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Prefeasibility Report of Integrated Steel Plant at Bhilwara, Rajasthan

Jindal Saw Limited

PRE-FEASIBILITY REPORT

OF

INTEGRATED STEEL PLANT

AT

Village Pur, Dist: Bhilwara

(RAJASTHAN)

Jindal Saw Limited, 12, Bhikaji Cama Place,

New Delhi-110066

AUGUST 2014


Jindal Saw Limited

Table of Contents

______________________________________________________________________

Chapter Title Page

______________________________________________________________________

1.0 Executive Summary 3

2.0 Introduction of the Project 9

3.0 Project Description 17

4.0 Site Analysis 36

5.0 Planning Brief 41

6.0 Proposed Infrastructure 43

7.0 Rehabilitation and Resettlement (R & R) Plan 47

8.0 Project Schedule & Cost Estimates 48

9.0 Analysis of Proposal 50

Annexure#1 Preliminary Layout 53

Annexure #2 Land Related Papers 54 - 62


Jindal Saw Limited

1.0 EXECUTIVE SUMMARY

M/s JINDAL SAW LIMITED (JSL) proposes to install an integrated Steel Plant at village

Pur, District Bhilwara (Rajasthan) through a combination of BF-BOF route and DRI

route, with captive power generation using the waste heat and gases. The finished

products planned in the project are Pig Iron (0.1 MTPA), Sponge Iron (DRI- 0.65

MTPA), Alloy Steel rounds of various grades (0.35 MTPA) and Re-Bar of various

grades (0.725 MTPA). The integrated steel plant is a backward integration process

where iron ore being mined out from JSL’s adjacent Iron Ore Mines shall be used.

Environmental clearance for 7 MTPA iron ore mining and 2.5 MTPA iron ore

concentrate using Beneficiation Plant has been obtained from Ministry of Environment

and Forests, Govt of India. Out of 2.5 MTPA iron ore concentrate available, 1.2 MTPA

concentrate is being used to produce pellets using Pellet Plant and 1.3 MTPA

concentrate shall be used in the proposed integrated Steel Plant.

Proposed project, purpose, location, capacity and use of finish products

The proposed project is for setting up of integrated steel plant and sponge iron

manufacturing utilising available iron ore concentrate and pellet to produce pig iron,

sponge iron and steel products (alloy steel round, Re-bars). The project is proposed at

a location adjoining to existing mining lease area of JSL’s Dhedwas Iron Ore, Copper

and Associated Minerals Mine. The units size and production capacity of various

production facilities proposed under this project is as below:-

Name of Unit Size & Production Capacity, Product

1 Sinter Plant 170 sq.m (1850000 TPA Sinter)

2 Blast Furnace 925 cubic m. (1005000 TPA Hot Metal)

3 DRI Plant 4 x 500 TPD (650000 TPA Sponge Iron)

4 Basic Oxygen Furnace

(BOF)

100 tons (1000000 TPA Liquid Steel)

5 Steel Refining

(LRF+VD/VOD)

100 tons (Matching capacity with BOF)

6 Continuous Casting Machine

(CCM)

9/16, 5 strand combi-caster (1000000 TPA Steel

Round and Billets)


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7 Rolling Mill 725000 TPA (Rebar/ TMT)

8 Captive Power Plant 75 MW (through recovery of waste heat &

gases)

9 Supporting Utilities RMH Yard, DM Plant, Oxygen Plant, Laboratory,

etc

The various finished products envisaged in the proposed project are as below:-

Product Capacity Use of finished product

Pig Iron (MT/Annum) 50000 - 100000 Captive use and sale to

foundries

Sponge Iron (DRI)

(MT/Annum)

600000-700000 Captive use and sale to small

steel manufacturers

Alloy Steel

Rounds(MT/Annum)

300000-350000 Stock transfer to Jindal saw

Nasik unit for seamless pipe

manufacturing

Re-bars (TMT)

(MT/Annum)

725000 Sale for housing and

infrastructure projects

Power (MW) 75 Captive utilization

Land Requirement and Land type of project area:

The proposed project site is located adjoining to the Dhedwas Iron ore and associated

minerals mine of JSL at village Pur, District Bhilwara, Rajasthan. No forest land is

involved in the proposed project site. The transportation infrastructure is already

available and maintained in the existing mining lease area. NH 79 is at a distance of 2

km from project site in East direction. Nearest railway station (Bhilwara) is at a distance

of 9.1 km from project site in East direction.

The total land requirement for the proposed integrated steel plant project is 76 acres.

Jindal Saw Limited already purchased 88.76 acres of industrial land. Out of 88.76


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acres, 40.76 acres land has been utilised to establish the 1.2 MTPA Pellet Plant. 48

acres land is therefore available to establish the Integrated Steel Plant and JSL has

applied to Government of Rajasthan for allotment of adjacent 28 acres waste land

belonging to the government. The land allotment is under process and same will be

completed before submission of final EIA report.

Water Requirement –Quantity and source for industrial and domestic use

The water requirement of the proposed plant will be met from treated sewage in the

Company’s STP at Kewara, near Bhilwara Town. For drinking water, stored rainwater

will be treated and used.

The water consumption for the proposed project will be 14 MLD. This requirement will

be met through the expansion of present company owned Bhilwara city sewage

treatment plant (STP) from 10 MLD to 20 MLD. For drinking requirements of employees

40 KL water will be required per day.

Power Requirement

Power for the proposed project will be available from RVVNL, Rajasthan, by existing

transmission line from GSS grid to the site. The total power requirement for the

proposed project is 90 MW which will be fulfilled by adding two 50 MVA transformers

in existing 220 KV substation .Also a captive power plant of 75 MW is proposed in this

project utilising available surplus blast furnace and basic oxygen furnace (BOF) off

gases and recovery of waste heat from flue gases of various processes.

Manpower requirement at construction and operation phases

The construction will be done by the contractors and estimated 500 persons will be

employed during this phase. JSL’s project monitoring team will carry supervisory

activities. For operational phase manpower requirement estimate is given below:-

Type of employment Skilled Un-Skilled

Direct 1500 500

Indirect 200 500

Total 1700 1000


Jindal Saw Limited

Employment shall be generated for local people in surrounding villages and only highly

skilled manpower will be sourced from outside area.

Type and Quantity of solid and liquid waste to be generated and its management

Unit Name Generation MT/Month

Use

Sinter ESP & Cyclone Dust

2000 Reuse in sinter plant

Blast Furnace BF Slag 27000 Sale to cement manufactures

BFG bag filter dust


Sponge Iron Plant (DRI)

Char 6000 Reuse in sinter plant

Steel Melting Shop

Slag 8000 Recovery of Fe from slag and then converted into Precious Slag Balls; used for various uses

Re bar Mill(TMT)

Mill Scale 400 Reuse in sinter plant

Captive Power Plant

Waste Heat and energy

75 MW power

Captive use

Other types of wastes generated from the project are shown below:

Waste generated Quantity Disposal plan

Used / Spent oil 100.00

KL/annum

Will be send to registered recycler

Empty / Contaminated Drums

5000 Nos /

annum

Hazardous materials contaminated drums

will be send to registered recycler,

Sewage Sludge 300 Kg/ Day Will be used for Plantation & Green belt

Cotton waste / Oil soaked cloths

5 MT/ Year Will be send to registered recycler

Burnt / Used Refractory

10000 MT/

annum

Sale to refractory manufacturer for Re-

cycle, / Landfill

Ion Exchange Resins

5 MT/ annum Will be send to registered recycler


Jindal Saw Limited

E-waste - Will be send to registered recycler

Green belt development programme

Around 25.5 Acre of area, out of 76 Acre of total project area, which is about 33.5%,

has been allocated for green belt development. It is proposed to plant more than 600

trees per Acre of land area. The schedule of plantation as given in below Table will be

followed. Layout plan showing green belt area for the proposed project is shown in

attached layout:

Year Area (Acres)

No. of Saplings to be Planted

First 5.1 3100

Second 5.1 3100

Third 5.1 3100

Fourth 5.1 3100

Fifth 5.1 3100

Total 25.5 15500

Rehabilitation and Resettlement Plan

The proposed project is within existing industrial land owned by JSL. The additional

land required for the project is being allotted by the government from the notified

Government waste land. No human settlement exists on the identified land. No

agriculture activity is done on the identified land. The land does not belong to private

ownership. Hence no Rehabilitation and Resettlement is required.

