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AMENDMENT IN ENVIRONMENTAL CLEARANCE

(No.J.11011/365/2006-IA.II (I) dated 22-2-2007

and amendment dated 14-11-2008)

FOR

CHANGE IN STEEL MAKING PROCESS TECHNOLOGY

&

CHANGE IN PLANT LAYOUT

AT KERJANG, DISTRICT ANGUL, ORISSA

JINDAL STEEL & POWER LIMITED

FEBRUARY 2013

Amendment in EC of Integrated Steel Plant & CPP Village-Kerjang, Dist-Angul, Odisha

Jindal Steel and Power Limited ______________________________________________________________________________________

____________________________________________________________________________________ 2

CONTENTS

Contents

Page Number

1.0 Background Information 3

2.0 Suggested Changes / Amendments in EC 4

2.1 Changes in Steel Making Technology 5

2.1.1 Justification for Changes in Steel Making Technology 5

2.2 Changes in Plant Layout 6

2.2.1 Justification for Changes in Plant Layout 9

3.0 BOF Convertor Process of Steel Making 10

3.1 Pollution Control System 27

3.2 Gas Recovery System 37

3.3 Material Balance 39

4.0 Water Balance and Management Scheme 40

5.0 Air Emission Control and Load Calculations 40

6.0 Solid Waste Generation and Load Calculation 43

7.0 Pollution Load Statement 45

8.0 Conclusion 47

Appendix 1 Copy of EC Letter obtained from MOEF 48

Appendix 2 Plant Layout Submitted to MOEF in July 2011 Back Pouch

Appendix 3 Now Proposed Revised Plant Layout Back Pouch

Appendix 4 Proposed Layout of SMS Back Pouch



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1.0 Background Information

Jindal Steel & Power Limited (JSPL) is constructing a 6.0 MTPA Integrated Steel

Plant and 1142 MW Captive Power Plant at village Kerjang, District Angul in

Orissa. Environmental Clearance for the project was granted by the Ministry of

Environment & Forests, Government of India (MoEF) vide letter

No.J.11011/365/2006-IA.II (I) dated 22-2-2007 and amendment dated 14-11-

2008. [copy of the EC letter is given in Appendix 1)

The name of the units for which EC has been obtained from Industry Committee

and proposed amendment is shown in Table below:

Name of the Unit

Name of Product

Unit Capacity as mentioned in EC

Amendment Sought from MOEF

1 Pellet Plant Iron ore pellets MTPA 5.0 -- 2 Coal Gassifiers Coal gas Nm3/year 4000 x 106 -- 3 DRI Plant

(Gas based) Sponge iron MTPA 4.0 --

4 Blast Furnace Pig Iron MTPA 3.2 -- 5 Coke Oven &

Byproduct Plant Coke MTPA 2.0 --

6 Sinter Plant Sinter MTPA 4.0 -- 7 Steel Melting

Shop Steel MTPA 6.0 3.0 MTPA based

on EAF route 3.0 MTPA based on BOF route

8 Rolling Mill Steel Product MTPA 6.0 -- 9 Ferroalloy Plant Ferroalloys MTPA 0.08 -- 10 Lime-dolime

Plant Lime / Dolime TPD 3000 --

11 Process Gas/ Pressure Recovery Turbine*

Electricity MW 62 --

12 Coal based Power Plant

Electricity MW 1080 (8x135 MW)

--



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Note: i) In addition to above main units, 7200 TPD Oxygen Plant was also

proposed in Form 1 Application and EIA, which remains unchanged.

ii) For meeting the process steam, 3 x 180 TPH coal based steam boilers

were also proposed in Form 1 Application and EIA, which remains

unchanged.

*iii) 2 x 15 MW mixed gas based turbines, 14 MW blast furnace top gas

pressure recovery turbines and 2 x 9 MW coal gas pressure recovery

turbines

In addition to above, JSPL has taken the Environmental Clearance for 6.5

MTPA coal washery inside the same premises vide letter no. J-

11015/1015/2007-IA.II (M) dated 13th October 2009 (From Coal Mining

Committee). This unit remains unchanged.

JSPL has also submitted application to establish 4 MTPA coking coal

washery and 6.5 MTPA non-coking coal washery inside the same

premises and obtained TOR for conducting the EIA study (From Coal

Mining Committee). This proposal remains unchanged.

2.0 Suggested Changes / Amendments

Following changes are proposed for approval of the Expert Appraisal Committee

(Industry) of MOEF

1. Change in Steel Making Technology, keeping the steel production same.

Also to modify the configuration of casters and rolling mills, while capacity

keeping same at 6 Mtpa each.

2. Change in Plant Layout keeping the total plant area same. .



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2.1 Change in Steel Making Technology

The 6 MTPA SMS process was entirely based on Electric Arc Furnace Route,

comprising 3 x 200 tons capacity EAF (2 vessels in each Conarc type furnace,

totaling to 6 vessels) and 6 x 200 tons capacity Laddle Refining Furnace (LRF)

and 2 x 200 tons RH-TOP for production of special quality slabs has been

proposed. Conventional slab casting technology comprising 3 x 1 strands and 1 x

1 strand casters has been proposed.

Now the 6 MTPA SMS process has been bifurcated into Electric Arc Furnace

Route and Basic Oxygen Furnace Route. 2 x 250 tons capacity EAF shall be

established to produce 3 MTPA Steel. 2 x 250 tons capacity BOF shall be

established to produce 3 MTPA Steel. The capacity of LRF, RH-TOP and Slab

Caster have also been updated accordingly to suit the heat size of 250 tons.

Regarding the Casters, a total of 4 Slab casters (all single strand) were planned

earlier with a total output of 6 Mtpa. Now also the no. of casters will remain same

at 4 with 6 Mtpa output. Configuration will be:

a) One Slab Caster (1 strand)

b) Two Thin Slab Casters (1 strand each)

c) One Billet Caster (8 strand)

The Plate Mill shall also have facilities for the heat treatment with total capcity

of325000 TPA and cold leveller to produce plates of high quality. Two heat

treatment furnaces shall use the clean syn gas produced at coal gasification

plant as a fuel and the exhaust will be vented through the stacks of atleast 30 m

height. As for Rolling Mills, the existing clearance is for 6 Mtpa with a

configuration of one Plate Mill with a capacity of 1.5 Mtpa capacity and One Hot

strip mill with the balance capacity. New Capacity shall remain 6 Mtpa and the

configuration shall be:

a) One Plate Mill of 1.5 Mtpa capacity

b) One Hot Strip Mill (Compact Strip Type) of 3.1 Mtpa capacity

c) One Bar Mill of 1.4 Mtpa capacity



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It may be mentioned here that, change in configuration has been done keeping

the capacity same as the existing EC and the emission levels for solid, liquid and

gaseous wastes will not exceed the emission levels w.r.t. existing configuration of

Casters and Rolling Mills.

2.1.1 Justification for Change in Steel Making Technology

Steel making using the Electric Arc Furnace route is economically viable when

plenty of cheap scrap is available in the market. This scrap is mixed with Hot

Metal and Sponge Iron in EAF to produce steel. Since more scrap and sponge

iron is used in EAF, the electricity consumption is significant.

In the present scenario at JSPL Angul, the Hot Metal availability from Blast

Furnace is more than sufficient to mix some sponge iron and produce steel using

the BOF route. Oxygen lancing in BOF will generate gases having high calorific

value due to suppressed combustion. Power consumption is about 85% lower in

BOF compared to EAF. This ensures production of steel at low cost.

In EAF route the exhaust gases coming out of the furnace are discharged into

the atmosphere after capturing it using hood and cleaning in Bag Filter. In the

BOF Route the exhaust gases have very high Carbon Monoxide (upto 50%),

resulting in very high calorific value (about 2000 kcal/Nm3) of gas, which could be

suitably used in the Reheating Furnaces, thereby reducing the Furnace Oil

consumption. The flue gas of BOF convertor shall be treated using Dry Process

through Electrostatic Precipitators. Any unutilized portion of the BOF Gas shall

be flared using suitably designed flare stack, ensuring soot less flare.

Environmental Benefits of BOF : Low air pollution because of higher content of

hot metal as input, low slag generation (11.8% in BOF compared to about 22% in

EAF because of lower content of sponge iron as input) and possibility of energy

recovery from exhaust gas (because of use of higher oxygen lancing and



____________________________________________________________________________________ 7

resultant suppressed combustion). The yield of liquid steel from metallics using

BOF route is about 90% compared to about 85% using EAF Route.

2.2 Change in Plant Layout

As per the MOU signed between JSPL and the Govt of Orissa, about 6000

acres land has been identified to establish the project. As per the MOU,

IDCO would purchase the land and hand over to JSPL. The break-up of

the land as given in the EIA Report (August 2008) is as follows.

S.No Name of the Unit

Land requirement as given in the EIA Report 2008

(in hectares) 1 Coal Gasification Unit 159.41 2 Steel Plant 639.19 3 Power Plant 253.99 4 Common Facility 112.12 5 Ash Pond & Dump Yard 245.5 6 Water Reservoir 101.17 7 Approach Roads 21.63 8 Railway Yard 105.04 9 Green Belt 368.66

10 Mics Uses 153.675

TOTAL 2160.385 ha

(5338.341 Acres)

Subsequently, during the detailed engineering, the land requirement has

been further optimized to 2016.787 ha. The same has been communicated

to the MoEF along with the layout map showing 33% green belt as per the

EC condition vide JSPL letter dated 10th January 2011. The break-up of

the revised land requirement as submitted to MOEF on 10-1-2011 is as

follows:

Name of the Unit Land requirement in ha A PLANT AREA

Coal Gasification Unit 89.279 Steel Plant 608.753 Power Plant 197.454



____________________________________________________________________________________ 8

Common Facility 85.231 Ash Pond & Dump Yard 183.669 Water Reservoir 84.617 Green Belt 621.041 Sub Total (A) 1870.044 B OUTSIDE PLANT AREA Land requirement in ha

Approach Roads 20.627 Railway Yard 105.04 Water Pipe Line 21.076

Sub Total (B) 146.743

TOTAL2016.787 ha (4983.48 ac)

Meanwhile the High Level Clearance Committee of Government of Orissa

further optimized the land requirement of the project to 1753.3 ha, which

includes 1416.4 ha for core plant area, 128.7 ha for township, 35.8 ha for

offsite facilities like intake water pump house, water pipeline and coal

conveyor corridor and 157.5 ha for developing the railway siding.

Based on this the core plant layout has been again optimized to 1416.4

ha. This has been has been communicated to the MoEF vide letter dated

26th July 2011 along with the revised Layout Plan.

The Plant Layout submitted to MOEF on 26th July 2011 is shown in Appendix 2 .

JSPL received the lease document of the entire 1416.4 ha land. As on date

physical possession of 867 ha land is available with JSPL where the project

construction work is going on. Considering the fact that physical possession of

the balance land will take more time than anticipated and therefore to meet the

scheduled commissioning target, revision of plant layout has become inevitable.

However the total land for setting up the core plant will remain1416.4 ha, as

already furnished to MOEF.

