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TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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CONTENT
Chapter Description Page No.
1 Introduction 2-9
2 Description of plant 10-20
3 Site details 21-23
4 Services, utilities & manpower requirement 24-26
5 Environmental management 27-32
6 Cost consideration 33
7 Plant Layout 34
8 Google image of 10km Radius surrounding TBSL 35
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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CHAPTER-1: Introduction
01.01 Preamble
Capacity, production and processing of steel in India have grown at a frenetic
pace in the last half decade. Growth of this sector is an evidence of the
growing resilience of the Indian steel industry and its ability to adapt its
workings to changing dynamics of the input and products markets. In this
case, rise of the steel processing industry has helped the Indian industry –
especially the hot and cold steel processing – to overcome a crippling
shortage for processed steel. The primary push for the growth of this sector
has come from the rapid expansion of secondary steel processing in India in
the last decade and a half.
Steel being a basic commodity for all industrial activities, quantum of its
consumption is considered as an index of industrial prosperity. Since
independence, there has been a substantial growth in the steel sector in India
from 1.5 MTPA in 1950-51 to more than 80.0 MTPA at present.
Hence, short-term and long-term strategies are necessary in planning the
development of the steel industry in the country to improve the productivity
and level of per capita steel consumption.
The strategies may include setting up of new steel processing plant facilities,
or expansion of the existing steel processing plants, or installation of
upstream / downstream facilities in already existing plants, for production of
semis for processing / finished products.
The National Steel Policy of India has declared a target of producing 110
million tonnes of steel by the year 2020, up from 80.0 million tonnes at
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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present. This has given an incentive to all the major steel producers of India
to work out to add capacity.
Tata BlueScope Steel is an equal joint venture between Tata Steel and
BlueScope Steel, Australia. The company operates in the SAARC region in the
field of coated steel, steel building solutions and related building products.
The Company was founded in year 2005 and operates in the South Asian
Association for Regional Cooperation (SAARC) region. Its Coated Steel
Business manufactures and supplies 55% Al-Zn Alloy coated
ZINCALUME® steel and pre-painted COLORBOND® steel for building and
construction industry. The company has a state-of-the-art coated steel
manufacturing plant at Jamshedpur with an annual metal coating capacity of
250,000 t and a paint line capacity of 150,000 t. The plant is accredited with
ISO 9001, ISO 14001 and OHSAS 18001 certifications - a testimony to its
quality and performance.
The demand for coated steel is increasing due expanding steel market and
shift from GC (Galvanized Corrugated) and other conventional roofing and
walling solutions. The coated steel products ZINCALUME® steel and
COLORBOND® steel finds its usage in various applications like Pre-
Engineered Buildings (PEB), colour coated roofing and walling, Solar
structures, silos, LGFS, Pipe cladding etc.
Tata BlueScope Steel Limited manufactures and sells roll-formed roof and
wall-cladding profiles as well as lightweight PEB structures under its 3 brands.
LYSAGHT® brand caters to the B2B segment, DURASHINE® brand is the
flagship retail brand and EZYBUILD® Solutions meets the requirements of
Light Gauge Structural Solutions.
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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Tata Blue scope Steel Limited, located under Jamshedpur Notified Industrial
Area at Bara, PO-Agrico, Jamshedpur district East Singhbhum,(JHK) proposing
to expands the capacity of Colour coating line by adding one more CCL
capacity 150,000MT/year in addition to existing CCL of 150,000MT/year. The
expansion would boost up the economy of the backward areas of Jharkhand
State along with boost up the economy of the Jamshedpur, East Singhbhum.
No additional land area is required as the expansion will be executed in the
existing available land. The available land area is 24 h land at Bara Ash pond
owned by Tata steel and the area falls under Jamshedpur Notified Industrial
Area.
Tata BlueScope Steel is an equal joint venture between Tata Steel and
BlueScope Steel in the field of coated steel, steel building solutions and
related building products. The Company was founded in year 2005 and
operates in the South Asian Association for Regional Cooperation (SAARC)
region. Tata BlueScope Steel maintains high standards in the area of Safety,
Health and Environment and has been certified by SGS for ISO 9001: 2008,
ISO 14001: 2004 & OHSAS 18001: 2007 certifications.