Project schedule and cost of Project

Likely date of start of construction: Within two months after obtaining EC

Likely date of completion of construction: March 2017 (24 month after EC)

The estimated project cost is as below:

Civil 290 crores

Structure 500 crores


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Equipment 910 crores

Erection 120 crores

Pollution control

equipment

180 crores

Total cost 2000 Crores

Financial and Social Benefits

Emboldened by buoyancy of the Indian economy, the Ministry of Steel, Govt. of India,

has revised the goal and projected a capacity of 180 MTPA by 2019-20. This creates

huge opportunity for investment in steel industry with high returns. The iron ore deposit

of the region was explored by GSI in the year 1969-70. It remained unexploited due to

its poor grade. The opening of the mine and beneficiating the ore has provided

employment to some 1000 persons, besides paying royalty to State Govt. to the tune of

Rs. 21.00 crore per year. It will increase to about Rs. 50.00 crore per year as the

production increases. Setting up of steel plant will help local people to get quality steel

Rebar (TMT) locally instead of getting from M.P., Bihar and Orissa etc. Apart from this

the project will employee additional 2000 persons and in-direct employment to 700

persons in transport, upkeep & maintenance, ancillary units. The project will generate

Rs 700 crore per year indirect tax revenue.


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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of project and project proponent

2.1.1 Project proponent

M/s Jindal Saw Limited is a company incorporated in the year 1985 under the

Companies Act, 1956 and is pioneer in manufacturing and supplying of large diameter

pipes, seamless tubes and pipes, ductile iron and cast iron pipes.

Jindal SAW Ltd. is a part of the O.P. Jindal Group, Country's one of the topmost

industry houses and the foremost indigenous steel producers and exporters. It is the

first company in India to manufacture Submerged Arc Welded (SAW) Pipes using the

internationally acclaimed U-O-E technology.

Jindal SAW Ltd. is in a commanding position in Indian market, being the undisputed

leader with a turnover in excess of Rs. 7500 Crore.

With integrated facilities at multiple locations and an ever expanding market

opportunity, Jindal SAW Ltd. has diversified from a single product company to a multi-

product company, manufacturing large diameter submerged arc welded pipes and

spiral welded pipes for the energy transportation sector; carbon-alloy and stainless

steel seamless pipes and tubes manufactured by conical piercing process used for

industrial applications; and Ductile iron (DI) pipes for water and sewage/wastewater

transportation. Besides these, the company also provides various value added products

like pipe coatings, bends and connector castings to its clients.

JSL has been granted a mining lease for Iron Ore, Copper and Associated Minerals

over an area of 1556.7817 Ha near Dhedwas Village, Bhilwara District Rajasthan for 30

years starting from 8th December’10.


Jindal Saw Limited

Jindal Saw Limited is currently operating a 2.5 MTPA capacity Iron Ore Beneficiation

Plant and 1.2 MTPA Pellet Plant at Bhilwara (Rajasthan). We are now setting up a

integrated steel plant for production of about 1.0 MTPA of billets / rounds and TMT bars

through Sinter Plant - Blast Furnace - Basic oxygen furnace(BOF)-Sponge Iron

Plant(DRI)-Ladle refining furnace-vacuum degassing(VD)/Vacuum oxy

Decarburization(VOD) - Continuous Casting - Rolling Mill route. A DRI plant of about

0.65 MTPA from available pellet by coal based rotary kiln process is also being set up

to meet captive requirement in steel making and sales to nearby market. These

facilities will use the iron ore concentrate / pellets produced from its own Beneficiation

and Pellet Plants located at the same site.

2.1.2 Identification of project

PROJECT AT A GLANCE

Project proponent M/s JINDAL SAW LTD, Bhilwara, Rajasthan

Company Name M/s JINDAL SAW LTD

Type of project 1.0 MTPA integrated steel plant+0.65 MTPA DRI Plant

Category of Project Category A , Sector 8 , Schedule 3a – Integrated steel

plant

S.No in the schedule as

per EIA notification, 2006

Schedule 3,Integrated Steel Plant

Total area 76 Acre

Location Bhilwara district ,Rajasthan at Captive mine head

Village Pur

Khasra numbers 6711, 9697/6711, 6737, 6731, 6740,

6735

District Bhilwara

State Rajasthan

Latitude 250 19’ 1.99” to 250 19’ 57.12” N

Longitude 740 32’ 15.76” to 740 33’ 4.86” E

Highways-NH-79-Approx.2.0 km- East

Railways- Bhilwara Railway Station-Approx 9.1 km-

East


Jindal Saw Limited

Near by Features

Airport- Dabok Airport-Approx .102 km-South West

Village /Town-Pur Village-Approx.2.0 km-South

Eco- Sensitive area No National Park, Wildlife Sanctuary, biosphere

reserve area within the10 km radius of project site

In this project sinter plant, Blast furnace, Basic oxygen furnace (BOF),Sponge Iron

Plant (DRI), Ladle refining furnace, Vacuum Degassing (VD)/Vacuum Oxy

Decarburization (VOD) and Rebar mill will be used to produce Pig iron, Sponge Iron

(DRI) Alloy steel round and Re-bars (TMT).

Demand Domestic/Export

The Pig Iron, Sponge Iron (DRI) and Re-bars (TMT) produced shall be sold in

Domestic market and company will explore export potential of the Re-bars (TMT).

Alloy steel rounds will be used by Jindal saw other unit at Nasik for seamless pipe

making. Partial quantity of pig Iron and DRI will be used in Blast furnace / Basic

oxygen furnace (BOF).

Details of proposed finished product

Product Capacity

Pig Iron (MT/Annum) 50000 – 100000

Sponge Iron (DRI) (MT/Annum) 600000-700000

Alloy Steel Rounds(MT/Annum) 300000-350000

Re-bars (TMT)( MT/Annum) 725000

Power (MWH) 75


Jindal Saw Limited

2.2 Brief Description of Nature of the project

Integrated steel plant consisting of Sinter plant, Blast furnace, Basic oxygen furnace

(BOF), Sponge Iron plant (DRI), Ladle refining furnace, vacuum degassing

(VD)/Vacuum Oxy Decarburization, Rebar (TMT) rolling mill and power plant. Detail

project description with process details is given in point no 3.5.

2.3 Need of the Project and its importance to the country and or region

Steel is a basic commodity for economic growth of any country and the per capita

consumption is a measure of prosperity of a country. India is just entering the

developing mode. The per capita steel consumption has risen from 38 kg in 2005-06

to 59 kg in 2011-12. It is envisaged to rise to 77 Kg per capita by the year 2019-20,

which as per historical trends puts the country on the curve of steep growth.

The crude steel production capacity had increased from 51.17 million tonnes per

annum (MTPA) in 2005-06 to 89.29 MTPA in 2011-12. About 4.04 million tons of

steel have been exported in the year 2011 – 2012 (Annual Report, 2012-2013,

Ministry of Steel). The year wise production of steel is given in below Figure


Jindal Saw Limited

MT

Production Capacity (MT) Production (MT)

80

70

60

50

40

30

20

10

0

2007-08 2008-09 2009-10 2010-11 2011-12

Year

Figure: Production Capacity and Actual Production of Steel in India

(Annual Report, 2012 – 2013, Ministry of Steel, Government of India)

The world wide steel scenario also shows a continuous growth in steel production.