The now proposed revised land break-up is shown below:



____________________________________________________________________________________ 9

Name of the Unit

Land Requirement (in hectares)

Now Proposed A PLANT AREA

Coal Gasification Unit 63.7 Steel Plant 415.7 Power Plant 116.8 Common Facility 90.4 Ash Pond & Dump Yard 183.7 Water Reservoir 78.8 Green Belt 467.3

Sub Total (A)1416.4 ha

(3500 acres) B OUTSIDE PLANT AREA

Approach Roads & Water Pipe Line 35.8 Railway Yard 157.4

Sub Total (B) 193.2 ha

TOTAL1563.043 ha

(3860.7 acres)

The now proposed revised Plant Layout based on above Table is shown in

Appendix 3.

2.2.1 Justification for Change in Plant Layout

1.2 MTPA Plate Mill and 4 x 135 MW Captive Power Plant is already

commissioned. Coal washery and lime plant shall be ready for commissioning

soon. Coal Gasification Plant, Gas based DRI Plant and Steel Making Shop (EAF

Route) are ready for commissioning in March 2013. The following Table shows

the various stages of construction of the Integrated Steel Plant:

Sl. No

Plant Status



____________________________________________________________________________________ 10

1 Power Plant

(8 x 135 MW)

4 units are already commissioned. 2 Units are in advance stage of construction.

2 Coal Gasification Plant

(14 Gassifiers)

7 Gassifiers are in advance stage of construction and will be ready by March 2013.

4 DRI (gas based)

(2 x 2 MTPA)

1 unit of 1.8 MTPA capacity is in advance stage of construction and will be ready by March 2013.

5 Oxygen plant

1200 TPD plant is in advance stage of construction and will be ready by March 2013.

6 Lime and dolime plant

1000 TPD is in advance stage of construction and will be ready by February 2013.

7 SMS 1.5 MTPA SMS is in construction and will be ready by March 2013.

8 Plate mill 1.2 MTPA Plate Mill commissioned and started commercial production based on the steel slabs brought from Raigarh Plant of JSPL

9 Structural Beam Plant

A structural beam making plant based on automatic welding machines have been installed to produce 7000 MT of structural steel to meet the internal need of the project construction work

10 Automatic plant for making fly ash based construction product

An imported fly ash based construction materials plant has been commissioned to produce fly ash bricks, concrete panels, kerbstones, etc

11 Raw material handling section

Raw material handling system for the power plant has been commissioned.

RMH Yard for the steel plant is under advance stage of construction and will be ready by March 2013.

12 Process steam boiler One unit of 180 TPH process boiler is ready for commissioning



____________________________________________________________________________________ 11

JSPL decided to shift the blast furnace, pellet plant, coke oven and sinter plant

from the west side to east side and shift the ash pond from east side to west side

of the plant layout. This will enable JSPL to immediately start constructing the

remaining units and synchronize them with the units that are ready for

commissioning.

3.0 BOF Pro cess of Steel Making

Hot Metal Handling

Hot Metal will be delivered to the BOF shop via Torpedo Ladles. Re-ladling into

the hot metal charging ladles takes place at the reladling pits while charging

ladles are brought via transfer cars. The ladle will then be picked up by EOT

crane and placed on the transfer cars at HMDS for pre-treatment of hot metal in

the desulphurisation station. For accurate weighing of the hot metal being

charged into the ladle from the torpedoes, weighing arrangement is provided in

the charging ladle transfer cars as well as in the EOT cranes.

Hot Metal Desulphurisation Process Description

To meet the increasingly stringent demand for higher quality steels, it is the

intention of JSPL to install hot metal desulphurisation facilities to treat the liquid

hot metal between the blast furnace and the BOF Convertor. The hot metal will

be desulphurised by the deep injection of a combination of desulphurization

agents.

The layout for phase 1 will consist of one twin unit (1 x twin station). The powder

system will be serviced by its own powder storage facility. Future provision for

ECO injection with lime will be allowed for in the layout. Each station will be

equipped with deslagging and fume extraction facilities.

Hot metal is desulphurised in the transfer ladle by the injection of a mixture of

calcium carbide and magnesium, through a refractory coated immersed lance.



____________________________________________________________________________________ 12

There are two possible injection combinations of the desulphurisation reagents

including calcium carbide on its own (mono-injection) and calcium carbide and

magnesium in combination (co-injection).

Prior to treatment, the weighed hot metal transfer ladle is placed on a ladle

transfer car (with a combined tilting frame) by the overhead ladle handling crane.

The ladle car is driven inside the refractory faced enclosures, which are sealed

when the ladle is inside the enclosure by a wall mounted on the car.

A sample taken from the transfer ladle prior to treatment is analysed, and the

result is used to calculate the amount of lime, calcium carbide and magnesium

required to achieve the necessary amount of desulphurisation. The calculation is

done automatically by the control system, once the initial and required final

sulphur levels are known. The injection lance, which is a thick walled steel tube

inside a refractory coating, is positioned above the ladle, and then lowered

through a port in the enclosure cover.

Co-injection proceeds as follows:

Before the tip of the lance enters the hot metal surface, the powder transport gas

is switched on, and then the calcium carbide powder begins to flow though the

lance. Once powder flow is established, the lance is driven down into the hot

metal to a predetermined position above the refractory bottom of the ladle.

During injection the actual rate of injection is measured by the load cells on which

the powder injection dispensers are mounted, and calculated by the control

system. The actual achieved injection rate is compared with the required rate on

a continuous basis. Any difference between the measured rate and the required

rate is used to drive the material flow control valves below the dispensers. These

valves open or close automatically to increase or decrease the actual rate of

injection in order to maintain the preset rate.



____________________________________________________________________________________ 13

When the lance has reached its fully immersed position, magnesium is

introduced into the powder stream. As the magnesium begins to be injected, the

rate of calcium carbide injection is automatically reduced, so that the total rate of

material injection remains constant.

When all the required magnesium has been injected, the rate of calcium carbide

injection increases again, back to the original figure. When all the calcium

carbide to be injected approaches its end figure, the lance begins to retract and

leaves the surface of the hot metal as the last of the powder is being blown.

Powder flow is established before the lance enters the hot metal and maintained

until the lance leaves the hot metal to prevent blockage of the lance tip.

All the required measured values are displayed on the VDUs in the control room.

Control of the injection process is automatic once initiated by the operator.

When all the powder has been discharged from the lance, the transport gas

continues to flow for a short period of time, to ensure the powder line is clear,

and then shuts off.

The lance is retracted to its top position, and the lance port in the fume enclosure

hood is sealed by an actuated sealing flap. The lance unit also incorporates an

automatic sampler, which can be used to take a temperature measurement, or a

two in one type chemical and temperature sample, through the port in the fume

enclosure hood.

When injection is complete, the carry-over slag plus the slag formed on top of the

ladle during injection is removed by a slag skimming machine.



____________________________________________________________________________________ 14

This is done by rotating the ladle in its tilting frame on the transfer car. To

achieve this movement, a pair of hydraulic cylinders lift the tilting frame at one

side tilting the ladle over the slag pot.

The angle of ladle rotation is variable, depending on the ladle freeboard. Slag is

removed from the hot metal surface over the rear lip of the ladle by a slag

skimming machine. Each treatment station has its own slag skimming machine.

Slag is collected in slag pots placed on the slag pot transfer car within the

enclosure. Once a slag pot is filled up a slag pot car will transfer the same to the

slag yard where the filled-up slag pot will be emptied and an empty slag pot will

be picked up for transport to the deslagging position.

At the end of the deslagging process the ladle is rotated back to its vertical

position by the hydraulic cylinders.

Throughout the injection and deslagging process fume generated is removed

from the enclosures by extraction ducting connected back to the secondary fume

system.

After injection and deslagging, a sample is taken from the ladle. The ladle

transfer car is then driven to its parked position and the ladle removed by the

overhead crane and transferred to the furnace.

Each station is equipped with independent injection dispensers, one for calcium

carbide and one for magnesium. These dispensers are refilled between

treatments. Refilling can be done automatically, or by operator selection. In either

case the process is as follows.

First the dispenser is depressurised. Powder material, calcium carbide or

magnesium as required, is then pneumatically transferred from the transport

dispensers below the three main storage silos to the injection dispensers.

Material is transferred in fixed batches, and refilling continues until the injection



____________________________________________________________________________________ 15

dispenser contents reach a preset high level, or the operator overrides the

process.

Control and monitoring of the injection and refill process is from the central

control room.

Scrap Handling

The scrap mix to be charged as a coolant into the converter shall consist of

return scrap. The above shall be handled in the scrap yard where a scrap loading

crane is available for loading scrap from the storage boxes into one of the scrap

chutes. The chutes shall be placed on mobile scrap chute transfer car. After

transfer to the charging bay, the scrap will be charged into the converter by

cranes.

Material Handling System

Flux Charging System

Flux material for converters will be taken over at the top of flux bunkers within the

steel making plant for further distribution into the different bins.

Charging System for Fluxes and Coolants

From the high level bin system including vibrating feeders, weighing hoppers,

chutes etc. the material is charged into the converters, mainly fluxes such as

burnt lime, raw dolomite, burnt dolomite as well as iron ore and / or DRI for

cooling purpose.

Ferro Alloy Charging System

Ferro alloys shall be transferred from outside the plant to the storage bins for

tapping additions by means of conveyor system. From here the ferro alloys will

be fed into the ladle by means of vibrating feeders, weigh hoppers, belt

conveyors etc. The addition system for daily storage of alloys to be charged into

each ladle during tapping is designed for the main amount of additions (approx.

80 – 90 %).



____________________________________________________________________________________ 16

BOF Converter Plant

The 2 BOF converters will be designed including all facilities (e.g. oxygen

blowing equipment, off gas system, bin system etc.) for parallel operation of 2

converters. Downtimes have to be considered for relining. During relining,

production can be performed by single vessel operation.

Two water cooled lances (one operating and one standby) will be provided for

each converter. The bottom will be equipped with an inert gas stirring system.

The converters will operate with slag free tapping systems. Self propelled steel

transfer cars as well as slag pot transfer cars have to handle the liquid material.

The above conditions require a hot metal input of about 80%, cooling will be

provided by mainly scrap charged via scrap chute as well as DRI / iron ore

feeding via bin system. The required fluxes for slag formation will mainly consist

of burnt lime and burnt dolomite. The combined blowing practice will be

favourable for handling the increased phosphorous content of the hot metal and

allows blowing with only one slag.

The converter will be operated with a top lance for oxygen blowing and with

bottom stirring of inert gases. The typical advantage of such combined blowing

technique will be the close approach to the equilibrium of metallurgical reactions

and the resulting smooth blowing process and benefits of material yield.

The liquid steel will be tapped slag free from the BOF, in order to eliminate the

negative influence of the furnace slag (FeO, MnO) during further processing and

casting of the steel. The required deoxidation materials, the slag forming

additions as well as deoxidation agents and ferro alloy additions (approx. 90 % of

the required amount) will be added during tapping. The ladle is stirred during and

after tapping for homogenisation purposes. For this 2 nos. on-line Argon Rinsing

Stations (ARS) are installed.

The ladle will be transferred to the Ladle Furnace Stations and will be positioned

into one of the Ladle Transfer Cars.



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Ladle Furnaces

The Ladle Furnaces (LF) are designed as a single station furnaces.

Description of LF Process

Main features of the LF process are:

• Ladle with liquid steel is placed onto the ladle transfer car.

• Bottom purging system gets automatically connected by means of auto

couplers and purging started.

• Transfer car with ladle is positioned below ladle roof (after necessary

interlocks are satisfied).

