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M/s Jindal Stainless LimitedPFR Report of Proposed modification cum Expansion (1X600 m³ Blast Furnace & 1 X 110m² Sinter Plant)of 1.6 MTPY Stainless Steel Plant At- Kalinga Nagar Industrial Complex, Jajpur District, Odisha.

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CHAPTER - I

EXECUTIVE SUMMARY

1 Name of the project Proposed modification cum expansion (1 X 600m³Blast Furnace & 1 X 110 m² Sinter Plant) of 1.6 MTPYStainless Steel Plant.

2 Sl. No. in the schedule 3(a) Metallurgical Industries

3 Registered Office Jindal Stainless Limited

O.P. Jindal Marg

Hisar-125005, Haryana4 Name of the promoters Mr. Tarun Khulbe

5 Present Business Steel, Power, Ferro Alloys, & Coke

6 Area of Plant 1240 Acres (Proposed Expansion is within existing

plant premises)

7 Topo Sheet No. 73 G-16

8 Latitude

Longitude

20⁰ 53’ N to 20⁰ 59’ N

86⁰ 00’ E to 86⁰ 05’ E

9 Proposed Capacity 0.6MTPA (1 X 600 m³ Blast Furnace) & 1.2 MTPA (1 X

110m² Sinter Plant)

10 Cost of Project 500.00 Crore

11 Manpower Requirement 355 persons

12 Power Requirement Will be sourced from existing Captive Power Plant

13 Nearest Railway Station/airport along

with distance in kms.

Sukinda Road – 1 km, Jakhapura – 5.28 km, Jajpur

Keonjhar Road – 12 km

Bhubaneswar Airport – 110 km

14 Nearest town, City, District Head

quarters along with distance in kms.

Duburi- 7 km

District Head quarter Jajpur- 35 km

15 Village Panchayats, Zilla Paris

had,Municipal corporation, Local

telephone nos. to be given) body

(complete postal addresses

with telephone no.s to be given)

Tehsil-Danagadi

District- Jajpur, Odisha-755026



1.0 Introduction

1.1 Identification of Project and Project Proponent

M/s Jindal Stainless Limited (hereinafter referred to as ‘JSL’), having its registered office at O.P.

Jindal Marg, Hisar-125005, has proposed modification cum expansion (1 X 600m³ Blast Furnace

& 1 X 110 m² Sinter Plant) of 1.6 MTPY Stainless Steel Plant At- Kalinga Nagar Industrial

Complex, Jajpur District, Odisha.

JSL, a part of the $ 18 billion USD, OP Jindal group is the largest integrated manufacturer of

stainless steel in India and is ranked amongst the top 10 stainless steel manufacturers in the

world, with a capacity of 1.6 million tons. A leader and a name synonymous with Enterprise,

Excellence and Success, the company’s ethos mirrors most characteristics similar to the metal it

produces; Akin to stainless steel JSL is innovative and versatile in its thought process; strong and

unrelenting in its operations. JSL has crafted its success story by fully integrating its operations

based on a strategy of both, backward and forward integration, starting from mining, melting,

casting, hot rolling to cold rolling and further value additions .

This has been the driving philosophy of the company from its one unit presence in the early 70’s

to its present multi- location presence across the globe. An ISO: 14001 compliant, JSL product

range includes: Ferro Alloys, Stainless Steel Slabs, Blooms, Hot Rolled Coils, Plates and Cold

Rolled Coils/ Sheets, Stainless Steel Strips for Razor Blade Steel and Coin Blanks for mints in India

& EU.

1.2 Employment Generation

It is estimated that the total employment generation due to the proposed expansion project will

be 355 in numbers.

2.0 Project Description

2.1 Location

The proposed expansion will be located within the existing plant premises of JSL At- Kalinga

Nagar Industrial Complex, Jajpur District of Odisha State under Survey of India toposheet no. 73

G/16 (Ref: Topo sheet 73G/16 & 73k/4). The Latitude lies between 20⁰ 53’ N to 20⁰ 59’ N and

Longitude lies between 86⁰ 00’ E to 86⁰ 05’ E of the proposed site respectively.

2.2 Site Selection Criteria

Site is located within the existing plant premises of JSL At- Kalinga Nagar Industrial Complex,

Jajpur District of Odisha State. The site has following facilities:

Proximity to the sources of base raw material,



Availability of common Infrastructure facilities / utilities (water / power etc.),

Availability of land, approach roads & accessibility

Topography of land and geological aspects

Nearness to rail head, transport logistics

2.3 Technology of site Selection

Technology selection involves an analysis of past achievements, present status and future

prospects of each technology under consideration keeping in view the following criteria.

Availability of project plant capacity/module.

Suiting to selected product mix & raw materials

Conservation of scarce inputs such as power & water.

Considerations of capital cost & maintenance cost.

Delivery schedule

Operational flexibility

2.4 Project Profile

JSL is successfully operating 1 X 0.425 MTPA Coke Plant; Steel Melt Shop (2 X 100 T,100/50 MVA

Electric Arc Furnace (EAF), 1 X 150 T Argon Oxygen De-carburizer (AOD), 1 X 150 T Ladle

Furnace, 1 X 1 Strand Continuous caster); Hot Strip Mill (1 X 300 TPH Reheating Furnace, 1.6

MTPA HSM, 1 X 100,000 TPY Hot rolled plate facility); Cold Rolling Mill Complex (1 X 8,25,000

TPY DRAP, 1 X 4,50,000 TPY WRAP); Ferro- Alloy plant (2 X 33 TPH Cr Briquette Plant, , 2 X 60

MVA + 3 X 27.6 MVA for producing Ferro Alloys); Captive Power Plant (2 X 125 MW Coal based

thermal power plant, 1 X 13 MW Fe-Cr Waste Heat Recovery Boiler (WHRB) power plant); 1 X

420 TPD Oxygen plant at- Kalinga Nagar Industrial Complex, Jajpur district of Odisha. Now, JSL

has proposed to install upstream facilities to support 1.6 MTPA steel plant by adding 1X 600 m³

blast furnace and 1 X 110 m² sinter plant.



Table.2.1 Proposed expansion capacity

Sl.No.

Particulars Capacity (Installed/to be installed)

Existing Expansion1 -- Sinter Plant 1X 110 m²2 -- BF 1 X 600 m³3 COBP -- 1 X 0.425 MTPA4 Steel Melt Shop (SMS)a. EAF -- 2 X 100 T,100/50 MVAb. AOD -- 1 X 150 Tc. LF -- 1 X 150 Td. Slab Caster -- 1 X 1 Strand5 Hot Strip Milla. Reheating Furnace -- 1 X 300 TPHb. HSM -- 1.6 MTPAc. Hot rolled plate facility -- 1 X 100,000 TPY6 Cold Rolling Milla. DRAP Line -- 1 X 8,25,000 TPYb. WRAP -- 1 X 4,50,000 TPY7 Ferro Alloy Planta. Cr- Briquette Plant -- 2 X 33 TPHb. Ferro Alloys Plant -- 2 X 60 MVA + 3 X 27.6 MVA8 Captive Power Planta. Coal based -- 2 X 125 MWb. Fe- Cr WHRB -- 1 X 13 MW9 Oxygen Plant -- 1X 420 TPD