There was a growth of average 5.9% in world crude steel production from 752 million

tons in 1995 to 1329.7 million ton in 2008. In the year 2012 it has increased to 1547.8

million tons. Global Steel Production has been growing consistently, driven by the

growing demand all over the globe. The Indian steel industry is ranked 4th in the world

with an annual production of 76.97 million tons in 2012. China leads the global output

with 716.5 million tons in year 2012. The global steel production (million tons) during

the year 2012 is depicted below in below Table.


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World Crude Steel Production in the year 2012

Rank Country Quantity in million tons

1 China 716.50

2 Japan 107.20

3 USA 88.60

4 India 76.97

5 Russia 70.60

6 South Korea 69.30

7 Germany 42.70

8 Turkey 35.90

9 Brazil 34.70

10 Ukraine 32.90

Top 10 countries 1275.97

Total 1547.80

2.3.1. Importance to the Country:

Considering the recent trend in production and consumption of steel globally and in

India, the National Steel Policy, 2005 had projected 110 MTPA steel making capacity in

India by 2019-2020 at 7.3% growth rate. It was noted subsequently in year 2006-07

that domestic production grew at 10.9% and domestic consumption by 11%.


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Emboldened by buoyancy of the Indian economy, the Ministry of Steel, Govt. of India,

has revised the goal and projected a capacity of 180 MTPA by 2019-20. This creates

huge opportunity for investment in steel industry with high returns.

2.3.2. Importance of the Project to the Region

The iron ore deposit of the region was explored by GSI in the year 1969-70. It remained

unexploited due to its poor grade. The opening of the mine and beneficiating the ore

has provided employment to some 1000 persons, besides paying royalty to State Govt.

to the tune of Rs. 21.00 crore per year. It will increase to about Rs. 50.00 crore per year

as the production increases. Setting up of steel plant will help local people to get quality

steel Rebar (TMT) locally instead of getting from M.P., Bihar and Orissa etc. Apart from

this the project will employee additional 2000 persons and in-direct employment to 700

persons in transport, upkeep & maintenance, ancillary units. The project will generate

Rs 700 crore per year indirect tax revenue. This project will be first integrated steel

plant in the state of Rajasthan.

2.4 Demand – Supply gap

There is no primary steel producer in Rajasthan. The proposed steel plant will fill this

vacuum of quality Rebar (TMT) and sponge Iron (DRI) requirement in Rajasthan and

nearby areas. .

2.5 Import vs Indigenous Production

Proposed steel plant will meet the Indigenous demand of quality steel and reduce the

import requirement of steel.

2.6 Export Possibility

Re-bars (TMT) can be export to Nepal and other nearby countries.

2.7 Domestic/ export markets

Alloys steel round will be consumed in Jindal Saw other unit to produce seamless

pipes.


Jindal Saw Limited

Pig iron will be consumed in steel melting shop and balance can be sold in the market.

Some quantity of sponge Iron will be consumed in steel melting shop and blast furnace

and balance quantity can be sold in the market.

For Re-bars (TMT) there is huge market is available in Rajasthan and nearby areas.

The rebar production will give boost to the state infrastructure development.

Re-bars (TMT) can also be export to Nepal and other nearby countries.

2.8 Employment generation (Direct and Indirect) due to the project

Type of employment Skilled Un-Skilled

Direct 1500 500

Indirect 200 500

Total 1700 1000


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3.0 PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects, if any

This is a brown field project and the project have interlinks with mining and

beneficiation plant for which EC has already been obtained & commercial production

already going on.

3.2 Location with coordinates

Location (map showing general location, specific location, and project boundary and

project site layout) with coordinates is attached. The location of site with type of land

and boundary coordinates is as below:

Feature Description

Site Village: Pur, District: Bhilwara, Rajasthan

Type of land/ land

use

Existing Industrial land & Government waste

land.

Latitude and longitude of proposed plant site

Latitude Longitude

250 19’ 1.99” to 250 19’ 57.12” N 740 32’15.76” to 740 33’ 4.86” E


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Google Map of Project Site

Project Layout with coordinates is attached as Annexure #1


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3.3 Details of alternate sites considered and the basis of selecting the proposed

site, particularly the environmental considerations gone into should be

highlighted

The proposed project site is adjoining company’s existing beneficiation plant where iron

ore concentrate is being produced, which is the main raw material for the steel plant.

Jindal Saw is already in possession of 88.76 Acre (143.14 Bhiga) industrial land from

which 48 Acre land has been earmarked for this project. Jindal Saw has already

applied to Government of Rajasthan for allotment of 28.05 Acre adjoining government

waste land for industrial purpose; hence no alternate site was considered as developed

infrastructures are already available there.

3.4 Size or magnitude of operation

The company proposes to install 1.0 MTPA integrated steel plant unit (Primary steel

making route) & 0.65 MTPA DRI plant consisting of following units:

S.N. Units Size/ capacity

1 Sinter plant 170 sq.m./18,50,000 MT Net sinter

per annum

2 Blast Furnace 925 cubic m./10,05,000 MT Hot

Metal per annum

3 Basic Oxygen Furnace

(BOF)

100 ton/10,00,000 MT Liquid steel

per annum

4 Sponge Iron plant (DRI) Capacity 2000 TPD/6,50,000 MT per

annum

5 Secondary

Metallurgy(LRF+VD/VOD)

100 ton/Matching capacity with BOF


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6 Continuous Casting

Machine (CCM)

9/16 ,5 strand combi

caster/10,00,000 MT round and

billets per annum

7 Rebar (TMT) Rolling Mill 7,25,000 tons per annum,

8 Captive waste heat &

energy recovery Power

Plant

75 Mega Watt

9 Supporting Utilities


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3.5 Project Description with process details

Process flow for Steel making:

A brief process flow of steel making process is given below.


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Process flow for DRI Making:

A brief process flow of DRI production is given below

The overall preliminary project layout is attached herewith. (ANNEXURE 1)

Project Description with Process details

Integrated steel plant consisting of Sinter plant, Blast furnace, Basic oxygen furnace

(BOF), Sponge Iron plant (DRI), Ladle refining furnace, vacuum degassing

(VD)/Vacuum Oxy Decarburization, Rebar (TMT) rolling mill and power plant. Detail

plant description with process detail is as below:-


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Sinter Plant

Main Features of Sinter plant

• Sinter Grate Bar Area - 170 SqM

• Sinter Productivity - >1.3MT of Sinter / SqM / Hour

• Design parameter - 1.5 MT of Sinter/ SqM /Hour with

100 % Iron ore concentrate

• Type of Sinter Machine - Linear Sinter Machine with Annular

Cooling bed, fired by BF Gas / FO

Sinter Plant Process

Physical and metallurgical preparation of the iron ore burden is undertaken to improve

permeability and reducibility. Prior to the sintering operation, raw materials are blended

and some flux materials are added. After blending, the iron blend is transferred from

preparation bunker to storage bunker. Coke breeze (small-grade coke with particle size

of ‹ 5mm) is used as fuel for the sintering process. The ore blend and coke breeze are

mixed and dampened to enhance the formation of micro pellets which improve the

permeability when placed on the sinter bed.

The sinter plant essentially consists of a large grate of heat resistant cast iron. The

material to be sintered is layered to form 700 mm deep bed, although shallower beds

are common in older plants, which is placed on top of a thin layer of recycled sinter.

This bottom layer protects the grate from the direct heat of the burning mixture. The

grate passes through a canopy of gas burners that ignites the coke breeze in the

mixture, starting a down-draft process through the entire length of the sinter bed. As the

sinter mixture proceeds along the grate, the combustion air is drawn downwards

through the mixture. This generate sufficient heat (1300°C-1480°C) to sinter the fine

particles together into a porous clinker referred to as sinter. Exhausted gases are

treated to remove dust before emitted to atmosphere. The produced sinter then


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crushed and screened to obtain the proper dimension for the burden of the blast

furnace.

Blast Furnace

Key feature of Blast furnace

• BF Volume - 925 M3

• BF average Productivity - >3.2 MT of HM / M3/ Day

• BF design Productivity - 3.5 MT of HM / M3/ Day

• Net Coke Ratio - 400 Kg per Mt of HML , PCI Injection 160

Kg per Mt of HML

• Fe in Burden - > 56%

• Hot Blast Temperature - > 1200 – Degree C.