The plant location is shown in the topographical map attach herewith. The
entire area surrounding the plant is under Jamshedpur Notified industrial area
having population scattered stretched in the area. The existing plant site is
well connected by the Road. Tata Nagar is the nearest railway station from
the existing plant site, which is around 6.2 km away from it in SW direction.
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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FIGURE 1.1: STUDY AREA (10 KM RADIUS)
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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01.02 METEOROLOGY OF THE AREA:
The nearest meteorology station is located at Jamshedpur operated by
meteorological department. The height of the station is 129 M above mean
sea level which matches closely with the plant at Jamshedpur East
Singhbhum. Based on above the region experiences hot summer and cold
winter, Strong wind is experienced in summer and on the eve of Monsoon
and during winter season calm condition prevails. The characteristics of
weather are
Average wind speed : 4.05 Km/Hr.
Predominant wind direction : West- Northwest
Mean maximum temperature : 42.5°C
Mean minimum temperature : 15.4°C
Average rain fall : 1100-1400 mm
1.2 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT
1.2.1 Identification of Project Proponent
Tata BlueScope Steel is an equal joint venture between Tata Steel and
BlueScope Steel, Australia. The company operates in the SAARC region in
the field of coated steel, steel building solutions and related building
products. TBSL is among the largest producer of coated and painted steel
strips/coils in India.
TBSL has deployed state – of- the – art technology in its production
processes. Tata BlueScope Steel has won prestigious certifications and
maintains high standards in the area of Safety, Health and Environment
and has been certified by Underwriters Laboratory Inc for ISO 9001: 2008
as well as by M/s. UL MSS India for the ISO 14001 & OHSAS 18001
certifications. Pollution prevention & control systems have been installed
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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for the various processes at the factory are of latest design and it
upgraded regularly.
Tata Steel BlueScope Steel is in the field of coated steel, steel building
solutions and related building products and located at Bara, PO Agrico,
Jamshedpur, District East Singhbhum, (Jharkhand). The JSPCB has issued
CTE to this unit vide letter no JA/2655/w/332 dated 1/2/07. (Copy of letter
has been attached). The NOC is granted to TBSL for setting up of plant for
manufacturing of Zinc Aluminum coated steel strip and polyester paint
coated strip at Bara ash pond area, P.O.-Agrico dist.-East Singhbhum
(JHK). The NOC was granted for following production facilities at above
location:
1) Zinc-Aluminium coated steel strip – 100,000 MT/Year
2) Poly Ester paint coated steel strip – 150,000 MT/Year
Consent to Operate for the same has been obtained from Jharkhand State
Pollution Control Board. The latest CTO issued is valid till 2019.
Compliance reports are also submitted regularly.
1.2.2 Project Identification
DETAILS OF THE PROJECT
S. No. Particulars Details
1. Nature of the Project Expansion of capacity by addition of one more
Colour Coated Line capacity
150,000MT/Year(Total capacity of Poly ester
paint coated Strip 300,000MT/Year)
2. Cost of the expansion
project
Rs 300 Cr
3. Cost of EMP a) 12 Cr. – Capital Cost
b) 0.6 Cr – Recurring Cost
4. Total Plot Area 24h
5. Greenbelt Area 7.2h
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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6. Project Location Under Jamshedpur Notified Industrial Area
A. Village Bara
B. Tehsil Jamshedpur
C. District Jamshedpur- East Singhbhum
D. State Jharkhand
7. Toposheet No. 73 J/1 & 73 J/2, 73 J/5 & J/6
8. Location co-ordinate The GPS coordinate as observed for the plant
Centre is given below:
NW: 220 49’ 0.07’’N 86◦ 13’ 58.14’’ E
NE : 220 49’ 2.94’’N 86◦ 14’ 15.27’’ E
SE : 220 48’ 49.99’’N 86◦ 14’ 21.50” E
SW: 220 48’ 48.97’’N 86◦ 13’ 59.75” E
Environmental Setting
10. Climatological Data of Study Period :
A. Temperature Max. – 47 °C
B. Relative Humidity 87%
C. Mean Annual Rainfall Avg. 1100-1200 mm
11. Nearest Railway Station Tata Nagar (6.2 km, SW)
12. Nearest Highway NH-33 (2.2 km, N)
13. Nearest Airport Sonari, Jamshedpur (6.3 km, W)
14. Protected forest 3.3 km, N,NE
Wildlife Sanctuary 8.5 km N Dalma
15. Nearest Densely Populated Area Jamshedpur (6.0 km, w)
16. Nearby Water Bodies 3 Subarnarekha River(440m, N)
4 Kharkai River (6.8 km, SW)
5 Dimna Lake (5.2 km, N)
6 Chandil Reservoir (26.5 km, NW)
17. Soil Type Silty loam
18. Seismic Zone Zone II
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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1.3 SITE SELECTION
The proposed expansion of existing secondary metallurgical unit is going
to be executed in vacant land in existing plant premises. The plant is
situated at an ideal location, as it is benefited with well-developed road
connectivity to Jamshedpur and to railway station Tata Nagar (6.2 km,
SW) & NH 33 in North direction at a distance of 2.2 km only.