Table 1.1 Raw Material Requirement & Source

Sl no Raw materials Qty inMTPA

Source Mode ofTransportation

1 Coke 0.30 Internally form own coke oven plant Road2 PCI coal for BF 0.10 Import Rail/Road3 Coal for SP 0.07 Talcher / Imports Road/Rail4 Iron ore lump for

BF0.50 Koida / Barbil / Daitari (OMC) / Joda /

Keonjhar / Outside OdishaRoad/Rail

5 Iron ore fines for SP 1.00 As above Road/Rail6 River sand for BF 0.02 Locally Road7 Lime stone 0.07 Odisha / Rajasthan / Import Road/Rail8 Dolomite 0.09 Jharkhand / Rajasthan / Chattishgarh Rail/Road9 Dunite 0.008 Salem Rail/Road10 Quartz 0.004 Andhra Pradesh / Chattishgarh Rail/Road11 Quick lime 0.15 Rajasthan / Imports Rail/Road12 Burnt lime 0.07 Rajasthan / Imports Rail/Road13 Manganese ore 0.004 Joda / Koida / Barbil / Andhra Pradesh /

MOIL / ImportsRoad/Rail



2.5 Water & Power Requirement

The total requirement of fresh water for the proposed expansion project is 144 m³/hr. The total

water requirement will be met from the existing water intake well at Brahmani River under

existing water agreement. There will be no additional water requirement beyond present water

agreement. Power required for the operation of Blast Furnace & Sinter Plant will be sourced

from existing Captive Power Plant.

3.0 SITE ANALYSIS

3.1 Connectivity

The nearest national highway is NH-5, and is about 20 km East of the project site. The plant is

bounded by East Coast Railway’s line connecting Jakhpura and Daitari stations on the east and

the Jajpur- Talcher state highway on the north. The nearest railway station is Sukinda Road on

Jakhapura- Bansapani branch line passes just to the east of the project site. The Jajpur Keonjhar

road railway station on Howrah- Kharagpur- Bhubaneswar- Vishakhapatnam line is about 12 km

towards East of the project site. The nearest seaport is at Paradeep is about 102 km from the

project site.

The proposed expansion will be within the existing plant premises. Selection of the site for any

project is the most important aspect for its successful operation & better economic viability.

Proximity to Raw material source, assured supply of fuel and other infrastructural support are

required to be essentially examined while selecting the site of the plant. The following basic

requirements are necessarily required to be fulfilled.

Easy & nearer access to Raw Material such as Iron Ore etc.

Availability of water from continuous source.

Power supply/ evacuation arrangement.

Nearer access through road.

The proposed site has the following preliminary advantages.

The site is situated in Kalinga Nagar Industrial Complex, Jajpur in the state of Odisha.

Water is available from water intake well built at river Brahmani which is 12 km from project

site.

The site is already well connected with Road as well as Rail. Thus the approach is excellent.



Soil condition of the site is also favorable.

3.2 Present Land Use & Existing Land Use Pattern

The total land required for proposed expansion is estimated around 80 Acre within the existing

plant premises of total land of 1240 Acre. The land comes under the KNIC which is designated as

industrial area by IDCO, Bhubaneswar.

3.3 Topography

The topography of the project area is more or less flat without undulations (within existing plant

premises).

3.4 Existing Infrastructure

JSL’s existing 1.6 MTPA stainless Steel Plant is in operation over 752.97 Acre out of total land of

1240 Acre.

3.5 Climate data from secondary source

The study area lies in tropical region where climate is characterized by very hot summers and

cool winters. The annual temperature ranges from a maximum of 47.7°C to a minimum of 7.8°C.

The average annual rainfall as recorded at IMD observatory at Cuttack is 1475 mm (74 rainy

days). The South-west monsoon lasts from mid June to mid September and the area gets more

than 80% of the annual rainfall during this period.

4.0 LANDUSE PLANNING

Total land required for the proposed expansion is 388 Acre within the existing plant premises of

total land 1240 Acre.

5.0 PROPOSED INFRASTRUCTURE

5.1 Industrial Area

The setting up of the 1 X 600 m³ Blast Furnace and 1 X 110 m² Sinter Plant along with their

auxiliary facilities required 80 acres land within the existing plant premises. Company uses

nearest railway siding and road for goods transportation and equipped with all other required

facilities.

5.2 Green Belt

A greenbelt development plan already prepared and implemented along with the existing plant.

Total green belt area is of 409.2 Acres (33%) of total land of 1240 Acre which is already being

developed.



5.3 Others

Additional garland drain around the proposed plant along boundary is envisaged to collect

surface run-off during rainy season.

Existing road and rail network will be utilized for raw material and final products

transportation

6.0 REHABILITATION & RESETTLEMENT (R & R) PLAN

The proposed project is a modification cum expansion of the existing plant and will be build

in existing available land, hence there will be no displacement of residents.

Local people will be engaged for construction and operation activities. Surrounding area

have all the infrastructure facilities, hence no housing colony/township is envisaged.

7.0 PROJECT SCHEDULE & COST ESTIMATES

7.1 Project Schedule

The total project implementation schedule is 24 months from start of basic project engineering

work. The external agencies such as consultant, machinery suppliers, contractors of civil

construction and equipment will be selected carefully well in advance.

7.2 Project Cost

An indicative estimated capital cost of the proposed expansion is Rs. 500 Cr. Including the Pre-

operative expenses, contingency and interest during construction.

8.0 ANALYSIS OF PROPOSAL

The socio-economic benefits of the proposed project are as follows:

Improvement and construction of road network in the nearby villages.

Extension & renovation of Local School buildings with playgrounds.

Social awareness program will further improve the quality of life and standard of living such

as sanitation and hygiene, HIV Prevention Program etc.

Implementation of adult education and female education program in the villages

surrounding the project area.

Financial assistance to talented and poor students for higher studies. (Management /

Engineering / Medical Science)



CHAPTER-02

INTRODUCTION

2.1 Introduction

JSL has proposed for modification cum expansion (1 X 600m³ Blast Furnace and 1 X 110m²

Sinter Plant) of 1.6 MTPY Stainless Steel Plant at Kalinga Nagar Industrial Complex, Jajpur

district, Odisha.

2.2 Identification of Project and Project Proponent

JSL has planned to add one blast furnace and matching sinter plant as proposed. This will

support stainless steel making economically with the following process steps:

1. Transfer of hot metal from blast furnace and refining of the same into liquid steel

through existing EAF and finally tapping into ladle.

2. Transfer of liquid FeCr in EAF and after reduction liquid chromium pre melt is tapped

into the same ladle containing liquid steel.

3. Then the mixture of liquid steel and chromium pre melt, after de-slagging is treated

in AOD to produce stainless steel.

4. Carbon Steel not used in Stainless operations will get converted into Carbon steel

Slabs subsequently to HR Coil, thus lowering one product dependency.

To cater the requirement for hot metal for existing SMS, It is found plausible to add 600m3

Blast Furnace with matching 110m2 sinter plant for hot metal charging in EAF. In this way

heat energies would be utilized to maximum extent, thus improving the technological

process and efficiency with certain nominal additions in the configuration.

