related to sanitation

ii) Support towards industrial and vocational training for youth of marginal communities

iii) Support towards strengthening of existing medical facilities & allied camps/awareness programmes to cater to the local population

iv) Support towards repairing of local approach and link roads for better communication

v) Awareness and promotion for use of renewable energy

vi) Supply of potable water in the surrounding villages

6.5 CONNECTIVITY

State Highway (SH-20) runs on the northern side of the plant

which connects the plant to Jajpur Road. East Coast railway line

connecting Jakhpura and Daitari stations runs parallel to the plant

boundary on the eastern side. The site is also well connected by roads,

including National highways, to Bhubaneswar/Cuttack and Paradeep

Port. NH-53 (old NH-200) runs parallel to the site in western direction at

an aerial distance of about 4.5 km. The Jajpur Keonjhar road railway

station on Howrah- Kharagpur- Bhubaneswar- Vishakhapatnam line is

about 12 km towards East of the project site. The nearest international

airport is at Bhubaneswar, about 110 km by road from the plant site.

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 6 - Proposed Infrastructure (cont’d)

6-3

Paradeep port and Dhamra Port are about 120 km and 140 km

respectively by road from the plant site. Nearest town is Jajpur. No new

external rail and road connectivity has been envisaged in this proposed

project.

6.6 DRINKING WATER MANAGEMENT

The total water requirement for drinking & sanitation would

be 1 KLD which is proposed to be drawn from the existing drinking water

system. The sewage water received from the toilets of office buildings

areas would be fed to the existing sewage treatment plant.

6.7 INDUSTRIAL WASTE MANAGEMENT

The proposed project would generate various types of wastes

which have been mentioned in Chapter-3.

6.8 SOLID WASTE MANAGEMENT

Major solid wastes produced in the proposed project would

be namely blast furnace slag. The solid waste management has been

discussed in details in Chapter-3.

6.9 POWER REQUIREMENT AND SUPPLY/SOURCE

The tentative power requirement of the proposed system is

given below:

Area Power requirement, MW

Blast Furnace 16.5

Sinter Plant 9.5

Utilities 5

Total 31.0

The required power will be sourced from existing captive power plant.


7-1

7 - REHABILITATION AND RESETTLEMENT

The proposed project does not require additional land and

would be housed within the available plant boundary. Hence, there

would not be displacement of any human settlement. Hence there are no

issues relating to ‘Rehabilitation and Resettlement’.


8-1

8 - PROJECT SCHEDULE AND COST ESTIMATE

This chapter indicates the Project Schedule and the

estimated Capital Cost.

8.1 SCHEDULE

The project is envisaged to be implemented within a period of

twenty four (24) months from the receipt of EC. Pre-ordering activities

are envisaged to be completed within 6 months from the date of receipt

of EC. An implementation schedule, in the form of bar charts, for pre-

ordering activities is shown in Fig. 8-1.

Duration in Months Sl.

No.

Activities 1 2 3 4 5 6

1 Issue of Tender & receipt of offer

2 Tender discussion & Evaluation of bids

3 Price Bid evaluation & finalisation of L1 bid

FIG. 8-1 - IMPLEMENTATION SCHEDULE FOR PREORDERING ACTIVITIES

The preliminary overall implementation schedule for the

project, indicating the time period required for completing the major

activities like ordering of main process equipment, basic & detail

engineering for the project, manufacturing & supply to site, construction

(civil & structural work and erection including cold trials/testing).