• Maximum design Hot blast Temp -1300 – Degree C

• Feed Ratio -Sinter 80- 90% and Pellet 10-20 %

• Cold Blast Generation by Axial Flow Blower.

• 01 axial blower coupled with BPRT of 110 % of design cold blast

requirement+1 Centrifugal blower of 80% of design cold blast requirement.

• Stoves 3 Numbers, top fired with BF gas / FO for achieving dome temperature

of 1350 Deg C.

• Graphite Refractory at Hearth bottom, high conductivity carbon at the middle

and super micro pore carbon with mullite at the top.

• Stave Coolers at Bosh, Belly & Stack

• Closed loop evaporative cooling system


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• O2 Enrichment in blast up to 4-6% volume.

• Top Charging System – Bell less top

• BF gas de-dusting system - Dry type with multiple bag filter

• Pig casting machine – 2 strands with capacity of pig casting 2900 TPD

with 8 Kg pig.

• Slag Granulating

Blast Furnace Process

A blast furnace (BF) is an enclosed system into which the raw materials enter at the

top, while the products (molten iron and slag) are tapped from the bottom (the

hearth).The raw material mixture of iron bearing materials (iron ore pellets and sinters)

and additives (Slag former, such as limestone) is called the “burden”. The burden and

coke are fed into the top of the furnace via a sealed charging system to prevent furnace

gases from escaping. The solid burden moves downwards, counter current of a rising

stream of hot reducing gas. The hot reducing gas is provided by hot stoves and is

needed to transfer heat to the solid burden in order to raise the temperature for

reaction. The BF gas with residual calorific value is collected from the top of the furnace

for treatment and use.

The blast furnace is periodically tapped to remove the hot metal iron and slag from the

earth. For this purpose a tap-hole is opened in the side wall of the hearth. The tapped

metal has a temperature of approximately 1440-1500 °C. The slag and hot metal from

the furnace flows along the refractory or low cement covered runners and they are

subsequently separated at the skimmer in the cast house, after which each continues in

a separate runner. Liquid Hot metal is poured into ladles or torpedo cars. Slag flows in

runners to a granulation plant. At the end of casting cycle, the tap hole is closed by

injecting a heat resistant tap hole clay mixture, using a so-called “mudgun”.


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Rotary DRI KILN

Key Parameters:-

Capacity : - 650000 MT per annum

Type : - Coal based Rotary KILN

Length :- Approx 80 Mtr (For 500 TPD KILN)

Inner diameter :- Approx 4.5 Mtr (For 500 TPD KILN)

Waste Heat Recovery boilers : - 12.5 MW for each 500 TPD KILN

Process

Iron Ore and Non Coking Coal along with Dolomite are fed continuously to the charge

end of Rotary Kiln which is inclined at 2.5% of drum length. Coal is also injected

through a Coal Throw Pipe at the discharge end of Kiln. Due to the inclination and

rotation of Kiln the charge material moves along the length of Kiln and it is discharged

continuously after processing. To supply heat for the process air is blown into the Kiln

through central burner and air pipes mounted on the Kiln shell. As the charge moves

along the kiln, it is heated by the gases which flow in opposite direction. The first

section, approximately half of kiln is called preheating zone where iron ore, coal and

dolomite are dried and heated to reaction temperatures using the heat released from

the combustion of volatile matter and carbon in the coal . The second half of kiln is

called reduction zone where major amount of Oxygen contained in the iron ore is

removed leaving metallic iron (Fe). De-sulphurisation in the Rotary Kiln is effected by

calcined limestone/dolomite. The chemical reactions taking place at various zones in

the rotary kiln are as given below.

In the pre-heat zone, the reduction of iron oxide proceeds only to ferrous oxide (FeO)

(Equation 1).


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Fe3O4 + CO = 3 FeO + CO2 ............................ (I)

Final reduction to metallic iron occurs in the metallization zone by reaction of CO with

FeO to form CO2 and metallic iron (Equation II).

FeO + CO = Fe + CO2 ........................... (II)

Most of the CO2 reacts with the excess solid fuel in the kiln and is converted to CO

(Equation III).

CO2+C = 2CO ............................ (III)

The reduced iron ore -SPONGE IRON with unburnt char from rotary kiln gets

discharged into a Rotary Cooler. The heat will be dissipated indirectly by water spraying

into the outside of Cooler Shell. The material gets cooled to around 120°C.

Steel Melting Shop (Basic Oxygen Furnace (BOF) + VD/VOD+CCM)

Key Features

• Heat size - 100 Ton

• No of Heats per day(Average) - 32 Heats

• No of Heats per day(Design) - 36 Heats

• Tap to Tap Time - 40 – 48 Min

• Design - Fix vessel system.

• Design Volume/Ton ration - >1

• Charge mix - 85 % HM+6 % DRI ,rest scarp and Pig

• Annual Capacity -10 LTPA

• Gas cleaning - Primary cooling ,Primary & Secondary

dry type gas cleaning

• Gas holder - 50000 M³

• Secondary de-dusting - Common for BOF,LRF and VD/VOD

• Hot metal desulphurization - 100 Ton

• Ladle Refining Furnace (LRF) - one no,100 ton capacity


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• VD/VOD - one no,100 ton capacity with steam

ejector for alloy steel round only

• CCM - 5 Strand combi caster

Process

The oxygen steelmaking process converts the molten iron from the blast furnace - with

up to 20% steel scrap (DRI+Scrap+Pig) - into refined steel. High purity oxygen is blown

through the molten bath to lower carbon, silicon, manganese, and phosphorous content

of the iron, while various fluxes are used to reduce the sulfur and phosphorous levels.

The impurities and a small amount of oxidized iron are carried off in the molten slag

that floats on the surface of the hot metal.

Scrap Charging

The first step for making a heat of steel in a BOF is to tilt the furnace and charge it with

scrap. The furnaces are mounted on trunnions and can be rotated through a full circle.

Molten Iron Charging

Hot metal from the blast furnace accounts for up to 80 – 90 % of the metallic charge

and is poured from a ladle into the top of the tilted furnace.

Furnace Operation

The charged furnace is returned to an upright position and a water cooled oxygen lance

is lowered from the top; oxygen is blown into the bath at supersonic speeds causing

rapid mixing and heat from the oxidation of iron and impurities. Fluxes (burnt lime, burnt

dolomite, and fluorspar) are added to help carry off the impurities in the floating slag

layer. This step requires only about 15 minutes of an overall 45 minute tap to tap cycle

time.

Tapping

After the steel has been refined, the furnace is tilted (opposite to the charging side) and

molten steel is poured out into a preheated ladle. Alloys are added to the ladle during

the pour to give the steel the precise composition desired. In some steelmaking


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applications, further refining is conducted in the ladle to remove oxygen and sulfur from

the molten steel.

Ladle Refining Furnace (LRF)

Key Features of LRF

• Nominal Heat Size - 100 Ton

• Type - Single station with water cooled roof

• Transformer - 18 MVA

• Maximum heating rate - 4.0 ˚C/Min

• Treatment Time - <30 Min.

• Electrode Arms - Bus-bar type

After tapping the ladle is transferred on the tapping car to a position where the

overhead crane pick it up and transport it to the heating station where the remaining

slag builders are added. Ar/N2 bubbling is performed during all operations in the

secondary treatment station. The first heating period will last until the slag is fused, the

steel analysis is uniform and the steel temperature is high enough to enable good

sampling.

While waiting for the sample analysis, heating is continued and trimming alloying

additions are given as soon as the laboratory analysis is received. The temperature is

increased to the aim temperature for casting.

The main objectives of secondary metallurgy include mixing and homogenizing;

adjustment of chemical compositions; temperature adjustment; de oxidation; removal of

undesirable gases (e.g. hydrogen, nitrogen and oxygen); and improvement of the oxide

purity by separating non-metallic-inclusions.