• Ladle roof is lowered

• Steel temperature is measured and sampling done by means of

automatic or manual lance through the opening in the ladle roof.

• Arcing is started in lower taps

• Necessary quantity of calcined lime is added through the FAFA system

• Trimming alloys are added as per grade and sample analysis requirement

• Sample is taken for final analysis

• Arcing is shifted to higher taps and done as per final aim temperature

• Wire feeding is done as per requirements

• Arcing is stopped, roof lifted and ladle transferred out from treatment

position and lifted by EOT crane

General Description of Ladle Furnace plant

The Ladle furnace plant is designed for three-phase connection to the high-

voltage power supply. The furnace transformer with upstream high-voltage

switchgear plant, the hydraulic station and the low-voltage switchgear cabinet

with control cubicle are arranged near the furnace i.e., in the immediate vicinity of

the furnace.

The furnace is equipped with a roof, which has provision for lifting and lowering

by 3 brackets actuated by hydraulic cylinders. For automatic / manual



____________________________________________________________________________________ 18

temperature measurement, sampling and visual inspection / manual additions the

roof has a sliding working door which can be opened / closed by means of a

pneumatic cylinder.

The electrodes move up and down by means of hydraulically actuated

mechanism. The electrodes are clamped by clamping devices provided in the

electrode arms, which are in turn supported by electrode columns. The electrode

columns are guided by means of electrode guiding system consisting of a set of

rollers. This guiding system ensures proper vertical movement of the electrodes

through the openings in the roof.

A central control panel is provided in the control room of the furnace. All

necessary controls (Level 1) are provided in the main control room.

Level 2 Technological Process Control System for LF

A level 2 process automation computer system is supplied.

The system is implemented in a manner that in case of computer failure or Level

1 - Level 2 link failure the ladle furnace operations can be continued with the

Level I system. All equipment and software will conform to internationally

accepted standards.

Major Safety features of Ladle Furnace

1. The PLC system does not allow arcing to take place unless the hydraulic

system, cooling water system & the fume extraction system is in healthy

and running condition

2. The Ladle placed on LF station for treatment cannot be taken out unless:

a) Electrodes are fully raised.

b) Temperature & Sampling lance is fully retracted

c) Roof is raised

3 In case of power failure or pumps ceasing to work, emergency water

system is provided to cool the LF roof for approx 30 mins.

4 In case of power failure following operations can be carried out with the

help of accumulator provided in the hydraulic system :



____________________________________________________________________________________ 19

a) Electrode lifting

b) Roof lifting

5 Various protection relays have been provided in the HT systems to take

care of the fault conditions.

6 Various protection relays have been provided in the transformer for

protection against:

a) Oil surges

b) Gas formation

c) Over temperature winding, oil and water.

7. All the individual system i.e., FAFA system, wire feeder etc are interlocked

through software for safe sequential operation.

RH process

The basis of the recirculatory process is as follows:

A refractory lined vacuum vessel is equipped with two refractory lined nozzles,

attached to the bottom of the vessel.

Prior to the treatment, the vessel is lowered until the nozzles are immersed in the

molten steel to a predetermined depth in the ladle. The vacuum vessel is then

evacuated by a set of powerful vacuum pumps.

The atmospheric pressure on the surface of the liquid metal in the ladle forces

columns of liquid metal up the nozzles. Atmospheric pressure is capable of

supporting a column of liquid steel 1.4m in height.

To achieve the required movement of metal from the ladle into the vacuum

vessel and then back to the ladle, argon is used. The argon is injected through

small bore pipes into one of the two nozzles attached to the vessel bottom. The

effect of the argon is to lower the bulk density of the resulting mixture. This

causes an increase in the height of the liquid steel column local to the so called

`up leg’. The effect of this, plus the lift imparted to the steel by the rising argon

bubbles, is to produce a movement of liquid metal up the `up leg’, across the

hearth of the vacuum vessel, and down the `down leg’, back to the ladle. The

rate of metal recirculation is dependent on geometric factors such as the inner



____________________________________________________________________________________ 20

diameter of the nozzles, and also the rate of argon injection. In practice,

recirculation rates of 100 tonnes/minute or more are achieved.

As the metal enters the vessel it is exposed to the low-pressure conditions within

the vessel. This encourages reactions that are pressure dependent, such as the

carbon-oxygen reaction. At lower pressures hydrogen is removed by diffusion

from the metal surface.

Alloying elements added under vacuum via the vacuum lock give high and

consistent recoveries due to the absence of atmospheric oxygen and the fact

that the metal surface within the JSPL Ltd. vessel is slag free. Additions made to

the vessel are dissolved and washed across the bath, down the `down leg’ and

back into the ladle. Homogenisation of the ladle contents can be achieved in less

than three minutes.

A colour TV camera is provided, mounted on the alloy addition chute flange to

enable the reaction in the vessel, and the alloys falling through the alloy port to

be observed. This also serves to monitor the start of any possible blockage in the

alloy chute.

To minimise temperature losses during treatment, the vessel refractory

temperature is maintained at 1350oc - 1450oc throughout the campaign. This is

done by the multi function lanceunit which passes through a port in the hot off-

take. The vessel refractory temperature is continuously monitored. A high vessel

temperature is important to prevent skulling.

The proposed unit will be a duplex installation, i.e. there will be two treatment

stations, with the vacuum system, the alloy addition system and vessel handling

& relining facilities being common to both. Each treatment station will have its

own transfer car, vacuum vessel with hot off-take & gas cooler, vacuum lock

arrangement, top lance, , etc.



____________________________________________________________________________________ 21

This configuration will help cut down the net cycle time of the overall unit to the

treatment time only, with all other activities of one treatment station like ladle

transfer & positioning, temperature measurement and sampling, calcium

treatment, etc. falling within the shadow of the degassing time of the other

treatment station.

Metallurgical

The major benefits of the vacuum treatment of un-killed steels are as follows:

By subjecting the liquid steel to a vacuum, the carbon-oxygen reaction is

encouraged to proceed further than it could possibly do at atmospheric pressure.

This is because the reaction is pressure dependent, and the product, carbon

monoxide, is continuously removed from the system. The oxygen content of the

steel is therefore reduced, prior to the addition of deoxidants. The lower initial

level of oxygen in the liquid steel means that less de-oxidants are required, and

fewer non-metallics are formed by reaction with residual oxygen.

The addition of de-oxidants such as aluminium in vacuum eliminates the

possibility of atmospheric oxidation, or immediate contact with slag. These

factors lead to a higher, and perhaps more important, more consistent recovery

of aluminium. The consequence is tighter control of aluminium content and the

confidence to aim for the lower end of the specification, both important

advantages in subsequent continuous casting.

Vacuum degassing is, in addition, an extremely efficient means of mixing and

homogenizing the ladle contents. Vigorous mixing promotes the agglomeration

and flotation of non-metallic inclusions, particularly alumina. Homogenisation of

he ladle contents produces very uniform Tundish temperatures, another

important advantage during continuous casting.



____________________________________________________________________________________ 22

The practice of vacuum decarburisation or vacuum carbon deoxidation, followed

by the addition of aluminium leads to a number of other benefits.

Low silicon levels can be achieved since the intimate mixing of aluminium and

ladle slag, which takes place during ladle additions at tap, is avoided. High

carbon ferro manganese can be added at tap, rather than the more expensive

low carbon grade.

The ability to produce low carbon or ultra low carbon grades by vacuum

decarburization takes an excessive wear load from the convertor, and opens up

new potential markets for extra deep drawing, single coat enamel, pearlite free

grades, etc. Ultra low carbon grades (if) cannot be produced without vacuum

degassing facilities.

Multi function top lance system

The multi function top lance system was developed by SMS Mevac. It offers a

much greater flexibility to the RH degassing process, and consists of a lance unit

which is located in a port in the hot off-take above the vessel, on the vertical

centre line of the vessel. The central bore of the lance ends in a specially

designed copper nozzle, designed to blow oxygen onto the steel in the vessel

during vacuum treatment. Oxygen blowing can be used for a variety of

metallurgical reasons, including increased decarburisation from higher initial

carbon levels, accelerated rates of decarburisation from normal initial carbon

levels and steel reheating in combination with aluminium. In this case, steel

reheat rates of more than 4oC/min net are easily achieved.

The inner oxygen blowing lance is surrounded by a water cooled outer jacket.

Between treatments, the fuel gas is blown down the inner oxygen tube and

combustion oxygen is blown down the annular gap between the oxygen tube and

the outer water cooled jacket. Oxygen and fuel gas mix at the lance tip to

produce an intense flame which maintains the vessel refractories at high

temperature.



____________________________________________________________________________________ 23

Gas flow rates are monitored and controlled to achieve preset rates of heating or

preset plateau temperatures.

The lance unit is located in a port in the hot offtake which incorporates a vacuum

tight seal. During normal operation the lance remains entered into the hot offtake

port, but is designed to be removed during hot offtake changing.

Procedure

There are two basic process routes, namely the so-called light treatment practice

and the full vacuum degassing practice. The operational procedure is similar in

both cases, but differs in detail.

The basic procedure is as follows:

The converter or furnace is tapped into a well preheated ladle (preheat 1000oc or

more). Although not extremely critical, the ladle slag depth should be limited, if

possible. During tap, additions of high carbon ferro manganese can be made, if

required, prior to light treatment. A sample is taken after tap.

The ladle is then transferred by the converter ladle car and shop crane to the

degassing unit transfer car. When the ladle arrives, the ladle freeboard is

measured and temperature and chemical sample taken with an automatic

sampler.

With the ladle positioned under the vacuum vessel, the vessel is then lowered

until the nozzles are immersed to a predetermined depth in the steel. This depth

is known from the freeboard measurement previously taken.

Before the vessel is lowered, the gas supply to the `up leg’ of the vessel is

switched from nitrogen to argon (nitrogen is used between treatments for

economic reasons). This is done automatically.

The argon flow is controlled at a predetermined rate. With the nozzles fully

immersed, and the argon being introduced into the `up leg’ at the predetermined

rate, the vacuum system is switched on. The pressure within the vessel begins to

fall, and is continuously monitored in the control room. A tv camera looking down



____________________________________________________________________________________ 24

the alloy chute gives a picture of the metal flow through the vessel on a colour

monitor in the control room.

The degree of vacuum achieved depends on the length of the treatment, and the

combination of vacuum pumps selected. For a light treatment for example, a final

vacuum level of 50 mbar or more is adequate. This pressure can be achieved, if

required, by using only part of the full steam ejector vacuum system. The vacuum

level gradually falls as the gas is removed from the steel.

For low carbon steels, or for full degassing purposes, the various stages of the

steam ejector can be preselected and then switched in automatically at their

optimum preset operating pressures.

In the case of the light treatment practice, an oxy-temperature measurement is

normally taken from the ladle after a pre-set degassing time (about 3 minutes).

Aluminium is then added, based on the measured free oxygen content of the

steel. The required aluminium addition is composed of two components, one to

remove the remaining oxygen on a stochiometric basis, and the other to bring the

aluminium content within the analysis range.

Having added the aluminium, a second check oxy-temperature measurement is

taken after about 3-4 minutes mixing.

Any required carbon or ferro manganese addition will already be known from the

tap analysis, displayed in the control room.