The site has all the necessary infrastructural facilities like electricity, water
distribution system, drainage system, banking, postal services,
communication means, transportation facilities, etc.
Following factors were considered while selecting the site for the existing
plant:
1. Nearness to National Highway (NH-33), which is 2.2 km in North
direction from the plant site, makes it easier to dispatch finished
materials for market. The nearest railway station is Tata Nagar which
is 6.2 km in SW direction from the project site.
2. Environmental considerations such as distance from major roads and
safety distances from nearby villages have been taken into
consideration.
3. There is availability of social infrastructure and man-power.
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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CHAPTER-2: DESCRIPTION OF PLANT AND MANUFACTURING PROCESS:
02.01 SCENARIO OF STEEL INDUSTRY:
THE steel industry in the world, which was characterized as a sunset
industry two decades ago, is experiencing a vast change in scenario. The
fast developing Chinese steel industry has far outstripped the world steel
giants. United States, Russia and Japan, which were leading steel
producers, are no more in a position to claim that position.
India is the world’s third-largest producer of crude steel (up from eighth
in 2003) and is expected to become the second-largest producer by the
end of 2016. The growth in the Indian steel sector has been driven by
domestic availability of raw materials such as iron ore and cost-effective
labour. Consequently, the steel sector has been a major contributor to
India’s manufacturing output.
The Indian steel industry is very modern with state-of-the-art steel mills.
It has always strived for continuous modernisation and up-gradation of
older plants and higher energy efficiency levels.
India’s crude steel production grew by 9.4 per cent year-on-year to at
81Million Tonnes (MT) in August 2016. During April-August 2016, crude
steel production in the country grew by 7 per cent year-on-year to 39.98
MT. Over April-August 2016, steel imports fell 34.5 per cent year-on-year
to 3.01 MT, while steel exports rose 23.6 per cent year-on-year to 2.38
MT. Steel consumption in the country is expected to grow 5.3 per cent
year-on-year to 85.8 MT during FY2016-17, led by growth in the
construction and capital goods sector.
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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India is expected to become the world's second largest producer of crude
steel in the next 10 years, moving up from the third position, as its
capacity is projected to increase to about 300 MT by 2025. Huge scope
for growth is offered by India’s comparatively low per capita steel
consumption and the expected rise in consumption due to increased
infrastructure construction and the thriving automobile and railways
sectors.
China, producing less than a million tonnes of steel prior to revolution in
1949, has now become the largest steel producer in the world. During
2005 the global steel production stood at 1132 million tonnes, showing a
rise of 6 per cent over the last year. The countries in South America, CIS
(former Soviet Union) Europe and North America have actually shown
negative growth. The Asian continent for the first time produced more
crude steel than the rest of the world combined. Major shift has taken
place because during 2005 with China producing 349 million tonnes of
steel, accounting for 32 per cent of the world steel production. During
2005, Chinese steel production increased by 69 million tonnes i.e. by 25
per cent. Chinese steel output was more than three times that of Japan
and four times of USA during 2005.