JINDAL STAINLESS LIMITED Installation of 148 m2 Sinter Plant and 680 m3 Blast Furnace within the existing Plant at Kalinga Nagar Industrial Complex Pre-Feasibility Report 8 - Project Schedule and Cost Estimate (cont’d)

8-2

8.2 CAPITAL COST ESTIMATE

The capital cost of the project is estimated at

Rs. 805 cr. including IDC of Rs. 70 cr. The details are given below:

Blast Furnace .. 300 crore

Sinter Plant .. 210 crore

Gran Shot/Pig Casting .. 40 crore

Infrastructure .. 150 crore

Sub Total .. 700 crore

IDC .. 70 crore

Others .. 35 crore

Total .. 805 crore


9-1

9 - ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS OF THE PROJECT

The proposed project of installation of Sinter plant and Blast

Furnace would

i) generate local direct & indirect employment opportunities and improve local income

ii) improve and build road network in the adjoining

villages iii) strengthen school buildings with playgrounds iv) provide the drinking water facilities v) promote diversification in skill set amongst young

adults vi) provide & conduct the free eye & health check up

programmes vii) further improve social awareness programme such as

sanitation and hygiene viii) augment the development of ancillary small-medium

scale industries, trade & commercial establishments and local entrepreneurship

ix) contribute to the Central and State Govt. revenue

through road tax, income by registration of trucks & trailers, income tax, corporate tax, GST etc

The peripheral development activities that would be

undertaken by the proposed project under Corporate Environment

Responsibility (CER) will focus on marginal communities and attempt to

bring forward an overall social development with emphasis in the areas

of education, training, health and social & physical infrastructure.

LT S/S

roll shop

65.00FGL

46.00FGL

48.00FGL

48.00FGL

48.00FGL

52.00FGL

48.00FGL

45.00FGL

52.00FGL

65.00FGL

CAL = 711.124 m (FM TOPT)

CAL = 711.097 m (FM TOPT)

7.6 M

SPACE FOR CRANE MOVEMENT & UNLOADING PLATFORM ( 700 M x 30 M)

HIGH MAST LIGHT HIGH MAST LIGHT

46.00FGL

56.50FGL

65.00FGL

51.50

53.50

X 1200

X 1300

X 1900

X 1600

X 1700

X 1800

X 1500

X 1400

X 2000

X 2100

X 2200

X 2400

X 2300

X 4000

X 4200

X 3900

X 4400

X 4300

X 2900

X 2800

X 2700

X 2600

X 2500

X 3200

X 3300

X 3400

X 3100

X 3000

X 3700

X 3800

X 3600

X 3500

X 4100

Y 2500

Y 2400

Y 2300

Y 2900

Y 2800

Y 2700

Y 2600

Y 3200

Y 3100

Y 3000

Y 3600

Y 3500

Y 3400

Y 3300

Y 3900

Y 3800

Y 3700

Y 4200

Y 4100

Y 4000

Y 2200

Y 2100

Y 2000

Y 1900

Y 1800

Y 1700

Y 1600

Y 1500

Y 1400

Y 4300

Y 4400

Y 1805.072

SECURI

TY BAR

RACK

AIR

SMS AREA

JCL AREA

RAW MATERIAL STORAGE AREA

MRSS AREA

POWER PLANT



CRM AREA

JUSL TRANSFERED BOUNDARY (332.43 ACRE)

PROPOSED FACILITIES (44.74 ACRE)

CALCINING

SEPARATION

PLANT

AIR

SEPARATION

PLANT

PLANT

RESERVOIR AREA

FERRO ALLOY PLANT AREA

JUSL AREA

GREENBELT

ASSEMBLY POINT

RESERVOIR AREA

AREA

JUSL AREA

JUSL

AREA

GATE

MATERIAL ENTRY GATE

GATE

EMERGENCY

GATE

EMERGENCY

GATE

ENTRY & EXIT

GATE

EMERGENCY

MATERIAL

GATE

RAIL

GATE

CRM AREA

JUSL PLANT BOUNDARY

HSM AREA

JUSL PLANT BOUNDARY

PROPOSED BF & SINTER PLANT AREA

PROPOSED BF & SINTER PLANT AREA

SINTER PLANT AREA

BLAST FURNACE AREA

RAW MATERIAL

JSL EXISTING BOUNDARY (785.52 ACRE)

PROPOSED JUSL BOUNDARY (49.59 ACRE)

JCL AREA (72.46 ACRE)

LEGEND


JAJPUR,ODISHA

PRE-FEASIBILITY REPORT FOR INSTALLATION OF

130 SQM SINTER PLANT & 680 CUM BLAST FURNACE

CONSULTING ENGINEERS, KOLKATA

M. N. DASTUR & COMPANY (P) LTD

PLANT GENERAL LAYOUT

11555-97A-000-ENV-0001 0

1. ALL QUANTITIES ARE IN TONS PER YEAR ON NET AND DRY BASIS,

UNLESS OTHERWISE SPECIFIED.