In the cases where the temperature is too high for casting, coolant scrap can be

added during vacuum treatment as a rapid way of reducing temperature. The

scrap size must be the same as the ferro alloys, since it is added through the

same system. Coolant scrap should also be free of volatiles such as zinc.

At the completion of alloying, the vacuum vessel is flooded back to atmospheric

pressure. The vessel is then raised from the ladle, final samples are then taken,

before the ladle is transferred to the wire feeding station. At the wire feeding

station cored ca wire will be fed through a wire feeder along with soft argon

purging of the steel through the porous plug. Thereafter the ladle will be

transferred to the caster. The wirefeeder station will be provided with a fixed type

fume collection hood which will be connected to the shop dedusting system.



____________________________________________________________________________________ 25

For ultra low carbon grades, the full vacuum system is required to achieve final

vacuum levels of 1 mbar. In this case the treatment time is extended, and

deoxidants are not added until the vacuum pressure trace has levelled out,

indicating that the carbon-oxygen reaction is complete. During treatment the co

and CO2 content of the exhaust gases is monitored. The progress of

decarburisation can be assessed from the co content of the exhaust gases.

The procedure after vacuum decarburisation however, is similar to that for light

treatment.

Start conditions:

For self decarburization

Initial tap carbon levels up to 0.050% are acceptable for final carbon levels down

to 0.015%. For ultra low carbon levels tap carbons in the range 0.025 - 0.035%

are normally required. Higher start carbon levels are made possible by the use of

the oxygen lance for forced decarburisation. For light treatment practice, only

part of the full vacuum system is required. For full decarburization to produce

ultra low carbon grades the full steam ejector system is required.

Multi function lance practice

Decarburisation

Using the oxygen lance raises the upper limit on tap carbon. In this case it will be

possible to present steel to the degassing unit with carbon content for example of

0.060%, and, by using the oxygen lance under vacuum, reduce the carbon

content to, for example, 0.030%. From this point, a normal light treatment

practice would follow, as previously described, resulting in a final carbon level

down to 0.015%, or any intermediate value as required.

For ultra low carbon steels, the procedure would be in principle similar, except

the carbon content would be reduced by oxygen blowing in the vacuum vessel

down to about 0.020%. Full decarburisation practice would then proceed as

described previously, using the full vacuum system.



____________________________________________________________________________________ 26

The oxygen blow facility can also be used to accelerate the rate of

decarburisation from normal initial carbon levels.

Reheating

After deoxidation the steel can be reheated, if required, by using the oxygen

lance. The operator selects the required amount of reheat, which could be 10oc,

20oc, 30oc etc. The plc then automatically calculates the amount of oxygen and

aluminium required to achieve the requested reheat. Oxygen is blown at a

controlled, preset rate and aluminium is added during the oxygen blow. The steel

is then reheated by the exothermic reaction between oxygen and aluminium.

Reheat rates of 4oc per minute or more are achieved. After the required amount

of oxygen has been blown, and the required amount of aluminium added, the

PLC automatically stops the reheat process. The operator can then take a check

measurement for temperature and aluminium content (Celox sample) after

allowing a couple of minutes mixing to homogenize the ladle contents.

The ability to reheat the steel gives the RH process a much greater degree of

flexibility and versatility.

Hydrogen Removal

In certain grades of steel such as HIC plate steels, rail steels, high carbon steels

etc hydrogen levels are critical. The RH process is an extremely effective method

of removing hydrogen.

Hydrogen is removed during degassing by diffusion from the surface of the metal

to the low pressure atmosphere in the vacuum vessel. The effective removal of

hydrogen therefore requires, apart from low pressure conditions, a high surface

area between the metal and the vacuum.

In the case of the RH, the metal within the vessel is slag free, the depth of metal

is low, and the argon bubbles greatly enhance the surface area exposed. All

these factors, plus the high rate of recirculation of the RH process, produce a



____________________________________________________________________________________ 27

very high surface area to volume ratio, and result in the fact that the RH is a very

effective method for removing hydrogen.

The design is the so-called rocker system. In this design the vacuum vessel, hot

off take and gas cooler are all located on a platform which is supported at one

end of a double lever arm arrangement. The lever arms are pivoted about a

centre point and counterweighted at the other side of the pivot point. Movement

is achieved by a hydraulic ram attached to the counterweight box. Since the

counterweight is slightly heavier than the vessel and platform, the system is fail-

safe, in that the platform can be raised by bleeding the ram, in the event of total

power failure.

Ladles are presented to the degassing unit by a ladle transfer car which also

serves to remove the used vacuum vessel and replace it with the relined and

preheated replacement vessel.

The steam ejector vacuum system and the ferroalloy addition system are both

supported and enclosed by freestanding structures.

Ancillary equipment such as vessel wrecking, rebricking and preheating stations

can be located adjacent to the operating unit or in some adjoining bay.

Control and monitoring of the process is done from a control room local to the

unit.

Liquid Material Handling

After tapping, the steel ladle will be transported to the teeming bay by a steel

transfer car. Further transportation to the Ladle treatment and caster will be

provided by crane.

The empty ladle returning from the caster will be prepared for the next heat as

follows:

• tilting to remove the remaining steel and slag

• � teeming nozzle inspection/replacement

• � stirring plug inspection/replacement

• � preheating up to about 1,200 °C



____________________________________________________________________________________ 28

Ladle inspection and repair stand as well as ladle preheating station will be

provided for the above activities.

Slag Handling

The slag from the converter shall be transported in slag pots placed on the rail

bound slag transfer cars to the slag handling area. The slag pots will be handled

by overhead cranes for dumping into the slag pits. After that the slag pots will be

lime coated for reuse and transferred back.

3.1 Pollution Control System

BOF – Gas Cleaning Plant (DRY System)

Primary Gas Cooling Systems: The lower hood of the cooling stack and the

cooling stack will be designed for the gas flow rates, based on a reacting oxygen

shown below and a combustion factor of n = 0.1. In order to minimize skull build

up on the membrane wall, a round conical shape has been selected in the lower

section of the hood with an inside diameter shown below. The waste gas leaving

the converter is collected in the attached hood cooling system above the

converter. At the hood inlet an adjustable skirt is installed to close the opening

between converter mouth and hood inlet during the blowing process. This will

limit the access of ambient air to the gas and the combustion of the primary

converter gas will be kept below 10 %. At the outlet of the Gas Cooling System

the gases are cooled down to approx. 900°C.

The flow rate of primary gas and therefore also the total flow rate of LD-gas

during the blowing period is not constant but fluctuates over a wide range. To

assure a good capture efficiency and high LD-gas quality, the flow of LD-gas

through the system has to be carefully and accurately controlled. This is assured

by continuously adjusting the flow rate in such way, that the pressure at the

cooling stack inlet varies only insignificantly around zero (P0). SMS Siemag

favours a cascade control concept based on a radial type ID fan (IDF) equipped



____________________________________________________________________________________ 29

with an inlet guide van damper (IGVD). Small adjustments of the gas flow rate

will be controlled by the IGVD, larger fluctuations will be controlled by the

revolution speed of the IDF by means of a VVVF-control unit (Frequency

converter).

Due to this minimized waste gas quantity, the SMS Siemag Dry type System with

a pressurized close loop hot water system will be reduced to a minimum of

operating costs.

Description:

The cooling water is forced by cooling water circulation pumps through the

cooling hood tubes of the different hood sections. From the outlet it is passed

through a fin-fan heat exchanger to remove the heat to the atmosphere. The

design parameters of the heat exchanger are calculated to use the time between

the blowing cycles for cooling of the water back to the initial starting temperature.

This will ensure the most economical size of the equipment.

From the heat exchanger the cooled water is returned into a pressurized storage

tank and picked up by the pumps for the next circulation cycle. The storage tank

is designed to contain a water volume for two complete cycles during one

blowing period. Nitrogen is used to pressurize the storage tank. The pressure is

maintained at approx. 11 to 14 bar (g) and nitrogen is added if necessary through

an automatic control valve. The pressure is designed to prevent the water in the

system from boiling during the heat. The advantage of this system is the easy

operation and almost no feeding water requirement.

Primary Gas Cleaning System (Dry System)

The BOF waste gas cleaning system is designed as a dry-type cleaning system

for high efficiency.



____________________________________________________________________________________ 30

cleaning and further cooling of the LD-gas. The system is designed for

subsequent converter gas recovery. This type of Cleaning System is a technical

solution to comply with today’s most stringent environmental requirements.

The Gas Cleaning System is only in operation with full capacity during blowing

time. After passing through the cooling stack (CS), within that the gas

temperature is reduced, the LD gas enters the adjacent gas conditioning tower

(GCT) with a temperature of max. 1000°C. The gas is heavily laden with dust

particles from the converter process, mainly with iron, iron oxide but also other

particles from slag, flux charges (lime and others) and hot metal. The range of

particles sizes vary from approx. 0.1 micron up to some mm.

In the GCT, connected gastight via a special designed high temperature

compensator, the LD gas is being cooled and conditioned by evaporation of

injected water. Coarse dust particles are separated in dry state and transported

to the coarse dust silo. The conditioned LD gas exits the GCT at about 200°C.

By means of the following horizontal 2nd generation dry-type electrostatic

precipitator (ESP) the remaining fine dust load is further reduced to the

requested clean gas dust content. The dust is also collected in dry state and

transported to the fine dust silo.

The gas is transported through the Gas Cleaning system by means of an induced

draft fan (IDF). Depending on the actual CO content a switch-over station will

direct the gas either to the Flare Stack (FS) or with sufficient CO content to the

gas holder (GH) (not within the scope of supplies of this specification).

A subsequent Gas Cooler (GK) installed in the gas duct to the GH further cools

down the LD Gas to temperatures in the range of 60-70° appropriate for the

gasholder operation. The gas will then be fully saturated.

_____

_____

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GK)

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_____________

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_____________

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de the ESP

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patented d

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patented S

mal dilatatio

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design of SM

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s. As the

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on of each

_____________

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rent compo

are evenly

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electrodes

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discharge e

arthed.

MS ELEX d

discharge

the gas flo

electrons a

ged. Force

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s. The dus

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h plate and

Amend

____________

____________

ositions due

distributed

rforated pla

s and colle

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behaviour.

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plate syste

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e to the cha

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. Electrons

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migrate to

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periodically

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___________3

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____________________________________________________________________________________ 35

center of the ESP into individually suspended hanging and standing plates. In the

center all plates of one plate wall are guided by the rapping bar which transfers

the rapping impulse into each plate individually.

This unique design facilitates the opportunity to spread the passages for inside

passages maintenance access up to 700mm at rapping bar level. The collecting

plate material for the first field is 1.7335 (13CrMo4-5), thickness is 2mm. The

fields 2-4 are of material 1.0116 (St37-3G), thickness is 1,25mm. The patented

SMS ELEX discharge electrode frame is also designed to allow thermal dilatation

of the electrodes. The tubular electrodes are fixed at one bar of the frame only.

The other two bars at the top and the bottom of the frame are meant for guidance

only. Hence, mechanical stress and consequential damage to the electrodes can

be avoided.