Per capita consumption of steel in the world was estimated to be 170 kg
during the year 2005. However in India it stood at only 35 kg during the
same year. Indian steel production was 38 million tonnes, which
accounted for only 3.4 per cent of the world steel output. In view of the
fact that Indian population is 16 per cent of the global population, the
production of steel is much lower in India. Although India is the second
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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largest populated country in the world, it ranks eighth in steel
production.
TBSL proposed to expand the existing Colour Coating Line Product
capacity from 150,000MT/year to at existing location by adding another
Colour Coated Line with similar capacity of 150,000MT/Year at Bara, PO
Agrico, Jamshedpur district East Singhbhum(JHK). No additional land area
required as the proposed capacity of CCL will come up in exist plant
premises. The total land area is 24h, as per EIA notification 14th Sep’2006
this project falls in category ‘A’ and therefore this project required
Environment clearance from MOEF&CC.
THE PROJECT
The existing plant production capacity is not sufficient to meet the
domestic requirement of Colour coated Steel Strip. To meet the domestic
requirement and demand of construction industry, this expansion is
essential. It is also essential to sustain in the market product quality
demand on modern equipment.
The project is expected to have a high development impact, as it aims at
Enabling a company to become more globally competitive.
Efficiency increases to support cost optimization.
Speciality steel niche product catering to growing construction
marketing nationally & internationally.
Attain global leadership in coated steel business.
02.02 Existing Plant
The existing plant have production facilities for value addition of cold
rolled hard coil by metal alloy coating and further Polyester Paint
TATA BLUE SCOPE STEEL LIMITED
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Coating of the cold rolled steel strips for improved corrosion
protection properties and aesthetic appeal.
The production plan of existing plant as follows:
Zinc-Aluminium(Galvalume/Zinc alum) -100,000 TPY
Polyester Paint coated strip – 150,000 TPY
The strips will be varying from 600 mm to 1270mm wide and 0.25mm
to 1.3 mm thick as being produce from Cold Rolling Mill of Tata Steel
Plant at Jamshedpur. The metal coating thickness on both sides would
be of 300 to 500 gm/sq. m and paint coating thickness would be of 15
to 35 microns.
Manufacturing Process:
The manufacturing process is a mechanical one. The feed stock for both the
line is hard cold rolled strips in coil form.
Metal Coating Line: the MCL is a continuous process line as illustrated in
Figure 2.1. The line would have sequential operations like (i) alkali
degreasing followed by rinsing and hot air drying (ii) last trace of oil removal
in a non-oxidizing furnace having 95% N2 and 5%H2 atmosphere (iii)
continuous annealing at a temperature of around 8000C (iv) cooling the strip
to a temperature of around 6000C prior to passing through molten zinc and
aluminum bath. The metal thus coated on the strip would be water quenched,
air dried and finally passed through dilute chromic acid bath for passivation of
the coated metal surface. The coated metal strip is mechanically coiled for
dispatch.
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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Paint Coated Line: this line is shown in fig-2.2 is similar to metal coating
having process steps as alkali cleaning, chromate passivation, polyester based
primer paint coating, followed by baking, quenching, drying and final paint
coating followed by baking again, quenched, dried, embossed and sizing of
painted coil strips for dispatch.
02.03 RAW MATERIALS REQUIREMENT:
The requirement of principal raw materials and chemicals, other than cold
rolled steel strips as feed stock would be caustic soda for preparation of
alkaline degreasing solution, chromic acid for passivation, zinc ingots,
Aluminum ingots and polyester paint products.
The estimated monthly consumption of these raw materials and chemicals is
indicated in the Table-2.1:
Table-2.1: Average monthly Consumption of Raw Material and Chemicals
S.
No.