Item Valuation

Replacement of imported MSscrap

Hot metal will completely replace imported MS scrap,thus saving FOREX and utilizing local raw materials.

Productivity Approx. 20% increase in productivity

Power Approx. 25 to 30% reduction in power consumption

Electrode Approx. 30-35% reduction in electrode consumption

Quality of steel

-Nitrogen

- Tramp elements

- Reduction in % Phosphorous

An improvement in quality of steel as follows

Nitrogen reduction from 140 ppm to 60 ppm or below

Reduction in percentage of tramp elements from 0.2%to 0.134%

Reduction in %P level from 0.035 to 0.025



It has been estimated that with hot metal usage in EAF will economically optimize the

process due to following potential benefits:

2.3 Description of nature of Project

JSL proposes upstream modification in 1.6 MTPY Stainless Steel Plant at Kalinga Nagar

Industrial Complex, Jajpur district, Odisha with addition of 1 X600³ Blast Furnace and 1 X

110m² Sinter Plant.

Table 2.1 Project Profile

Sl. No. Particulars Install Capacity

Existing Expansion

1 -- Sinter Plant 1X 110 m²

2 -- BF 1 X 600 m³

3 COBP -- 1 X 0.425 MTPA

4 SMS

a. EAF -- 2 X 100 T,100/50 MVA

b. AOD -- 1 X 150 T

c. LF -- 1 X 150 T

d. Slab Caster -- 1 X 1 Strand

5 Hot Strip Mill

a. Reheating Furnance -- 1 X 300 TPH

b. HSM -- 1.6 MTPA

c. Hot rolled plate facility -- 1 X 100,000 TPY

6 Cold Rolling Mill Complex

a. DRAP Line -- 1 X 8,25,000 TPY

b. WRAP -- 1 X 4,50,000 TPY

7 Ferro Alloy Plant

a. Cr- Briquette Plant -- 2 X 33 TPH

b. Ferro Alloys Plant -- 2 X 60 MVA + 3 X 27.6 MVA

8 Captive Power Plant

a. Coal based -- 2 X 125 MW

b. Fe- Cr WHRB -- 1 X 13 MW

9 Oxygen Plant -- 1X 420 TPD

2.4 Need of the project and its importance to the country and/or region

Steel is traditionally considered the backbone of national economic development. It is a

major Input into sectors which support economic growth such as infrastructure, machinery,



power and railways, as well as being important for fast growing sectors, in particular

automobiles and consumer durables. In 2013 global crude steel output reached 1,607 million

tonnes up by 3.5% as compared to 2012.

As suggested by Brief report on Iron & Steel Industry in India March, 2013 by Corporate

Catalyst India, the demand for steel in India is expected to rise about 7 percent in this

financial year as compared to the last financial year. The overall outlook for the steel sector

is positive and the demand is likely to pick up on the back of revival in economic growth and

the Government’s measures to ease infrastructure investment rule.

India is currently the World’s fourth largest producer of crude steel after China, Japan and

US. India is expected to leave behind USA and Japan in a couple of years. The steel

production is expected to reach 200 million tons by 2020 as compared to 81 million tones

recorded last year.

Another positive factor for steel industry is the very low per capita steel consumption of

India as shown in figure-2.2 below.

Figure-2.2 (Source – 2012 Steel Industry Outlook, BOC International)

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Projection of Demand and Capacity

Steel demand has been forecast based on a projected growth path of the GDP as growth in

steel demand is closely linked to the growth in GDP and the intensity of steel use in the

economy.

Table-2.4 Source – Report of the working Group on Steel Industry for Twelfth Five Year Plan

Item 2010-11 2016-17

Demand for Carbon Steel 62.14 108.3

Demand for Alloy/Stainless Steel 3.47 5.0

Total Domestic Demand for Steel 65.61 113.3

Net Export (-)3.34 2.0

Production (net of double counting) 62.27 115.3

Category-Wise Consumption (Carbon Steel)

- Bars & Rods 24.44 43.6

- Structurals 5.62 9.3

- Rly. Materials 1.1 1.4

Total Long Products 31.16 54.3

- Plates 4.76 7.2

- HR Coils/Skelp/Sheet (excl. double counting) 13.07 22.6

- CR coils/sheets (excl. double counting) 6.00 11.2

- GP/GC 4.74 8.8

- Electrical Sheets 0.49 0.8

- Tin Plate/TFS 0.40 0.60

- Pipes 1.54 2.80

Total Flat Products 30.99 54.0

Total Carbon Steel 62.14 108.3

Total Requirement of crude steel - 139.9

Likely Capacity of Crude Steel 78.0 140.0

The Statistics presented above clearly indicates that the Steel industry around the world is

poised for growth. The Indian steel industry entered into a new development stage from

2005-06, riding high on the resurgent economy and rising demand for steel. Rapid rise in

production has resulted in India becoming the 4th largest producer of steel.



The scope for raising the total consumption of steel is huge, given that per capita steel

consumption is only 73.3 kg – compared to 210 kg across the world.

Steel consumption in India is closely associated with manufacturing, housing and

infrastructure sectors. Being a developing country, most of the industries are far away from

their maturity which kept the steel consumption rate intact in domestic market even during

the testing times of recession.

The “Make in India” focus of the new Government coupled with special focus on Sectors

like Automobile and its components, Railways, Construction, Defence Manufacturing,

Thermal Power, Food Processing, Oil and Gas, Tourism and Hospitality which should in

turn provide a positive direction to the Stainless Steel Industry.

2.5 Employment Generation (Direct & Indirect) due to the project

It is estimated that the total requirement of manpower for the whole organization will be

355 in numbers. Department-wise/ division- wise manpower is given in table.

Table 2.5 Category – Wise Manpower Requirement

Sl. No Category Proposed Manpower

1 Managerial Staff 322 Executives 573 Skilled 1084 Unskilled 1505 Office staff 8

Total 355



CHAPTER - 03

PROJECT DESCRIPTION3.1 Type of Project

The proposed project is a modification cum expansion of 1.6 MTPY Stainless Steel Plant by

installing 1 X 600m³ Blast Furnace and 1 X 110 m² Sinter Plant. The plant will also be

equipped with the most efficient auxiliary sub systems, material handling facilities and

pollution control equipment.

3.2 Location of the Project

JSL has proposed modification cum expansion of 1.6 MTPY Stainless Steel Plant by installing 1

X 600 m³ Blast Furnace and 1 X 110 m² Sinter Plant at Kalinganagar Industrial Complex, Jajpur

district of Odisha state. The proposed project site falls under the Survey of India Toposheet

No. 73 L/1. The Latitude lies between 20⁰ 53’ N to 20⁰ 59’ N and Longitude lies between 86⁰ 00’

E to 86⁰ 05’ E of the proposed site respectively.

Figure 3.1 Plant Location



CHAPTER - 03















CHAPTER - 03















Figure 3.2 Topo Map (10 km Radius)









3.2.1 Land Requirement

Total Land required for the proposed expansion is 80 Acre, which is available within the existing

plant premises of total land of 1240 Acre.