For the first field the discharge electrodes are fabricated of special material to

resist high temperature which may occur due to glowing dust. The material of the

tubular part is of 1.7335 (13CrMo4-5) material with 2mm thickness, the spraying

tips of heat and scale resistant 1.4742 (X10CrAlSi18) material with 3mm

thickness. The discharge electrodes of fields 2-4 are fabricated of 1.0338 (St4

K40), both tubular part (thickness 0.6mm) and spraying tips (thickness 1mm). In

order to prevent the casing and the ESP internals of any damage caused by

deflagrations the ESP is equipped with sufficient number of SMS ELEX pressure

vent valves (certified according to directive 94/9/EC).

Each field is equipped with one high-voltage rectifier located either at the top of

the ESP casingor in an electrical room, and is controlled by a special control

cabinet with automatic oltage control.

All auxiliary equipment such as rapping systems, dust scraper, dust conveyor are

controlled by an additional low-voltage switch-gear cabinet.



____________________________________________________________________________________ 36

Scraper bearings inside the ESP are grease lubricated. In order to avoid coking

of high temperature lubrication grease the lubrication pipes and bearings are

cooled by Nitrogen rinsing.

The ESP is provided with necessary access and maintenance platforms.

The ESP casing is provided with thermal insulation as per the technical

requirement

Dust Transport and Storage System (DTS and DSS)

There will be two independent dust transportation and storage systems at each

BOF. One for the coarse dust from the conditioning tower and one for the fine

dust from the ESP.

The transport to the dust silos is carried out depending on the layout by a

mechanical or pneumatic transportation system.

ID Fan (IDF)

Downstream of the ESP the radial type ID fan is located.

Flare Stack (FS)

The flare stack is provided with a flare tip and with a flare ignition device with

blower in order to make sure that no CO-containing gas is released into the

atmosphere without having been passed through the high-temperature reaction

zone provided by the pilot burner for ignition purposes..

For example, natural gas or coke oven gas may be used as lighting-up gas for

the pilot burner. The ignition burners which are located at the flare tip will be

supplied with gas and combustion air by means of the separate pipes.

In case of power failure or ID fan failure the flare stack will be purged by means

of a Nitrogen injector.

LD Gas Duct (LGD)

The LGD connects the various elements of the gas cleaning system, such as

GCT, ESP, IDF, GK and SOS with the FS on one end and the Main Recovery



____________________________________________________________________________________ 37

duct on the other hand. The LGD consists of various elements/segments with

different diameter (as a contribute to the temperature and pressure regime) and

length (to allow a convenient positioning of the a. m. equipments within the layout

of the steel plant).

Secondary Emission Control Systems

The secondary fume collection system will be designed to collect the fumes from

the following emission sources:

• � Torpedo car re-ladling

• � Injection & de-slagging in Twin desulphurisation station

• � Converter charging, blowing (secondary fumes only) and tapping

• � Flux and alloy charging system at the BOF Converters

• � Ladle Furnaces with their material handling system

• � Wire Feeding & Material handling system at the RH

• � Argon Rinsing Station

• � Ladle breakout stand

• � Tundish breakout stand

Plant description

The fumes are collected in specially designed hoods, arranged as close as

possible at the emission source. In the suction ducts of each hood there are

motor operated dampers installed for appropriate on/off operation and

intermediate positions.

The fumes are then guided to a gas mixer where the gases are homogeneously

mixed and subsequently to a Bag Filter system where the dusty gas get filtrated

and released to the atmosphere by self supported chimney at a certain height in

line with the local pollution norm.

The suction of gas from various source as explained above through the duct,

mixer and Bag Filter is created by four number (three in working condition + one



____________________________________________________________________________________ 38

in standby condition) ID fans located at the out let of the Bag Filter. The dust

disposed of below the gas mixer and Bag Filter will be pneumatically conveyed to

the dust storage silo suitable for 24 hours capacity. The dust will be unloaded

from the storage silo at regular intervals by trucks.

3.2 Gas Recovery System

The LD-Gas Recovery System mainly consists of:

• Switch over Station (SOS)

• Gas cooler (GK) with re-cooling-system

• Gasholder (GH)

• Gas export Station (BFS)

• Nitrogen injection system (NI-System)

• Switch-over Station (SOS)

For switching-over the gas from flare stack operation to gas recovery operation

and vice versa, a switch-over station is used. This gas switch-over station mainly

consists of two bell shaped valves (cup valves) which are adjusted hydraulically

and separately from each other. By means of this station, the system can be

switched over without any pressure surge. The signal for switching over the

system is given by PLC based on interlocks and process variables. The signal for

switching over the system is given by the CO and O2-analysis. The system is

controlled by means of the differential pressure measurement. For the control,

the pressure is measured at two representative points of the system and is set

against the preset values.

During switching-over, the valve closes the direct way to the flare gas stack.

During pressure compensation the cup valve with control contour opens the way

to the gas holder. At blowing end, first the way to the gas holder starts closing

and then simultaneously the direct way to the clean gas stack is opened fully. In

case of emergency both cup-valves move into fail safe position.



____________________________________________________________________________________ 39

In the ducts of the switch-over station several connections for injection of

nitrogen are arranged in order to purge the ducts during the switch-over

sequence and to flush the system free from gas and / or air pockets.

The main recovery duct interconnects the switch-over stations of the individual

converters with the inlet of the gas holder. The dimensions follow the

requirements of Converter Operation Pattern.

Gas Cooler (GK)

A Gas Cooler (GK) is installed in the duct after the SOS to reduce the waste gas

temperature from approx. 150°C - 200° C inlet temperature to a level of 60 – 70°

C. This is vital for a long lifetime of the gasholder sealing. As a side effect, the

cooling reduces the gas volume.

The GK is designed as a counter-flow cooler, which means the gases enter the

cooler in the lower part and leave at the top. The cooling water is injected

through nozzle-banks with several individual nozzles. The cooling water is

internally circulated by pumps. At least one pump is in operation, while one is

always in stand-by mode.

In order to keep the dust concentration in the re-circulated water on the desired

level, a small amount of water will be continuously exchanged. Losses due to

exchange are compensated by feeding fresh make-up water.

A Goggle Valve (GV) and a gastight shutoff-damper are installed at the inlet of

the GK. A U-Seal valve along with a double excentric butterfly valve will be

installed before the interconnection to the recovery duct. This provides a

complete separation of the individual recovery installation of the Converter from

the common Recovery System.



____________________________________________________________________________________ 40

3.3 Material Balance of EAF and BOF

Material Balance of EAF Route of Steel Making (6 MTPA, from EIA Report August 2008 Input Quantity, TPA Output Quantity, TPA 1 DRI

(@ 0.64 t/t) 3,840,000 Steel Slabs 6,000,000

2 Hot Metal (@ 0.494 t/t)

2,964,000 Slag 1,080,000

3 Cold Pig (@ 0.005 t/t)

29,400 Cut ends, rejects (scrap) 348,000

4 Lime (calcined) (@ 0.072 t/t)

431,800 LOI 54,300

5 Dolomite (calcined) (@ 0.0103 t/t)

61,800 Flue dust 296,880

6 Fluorspar (@ 0.00213 t/t)

12,780

7 Return scrap (@ 0.058 t/t)

348,000

8 Ferroalloys (@ 0.0152 t/t)

91,400

Total 7,779,180 7,779,180

Material Balance of EAF Route of Steel Making (3 MTPA, as proposed) Input Quantity, TPA Output Quantity, TPA 1 DRI

(@ 1.1328 t/t) 3,398,400 Steel Slabs 3,000,000

2 Hot Metal (@ 0.0988 t/t)

296,400 Slag 647,040

3 Cold Pig (@ 0.001 t/t)

2,940 Cut ends, rejects (scrap) 174,000


215,900 LOI 27,150


30,900 Flue dust 148,440

6 Fluorspar (@ 0.00213 t/t)

6,390


45,700

Total 3,996,630 3,996,630 Requirement of oxygen is 42 Nm3/ton of steel produced

Requirement of power is 490 KW per ton steel produced

PM emissions limit is 20 mg/Nm3.

Solid waste generation is 265 kg/ton of steel produced

Water consumption: 1 m3/ton steel produced

Material Balance of BOF Route of Steel Making (3 MTPA as proposed now) Input Quantity, TPA Output Quantity, TPA 1 DRI

(@ 0.1067 t/t) 320,000 Steel Slabs 3,000,000



____________________________________________________________________________________ 41

2 Hot Metal (@ 0.8883 t/t)

2,665,000 Slag 354,000

3 Return scrap (@ 0.116 t/t)

348,000 Return scrap 174,000


150,000 LOI 5,000


30,000 Flue dust 25,000


45,000

Total 3,558,000 3,558,000 Requirement of oxygen is 54Nm3/ton of steel produced

Requirement of power is 46 KW per ton steel produced

PM emissions limit is 20 mg/Nm3.

Solid waste generation is 126 kg/ton of steel produced

Water consumption: 1 m3/ton steel produced

4.0 Water Balance and Management Scheme

The consumptive water requirement of the existing SMS (EAF Route) is 2033

kl/hour. The wastewater generation is 650 kl/hour. There will be no change in the

consumptive water requirement of the SMS and wastewater generation after

changing to BOF Route. The wastewater shall be taken to the Oil and Grease

Separator and Settling Tank and after treatment the water will be recycled. No

wastewater shall be discharged outside the premises.

5.0 Air Emissions and Load Calculations The nature of emissions from the Integrated Steel Plant and Power Plant,

including the emission inventory is shown in Table below. The air pollution load

will decrease by using BOF Route.

Source of Emissions

Description of Source

Pollutants

Stack height M

Stack dia m

Gas Temp (K)

Flow Rate (Nm3/hr)

World Bank Standard (mg/Nm3)

Design Limit (mg/Nm3)

Exit Velocity m/s

Emission Load g/s

Power Plant Flue of

each 135 MW units, Total 8 flues

PM 275 3.5 421 392270 (each flue)

50 40 16 35.2 SOx 2000 1720 1499.2

NOx 750 750 653.6



____________________________________________________________________________________ 42

Pellet Plant Single stack

attached to ESP

PM 70 3.0 388 263850 50 50 13.5 3.6 SOx 2000 30 2.2 NOx 320 320 23.5

Three stacks attached to Venturi Scrubber

PM 30 1.0 m 298 22620 (each flue)

50 50 8.0 0.9

Four Stacks attached to 4 bag houses

PM 30 1.0 m 298 14140 (each flue)

50 30 5.0

0.8

DRI Plant Two Stacks

attached to gas heater

PM 40 3.0 326 23260 (each flue)

50 10 15 1.0

SOx 2000 350 28.2

NOx 320 320 57

Blast Furnace One Stack

attached to Stoves

PM 65 3.6 473 196230 50 10 8.5 0.6

NOx 750 750 41

F 5 5 0.27

Two Stacks for Cast House Dedusting

PM 45 4.0 353 286430 (each flue)

50 50 7.5 8.0

One Stack for Stock House dedusting

PM 45 3.0 333 204950 50 50 9.0 2.9

SMS Three

Stacks attached to 3 Bagfilters

PM 70 6.1 403 622380 (each flue)

20 50 8.0 25.8 SOx 2000 50 25.8 NOx 750 320 165.9

Coke Oven Two Stacks

attached to 4 batteries

PM 135 2.0 553 45710 (each flue)

50 50 7.5 1.2 VOC 20 20 0.25 Benzene

5 5 0.06

SO2 800 60 1.6 NOx 500 500 12.8

Coal Gasifiers Two Stacks

attached to 2x 7 sets of gasifiers

PM 40

2.0 553 42660 (each flue)