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The Ladle Furnace will be equipped with a specially designed roof which reduces the

air infiltration into the ladle furnace and thus minimizes the:

• Side oxidation of the electrodes and thus the electrode consumption

• Oxidation of the slag and thus the FeO content and consequently the oxygen

content in steel

• Hydrogen pick-up from the furnace atmosphere

• Nitrogen pick-up from the furnace atmosphere.

Vacuum Degassing (VD)/Vacuum Oxy Decarburization

Key Features

• Nominal Heat Size - 100 Ton

• Type - Vacuum Tank in fixed chamber

• Pumping system - By steam ejector

• Display of slag & stirring process - By Camera

• Treatment Time - Less than 30 Min.

VD is the only method which can reduce the gas (Hydrogen, Nitrogen and Oxygen)

levels in the steel and by VOD process we can reduce the carbon and make the high

chrome steel.

The VD/VOD process is characterized by ladles with entire liquid steel content being

exposed to the vacuum during the treatment. For the VOD process we have to inject

oxygen under vacuum to reduce the carbon.

In this process ladle rests in stationary vacuum tank. The tank will be close vacuum

tight with a tank cover. The required vacuum pressure will be built up by starting of the


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vacuum pump. The pressure is lowered to the vacuum level needed for the

metallurgical reactions.

Since the vacuum can become metallurgical effective only on bath surface, the bath is

subjected to force circulation through inert gas bubbling.

Continuous Casting Machine (CCM)

Key Features

Capacity - 1.0 MTPA

Machine Radius - 9 Meter

Bending-Unbending Length - 16 Meter

No of Strands - 5

Mould Oscillating unit - Hydraulic

Mould Stirring - Electromagnetic Stirrer of external type mould

Billet Cutting - Oxy-Cutting Torch Machine

Mould Technology - Cartridge Type

Mould Level Control - By Radioactive source and PLC

Out Put Products - 130/160 mm Billets and 160/200/220 mm Rounds

Cooling Bed - Walking Beam type

Tundish Capacity - 22 Ton

Flow Control - By electro-Mechanical stopper mechanism.

Casting - Closed type submerged


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Process

The liquid steel after secondary metallurgy is transported to the “tundish” of CCM. This

is an intermediate ladle with controllable outlet. The ladles are preheated prior to

accepting a liquid steel charge in order to avoid temperature stratification in the

tundish.When the liquid steel reached the desired temperature; it is poured into the

tundish. From the tundish it passes to a short water-cooled copper mould in which no

air is present and which performs oscillating movements to prevent the steel from

sticking. The mould gives the metal the desired shape. When the metal leaves the

casting mould, a “skin” of solidified steel has formed and a large number of rolls guide

the cast steel with a gentle curve toward a horizontal position. At this point, the endless

casting is cut into pieces with torch cutter. Billets and round are cast in this way.

Re-bar (TMT) Rolling Mill

Key Features

• Capacity - 725000 TPA

• Reheating Furnace - 150 TPH capacity with BF gas as fuel and LPG/HSD/LDO for initial start-up

• Mill Type - High speed rolling through Block mill

• Input Billet size - 150/160 sq x 12000 mm

• Input Temperature - Minimum 950 °C.

• Finish product - 8 to 40 mm Rebar and grade as per IS 1786-2008

• Packing - 100 kg sub bundle for 8,10 and 12 mm and 3-5 ton master bundle for all sizes

• Mill floor Level - + 5 meter

• Mill productivity - Max 150 TPH

• Automation Level - Level-2


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Hot/cold billets received form CCM is charged in pusher type reheating furnace. After

being heated up to rolling temperature (1150°C) billets are discharged from the furnace

and transferred to mill via a roller table fitted with thermo insulated hoods and billet

reject table.

The rolling mill (Roughing mill and Intermediate mill) is composed of 14 rolling units

consisting of double support housing less “Cartridge type stands followed by 8 stand

block mill.

The products are continuously rolled accordingly to schedule two high stands and in

finishing mill in H-V arrangement with fixed rolling line and without bar torsion.

To give the mill maximum flexibility, each stand is independently driven.

The smallest size of deformed bars is rolled using High speed single strand rolling. An

offline quick roll changing system is provided for finishing stands roll changing so that

very short stoppage of the plant for size changing.

A low tension control system is provided on the roughing/intermediate mill, while looper

are used in the intermediate/finishing mill to assure tension free rolling allowing the self

adjusting of mill drives, to actual rolling condition.

During the rolling process, head and tail cropping are carried out automatically by

start/stop crop shears arranged after rougher and intermediate mill. (In emergency

situation bar can also be chopped automatically by these shears).

After the rolling mill stands there is water quenching line (For TMT process).

TMT is a surface quenching and self-tempering process directly executed from the

rolling heat. The present description is exclusively devoted to the heat treatment of hot

rolled bars for concrete reinforcement.

Principle of the TMT process

According to the TMT process, a bar leaving the fast finishing blocks, is submitted to a

special heat treating cycle involving three stages :


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a) The first stage is a drastic water cooling operation applied to the bar as it leaves the

last finishing stand. At the end of this operation, the bar has a surface layer of

martensite, an austenite core and an intermediate layer composed of a mixture of

austenite and martensite, with the martensite content decreasing from skin to core.

b) In the second stage, the bar leaves the area of water cooling and is exposed to air:

the core re- heats the quenched surface layer by conduction and the martensite formed

during the first stage is subjected to self-tempering which ensures adequate ductility

while maintaining a high yield strength level.

c) The third stage occurs as the bar lies on the cooling bed. It consists of a semi-

isothermal transformation of the remaining austenite. The product of this transformation

is a mixture of ferrite and pearlite or ferrite, pearlite and bainite, depending on several

factors, viz. :

- The steel composition;

- The bar diameter;

- The finishing temperature of the rolling sequence;

- The efficiency and duration of cooling during the first stage.

A start-stop walking beam type cooling bed is foreseen to collect and cool the bars

multiples coming from the dividing shear. The cooling bed is fitted with variable

speed driving group and multi-groove lining-up rollers.

The bars already aligned by the lining-up roller table, are conveyed at the end of the

cooling bed where, the automatic, regular formation and extraction of bar layers at

cooling outlet is assured by a system of chain and liftable device, which carry

the multiple length bar layer in “as formed” position to the exit roller table.

At cooling bed exit side the layer of bars is cut to length on static mode by a Heavy

Duty Cold Shear.


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Finishing Services

To avoid handling short bars (shorter than a sub- multiple length) in the cold cut area,

the exceeding partial sub-multiple can either be chopped with the shears along the

mill (tail pre-optimization). However at the entry of the bundling forming area is

foreseen a set of cradles in order to recover the scrap layer, containing the short bars

which could be in the last layer coming from cooling bed area.

Bundling station

A feeding device, consisting of a table with translating trolleys, which brakes and

unloads the layers of bars from the roller table and deposit to the chain transfer.

Bundle strapping and collecting station

Then the bundles are deposited onto a roller table with vertical idle roller. While the

bundles move forward on the roller table, hydraulic binding machines arranged

sideways tie them. The final collecting system comprises a weighing station (placed

under the roller table) and a step-by-step chain conveyor to allow and facilitate the

bundle removal in-groups, by means of crane.

Power Plant

Surplus blast furnace gas, basic oxygen furnace (BOF) off gas and waste heat

recovered from Sinter plant, BOF and DRI will be used as fuel in boiler to produce

power. In-house generation of electricity will reduce transmission & distribution loss

(T & D loss), which would have occurred in case of supply of electricity from grid

power plant.

The major systems involved in the CPP are a boiler, a bleed cum condensing type

Turbo-generator and water treatment plant.

Apart from above central utility plants will consist of Air Separation Unit, Water

treatment plan, Compressor house, Sewage water treatment plant.