Table 3.1 Land Use Break-up

Sl.No. Major Facilities Area in Acres1 Total area of plant 1240.00

ST1 Sub Total-1 (Plant and other facilities) 752.97

ST1.1Ferro-Alloys Complex ( 2x 60MVA Furnaces, 3 x 27.6MVA Furnaces,Briquetting Plant & Raw Material handling System, Jigging Plant,Product Handling, Pig Casting Machine etc)

112.25

ST1.2 Coke Oven & By-product Plant ( COBP) 64.00

ST1.3 Captive Power Plant (CPP), WTP 41.00ST1.4 Main Receiving Sub-station (MRSS) 11.90ST1.5 Coal Handling Plant 60.17ST1.6 Reservoir ( Present & Future) 44.17ST1.7 Temp Ash Pond 19.30ST1.8 Central Office (Stainless House) Complex 63.00ST1.9 LPG / Propane / Ammonia ( Fuel Station) 19.80

ST1.10 Railway siding 61.00ST1.11 Central Stores (I&II) & Central Growth Shop 32.14ST1.12 Steel Melting Shop , Scrap yard, Material Handling System 67.60

ST1.13 Hot Strip Mill (HSM) , Slab Yard, Coil Yard, Plate Finishing Shop (PFS),Bell Annealing Furnaces (BAFs) 49.44

ST1.14 Cold Rolling Mill Complex & Finishing Lines ( HAPL, CAPL, HR CTL, HRClitter, CR CTL, CR Slitter, SPM etc) 64.90

ST1.15 Oxygen Plant 3.00ST1.16 Metal Recovery Plant & Slag Dump 39.30

ST2 Sub Total-2 (Expansion project) 388.40

ST2.1 Lime Plant & Lime Stone Storage 22.50

ST2.2 Blast Furnace (BF), Pig Casting Machine, Hot Metal Track, Sinter Plant(SP), Raw Material Handling System (RMHS) 80

ST2.3 Vacant Land 285.9

ST3 Sub Total-3 (Exclusive green belt area) 98.63

ST3.1 Physical Area utilized Exclusively for Green Belt 98.63



3.2.2 Plant Layout

The layout of the plant, when developed will have the following features.

1. Process departments will be consolidated into comprehensive production units requiring

short conveying distance and elevations.

2. The major utilities and service facilities will be centrally located in respect to points of high

consumption;

3. Sufficient space will be provided for ease of operation and maintenance.

4. The lengths of power cables will be minimized by suitably locating load distribution centers in

respect to process departments.

5. Outward movements of materials from customers/suppliers will be segregated from internal

plant traffic.

6. Sufficient space for storage of raw materials, finished products and solid waste disposal.

7. 33% green belt already developed within the existing plant premises



Figure 3.3 Plant Layout









3.3 Site Selection Criteria

Based on the following site selection criteria, the site was selected to, set up the proposed

expansion project.

Proximity to the source of fuel (Equidistance from mines and port)

Availability of water from the existing plant water source.

Availability of land, approach roads & accessibility

Topography of land and geological aspects

Nearness to rail head, transport logistics

Distances from the ecologically sensitive areas, wildlife sanctuaries, forest, historical

monuments etc.

3.4 Manufacturing Process & Description of Equipment

3.4.1 Installation of 1 X 600m³ Blast Furnace

It is proposed to install one blast furnace with 600 m3 useful volume along with auxiliary

facilities. The blast furnace is envisaged to operate with sized iron ore, sinter, coke, coal dust,

fluxes and additives. The furnace will produce 600,000 tpy of gross hot metal. Coke will be

supplied from existing recovery type coke oven battery complex. The blast furnace will be

provided with coal dust injection facility to reduce the requirement of coke. It will also be

supplied with humidified and oxygen enriched air blast. The hot metal produced will be generally

sent to the steel melting shop. Surplus hot metal will poured in two double strand pig

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

BF top gas will be cleaned in the dust catcher and gas cleaning system and distributed for further

consumption to the stoves, runner drying, Reheating furnaces in Mills, sinter plant etc. the

balance BF gas will be utilized for generation of power in existing 13 MW WHRB Power Plant.

Following facilities are envisaged in the project:

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

conveyor

Blast furnace proper

Cast house with tilting runners and dedusting system

Stoves and waste gas chimney

Hot blast supply system including hot blast main, expansion joints, bustle main and tuyere

stock assembly

Dust catcher and dust discharge equipment

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



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

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

Stock house dedusting system, ventilation and air - conditioning system

Ladle repair shop (common for both BFs)

Pig casting machine (PCM)/Grain shot machine

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

Instrumentation, automation and process control system

Blower house and cold blast supply system

Compressor and compressed air piping

Shop electrics and illumination

Hoisting and handling facilities

Effluent and waste handling

Drainage and sewerage

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

Nitrogen

BF control room

Auxiliary facilities like laboratory, stores, etc.

Table 3.2 Blast Furnace Production Capacity

S.No. Name Quantity

1 Main product:Hot Metal 600,000 Tons/Year

2

By-product:Granulated SlagBF Gas

260,000 Tons/Year13x104 Nm3/hr (avg)14x104 Nm3/hr (max)

The operating parameters of the BF are indicated below:

Table 3.3 BF Operating Parameter

No. of operating day / yr 350No. of shifts / day 3No. of hot metal tapping / day 12

Molten slag will be granulated in the cast house slag granulation plant under normal operation

and 95% yield has been assumed in the system. However, if slag granulation is not done due to

slag quality variation or non-availability of slag granulation plant, then the slag will be discharged

in the dry slag pits.



Technological parameters of blast furnace

The major technological parameters of the blast furnace are given in table. The blast furnace is

envisaged to operate with sized iron ore, sinter, coke, coal dust, fluxes and additives.

Table 3.4 Technical Parameters

Parameter QuantityUseful volume, m3 600

Productivity, t/d/m3 2.85

Production, t/d (max) 1714

Coke rate, kg/thm: (dry) 410Slag rate, kg/thm 430Slag basicity (CaO/SiO2 ) 0.95Furnace top pressure MPa 0.15-0.18Hot blast temperature (design), deg. C 1,200Oxygen enrichment 3-5 %Blast volumes, Nm3/thm 1400Humidity of blast, g/Nm3 60 max.Gas volume (dry), Nm3/thm 1560CV of top gas, kcal/Nm3 750-780Coal dust injection 100-150 kg/thm

Figure 3.4 Process Flow Diagram Blast furnaces

























Figure 3.5 Material Balance - Blast Furnace

Description of plant and equipment

Blast furnace will be provided with one cast house, stock house, conveyor charging system, bell

less top charging system, three numbers of stoves, cast house slag granulation unit, slag pit, dust

catcher and gas cleaning system. Necessary pig casting and storage facilities, ladle repair facilities

and other miscellaneous facilities required for the plant has also been envisaged.

The hot blast to BF will be supplied through 12-14 numbers of tuyeres in the blast furnace. The

solid burden charged from the top will be smelted on its way down and liquid slag and hot metal

will be collected in the hearth. The same will be tapped through the tap hole. The hot metal and

slag from the tap hole will flow through the trough/runner systems. Hot metal will be tapped

into open top ladles. The slag will flow into the cast house slag granulation system. The outgoing

gases will be led through four off takes, two uptakes and one down comer to the dust catcher for

primary dust separation.