50 50 7.0 1.2 VOC 20 20 0.24 Benzene

5 5 0.06

SO2 800 50 1.2 NOx 500 500 11.8

Plate Mill One Stack

attached to Reheating furnace

PM 80 3.3 693 105925

50 50 8

1.5 SO2 2000 1400 41.2 NOx 460 460 13.5

Hot Strip Mill Two Stacks

attached to 2 Reheating furnaces

PM 80 3.3 693 145645 (each flue)

50 50 11 4.0

SO2 2000 1400 113.2 NOx 460 460 37.2



____________________________________________________________________________________ 43

Lime-dolo Plant Six Stacks

attached to Kilns

PM 50 2.2 383 74535 (each flue)

50 50 7.0 1.2 SO2 600 10 2.4 NOx 400 200 6.0

Two Stacks attached to dedusting units

PM 50 2.0 323 57390 (each flue)

50 50 5.5 1.6

Ferroalloy Plant Two Stacks

attached to Furnace

PM 45 3.0 393

135070

50 50 7.0

3.8 SO2 2000 300 22.6 NOx 320 320 24

Two Stack attached to dedusting Unit

PM 30 2.0 298 56550

50 50 5.0 1.6

Sinter Plant Stack

attached to ESP

PM 85 5.5 408 624700 50 50 10.0 8.7 SO2 500 100 17.4 NOx 320 200 34.7 F 5 5 0.9

Stack attached to Dedusting Unit

PM 85 3.0 408 139400 50 50 7.5 1.9

Process Steam Boilers Two twin-

flues Stacks attached to 4 x 180 TPH Boilers

PM 105 2.6 421 202940 (each flue)

50 40 15 4.6

SOx 2000 1260 184 NOx 750 750 169.2

In the EIA Report, 3 EAF, 6 LRF and 2 RH TOP were proposed. The emissions

from these EAF, LRF and RH-Top would be captured using Fume Extraction

System and taken to three Bag Filters for treatment. The outlet of Bag Filters

would be discharged using three numbers of 70 m tall stacks. The emission

inventory of SMS is shown in Table below:

Stack height, m

Stack diameter m

Exit Velocity m/s

Exit Gas Temp oK

Exit gas volume Nm3/Hr

Emission Limit, mg/Nm3

Emission Load, g/s

70 m 3 Nos.

6.1 8.0 403 622380 x 3 Nos

PM- 50 SO2- 50 NOx- 320

PM- 25.8 SO2-25.8 NOx-166



____________________________________________________________________________________ 44

In the proposed change, 2 EAF (250 tons), 2 BOF (250 tons), 6 LRF and 2 RH-

Top shall be established.

Stack height, m

Stack diameter m

Exit Velocity m/s

Exit Gas Temp oK

Exit gas volume Nm3/Hr

Emission Limit, mg/Nm3

Emission Load, g/s

70 m 2 Nos.

6.1 8.0 403 622380 x 2 Nos.

PM- 25 SO2- 50 NOx- 320

PM- 17.3 SO2-17.3 NOx-111

70 m 2 Nos.

3.6 8.0 403 216770 x 2 Nos.

PM- 25 SO2- 50 NOx- 320

PM- 3.0 SO2-3.0 NOx-38.5

6.0 Solid Waste Generation and Load Calculations

The inventory of solid wastes load from the Integrated Steel Plant and Power

Plant is shown below. The solid waste load will decrease by using BOF Route.

Name of the Unit Type of solid Waste

Quantity (TPA)

Utilization/ Disposal

1 Coal Gasification

Plant

Coal Ash 1584000 Used in land filling and road making. Unutilized portion of coal ash will be disposed in abandoned coal mines

2 Pellet Plant

Dust 81750 Dust will be reused in Pellet Plant. 100 % reused

3 DRI Plant

Dust Sludge

1982000

Dust and sludge will be used in Sinter Plant. 100 % reused

4 Sinter Plant

Dust 52000 Reused back for sinter making. 100 % reused

5 Blast Furnace

Slag Sludge & Flue Dust

854400 1176035

Granulated Slag will be sold for cement making. Sludge and flue dust will be 100% used in Sinter Plant.

6 Coke Oven &

Byproduct Plant

Bio sludge 50200 Bio-sludge is mixed with coal and reused in coke oven. 100 % reused



____________________________________________________________________________________ 45

7 Steel Melting Shop

& Rolling Mills

Slag Flue dust

1080000 50200

Slag will be given for metal recovery. Dust will be reused in sinter plant

8 Lime-dolime Plant Dust 746000 100% reused in sinter plant . .

9 Captive Power Plant

Fly Ash Bottom Ash

2134000 533000

Used in cement making, brick making, block making, wasteland filling and road making. Unutilized portion of coal ash will be disposed in abandoned coal mines

10 Ferroalloy plant,

Slag Dust

50000 67000

100% slag will be used in road making. 100% flue dust will be recycled

The solid wastes generation from 6 MTPA and 3 MTPA SMS based on EAF

Route is given below: The solid waste generated from 3 MTPA BOF is given

below (in tons per annum):

Name of solid wastes

Generation from 6 MTPA SMS based on EAF

Generation from 3 MTPA SMS based on EAF

Generation from 3 MTPA SMS based on BOF Route

Generation from 3 MTPA SMS based on EAF and 3 MTPA SMS based on BOF

SMS Slag 1,080,000 647,040 354,000 1,001,040

Flue Dust 296,880 148,440 25,000 173,440

There will be significant reduction in solid wastes generation due to change in

SMS process technology. About 7% in SMS Slag and 42% Flue dust.

7.0 Pollution Load Statement

Component Existing Pollution Load

with EAF Route

Pollution Load after

Change to BOF Route

1 Land 1563.043 ha

(3860.7 acres)

No change in land area,

except that Plant Layout

has been revised



____________________________________________________________________________________ 46

2 Water

Consumption

9700 kl/hr 9700 kl/hr

(No change)

3 Wastewater

Generation

100% reuse within plant

premises

No change in quality of

wastewater generation.

100% reuse within plant

premises

3 Air Pollution Load

PM

SO2

NOx

In g/s

PM- 25.8

SO2-25.8

NOx-166

In g/s

PM- 20.3

SO2-20.3

NOx-149.5

4 Solid Wastes

Generation

SMS Slag: 1,080,000 TPA

Flue dust: 296,880 TPA

SMS Slag: 1001040 TPA

Flue dust: 173440 TPA

5 Energy

Consumption

Approx. 700 MW Approx.600 MW

8.0 Conclusion

Jindal Steel & Power Limited (JSPL) is constructing a 6.0 MTPA Integrated Steel

Plant and 1142 MW Captive Power Plant at village Kerjang, District Angul in

Orissa. Environmental Clearance for the project was granted by the Ministry of

Environment & Forests, Government of India (MoEF) vide letter

No.J.11011/365/2006-IA.II (I) dated 22-2-2007 and amendment dated 14-11-

2008.

Following changes are proposed for approval of the Expert Appraisal Committee

(Industry) of MOEF

1. Change in Steel Making Technology, keeping the steel production same.

2. Change in Plant Layout keeping the total plant area same.

The earlier 6 MTPA SMS process was based on Electric Arc Furnace Route,

comprising 3 x 200 tons capacity EAF (Conarc type furnace) and 6 x 200 tons



____________________________________________________________________________________ 47

capacity Laddle Refining Furnace (LRF) and 2 x 200 tons RH-TOP for production

of special quality slabs has been proposed. Conventional slab casting technology

comprising 3 x 1 strand and 1 x 1 strand caster has been proposed.

Now the 6 MTPA SMS process has been bifurcated into Electric Arc Furnace

Route and Basic Oxygen Furnace Route. 2 x 250 tons capacity EAF shall be

established to produce 3 MTPA Steel. 3 x 250 tons capacity BOF shall be

established to produce 3 MTPA Steel. The capacity of LRF, RH-TOP and Slab

Casters are also updated accordingly due to change in heat size..

Environmental Benefits of BOF are low air pollution because of higher content of

hot metal as input, low slag generation and possibility of energy recovery from

exhaust gas (because of use of higher oxygen lancing and resultant suppressed

combustion). The metal recovery using BOF route is about 90%, compared to

about 85% using EAF Route. The electricity consumption is also lower in BOF

than the EAF Route.

The core plant layout has been optimized to 1416.4 ha. This has been has

been communicated to the MoEF vide JSPL letter dated 26th July 2011

along with the revised layout plan of the Integrated steel plant. JSPL

received the lease document of the entire 1416.4 ha land (3500 acres). As

on date physical possession of 867 ha land (2141.5 acres) is available

with JSPL where the project construction work is going on. Considering

the fact that physical possession of the balance land will take more time

than anticipated and therefore to meet the scheduled commissioning

target, revision of plant layout has become inevitable. Because of land

acquisition issues an adjustment of 23.5 ha (58 acres) land was done.

However the total land for setting up the core plant will remain1416.4 ha

(3500 acres), as already furnished to MOEF.



____________________________________________________________________________________ 48

JSPL decided to shift the blast furnace, pellet plant, coke oven and sinter plant

from the west side to east side and shift the ash pond from east side to west side

of the plant layout. This will enable JSPL to immediately start constructing the

remaining units and synchronize them with the units that are ready for

commissioning.

There will be net reduction in Pollution Load due to change in SMS process

technology. Water consumption and wastewater generation will remain same.

Entire wastewater generated from SMS shall be treated and recycled. The air

pollution load from the SMS will decrease after the change in process

technology. The solid waste generation from the SMS will also decrease after the

change in process technology. The land requirement for the SMS however

remains unchanged.

ENVIRONMENTAL CLEARANCE ‐NEW

(Steel & Power Plant)

F. No. J-11011/365/2006-IA II (I) Government of India

Ministry of Environment and Forests (I.A. Division)

Paryavaran Bhawan CGO Complex, Lodhi Road

New Delhi - 110 003

To, / ,.,fhe Executive Director

E-mail: [email protected] Telefax: 011: 24367668

Dated 14th November, 2008

Mis Jindal Steel & Power Limited 'Jindal Centre', 12 Bikaji Cama Place New Delhi 110 066

E-mail: [email protected]/[email protected] Fax No.: 011- 26161271

Subject: Integrated Steel Plant (6.0 MTPA) and Captive Power Plant (1,080 MW) at Kerjang, Angul, Orissa by Mis Jindal Steel & Power Ltd. - Amendment in environment clearance reg.

Ref. Your letter no. JSPLIANGULIMOEFIVRK dated 25 th January, 2008, 30th April, 2008, 10th June, 2008, 1st July, 2008, 15th July, 2008 and 19th August, 2008 3rd

September, 2008 and 22"d September, 2008. Sir,

Kindly refer above mentioned letters dated 25th January, 2008, 30 th April, 2008, 10th

June, 2008, 1st July, 2008, 15th July, 2008 and 19th August, 2008 3rd September, 2008 and 22"d September, 2008 wherein you have requested for the amendment in environment clearance accorded by the Ministry vide even no. letter dated 22"d February, 2007 for Integrated Steel Plant (6.0 MTPA) with Captive Power Plant (1,000 MW) at Angul, Orissa by Mis Jindal Steel & Power Ltd. as per the following configuration:

S. N. 1 2 3 4 5

6 7 8

2.0

Product (s)

Iron Ore Pellets (MT Coal Gas (Nm 3/yr)

. ＭＭＭＭｾＢＭＮ＠

ｾ＠

-i . Phase-I

1 x 3.5 5120 ｾｗｳ＠

Sponge Iron (MTPA Pig Iron (MTPA)

) -----_ ...