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The project fall under category A, schedule 3(a), Sector 8 – Metallurgical industry –

Ferrous , Primary route of EIA notification September 2006 and amendment thereof

3.6 Raw Material required along with estimated quantity, likely source,

marketing area of final products, mode of transport of raw materials and finished

products :

Raw Materials details

S. No.

Name Of Raw Material

Estimated yearly

quantity (MT)

Source Mode of transport

Sinter Plant

1 Iron Ore Concentrate

13,00,000 Captive Plant in Mines Conveyor

2 Mill Scale

14,000 Captive generation in CCM and SMS -

3 Quick Lime

69,000 Rajasthan By Road in Bulkers

4 Dolomite

43,800 Rajasthan By Road

5 Limestone

1,29,000 Rajasthan By Road

6 Coke Fines

87,500 Own production at Mundra, Gujarat + Purchase By Road

7 Bentonite

15,800 Kutch, Gujarat By Road

Blast Furnace

1 Pellet

3,00,000 Captive generation Conveyor

2 Coke

4,23,800 Own production at Mundra, Gujarat + Purchase By Road

3 Coal Fines

1,60,000 Import By sea + Road

4 Flux (limestone, quartzite, etc)

30,000 Rajasthan By Road

DRI

1 Pellet

9,00,000 Captive generation Conveyor


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2 Coal

5,20,000 Import By Road

3 Dolomite

50,000 Rajasthan, MP By Road

SMS

1 Steel Scrap

75,000 Purchase By Road

2 Lime

75,000 Rajasthan By Road in Bulkers

3 Ferro Alloys

15,000 Rajasthan, MP, CG, Orissa By Road

Details of saleable finished products

S.No. Name Of Finished Product

Estimated yearly

quantity (MT)

Market Area Mode of transport

1 Re-bar / Billet 7,25,000 Sales within Rajasthan, MP, Gujrat, UP, Haryana & Exports By Road

2 Alloy Steel Rounds 3,50,000 Jindal Saw Nasik Unit By Road

3 Pig Iron / DRI (Sponge Iron) 6,00,000

Sales within Rajasthan, MP, Gujrat By Road

3.7 Resource optimisation / recycling and reuse envisaged in the project

The various by products being reused & recycled are given below

Plant By Product Qty Generation MT/Month

Use

Sinter ESP & Cyclone Dust


Blast Furnace BF Slag 27000 Sale to cement manufactures

BFG bag filter dust


Sponge Iron Plant(DRI)

Char 6000 Reuse in sinter plant


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Steel Melting Shop

Slag 8000 Recovery of Fe from slag and left over will converted

to PSB and used

Re bar Mill(TMT) Mill Scale 400 Reuse in sinter plant

Captive Power Plant

Waste Heat and energy

75 MW power Captive use

3.8 Availability of water, its source, Energy / Power requirement and source

Availability and source of water

Jindal Saw has already established Bhilwara city Sewage Water Treatment plant (STP)

and treated water is being supplied by pipelines to its Mining & proposed project site.

The water for the proposed project will be obtained by the expansion of our existing

STP capacity from present 10 MLD to 20 MLD.

The total water consumption break up for existing and proposed project is as given in

table below

Name of Unit Water Consumption (m³/ day)

Existing pelletization & beneficiation plant 6000

Proposed New Units

Sinter plant 1200

Blast Furnace 4000

Sponge Iron Plant (DRI) 1800

Power Plant 250

Basic Oxygen Furnace(BOF) 1000

SMS(LRF+VD+CCM) 3500

Rebar Rolling mill 1100

Domestic and misc 1000

Total water consumption 19850


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Availability and source of electricity

Power will be sourced through the existing 220 KV substations. We will add 2

transformer of 50 MVA each fulfil the proposed steel plant requirement.

Power utilization within the premises

Sr

No Plant Power Consumption ( MW-Hr)

1 Existing plant 30

2 Proposed

Expansion

90

Total Average power consumption 120

In addition a captive power generation using waste heat & off-gases (Blast Furnace

Gas + BOF off gas) of 75 MW is proposed in the project

3.9 Schematic representations of the feasibility drawing which gives information

of EIA purpose - Already provided in Page 20


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4.0 SITE ANALYSIS

4.1 Connectivity

The connectivity of the project site with the major road/ railways/ ports and human

settlement is as given in table

Description Distance

Transportation

Road : ~ NH79 –approx 2 KM (East)

Rail : ~ Bhilwara railway station approx 9.1 km (East).

Nearest Town/City

Bhilwara town-approx 7 km north east

Nearest Village

Pur-approx 2 km south

4.2 Land form, land use and land ownership

The proposed project site is located adjoining to the Dhedwas Iron ore and associated

minerals mine of Jindal Saw Limited at village Pur, District Bhilwara, Rajasthan. No

forest land is involved in the proposed project site.

The total land requirement for the proposed integrated steel plant project is 76 acres.

Jindal Saw Limited has already purchased 88.76 acres of industrial land from

Government of Rajasthan. Out of 88.76 acres, 40.76 acres land has been utilised to

establish the 1.2 MTPA Pellet Plant. 48 acres land is therefore available to establish the

Integrated Steel Plant and Jindal Saw Limited has applied to Government of Rajasthan

for allotment of adjacent 28 acres waste land belonging to the government. The land

allotment is under process and same will be completed before submission of final EIA

report. The land ownership documents are attached as Annexure 2

4.3 Topography

The project region shows undulating topography, elevation of the study area was in the

range of 399-547 m. above mean sea level. The nearest habitation to the project site is

the Pur village, which is located at a distance of two kilometres towards South. Nearest


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Railway Station from project site is in Bhilwara at 9.1 km (East). NH-79 is at 02 km

(East) and SH-12 is 2.3 km South from Project site. The Kothari River is flowing from

West to East through the North (7.7 km from the project location. There are ponds, and

irrigation Canals present within study area.

4.4 Existing land use pattern

The land for the proposed project is part notified industrial land allotted by Government

of Rajasthan and part Government waste land (For allotment of Government waste

land , process is going on). The land allotment letter from Government of Rajasthan is

attached as Annexure -2.

4.5 Existing Infrastructure

The company is operating currently Iron ore beneficiation & pellet plant at the site.

Following infrastructure facilities are available at site

- Roads

- Water Reservoir

- 220 KV Electric sub station

- Drainage

- Communication system

- Emergency staff hostel

- Laboratory

- Stores

- Weighbridges

- Offices, canteen, IT Infrastructure

4.6 Soil classification

The project soil texture was found to be loam characteristics which were determined by

correlating the results of soil samples. The soil is in Brown to Blackish Brown colour.

The Gravel (<0.2 mm) was in the range of 3.2 % by weight to 46.8 % by weight.


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The pH of the soil samples was in the range of 6.64 to 9.80, which show that the soil

nature in between the neutral and alkaline. The Moisture Content in the soil ranged

from 5.18% to 10.4%. The Organic Matter and Organic Carbon in the soil varied from

0.67% to 1.43% and 0.39% to 0.83%, respectively. The Available Phosphorous,

Potassium and Total Kjeldahl Nitrogen (TKN) varied from 14.9 mg/100gm to 30.4

mg/100gm, 0.47 to 1.56 mg/100gm and 0.14 % by mass to 0.3 % by mass,

respectively.

The Calcium, Magnesium and Sodium in the samples ranged from 8.34 mg/100gm to

16.0 mg/100gm, 3.9 mg/100gm to 6.89 mg/100gm, 0.68 mg/100g to 1.48 mg/100g,

respectively. The Sodium Absorption Ratio (SAR) in the soil varied from 0.71 to 1.47,

which signifies that the soil is non-saline in nature.

4.7 Climate data from secondary sources

There are four prominent seasons in the project area, Summer, South West

Monsoon, Post Monsoon and Winter. The Summer season is from March to June

and is followed by South West Monsoon season, which lasts till the mid September.

The period from mid September to November constitutes the post monsoon season.

The Winter season is from December to February.