CALCINING PLANT

1 X 200TPD

LIME STONE

TO CALCINING PLANT

524,400

DOLOMITE 315,000

NOTES :

EAF

2X150 TON

59,000

CA

LC

IN

ED

LIM

E

25,050

CA

LC

IN

ED

D

OLO

39,095

MS

S

CR

AP

233,800

SLAG

CAPACITY OF PROPOSED FACILITIES

CALCINED DOLO

122,600

204,080

CALCINED LIME

TO CALCINING PLANT

SS

S

CR

AP

743,676

AOD

LF

408,700

2,200,000

LIQUID STEEL

2,200,000

LIQ

UID

S

TE

EL

SLAB CASTER

1X1 STRAND

SLABS

2,134,000

ASP

1 X 425 TPD

1 X 425 TPD

AIR

OXYGEN

NITROGEN

ARGON

1 X 150 T

1 X 150 T

1 X 150 T

1 X 150 T

SLAG

1X1 STRAND

OTHER ADDITIVES 68,100

OTHER FERRO ALLOYS 133,120

CAPACITY OF EXISTING FACILITIES

HAPL

0.8 MTPA

0.45 MTPA

805,000

789,880

HR PRODUCT

340,000

432,000

CR PRODUCT

CAPL

HYDRATED LIME PLANT

(BOO)

(BOO)

HAPL

0.8 MTPA

0.45 MTPA

805,000

789,880

HR PRODUCT

340,000

432,000

CR PRODUCT

CAPL

Fe Cr

1 X 13 MW

50 TPH AFBC BOILER

WHRB

LINES

FINISHING

LINES

FINISHING

Fe Alloy

0.25 MTPA

PLANT

METAL

50 TPH

PLANT

RECOVERY

80 TPH

SALE TO JUSL

1,610,000

HOT ROLLED COIL (ROLLED FROM JUSL)

(BOO)

1 X 450 TPD +1 X600 TPD

MS SCRAP 36,900

FeC

r

702,100

GRANULATED SLAG

268,845

151,730

GRANULATION PLANT

GRAN SHOT

RETURN FINES

SLAG

PRODUCT SINTER

BLAST FURNACE

840,140

HOT METAL

CH

AR

GE

C

OK

E

CH

AR

GE

S

IN

TE

R

QU

AR

TZ

IT

E

PC

I C

OA

L

LIM

E

LIM

E S

TO

NE

CO

KE

B

RE

EZ

E

CH

AR

GE

S

IN

TE

R

IR

ON

O

RE

F

IN

ES

DU

ST

, S

CA

LE

&

S

LU

DG

E

PY

RO

XE

NIT

E

CHARGE SINTER

DO

LO

MIT

E

339,900

1 x 680 cum

14,500

126,000

LIM

ES

TO

NE

58,000

148 SQM

SINTER PLANT

6,000

103,900

994,400

18,200

18,200

151,730

HOT METAL

134,000

1,206,000

1,206,000

1,340,000

688,410

HO

T M

ET

AL

1,206,000

151,730

GR

AN

S

HO

T

SIZ

ED

O

RE

263,800

4,000

6,000

MACHINE

GRAN SHOT

CONSULTING ENGINEERS, KOLKATA

M. N. DASTUR & COMPANY (P) LTD

PRE-FEASIBILITY REPORT FOR INSTALLATION OF


JAJPUR, ODISHA

130 SQM SINTER PLANT & 680 CUM BLAST FURNACE

PROCESS FLOW DIAGRAM

11555-97A-000-ENV-0002 0

Date post:	05-Oct-2020
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