Steel Products (Sla Rods, Plates and S

bs, Billets, Bars, trip) (MTPA)

Ferro Allo s TPA) e (TPD) Calcined Lime Dolim

Thermal Power Pia nt (MW) -----

2 x 1.7 1 x 0.35

3

.-1 x 50,000

2 x 350 -_ .. -----2 x 250

.. Phase-II Total Capacity

_ .. 1 x 3.5 7.0

2560 x 106 7680 X 106 ＭｾＮ＠

1 x 1.7 5.1 -- 0.35 3 6

1 x 30,000 80,000 3 x 350 1750

-----

2x 250 4 x 250

Now, you have proposed for revised configuration in the environment clearance accorded. The final configuration of the proposed project will be as follows:

2

I I I

----Proposed Final l Name of Units Product As per EC Proposed

I dated 22"d deletions additions Capacity Feb., 2007 ----,.

Pellet Plant Iron Ore Pellets 7.0 2.0 I -- I 501 Coal Gasifier Coal Gas 76S0 x 106 36S0 X 106 -- 4000 X 106

Nm3/year Nm3/year Nm3/year I DRI Plant Sponge Iron 5.1 1.1 -- 4.0

--

Blast Furnace Pig Irem ＭＭｾ＠ -- 2.S5 3.2 Coke Oven & Coke -- -- 2.0 2.0

ｾｹｰｲｯ､ｵ｣ｴ＠ plant - - --Sinter Plant Sinter 4.0 4.0 , -- , --

--

SMS Steel 6 -- -- 61 ---_. . --.. Ｚｾ＠ ---- ｾＮＭＮＭＭＭ .. ＭＭＭＬｾＭｾＮＭＭＭＢＢＭＭ

Rolling Mill Steel Products 6 _ . -- 6 .. -

Ferro alloy Plant Ferro Alloys O.OS -- -- O.OS Lime Dolime Plant Lime 1 Dolime 1 1750 TPD -- 1250 TPD 3000 TPD

- -- ＭＭＭＮＭＬＬＭＭＮｾＬＭＭＭ - ----- , .. ----"-Process gas 1 l Electricity -- -- 62MW I 62MW I , pressure recovery I turbines ,

I

Coal based Power Electricity 1000 MW -- -- 1080 MW Plant I (4x250 MW , (Sx135 MW -'------------

Total cost of the project will be Rs. 21,000 Crares instead of Rs. 15.000.00 Crores earlier proposed.

3.0 The matter has been examined in the Ministry. Based on the revised proposal and EIA/EMP report submitted incorporating increase in capacity of certain plants and installation of new plants, following additional specific conditions shall be included in the environmental clearance letter accorded by the Ministry vide letter no J-11 011/365/2006- IA II (I) dated 22nd

February, 2007:

i)

ii)

iii)

iv)

Continuous stack monitoring facilities for all the major stacks and adequate air pollution control systems shall be provided to control air emissions within 50 mg/Nm 3

and reports for ambient air, stack emissions and fugitive emissions submitted to the Ministry's Regional Office at Bhubaneswar, OSPCB & CPCB regularly.

The emission standards issued by the Ministry in May, 200S for the sponge plants shall be followed.

Total requirement of the water River Brahmani 1 Samil Barrage shall not exceed 14,700 m3/hr and prior 'Permission' should be obtained from the concerned department and a copy submitted to the Ministry's Regional Office at Bhubaneswar within 3 months of issue of this letter.

Proper and full utilization of coke oven gases in power plant using heat recovery steam generators (WHRB) shall be ensured and no flue gas shall be discharged into the air. Tar, NH3 should be cleaned in the process and H2S recovery from the coke oven shall be ensured. Coal tar, elemental Sulphur and crude Benzol shall be recovered from coke oven gas.

v) Wet quenching shall be adopted within one year of installation of coke oven and all the treated wastewater shall be used for wet quenching.

o .,

vi) The prescribed emission standards for coke oven plants as notified vide notification no. GSR 46 (E) dated 3'd February. 2006 shall be complied with.

vii) Biochemical treatment of phenolic wastewater shall be should be treated in BOD plant and used for quenching of hot coke to control emissions, dust suppression and green belt development. Cyanide as CN shall be controlled within 0.2 mg/litre and Ammonical Nitrogen within 50 mg/litre as per the standards notified under the E(P) Act. Elluent analysis reports shall be submitted to the Ministry's Regional Office at Bhubaneswar, OSPCB & CPCB regularly.

viii) Coal and coke fines shall be recycled and reused in the process.

ix) All the recommendations made in the Charter on Corporate Responsibility for Environment Protection (CREP) for the Coke Oven Plants shall be implemented.

x) 'Consent for Establishment' for the revised Integrated Steel Plant (6.0 MTPA) and Captive Power Plant (1,156 MW) shall be obtained from the Orissa State Pollution Control Board and a copy submitted to the Ministry's Regional Office at Bhubaneswar.

4.0 This letter may be kept with the original letter.

5.0 All the other terms and conditions shall remain same.

6.0 This has been issued with prior approval from the Competent Authority in the Ministry.

ｾ＠(Dr. P. B. Rastogi)

Director Copy to:-

1. The Secretary, State Department of Environment, Govt. of Orissa, Bhubaneswar, Orissa.

2. Chairman, Central Pollution Control Board, Parivesh Bhavan, CBD-cum-Office Complex, East Arjun Nagar, New Delhi - 110 032.

3. Chairman, Orissa Bengal Pollution Control Board, Parivesh Bhavan, A/11S, Neelkanthhanagar, Unit-S, Bhuvaneswar - 751 012, Orissa.

4. The Chief Conservator of Forests (Eastern), Regional Office (EZ), N3, Chandrasekharpur, Bhuvaneswar - 751 023, Orissa.

5. Adviser (IA II-I), Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New Delhi.

6. Monitoring Cell, Ministry of Environment and Forests, Paryavaran Bhavan, CGO Complex, New Delhi.

7. Monitoring Cell S. Guard File. 9. Record File.

ｾｾ＠(Dr. P. B. Rastogi)

Director

ENVIRONMENTAL CLEARANCE –OLD

(Steel & Power Plant)

F. ｎｾＮ＠ J·l1011138SI2006· IA II (I) . . Government of IndlR Ministry of Environment end For.sts

JI.A. Division) Plryavaran Shawan

CGO Campi •• , Ladhl ROld New Oelhl -l10 003

e.rnall : pb,rI.toa lft nlc.ln Tolef .. : 011 : 2436 7688 Dated 22'" FebnJary. 2007

To, / . oShri Anand Goyal

Deputy Managing Director Mis Jindal St., 1 & Pewsr Umited Jindal Centre . 12 Bika ji Cerna Place New DelhlttO 068

FIX No.: 011· 2818 12Tl E-mail : [email protected]/ [email protected]

Subject : Integrated Steel Plant (8.0 MTPA) and Captive Powlr Planl (1,000 MW) al ｋＧｾｬｮｧＬ＠ Angul, Orl ... by MIl Jlndll Stell & Power ｾｉ､Ｎ＠

Sir This has reference to your letter no. JSPUEMD/CORf'06.07101 daled 14" October.

2008 alongwith application and EIAIEMP and sub.equent clarifiea'on. furnl.had by you \lid. your Jett er dated 23'" November . 2006 and 20'" December , 2006 for env ironmental ･ｬ･ｾｬｲ｡ｮ｣･＠on the above mentioned project. The Ministry of Environm ent and Forests has examined your application. Il ls noted that Mia. Jindal St.el & Power Ltd. have propo.ed for Integrated Sloe! Plant (6.0 MTPA) and Captive Power Plant (1000 MW) .t ｋ･ｾ｡ｮｧＮ＠ Angul. Ori •••. No ｷｩｬ､ｬｾ･＠

sanctuary , elephant corridOC' , eeo1ogicalfy sansltlv, area, notified archaeolog lca l afte or criUc any polluted area e>data within 25 km area of the site. Ph.'o-wia. details for the procuellon of 6.0 MTPA .te.1 will be as follows :

Coal wi ll be sou rced from captive coa l mIn' and enVIronmenta l dearance Is yet to ｡ｾｯｲ､･､＠ 9Y the Minlatry. Total land requirement will be 2.160.365 Including le8.232 h • . forest land which Is SUbmitted to tha St.t. Forest ｄＬｰ｡ｲｴｭ･ｮｾ＠ Oris.o on 22'" November. 2006 for approval. The

proposal also Involves dIsplacement of pe rso ns and oustee! have to be rehablHlated . R & R Act iO" Plan Ii prepared and subm itt ed to the Stale Govt for Dpproval

2.0 Bag filters , rume extra ct ion system, cyclon e. ventury scrubber, Electr ost at\c Prec ipit ators (ESPs), waler spray ing fac ili ties elc . will be pro vi ded to contro l the fugitiv e/gaseous emissions below 100 mgINm'. Totel waler requirement Irom River Brahmanll Saml1 8arrege will be 14,700 mllhr . The wastewater will be treated in ETP and WIll be , 00% recycled and reused in the process , cosl dust suppress ion and gardening . No wastElwater will be re leased outs ide the plan t prem ises . SF slag will be so ld to ceme nt manufactu rers Dust from SF & SMS sludge ; ETP 81udge of ORI plant : coal ash from power plant & gas ifi er etc , will be used for backfilling captive coa t mines . Oust from li me do lomi te plant will be reused In lad le coating and wastewater treatment. SMS slag and olag and dust Irom lerro·alloy plant will be used lor road maKing. Mill sealo. will be sold to 51eel plants. He.rth layer and APCD dust from pellet plant will be reu,ed in Pell et plant. No char and accretions will be generated , Out of to lal fottd waste generated , 46.6''; win be reuti lized and 53.3% will bo disposed off In abandoned coal mines.

3.0 Public heering meeting was held on 21· Morch, 2006. 'Conoent lor Establishment' hs, been accorded by the Orissa Stote Pollution Control Board vide letter nO.220901Ind·Ii·NDC· 4103 dated 7" September. 2000. Total cosl oft/1e project is Rs. 15,000.00 Cror.s.

4.0. The Mini stry 01 Environment and Forests hereby accords environmental clearance to the above project under the pro vi sions or EIA Notification dated 14111 September, 2006 sub ject to strict compliance of the following spec ifi c and general cond iti ons:

A,

i)

/I)

III)

SPECIFIC CONOITIONS :

The gaseous emiss ions from various process units sha ll conform to the lo ad/mass b.sed .tandardS notified by thl. Mlnl.1ly on 19" May, 1993 Ｎｾ､＠ standard. prescribed flom time 10 time. The stale Board may specify more" &lrlngenl otandard. lor the relevant parameters keepIng In vIew the nature of the Industry and Its size and location. At no time, the emission level .hall go beyond the p",.cribed slandards. On· li ne continuous stac k emis sion. monitoring for all the major atacks will be car ned out and reports oubmltted to the DSPCB & CPCB. The emission /evels from all the sburces shall be Kept below 100 mglNm'. InterlocKing lacilffi •• ';hall be provided so'

lnat process can be automat ically stopped In eaee emission level exceeds the limIt.