The BF is being provided with state of art cooling system in conjunction with under hearth water-

cooling. The cooling system is a soft water cooling system

Fig 1-1 Material Balance of 1X600 Blast Furrnace

1X600 Blast Furrnace



Cast House: the cast house design is based upon the latest technology of cast houses

implementing the essential features such as long campaign trough and runner design, non

draining trough and cast house fume extraction system.

Hot Blast System: the hot blast stove design is based upon high temperature internal

combustion chamber stove technology. The cold blast from blowers will be heated in 3

regenerative type internal combustion chamber hot blast stoves The stove system will consist of

flue gas and combustion air facilities, flue gas exhaust, flue chimney, cold blast, hot blast system

and preheating system along with valves and controls. The fuel gas used in the hot blast stoves

is BF gas without any enrichment. The CV of BF gas alone is sufficient to achieve a hot blast

temperature of 1250 C. in order to achieve the required hot blast temperature, it has been

envisaged to install a preheated system for BF gas and combustion air. The temperature of BF gas

and combustion air is thus increased to 280 ˚C at the stove inlet.

Gas Cleaning System: the BF produces raw gas as a by-product of the iron making process. The

raw gas has a calorific value, which allows it to be used as fuel. However BFG must be suitably

cleaned prior to further use. The gas cleaning plant consists of dry gas cleaning system through

bag filters, this has an advantage of elimination of effluent treatment plant. Thereby no slurry is

generated. The dry dust is recycled back to Sinter plant. The clean gas is supplied to various

users. The normal gas composition % by volume as follows:

Pulverized Coal Injection System: the system will comprise of coal storage, raw coal handling,

drying unit and pulverizer, conveying facility, coal dust collection unit, storage bunker and

pulverized coal injection system.

Pig casting machine (PCM)/ Grain shot machine

For casting the hot metal into cold pigs two numbers of pig casting machines (PCM)/Garin Shot

machine of capacity 1,800 t/d each has been envisaged for the BF. The PCM will be equipped

with lime milk spray system, water spray for pigs cooling, etc. The pigs will be discharged into

the pig storage yard and thereafter handled by a magnet gantry crane. Each PCM will be

provided with hoists at the discharge end and lime milk preparation building. An under slung

crane has been envisaged in the pouring end for maintenance and shot disposal.

3.4.2 Installation 1 X 110 m² Sinter Plant

JSL has proposed to put up blast furnaces with 600 m³ useful volume. In order to meet the

requirement of 600 m³ Blast Furnace, one sinter machine with 110 m² of effective sinter area has

been envisaged to produce around 1.2 mtpy of product sinter annually.



Table 3.4 The basic design and operating parameter is indicated in the table

Sl. NO. Description Unit Value1 Number of Sintering Machine Set 1

2 Effective area of sintering machine m2 110

3 Productivity (rated) T/m2/h 1.37

4 Availability of sintering machine % 90.4

5 Annual working regime days/annum 330

6 Annual sinter production mtpy 1.2

7 Quality of sinter

7.1 Grade TFe 54~55%

7.2 Basicity CaO/SiO2 1.8~2.1

7.3 Sized of the finished sinter mm 5-50

7.4 Temperature 0C <120

7.5 Drum index (+6.35) % 74

8 Dust content in exhaust gas at stack mg/Nm3 Below 50

The following advanced features have been envisaged for the proposed sinter plant complex.

Electronic weighing and proportioning system

Circular sinter cooler

Energy efficient ignition furnace

Process gas and plant dedusting system using high efficiency ESP’s

Process control and automation using PLC

The sinter plant complex envisaged receipt of crushed fuel & flux, iron ore fines, BF returns fines

flue dust and RMP and proportioning unit. The sinter plant will consist of the following main

technological units:

Fuel and flux crushing unit

Flux screen unit

Proportioning unit

Primary mixing room

Secondary mixing room

Sintering and cooling unit

Waste gas de0dusting unit

Main exhaust fan unit



Cold sinter screening unit

Plant de-dusting units

The above units will be inter connected by conveyor galleries and junction houses for

conveying sinter mix, finished sinter, hearth layer and sinter return fines.

Dry type electrostatic precipitators of total 1026000 m3/h capacity at 160 ˚C – 250 ˚C shall be

envisaged for de-dusting of waste gases before entering the main exhausters. The unit will have

high efficiency to ensure less than 50 mg/Nm3 of dust in the outgoing gases from the stack.

Double cone dust valves and drag link chain conveyors will be provided for discharge of dust

from ESP hoppers. The dust from ESP will be moistened in a moistening drum and will be

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

to the atmosphere through a RCC stack of height 100 m after its dedusting in ESP.

The main exhaust fan unit is envisaged for suction of air through sinter mix bed on the sintering

machine. The capacity of exhauster is 17100 m3/min at 160 ˚C and 1600 mm WC suction at fan

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

provided in the main exhaust fan unit.

The suitable dedusting system has been envisaged at dust generation points in the sinter plant

complex.

Figure 3.6 Process Flow Diagram- Sinter Plant



















complex.




















complex.




Table 3.5 Material Balance- Sinter Plant

Sl No Material Balance for SinterInput Output

Item 104 t/a % Item 104 t/a %1 Iron ore fines 57.228 33.004 Sinter 100.001 57.6722 Fuel 6.500 3.749 Loss 18.396 10.6093 Lime stone 1.647 0.950 Bottom

material 15.000 8.651

4 Dolomite 8.284 4.777 Return ore 40.001 23.0695 Quike lime 5.000 2.884 - - -6 Bottom material 15.000 8.651 - - -

7 Added water 7.222 4.165 - - -8 Moisture 7.517 4.335 - - -9 Return ore from

sinter 40.001 23.069 - - -

10 Return ore fromBF 25.000 14.418 - - -

11 Dedusting fines 7.000 4.037 - - -

Sum 173.398 100.000 Sum 173.398 100.000

3.5 Raw Material Requirement

Table 3.6 Raw Material Requirement & Source

RAW MATERIAL REQUIRMENT FOR BF & SPSl no Raw materials MTPA Source Mode of

Transportation1 Coke 0.3 Internally form our own coke oven plant Road2 PCI coal for BF 0.1 Import Rail/Road3 Coal for SP 0.07 Talcher / Imports Road/Rail4 Iron ore lump for BF 0.5 Koida/ Barbil / Daitari ( OMC) / Joda /

Keonjhar / Outside OdishaRoad/Rail

5 Iron ore fines for SP 1 As above Road/Rail6 River sand for BF 0.02 Locally Road7 Lime stone 0.07 Odisha / Rajasthan / Import Road/Rail8 Dolomite 0.09 Jharkhand / Rajasthan / Chattishgarh Rail/Road9 Dunite 0.008 Salem Rail/Road

10 Quartz 0.004 Andhra Pradesh / Chattishgarh Rail/Road11 Quick lime 0.15 Rajasthan / Imports Rail/Road12 Burnt lime 0.07 Rajasthan / Imports Rail/Road13 Manganese ore 0.004 Joda / Koida / Barbil / Andhra Pradesh /

MOIL / ImportsRoad/Rail



3.6 Water Requirement

The total requirement of fresh water for the proposed expansion project is 144 m³/hr. The total

water requirement will be met from the existing water intake well at Brahmani river under existing

water agreement.