The climate of the study area was hot during the months of April to June, 2013. The

meteorological data of study area is given in below Table . The average (min-max)

temperature varies from 23° to 42° C.

Meteorological Data of Study Area

Sl.

No.

Months

Year

Avg. Max. Temperature

(°C)

Avg. Min. Temperature

(°C)

Avg. Rainfall Days

Avg. Precipitation

(mm)

1 April 2013 36 23 3 16

2 May 2013 42 30 5 27

3 June 2013 38 26 11 60


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Physiographically, the State of Rajasthan divided into 10 agro-climatic zones based

on agro- ecological conditions across the state. The study area falls in IV A – Sub

Humid Southern Plain.

The map of agro-climatic zones with marked project site is shown in below Figure.

Figure: Agro-Climatic Zones of Rajasthan

(Source: Agro-Climatic Regions and Crop Zones (Rajasthan), krishi.rajasthan.gov.in)


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4.8 Social infrastructure available

The basic amenities and facilities within the study area, as per Census of India, 2001

are given in below Table shows the basic amenities and facilities at different location

in the study area. Pur, Samodi, Dhedwas, Lakhshmipura, Malikhera, Dariba ,

salampuira

Basic Amenities and Facilities in the Study Area

Sl. No.

Habitation

Basic Amenities and Facilities

(As Per Census of India, 2001)

1. Dhedwas School: Primary School = 1,

Drinking Water Facility: Tank Water, Tube Well

Electricity: Available

2. Dariba School: Primary School = 2, Middle School = 1, Secondary School = 1

Medical Facilities: Not Available

Post Office = 0

Telephone Connection = 0

Drinking Water Facility: Tap water, Wells, Hand Pump

Electricity: Available 3. Samodi School: Primary School = 1

Medical Facilities: Family Welfare Centre = 1

Post Office = 1


Drinking Water Facility: Wells, Hand Pump


4. Pansal School: Primary School = 2, Middle School = 1, Secondary School = 0

Medical Facilities: Health Centre = 1

Post Office = 1


Drinking Water Facility: Tap water, Wells, Hand Pump, Tank Water, Tube Well

Electricity: Available 5. Lakshmi

pura School: Primary School = 1, Drinking Water Facility: Tube Well Electricity: Available


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6. Salampura School: Primary School = 1

Medical Facilities: Family Welfare Centre = 1

Post Office = 1




7. Mali

Khera#

School: Primary School = 1



8. Pur

Village#

School: Secondary and Senior Secondary School = 10 -12

Medical Facilities: Govt. Dispensary = 1, Vet nary Hospital =1, Ayurvedic Hospital = 1

Drinking Water Facility: Wells, Hand Pump, Tap Water, Tube Well


5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities, transportation etc) Town and

country planning/ Development authority classification.

The proposed project is brown field project and the state government has allotted it as

industrial land after conversion of waste land. Also the industrial area and the related

facilities are already developed hence no planning is envisaged.

Also, due to the presence of industries including The Rajasthan State Industrial

Development& Investment Corporation- RIICO (located about 4.5 km in the North East

direction from the project site), which are located near to the proposed project site, has

led to conducive infrastructural facilities like paved roadway and electrical substation,

for establishing an Industry.


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5.2 Population projection

There would not be any significant increase in the population of surrounding area as

the workers for the proposed project will come from the local residents in the

surrounding villages. No major influx of people in the area due to proposed project.

Only highly skilled manpower will be taken from outside if not available in the nearby

area.

5.3 Land use planning (break up along with green belt etc)

The detailed land use planning and the area break up is as given in the table

TOTAL AREA 307572 M² (76 ACRE)

PROPOSED EXPANSION 173572 M² (42.9 ACRE)

ROADS AND DRAINS 31000 M² (7.7 ACRE)

GREEN BELT 103000 M² (25.4 ACRE)

GREEN BELT 33.5 %

5.4 Assessment of infrastructure demand (Physical & social)

As the proposed project is with the existing industrial premises the basic infrastructure

like water, Electricity and road are available at the project site. Hence no major

infrastructure is envisaged at the project site.

5.5 Amenities/Facilities

Following facilities are available in the existing industrial premises:- Canteen Bachelors Hostel Sanitation Medical Safety department with all safety training facilities Fire Tender & Fire fighting services Conveyance for staff and workers Rest rooms for workers


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6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (Processing area)

The total industrial area earmarked by the company is 76 acres adjoining mine location

for this project.

6.2 Residential area (Non processing area)

No labour colony is envisaged for proposed project. Temporary resting quarters are

provided for the workers in the existing unit. Project site is very near to the Pur village

and Bhilwara city so Residential colony is not required.

6.3 Green belt

Around 25.5 Acre of area, out of 76 Acre of total project area, which is about 33.5.0%,

has been allocated for green belt development. It is proposed to plant more than 600

trees per Acre of land area. The schedule of plantation as given in below Table will be

followed. Layout plan showing green belt area for the proposed project is shown in

attached layout

Green Belt Development Implementation Schedule

Year

Area (Acre)

No. of Saplings to be Planted

First 5.1 3100

Second 5.1 3100

Third 5.1 3100

Fourth 5.1 3100

Fifth 5.1 3100

Total 25.5 15500

The list of plant species, which is proposed to be used for the green belt

development, is given in below.


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Sl. No.

Common Name

Scientific Name 1. Neem Azadirachta indica

2. Dhanbaher/ Amaltas Cassia Fistula

3. Kumat Acacia Senegal

4. Jand Prosopis Spicigera

5. Khaira Acacia Catechu

6. Karir Capparis deciduas

7. Jungle jalebi Inga dulcis

8. Imli Tamarindus Indica

9. Ber Zizyphus jujube

10. Babul Acacia Arabica

11. Peepal Ficus Religiosa

12. Vilayati babul Prosopis juliflora

13. Khejri Prosopis cineraria

14. Bargad Ficus benghalensis

The pit size for the plantation of saplings will be about 1 m × 1 m × 1 m. These pits

will be filled with soil and manure up to 2/3rd of its depth, about 5 to 10 days in

advance before plantation. After fifth year, efforts will be taken to replace the dead

plants, which have been planted during the five years.

6.4 Social infrastructure

The company is bound for the upliftment of social infrastructure in the surrounding area.

Dedicated fund shall be contributed for the development of hospitals, schools and

drinking facilities in the surrounding area.

6.5 Connectivity (Traffic and transportation road/rail/metro/ water ways etc)

The major road/ rail in the area are as given below


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Description Distance

Transportation

Road : - Highway NH-79 , 2 km (east) Highway SH-12 , 2.3 km (south)

Rail : ~ 9.1 Km (Bhilwara)

Nearest Town/City

~ 7 Km (Bhilwara)

Nearest Village

Pur (~ 2.0 Km)

6.6 Drinking water Management (Source & Supply of water)

Water required for drinking purpose will be about 10 m3/day (10 KLD) and met from

harvesting of rainwater. Shortfall will be met from purchased drinking water from

outside.

6.7 Sewerage system

The infrastructure for sewerage will be designed during master planning.

6.8 Industrial waste management

The industrial waste generated mainly will be in form of hazardous liquid waste and

solid waste. The hazardous waste generated will be as in table:


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Waste generated Quantity Disposal plan

Used / Spent oil 100.00

KL/annum

Will be send to registered

recycler

Empty /

Contaminated

Drums

5000 Nos

/ annum

Hazardous materials

contaminated drums will be

send to registered recycler,

Sewage Sludge 300 Kg/

Day

Will be used for Plantation &

Green belt

Cotton waste / Oil

soaked cloths

5 MT/

Year


recycler

Burnt / Used

Refractory

10000

MT/

annum

Sale to refractory

manufacturer for Re-cycle, /

Landfill

Ion Exchange

Resins

5 MT/

annum


recycler

E-waste Will be send to registered

recycler


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6.9 Solid Waste/by product Management

Plant By Product Qty Generation

MT/Month

Use

Sinter ESP & Cyclone Dust 2000 Reuse in sinter

plant

Blast Furnace BF Slag 27000 Sale to cement

manufactures

BFG bag filter dust 2200 Reuse in sinter

plant

Sponge Iron

Plant(DRI)

Char 6000 Reuse in sinter

plant

Steel Melting

Shop

Slag 8000 Recovery of Fe

from slag and left

over will be

converted to PSB

and sold

Re bar Mill(TMT) Mill Scale 400 Reuse in sinter

plant

Captive Power

Plant

Waste Heat and

energy

75 MW power Captive use


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6.10 Power requirement & supply/ source

Total power requirement of proposed plant will be 90 MW which will be fulfil from the

existing 220 KV feeder. We will add two 50 MVA transformers at existing 220 KV

substations.