ContlnuoLls on-line amb ient air quaUty monllor ing slat ions shall be setup al three location. oround the project oit. and ",porta submitted 10 the OSPCB & cpce.

In-plant control measures for checkIng fug itiv e emissions from aU the vulnerable sources shall be pro vided . Fume and duet extraction system wlth bag filters shall be provided In aleel melting shop , Electrfc Arc Furnac e and Lad le Refining Furnace , Coke oven (non-recovery type) .haJl be opera ted at negative pressure with no fug itive emissions. Bag filters shall b. provided to Pellel plant, DR plant, Lime kiln, Power plant, SMS, SAF, Cast house, raw materiel stock house 01 BF, raw malerial mixing section of SMS and malerlal transler point. 01 lime ､ｯｬｯｭｾ･＠ plant. ESP shall be provided to DRI Kilns and fime dolomilo plant. Gas cleaning plant shall be provided 10 BF. Cyclone 101l0wed by ventury scrubber ,/10/1 be provided 10 the BF. Further speciflc ｭ･｡ｳｵｲ･ｾ＠ lik e wate r sprinkling shall be carried out at the coal yard, ｷｳｧｯｾ＠tfpp ler and ｴｲｵｾ＠ tipp ler elc . Fugitive emissions sha ll be controlled, regularly mon itored and records mainta ined .

Iv)

v)

vi)

J

The power pl.nt Installed shall be b.,ed on con .... ntion.1 ｾｵｬｶＮｲｩＮ･､＠ fuel technology. COBI shell be sourced from captive coal mines and pri or env ironmental clearance from tho Mlnl,try sholl be obtained. ESP shall b. In.talled to keop SPM le\lol. below 100 mgfNm1 , Wastewater generated from coo ling lower blow down sha ll be used for ash handling and disposal. Fly ash shall be backfilled In captive coal mines.

Total requ irement of th e water River Brahman ! I Samil Barrage sha ll not exceed 14,700 m'lhr . 'Perm iss ion ' has been iiilceorded for the drawl of 7.000 m'lhr water for Phase I by the Depar tment Of Water Resources, Govt. of Ori SSi vide leiter dated 11 11 Dec., 2006 and 'Perm iss ion ' for phase II shall be Obta ined . The wastewater from scrubbera In OR Plant and Blast fumace sha ll be trested in ETP and reused ror duet scrubbing . Ha .... leve' , wastewater from SMS and Oxygen plant shan be uiWd for slag granulation; from elilet and Sieb ca.ter. Soft waler plant, DM water plant etc. in pellet making and CooJ ing water for re-(: ircu lation. The wastewater (rom power plan t sha n be used for ash sli Cing and coa l dust suppress ion . All the treated waslewalBr ShaH be recycled & reused either In the process or for green belt deve lopment. No effluent sha ll be discha rged outside th e premises end 'Zero ' dtscharge sha ll be adopted , Domestic wlstes . hell be treated In Sewage Treatment Pllnt (STP)

Ground water monHoring around Ihe solid waste disposal site I .ecvred landfill (SLF) shall be earned out regularly and ｲ･ｰｯｾ＠ sUbmlHed to the Ministry's Regional Office at ehuvane.hwar, epee and opce.

vU) Dust from pellet plant In Pe llet plant; from Lime dolomlle plant In ladle co.Hng snd wastewater Ireatment; from eF & SMS, sludge from GCP of SF, ETP Sludge of DRI pl.nt, coal ash from power plant, coal a.h from ga.ifler. sludge from eTP etc for backfilling captive coal mine.; SMS . 'ag and slag duat from ferro-alloy plant . hall be used for road makin g. SF slag shall be sold to ceme nt manufac tu rers . Mill scales of casting mach ine and ro ili ng mill shall be sold to steel pfa,nts. Fly ash and granu lated sla g shall be used In cement pl.nls . No char and accre tions will be generated . Used oil , hall be so ld to ｲ･｣ｹ｣ｬ･ｲｾ＠ and prep rocessors .

viii) POSSibiliti es sha ll be explored regardIng use of coa l ash by lhe cement manufac tunn g units. Sottom ash . hall be disposed off in a suitably de.lgned landfill a. per epes gu idell nes to prevenl leach lng to the sub -soil and underground aqu ifer.

Ixl The company sha ll ､･ｾｯｰ＠ rain water harvest ing, structures .to harvest the rain water for utilization In the lean aeason besIdes recharg in g the groun d water table .

x) Green belt shall be developed In at I .. ,t 33 ' .. area within and around the plant premis •• a. per the epes gUideline. In consultation with DFO.

xl) Occupat !onal Health Surv enlanca of the workers sha ll be done on a regular bas is and records maintained as per the FactorieS Act.

xii) Recommendations made in the CREP guide lines issued fo r the stee l plants shall be Implemented.

xm) No commencement or opera tion of the cement plant shall be carried out without obta ining prior environmenta l clearance for the cap!lve coal mine nom the MinIstry ,

B.

l

n.

liL

Iv.

v.

VI.

vII.

xiv) Comment. and recommendations of the Chief WIldlife Warden (CWLW), GoV!. of Orlss8 regard ing imp act or the proposed plant on the nearb y rese rv e and prote ct ed fores ts sha ll be obta in ed and suggest ions, if any , sha ll be implemen ted 10 3 time bound manne r,

xv) AI the .ffected peraons ,hall be .ultably compensatAd ｡ｾ､＠ｲ･ｨ｡｢ｬｬｾ｡ｬＮ･､＠ as per the norma and gu ide lines issued by the state GovemmeOi In co ll aborat ion With State Government .

xv ij No construct ion activity at the pro ject she sha ll be Init iated till the approva l for the '";88.232' h. forest land I. obtained ｾｮ､･ｲ＠ the Fore.t (Conservallon) Act, 1980 & subsequent amendments (rom the Stale I Centra l Government

GENERAL CONOITlONS:

The project authorities must strictly adhere to the st ipu lat ions made by the Ori ssa PoMlon Control Board (OS PCB) and Ihe State Government.

No further expansion Of modlficslion. in tho plont should be carried out without prfor approval of the Ministry of Environment and FOfO.t • .

At least four ambient air qualijy monitoring $lations shall be establl.had in the downward direction 8S well 8S where maximum ground level concentrat ion of SPM, SO: and NOx are anHelpated In consultalion wiln Ihe OSPCB. Data on ambient air quality and stack emi,slon should be regularly .ubmitled to thl. Ministry inctudfng ｾ｡＠ Regional OffICe at Bhopel and Ine OSPCBICPCB once In .Ix months. •

Industria l wastewa ter sha ll be properly co llected , treated 10 'as to conform to the .tandarda pre.cribed under GSR 422 (El dal.d l e· May, 1993 and 31· December, 1993 or as amended form time to time . The trealed wBs tewater shall be utilized for plantation purpose.

The overall noiae levela In and around the plant area ,h,U be kepi well wijhln Ihe atandards (85 dBA) by' providing nol.e conlrol measure. Including acoustic hood" silencers , enc losures etc. on all sources of no ise generat ion . The ambient nOrS! levels should conform to the atandard. prescribed under EPA Rule" 1989 viz. 75 dBA Ｈ､｡ｹｴｩｭｾＩ＠ and 70 dBA (nighttima).

The pro ject proponent sha ll also comply with all the environmenta l protect ion measures and .,feguard. recomm.nded In the EIA I EMP report. Further, the company mu.t undertake socio·economlc d ..... lopm.nt ,ctMtie. In the surrounding yillages Uk. community development programmes, educational programmes, drinking water aupply and heaitt1 care etc.

Aa menUoned In the EIAIEMP, R., 2,000.00 Crore. and Ra. 100.00 Crore. eamarked toward. the capital coat and racun1ng cosVannum for enVironmental pollution oontrol me •• ure. shall be Judlclou,ly uliliud to Implement Ine condilion •• tipulated by Ihe Mlnlatry of Env ironment and Forests as well as the State Governme nt The funds so crovlded sha ll not be divt!rled (or .nv /'Ilh-.r /'UJrf'\I"Ica

5

viii The Reglonsl Office of this Mioistry Rt Rh,lV.nA.hw., I cpca l OSPCB will ｭｍｾｯｲ＠ the stipu lated cond itions A six monthly comp li ance repo rt and the mon itored dala along with statistica ll nterprelat ion sha ll be subm Hted to them regu larly .

Ix. The Project Proponent shall Inform the public that the project has beeo eccorded envlronmental clearance by the Ministry and cop ies of the cfearance letter are 8ve l!able with the OSPCB/Commnte. and may elsa be seen at Web.rte of the Ministry of Environment aod Forest. al httpJenvtor n!C.in. This ahali be adve,tlsad within .even days from the date of issue ot the clearanco letter , at leilst in twQ local newspapers that are widely circu lated in the region of which one sha ll be in the vernacular language of the locality concerned Elnd a copy of the same shall be forwar ded to the Reg iona l office .

x. Project authorit ies sho uld Inform the Reg iona l Offi ce as weU 36 the MInistry , the date of tlnanc ial closure and tinal approval oJ the project by the concerned authorit ies end the date of commenc ing the land deve lopment work .

5.0. The Ministry may revoke or suspend the clearance , If Implementa Uon of any of the above conditions Is not satisfactory .

6.0. The Miolstry reserves Ihe right to lIIipulet. additiMal ｣ｯｮ､ｾｬｯｮｳ＠ if found necessary. Till! Company In a time bound manner wlllimplernent these co(,!d iti ona .

7.0. The above condrtlons will be enforced, Inter-ella under the provisions of the Water (Prevention & Conlrol of Pollution) Act, 1974, the Air (Prevenllon & Cootrol of Pollution) Act, 1981. the Environment (Prot.ctloo) Act, 1986, Huardous Wast •• (Management and Hendling) Rulea, 2003 and the Public (Insurance) UBbility ａ｣ｾ＠ 1991 along with their amendments and rules ｾ＠ ..

Copy to:-

(Dr. P. B. RIIlogl) Additiof1i11 Director

1. The Secretary, State Department of Env ironment , Govt . Of Orissa , Bhubaneswar . OrIssa .

2. Chairman, Central Pollution Control Board. Parivesh Bhavan. CBD-eum-Ofnce Complex, EastMun Nagar, New Delhi - flO 032.

3. Chairman, Orls.a Bengal Pollution Control Board, Parivesh Bhavan, N1 16, ｾ･･ｬｫ｡ｮｴｨｨＮｮＮｧＮｲＬＮｕｮｩｴＭＸＬ＠ Bhuvane.war - 751 012, Orissa,

4. v'rhe Chief Conservator of Forests (Eastem), Regional Ofnce (El), Al3. ChandrasekharptJr , Bhuvaneswar - 751 023, Orissa .

5. Joint Secretary (CCI-I), Minlalry of Envlronmonl and Forests, Paryavar.n Bhavan, CGO Complex, New Delhi.

8. Monitoring Cell, Ministry of Env iro nment and Forests , Paryavaran Shavan , eGO Complex, New Delhi.

7. ｍｯｮｾｯｲｬｮｧ＠ Cell 8. Guard File, ｾＮＮＮｩｯｊＧＱ＠Q RACOrd File . V'.!o I

(Dr. p , B. Rastogi) Add itional Director

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