Table 3.7 Water Requirement

S N Particulars UoM Circulating Fresh Makeup Drainage1 BF Clean Circulating Water System m3/hr 3,937 68 13

2 Blast Furnace Blower CirculatingWater System m3/hr 1,450 24 5

3 Clean Circulating Water System ofSintering Machine m3/hr 130 28 -

4 Turbid Circulating Water Systemof Blast Furnace Slag Granulating m3/hr 1,400 24 -18

TOTAL 6,917 144 0.00



Figure 3.5 Water Balance









3.7 Power Requirement

Power required for the operation of Blast Furnace & Sinter Plant will be sourced from existing

captive power plant.

Table 3.8 Power Requirement

Sl. No. Particulars Quantity in MW

1. Blast Furnace 16.52. Sinter Plant 9.5

3. Utilities 5Total 31

3.8 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for their

Management/Disposal

Proposed expansion project, all waste materials will be generated. Same will either be utilized back

into the process or disposed of as useful product like Blast furnace slag.

Sludge from Raw Water Clariflocculator and Backwash from Filtration Plant will be led to a

sludge pond for removing suspended solids. The overflow from the sludge pond will be diverted

for irrigation of green belt. The sludge from the sludge pond will be dried and utilized back into the

sinter plant or SAF.

Run-off water from the raw material storage yard will be routed through garland drains to

catch pits to settle out suspended solids. Acidic and Alkaline effluents will be generated at the DM

Water Plant. These effluents will be properly neutralized.

Cooling Tower Blow-down, Boiler Blow-down and part of the blow-down from the BF Circuit will be

utilised for slag granulation. Blow-down from the Oxygen Plant and part of the blow-down from

the Blast Furnace Circuit and will be used in the Pig Casting Machine.

Thus proposed plant will recycle water to the maximum extent possible. These effluents will mostly

contain salts of Calcium and Magnesium. Moreover, the water quality will be well within the

stipulated norms and will be reused for Slag quenching. Efforts will be made to harvest rainwater in

the plant. Run-off water from the office areas, shop roofs will be collected and stored for future

use.

High efficiency Pulse jet bag filters would be used inside the plant to mitigate and control process

dust. The plant systems will be designed to keep stack emissions to levels well below the stipulated

norm of 50 mg / m3.



The slag from the Blast Furnace will be granulated and sold to cement manufacturers. Other solid

wastes, which will be generated in the proposed expansion, include waste refractories, scrap,

scales, waste lubricants etc. Waste refractories will be sold as road building material or dumped

in landfills. All the scrap will be recycled fully. Waste lubricants will be sold to reprocessing

units. Scales will be recycled.

Table 3.9 Solid waste generation & Management (existing)

Sl.No. Item Item Source Quantity TPA Remarks

1FerroAlloysPlant

FeCr slag Furnace 1.2MT/T FeCr

50% Slag is reprocessed toZigging Plant and after Materialrecovery is utilized for land fillingwhile 50% pure slag is granulatedand utilized for Land filling withinand outside Plant.Storage is done at designatedlocation within the Plant

Bag house dust Furnace 50kg/T Fecr Recycled in Chrome Briquettes

2CaptivePowerPlant

Ash Coal

Depends on Coalquality. WithCurrentutilization of60% domesticand 40%Imported flyashgeneration isaround900tons/day

1. Nearly 85% of total ashgenerated is taken either by Flyash brick manufacturers or usedfor filling low land areas (withproper statutory clearance).2. Around 15 % is dumped to ashpond in the form of slurry.Evacuated yearly from there andused to fill low land areas.

3

CokeOven andBy-productPlant

Tar Sludge Decanter 6.8 mt/day atfull load Used at CRMHS for coal blending

Filter Cake Filter Press,ETP

0.8 mt/day atfull load

Used for briquette productionwhich is fed into SAF.

Bag Filter dust De-dustingunits 40 mt/month Used at CRMHS for coal blending

4SteelMeltingShop

AOD Bag FilterDust AOD 1,159 mt/month Used for briquette production

which is fed into SAF.EAF Bag FilterDust EAF 1,586 mt/month Used for briquette production

which is fed into SAF.

5 Hot StripMill

Roll grindingsludge

Roll grindingmachine 20 mt/month Used for briquette production


Scale Furnace andMill 980 mt/month Used for briquette production


Filter Cake HSM Utility 90 mt/month Used for briquette productionwhich is fed into SAF.

6 ColdRolling Mill scale DCW Quench

water 500 mt/month Used for briquette productionwhich is fed into SAF.



Mill settling pit.

Steel dust fromdust collector

Dustcollector unitof shotblaster(HAPL)

90 mt/month Used for briquette productionwhich is fed into SAF.

Grinding sludge Roll GrindingShop 1.5 mt/month Used for briquette production


Filter cakeNeutralisation's FilterPress.

2,170 mt/month Used for briquette productionwhich is fed into SAF.

Filter cakeNeolyteRecovery(CAPL).

30 mt/month Used for briquette productionwhich is fed into SAF.

Waste Water generation & management( Existing)

Process Unit

Wastewater

qty(m3/d)

Source Waste watercharacteristics Waste water management

Ferro Alloys Plant

Captive Power Plant 1550 CTBlowdown

Hardness (ppm):520-600TDS (ppm): 950-1000pH: 7.9-8.3

500 m3/d treated and used in process,1050 m3/d used for ash slurry making

Coke Oven and By-product Plant 480

AmmoniaDistillationColumn

pH, TSS, BOD, COD,Phenol, Cyanide

The Waste water generated is treated inBOD Plant/ PETP at Coke Oven and thetreated water is used for hot cokequenching process

Steel Melting Shop 50 Scale pit Treated at HSM and taken back forreuse.

Hot Strip Mill 450

BackWashfrom SMSand CRM

Suspended particles 450 m3/d water from SMS and CRMtreated by filter press.

Cold Rolling Mill

400 Backwash Hardness: 200Treated at HSM and 175m3/d reused atCRM, 200m3/d reused at HSM, 25m3/dreused at SMS.

500 Process

Hardness (ppm):10,000-13,000TDS (ppm): 20,000-22,000pH: 7.5-8.5

Treated at ETP and reused as follows:100 m3/d reused at Ferro Alloys Jiggingplant, 200 m3/d reused for slab and slagquenching, 200 m3/d reused at CRMHSfor dust suppression



3.10 Noise level

The noise generation can be broadly categorized into two type’s viz. Area and Point sources. All the

equipment used can be categorized as point sources and the vehicular traffic movement can be

treated as area source. All the equipment is designed to comply with the International Norms, Rules

and Stipulations on not exceed 75 dB (A).

All these noise generating equipment will be within the buildings and the presence of workers at

these equipment is either not required or Intermittent. People required for intermittent work near

high noise generating equipment will be provided with earplugs and their working hours in these

areas will be regulated. The noise levels at the periphery of the plant will be well within the

stipulated norms of noise pollution.

3.11 Green Belt Development



developed.