The Power utilization break-up of same is as mentioned in below Error! Reference

source not found.:

Sr

No Plant Power Consumption ( MW-Hr)

1 Blast furnace 16

2 Sinter plant 6.5

3 Sponge Iron Plant (DRI) 8.0

4 Steel melting

shop(BOF,LRF,VD,CCM)

21.5

5 Rolling mill 12

6 Misc 4

Total power consumption 68

75 MW power shall be generated through the waste heat recovery based captive power

plant


Jindal Saw Limited

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be adopted (Central/ state) in respect of the project affected

persons including home oustees, land oustees and landless laborers

Not applicable, because no human settlement or agriculture land is involved in the

identified project land. The proposed project is within the existing industrial premises. A

part of land, which is at present Government waste land required for the project, is in

process of allotment.


Jindal Saw Limited

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion

Likely date of start of construction: Within two months after obtaining EC

Likely date of completion of construction: March 2017 (24 month after EC)

8.2 Estimated project cost along with analysis in terms of economic viability

of the project

The details cost bifurcation is as mentioned below:

Civil : 290 crore

Structure : 500 crore

Equipment : 910 crore

Erection : 120 crore

Pollution control Equipment : 180 crore

Total Cost : 2000 crore


Jindal Saw Limited

Months

Weeks

1 EC

2 Kick-off Meeting

3 Design

4 Basic Design

5 Basic Design Review

6 Detail Design

7 170m2 Sintering System

8 925m3 Blast Furnace system

9 100t Converter System

10 120t/h Reheating Furnace

11 Rolling Mill

12 DRI(SPONGE IRON) Plant

13 Piping Design

14 Civil Work

15 Piling Foundation Design

16 Piling Work

17 Civil Works Construction

18 Fabrication of steel structure

19 Erection of steel structure

20 EQUIPMENT WORK

21 Machine Purchase

22 Machine Delivery

23 Refractory Mortar Delivery

24 Machine Installation

25 Cold Test

26 Commissioning

27 Start Up

28 Performance Test

23 24 25

PROJECT SCHEDULE OF 1.0 MTPA STEEL PLANT AND DRI PLANT18 19 20 21 2213 14 15 16 178 9 10 11 124 5 6 7

S.N.

1 2 3


Jindal Saw Limited

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and Social Benefits

Based on the future demand of steel in the market over the next 5 years, the proximity

of the present project to iron ore mines is an advantage with respect to price logistics.

The financial viability also shows a good rate of return from the project. Other financial

and social benefits that could be obtained from the proposed project is described

below:

The plant will result in considerable growth of service sector in the region.

Provide direct & indirect employment opportunities and development of peripheral

/ supporting services and amenities.

Supporting infrastructure development like road, power supply, reality sector

No environmental significant impacts are envisaged.

Best applicable mitigative measures have been proposed for management of

anticipated environmental impacts.

Community development activates will be initiated under CSR programs.

The project will provide significant revenue to the exchequer in the form of excise

and taxes etc.

The project will create opportunity for industrial development in the state.

Jindal Saw Limited has a focus on the all-round development of the communities in and

around the plant and in Bhilwara city and is actively promoting social & welfare

activities of the surrounding society. In past 2 years it has spent Over Rs 5.8 Crore for

various social & welfare activities of the nearby society. Over and above company

resources has also been deployed for improving society & welfare programs. Apart

from providing suitable employment for local populations, the key focus of Jindal Saw

social & welfare activities are

- Improving hygiene & sanitary conditions, Drinking water

- Green Belts development & Society parks

- Medical facilities & health awareness

- Education promotion & support


Jindal Saw Limited

- Support for natural calamities & emergencies

- Religious & Cultural activities support, Fodder for animals

Jindal Saw Ltd. has taken an initiative for maintenance of community parks. Presently,

more than 80 parks are being maintained by Jindal Saw Ltd. In addition to that to

maintain hygiene and healthy environment in and around the city, Jindal Saw has also

taken a task for community drainage maintenance.

Jindal Saw ltd works meticulously for the development of schools in villages around the

plant. Contribution has been made towards construction of boundary wall to

Government High School in Dhulkhera village, sponsorship cost for celebrating republic

day in Sophia Senior Secondary School, Bhilwara.

Jindal Saw ltd has also undertaken focused initiative for social & religious development,

sports & cultural activities, disaster relief and women welfare in & around villages.

Contribution has been made to Vishwa Hindu Parishad towards the sponsorship for the

Tailoring Training Centre for Ladies. Contribution has also been made to Shree Anand

Krishna Gaushala Sewa Samity, Suras village, for providing Fodder to Cattles and to

Sidhudhuni Hathipada Ashram, Pur village, as Sponsorship towards the procurement of

Cement Bags for the construction of temple. Jindal Saw has also contributed in

sponsorship towards marriages in the villages, drinking water facilities and higher

education.

Jindal saw ltd. has taken up a cause of health care with considerable commitment and

focus. Jindal saw organised a number of voluntary activities within the area of

community health. Regular blood donation drives are organized at plant site, witnessing

enthusiastic participation by Jindalites. Occupational Health Surveillance Camp was

also organized for general health check up and disseminating information on health

care.

Apart from these, a multipurpose Fire Tender is available with trained staff round the

clock for attending any type of fire emergency call in and around the plant site.


Jindal Saw Limited

Jindal Saw Ltd. constantly strives to move beyond regulatory standards and do more.

Jindal Saw is now building on community development to create a sustainable

framework that allows Jindal plant to amplify the positive impact they have.

In future these social & welfare activities will be continued and few new initiatives like

Girl Education, Skill development & industrial training and Sports promotion etc will be

added. In order to access need of nearby population a systematic “Need Assessment

Studies” will be undertaken with help of reputed institutes and local Government

bodies.

CORPORATE SOCIAL RESPONSIBILITY

Along with being a successful Business entity JINDAL SAW LTD. has an active sense

of social responsibility. As a Leading transnational, The Company is committed to be a

good corporate citizen wherever the company is engaged in business activities and

interests. The company’s Corporate Social Responsibility Programme voluntarily

integrates Social and Environmental concerns into their operations. As a responsible

corporate entity JINDAL SAW LTD. shoulders many responsibilities.

To work in tandem with the environment without upsetting the ever-fragile eco-system

is our philosophy. Strict environment management systems for air, water, and waste

treatment in and around the plants ensure stringent procedures and international

compliances. The organization attempts to give its workforce a quality life, hazard free

working environment, and drive them to a higher standard of living by providing them

access to amenities like housing, transportation, medical facilities, schools, and other

civic infrastructure. As part of community service, JINDAL SAW LTD. has adopted

many villages surrounding the plants. Active volunteers from the organization

undertake regularly literacy drives; organize free health camps, mobile eye-care units

and are continuously striving to make these villages independent and progressive.

For JINDAL SAW LTD. high-quality products and services are inseparably bound with

our obligation to society and environment. “Indeed adding value to all our

businesses”.


Jindal Saw Limited

ANNEXURE -1 PRELIMINARY PLANT LAYOUT


Jindal Saw Limited

ANNEXURE -2 LAND RELATED PAPERS


Jindal Saw Limited

pre-feasibility report - …environmentclearance.nic.in/writereaddata/online/tor/0_0_27_aug... ·...

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