pre-feasibility report€¦ · integrated steel plant with captive jetty of 52 mtpa handling...
TRANSCRIPT
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
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 (Continued)
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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
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 (Continued)
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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
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 (Continued)
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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
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 (Continued)
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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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
1 - Executive Summary (cont’d)
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
Power source & requirement
Annual energy consumption - 10,914 X 106 kWh, sourced from captive generating units & State Power Grid
Land details 2,980 acres (100% Government land)
Employment generation
Construction phase - Around 12,000-15,000 casual and contract workers
Operation phase - Approximately 12,000 direct employment
Implementation Schedule
84 months from ‘Go-ahead’ date
Capital Cost Around INR 65,000 crore
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
1 - Executive Summary (cont’d)
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
Power source & requirement
Peak demand - 9.5 MW/10,000 KVA, sourced from OSEB
Land details Abt. 180 acres (100% Govt. land)
Employment generation
Construction phase - Around 1,000 workers, Operation phase - Approximately 350 direct employment
Implementation Schedule
30 months from ‘Go-ahead’ date
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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:
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
2 - Introduction of the Project (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
3 - Project Description (cont’d)
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.
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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.
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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.
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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.
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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
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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
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Envisaged physical and metallurgical properties of pellet
would be as follows:
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.
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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
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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
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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,
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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
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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.
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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
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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
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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.
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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
would be as follows:
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
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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
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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
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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
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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
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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
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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
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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
Caster availability, days 315
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
Caster availability, days 330
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
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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
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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
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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:
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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
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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
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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
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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
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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
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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
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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.
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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.
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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
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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.
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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
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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.
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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.
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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.
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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.
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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
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(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
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(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 -
Moderate 1.0 B 1.0 B
Slow 0.5 B 0.5 B
4. Width for passing distance, Wp
Vessel Speed Fast 2.0 B -
Moderate 1.6 B 1.4 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.
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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
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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.
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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.
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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.
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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
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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
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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
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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.
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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
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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
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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.
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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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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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
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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
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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.
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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
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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.
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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.
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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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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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
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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.
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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
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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.
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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).
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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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.
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FIG. 3-7 - SCHEMATIC DIAGRAM
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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4-3
4.2.2 Integrated Steel Plant
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
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4 - Site Analysis (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
4 - Site Analysis (cont’d)
4-5
4.3.2 Integrated Steel Plant and Captive Jetty
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
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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.
4.4.2 Integrated Steel Plant and Captive Jetty
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.
4.5.2 Integrated Steel Plant and Captive Jetty
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.
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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
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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.
4.6.2 Integrated Steel Plant and Captive Jetty
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.
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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.
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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
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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.
5.3.2 Integrated Steel Plant and Captive Jetty
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
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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
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Odisha Coastal Zone Management Authority (OCZMA) for setting up the
project.
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
5.4.1 Iron ore grinding and desliming units
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
5.4.2 Integrated Steel Plant and Captive Jetty
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
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6 - PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA (PROCESSING AREA)
6.1.1 Iron ore grinding and desliming units
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.
6.1.2 Integrated Steel Plant and Captive Jetty
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
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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.
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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.
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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
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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
6.4.1 Iron ore grinding and desliming units
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
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6.4.2 Integrated Steel Plant and Captive Jetty
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.
6.5.2 Integrated Steel Plant
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.
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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.
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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.
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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.
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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.
8.1.2 Integrated Steel Plant
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.
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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.
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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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
8 - Implementation Schedule and Cost Estimate (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
8 - Implementation Schedule and Cost Estimate (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
8 - Implementation Schedule and Cost Estimate (cont’d)
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
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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.
JSW UTKAL STEEL LIMITED 13.2 MTPA Integrated Steel Plant with Captive Jetty
and 30 MTPA Iron Ore Grinding & Desliming Pre-Feasibility Report
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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K
V
D
is
t
r
ib
u
t
io
n
L
in
e
O
p
t
io
n
-
1
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
Drg No- JSWUSL/OD/0001 REV-01
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
Drg No- JSWUSL/OD/0002 REV-01
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)
5.78 MTPA FEED (GROSS 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
REGRINDING BALL MILL
DESLIMING CYCLONE
CLASSIFYING CYCLONE
SUMP & PUMP
SCREW SCRUBBER
JSW UTKAL STEEL LIMITED
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 .
CONCENTRATE THICKENER
LEGEND:
CONCENTRATE THICKENER
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
REGRINDING BALL MILL
CLASSIFYING CYCLONE
SUMP & PUMP
(-) 10 mm FINES
STOCK PILE
CIRCUIT - I
5 MTPA FEED (NET & DRY BASIS)
5.55 MTPA FEED (GROSS BASIS)
CIRCUIT - II
5 MTPA FEED (NET & DRY BASIS)
5.55 MTPA FEED (GROSS BASIS)
SCREW SCRUBBER
BINS
SCREW SCRUBBER
SUMP & PUMP
WET SCREEN
PRIMARY BALL MILL
SUMP & PUMP
SUMP & PUMP
CLASSIFYING CYCLONE
DERRICK SCREEN
REGRINDING BALL MILL
CLASSIFYING CYCLONE
SUMP & PUMP
(-) 10 mm FINES
STOCK PILE
CIRCUIT - I
5 MTPA FEED (NET & DRY BASIS)
5.55 MTPA FEED (GROSS BASIS)
SCREW SCRUBBER
PRELIMINARY
JSW UTKAL STEEL LIMITED
ODISHA
CONSULTING ENGINEERS, KOLKATA
M. N. DASTUR & COMPANY (P) LTD
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.
JSW UTKAL STEEL LIMITED
ODISHA
CONSULTING ENGINEERS, KOLKATA
M. N. DASTUR & COMPANY (P) LTD
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
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PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
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