Table 3.11 Detail of green Belt Development Compliance

Sl.No. Major Facilities UoM Unit1 Total area of plant acre 12402 Green belt area to be developed @33% acre 409.2

3As per statutory guidelines, number of plantationsrequired for the green belt @1,600 plants perhectare or @648 plants per acre

nos 265,162

4

Actual no of plants planted inside plant premises(refer letter to Forest Ranger, Tomka Range,Cuttack Forest Division on Jan 05, 2015) (includingthe exclusive green belt area of 98.63 area)

nos 287,499



Figure 3.6 Schematic Representations of the Feasibility Drawing Which Give Information of EIA Purpose.

Land Requirement80 Acre



CHAPTER - 4

SITE ANALYSIS4.1 General

JSL propose to install the aforesaid unit at Kalinganagar Industrial Complex, Jajpur district, Odisha.

4.2 Connectivity

The nearest national highway is NH-6, which is about 20 km E of the project site. The plant is

bounded by East Coast Railway’s line connecting Jakhpura and Daitari stations on the east and the

Jajpur- Talcher state highway on the north. The nearest railway station is Jakhapura. Howrah-

kharagpur- Bhubaneswar- Vishakhapatnam line, is about 10 km towards the E. The Jakhapura-

Bansapani branch line passes just to the east of the project site. The nearest seaport is Paradeep is

about 102 km from the project site.

The proposed expansion will be within the existing plant premises. Selection of the site for any

project is the most important aspect for its successful operation & better economic viability.

Proximity to Raw material source, assured supply of fuel and other infrastructural support are

required to be essentially examined while selecting the site of the plant. The following basic

requirements are necessarily required to be fulfilled.

Easy & nearer access to Raw Material such as Iron Ore etc.

Availability of water from continuous source.

Power supply/ evacuation arrangement.

Nearer access through road.

The proposed site has the following preliminary advantages.

The site is situated in Notified Industrial Area namely kalinganagar Industrial complex, Jajpur in

the state of Odisha.

Water is available nearer to the site throughout the year.

The site is already well connected with Road as well as Rail. Thus the approach is excellent.

Soil condition of the site is also favorable.

4.3 Land UseThe total land required for proposed expansion i.e. 80 Acre is within the existing plant premises of

total land of 1240 Acre.



4.4 Topography

The topography of the project area is more or less flat without undulations.

4.5 Existing land use pattern

Total required land is industrial land under Kalinganagar industrial Complex.

4.6 Existing infrastructure

JSL’s existing 1.6 MTPA stainless Steel Plant is in operation over 752.97 Acre of total land of 1240

Acre.

4.7 Climatic data from secondary sources

The study area lies in tropical region where climate is characterized by very hot summers and cool

winters. The annual temperature ranges from a maximum of 47.7°C to a minimum of 7.8°C. The

average annual rainfall as recorded at IMD observatory at Cuttack is 1475 mm (74 rainy days). The

South-west monsoon lasts from mid June to mid September and the area gets more than 80% of the

annual rainfall during this period.



CHAPTER – 05PLANNING BRIEF

5.1 Planning Concept

M/s Jindal Stainless Ltd. has proposed modification cum expansion (1 X 600 m³ Blast Furnace & 1 X

110 m² Sinter Plant) of 1.6 MTPY Stainless Steel Plant At- Kalinga Nagar Industrial Complex, Jajpur

District, Odisha.

5.2 Population Projection

With the establishment of proposed project infrastructure and social development will

simultaneously takes place. Project will contribute for rising up of the population as shall create job

opportunities and economic up liftment of the area. Plant activities will also boost the ancillary

industries, business and market establishments. The whole set up will invite both skilled and

unskilled workers from outside. This will result in increase in the population density due to the

industry.

5.3 Land Use Planning

The following is the Land use planning of the proposed area:

Table 5.1 Land Use Break-up

Sl.No. Major Facilities Area in Acres1 Total area of plant 1240.00

ST1 Sub Total-1 (Plant and other facilities) 752.97

ST1.1Ferro-Alloys Complex ( 2x 60MVA Furnaces, 3 x 27.6MVA Furnaces,Briquetting Plant & Raw Material handling System, Jigging Plant,Product Handling, Pig Casting Machine etc)

112.25

ST1.2 Coke Oven & By-product Plant ( COBP) 64.00ST1.3 Captive Power Plant (CPP), WTP 41.00ST1.4 Main Receiving Sub-station (MRSS) 11.90ST1.5 Coal Handling Plant 60.17ST1.6 Reservoir ( Present & Future) 44.17ST1.7 Temp Ash Pond 19.30ST1.8 Central Office (Stainless House) Complex 63.00ST1.9 LPG / Propane / Ammonia ( Fuel Station) 19.80

ST1.10 Railway siding 61.00ST1.11 Central Stores (I&II) & Central Growth Shop 32.14ST1.12 Steel Melting Shop , Scrap yard, Material Handling System 67.60

ST1.13 Hot Strip Mill (HSM) , Slab Yard, Coil Yard, Plate Finishing Shop (PFS),Bell Annealing Furnaces (BAFs) 49.44



ST1.14 Cold Rolling Mill Complex & Finishing Lines ( HAPL, CAPL, HR CTL, HRClitter, CR CTL, CR Slitter, SPM etc) 64.90

ST1.15 Oxygen Plant 3.00ST1.16 Metal Recovery Plant & Slag Dump 39.30

ST2 Sub Total-2 (Expansion project) 388.40

ST2.1 Lime Plant & Lime Stone Storage 22.50

ST2.2 Blast Furnace (BF), Pig Casting Machine, Hot Metal Track, SinterPlant (SP), Raw Material Handling System (RMHS) 365.90

ST3 Sub Total-3 (Exclusive green belt area) 98.63ST3.1 Physical Area utilized Exclusively for Green Belt 98.63

5.4 Amenities/ Facilities

Facilities like canteen, rest room and indoor games facilities will be provided in the proposed plant

as basic facilities to workers. No other additional facilities are proposed.

5.4.1 Water System

Source of Water

Total water required will be fulfilled by the water sourced for the existing plant from Bramhani

River.

Plant Water Requirement

Total fresh water requirement for the proposed expansion is 144 m³/hr.

Proposed water system

The average make-up water requirement of the plant is estimated at 144 m³/hr. The proposed

water systems comprise of make-up water system, drinking/sanitary water system, fire-fighting

water system and the waste water systems.

Fire Water System

The plant shall have its own firewater hydrant system to meet pressurized water demand in

case of fire inside the plant. The system shall have a dedicated fire water storage tank, one

electric motor driven pump, one diesel engine driven pump, two jockey pumps, firewater ring

main, numbers of fire hydrants with hoses couplings and water spray nozzles.



Dust Suppression System

Water mixed with wetting agents will be sprinkled at the various material transfer points and

ore storage areas. Bleed off Water from the re-circulation systems shall be used as sprinkling

water.

Distribution System

The distribution system of make-up, drinking, fire-fighting and re-circulating water will be

through pipelines of mild steel/GI welded/screwed construction, laid underground and duly

protected against corrosion. In shops, the pipes will generally be taken overhead. Valves and

other appurtenances will be provided on the pipelines system to facilitate control and proper

distribution of water.

5.4.2 Instruments & Control

The requisite instruments and control as well as audiovisual alarms and safety interlocks will

be provided for safe and efficient operation of the water system which will be complete with

necessary sensing devices, transmitters, actuators, control valves, instrument panel, cablings,

piping and other accessories.

5.4.3 Air Condition & Ventilation System

The equipments for the electrical and control rooms would require to be maintained in

controlled atmospheric conditions to obtain the best performance from them. The Central

Control Room & the PLC rooms of power plant will have adequate number of wall-mounted air-

conditioners. The sub-station premises with power boards/ transformer rooms shall have wall-

mounted axial fans with louvers to maintain positive pressure inside. Power for HVAC system

shall be derived from local PDBs. Natural ventilation by installation of roof monitors, inlet

louvers etc are envisaged for production buildings.

5.4.4 Fire Protection

Fire Detection & Alarm System (FDA)

An FDA system shall be housed in Main Control Room with smoke detectors installed in sub-

station, PLC room, etc. Portable CO2 fire extinguishers, sand buckets etc. shall be provided in

Main Control Room.



Fire Hydrant System: The Firewater stored in the firewater reservoir will be pumped to the

ring main. Fire hydrants will be provided at suitable locations for providing pressurized water,

from the ring main, for fire fighting.

Fire Extinguishers of different types and sizes will be installed in various areas of plant as per

the relevant Indian standards. The portable fire extinguishers will generally be of the types and

sizes given in the following Table.

Table.5.2 Fire Extinguishers

Type of extinguishers Sizes

CO2 Type Fuel oil station

DCP Type Control rooms

Foam Type Offices

Fire buckets Offices, Shop floors



CHAPTER-6

PROPOSED INFRASTRUCTURE6.1 Industrial Area

BLAST FURNACE

Cast house

Hot Blast system

Gas Cleaning System

TRT

Pig Casting machine

Pulverized coal injection system

Waste heat recovery system

De dusting system

SINTER PLANT

Fuel and flux crushing unit

Flux screen unit

Proportioning unit

Primary mixing room

Secondary mixing room

Sintering and cooling unit

Waste gas dedusting unit

Main exhaust fan unit



6.2 Green Belt



developed.

6.3 Connectivity

The nearest national highway is NH-6, which is about 20 km E of the project site. The plant is

bounded by East Coast Railway’s line connecting Jakhpura and Daitari stations on the east and the

Jajpur- Talcher state highway on the north. The nearest railway station is Jakhapura. Howrah-



kharagpur- Bhubaneswar- Vishakhapatnam line is about 10 km towards the E. The Jakhapura-

Bansapani branch line passes just to the east of the project site. The nearest seaport at Paradeep is

about 102 km from the project site.

6.4 Drinking Water management

The workers at the plant during construction shall be provided with water for their requirement and

for the construction activities. The construction labour will be provided with sufficient and suitable

toilet facilities to allow proper standards of hygiene. These facilities would be connected to a septic

tank and shall be maintained properly to have least environmental impact. Drinking water required

for the workers will be met from exiting drinking water plant.



CHAPTER - 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

No rehabilitation or resettlement plan is proposed as it is a modification cum expansion project of

existing plant.



CHAPTER- 08

PROJECT SCHEDULE & COST ESTIMATES8.1 Project Schedule

In this industry, any one of the following three alternate modes of project execution is

adopted;

Turnkey

Semi Turnkey

Packaged procurement mode

8.1.1 Planning of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the

project following activities will be given special attention

8.1.2 Pre Project Activities

Management approvals

Selection of location

Land acquisitions

Statutory Clearances

Financial Approvals and Tie ups

Selection of Consultants

Conceptual Design

Preparation of main machinery tender

Evaluation of tenders

8.1.3 Project Activities (Implementation Stage)

Firm up basic design

Main machinery order placement

Detailed engineering of the project

Statutory approval of Building plans

Preparation of Tender, Evaluation of tenders received and order placement for balance

machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment



Inspection of major machinery at suppliers works

Erection of all plant & machinery

Commissioning of the plant

8.1.4 Project Schedule

The plant will be implemented in 24 months from the date of receipt of Environmental clearance

from the Hon’ble MoEF & Odisha State Pollution Control Board.

8.1.5 Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely execution of

the project:

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in-house and from external agencies

A well chosen team of experienced personnel for project execution shall coordinate the

implementation of the project from in-house

Experienced engineering consultants with proven track records shall be selected for detailed

engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men, material and

tools and tackles, will be engaged for execution of the construction and erection work.

Effective project monitoring including project planning schedule and monitoring shall be

employed in this project. Timely execution and resources will be monitored using computer

based project monitoring tools. In case of deviations in project progress, all possible

corrective actions such as crashing of network etc. will be carried out.

The schedule may vary depending on the project status.

8.2 Project Cost

An indicative capital cost of the proposed Plant is Rs. 500 Crores, including the pre-operative

expenses, contingency and interest during construction.

A broad break-up of the indicative estimate of the Project capital cost is provided below:



Table.8.1 Summary of Pollution Control Equipments

Sl.

NoParticulars

Capital Cost

(Rs. in lacs)

Recurring cost perAnnum

(Rs. in lacs)

1 BF gas bag filter system 1500 270.00

2 Dedusting facilities of cast house 600 102.00

3 Dedusting system of ore bin 600 84.00

4 ESP on sinter head 300 25.00

5 Dedusting facility with ESP on sintertail

80061.00

6 Dedusting facilities of Sinter Plant fuelproportioning system

600108.00

7 Pig casting machine de dusting system 300 33.00

Total 4700.00 683.00

Table.8.2 Project Cost Estimate

Project Cost EstimatesSr. No. Item Cost in Crores (INR)

1 Land2 Site Development & Infrastructure 203 Civil & Structural Works 804 Plant & Equipment 2555 Integration Facilities 806 Erection & Commissioning 107 Consultancy & Engineering 108 Interest during construction9 Pre-operative Expenses 22.5

10 Contingency 22.5Total Project Cost 500

Means Of FinanceA Equity 500B Debt 0

Total Project Cost 500



CHAPTER- 09

ANALYSIS OF PROPOSAL9.1 Financial and Social Benefits

9.1.1 Improvements in the Physical Infrastructure

M/s. Jindal Stainless Ltd (JSL) has envisaged a lot of infrastructure developmental works in the

periphery area.

Improving and building road network in the adjoining villages

Strengthening school buildings with playgrounds

Providing the Drinking water facilities

9.1.2 Improvements in the Social infrastructure

Social awareness programme will further improve by the local authority such as sanitation and

hygiene, HIV Prevention Program.

Through this project, adult education and female education will be provided to the illiterate

adults and backward females of the villages in the project surrounding area. Sponsor education

to Poor Students of the Proposed Area.

The proposed project will set up training centre or tie up with Industrial Technical Institutes to

educate local youth as skilled labour.

Provide & conduct the Free Eye & Health Check up Programmes

9.1.3 Employment

It is estimated that the total requirement of manpower for the whole organization will be 355.

Department-wise/ division- wise manpower is given in table.

Table 9.1 Categories – Wise Manpower Requirement

Sl. No Category Proposed Manpower

1 Managerial Staff 322 Executives 573 Skilled 1084 Unskilled 1505 Office staff 8

Total 355

9.2 Other Benefits

Development of the local area in terms of an enlarged market.

Besides above, indirect benefits have also occurred to the region by way of increase in industrialproduction.

m/s jindal stainless limited - welcome to...

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