Raw Materials/
Chemicals
Forms &
Composition
Quantity
t/month
Source
1. Cold Rolled Coils Thin steel strip 21,000 Tata Steel Plant
2. Zinc Ingots Solid Zinc 99.8% 400 Indigenous
3. Aluminum Ingots Solid Al 99% 500 Indigenous
4. Caustic Soda Caustic Lye
NaOH=30-35%(w/w)
16-17 Indigenous
5. Chromic Acid Aq. SolutionCr2O3=2 to
3 %(w/w)
6-7 Indigenous
6. Paint Products and
thinner
Polyester, Epoxy, Kynar
etc
500 Indigenous
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PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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Fig-2.1A: indicative Illustration of metal coating line (MCL)
welder
cold rolled coil
cleaning &
degreasing
section
heat treatment
furnace
zinc bath
air "knives" (adjust
zine coating thickness)
chromate spray
skinpassing /
leveling mill
galvanised steel
Fig. - 2.2 : Schematic Diagram of the Galvanising Process
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PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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FIGURE 2.1 PROCESS FLOW DIAGRAM METAL COATING LINE
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TATA BLUE SCOPE STEEL LIMITED
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Fig. 2.2A: Schematic Diagram of the Paint/Colour Coating Line
2.04 Fuel:
The furnace including package boiler will be heated by LPG/Propane a clean
fuel gas. It is estimated that nearly 50t /day propane would be required.
Baking ovens of the paint line will be heated by hot waste gas of incinerator
for VOC emissions of paint line.
02.05 WATER
The process requires de-mineralized water for strip rinsing and quenching
operation. The clarified industrial water supply from the water supply network
of Jamshedpur Utilities & services Company Ltd (JUSCO) is made available to
TBSL. The coating lines would require around 90 m3/h of industrial water for
which a provision of 100m3/h of water supply from JUSCO is arranged.
JUSCO receives water from the existing river water intake pump houses. Of
total requirement of 90 m3/h industrial water, the DM plant of coating lines
would require around 40m3/h for various process operations.
02.06 TECHNOLOGY
TBSL uses technology from BlueScope Steel, Australia. The Coated Steel
business of Tata BlueScope Steel supplies zinc and aluminium alloy metallic
coated and pre-painted steel products under the brand names
ZINCALUME® steel and COLORBOND® steel. Its manufacturing plant at
stitchercleaning and
pretreatment
section
primer
applicators
galvanised
steel coilbaking curing
baking curing
finishing coat
applicatorssliter and shearer
(slit to narrow plate
then cut into sheets)
tension
levelling unit painted sheets
Fig. - 2.3 : Schematic Diagram of the Paint / Colour Coating Line
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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Jamshedpur has an annual metallic coating capacity of 250,000 tonne and
pre-painting capacity of 150,000 tons.
The demand for coated steel is increasing due expanding steel market and
shift from GC (Galvanized Corrugated) and other conventional roofing and
walling solutions. The coated steel products ZINCALUME® steel and
COLORBOND® steel finds its usage in various applications like Pre-
Engineered Buildings (PEB), colour coated roofing and walling, Solar
structures, silos, LGFS, Pipe cladding etc.
The Expansion:
Paint Coated Line: since there is a good demand for paint coated product in
the market instead of metal coated strips, TBSL has decided to add another
Colour Coating Line similar to the existing paint coated line having capacity
150,000MT/year. The line is similar to metal coating having process steps as
alkali cleaning, chromate passivation, polyester based primer paint coating,
followed by baking, quenching, drying and final paint coating followed by
baking again, quenched, dried, embossed and sizing of painted coil strips for
dispatch. This will add value to overall production and shall utilize half of the
metal coated strips and rest shall be purchased from the market(~50% of
feed strips shall be purchased).
Addition utility requirement has already been discussed and shall be arranged
from existing sources. Vacant land lying besides CCL shed shall be gain fully
utilized for establishment of this Colour Coated Line (CCL)
The product mix after this expansion shall be as follows:
a) Metal Coated Strips – 100,000 MT/Year
b) Colour Coated Strips – 300,000MT/Year
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PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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02.07 Plant Layout
Attached as separate sheet
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CHAPTER-3: SITE DETAILS
03.01 Site Location
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‘© 2017 Tata Blue Scope Steel Limited. All rights reserved’
03.02 METEOROLOGY OF THE AREA:
The nearest meteorology station is located at Jamshedpur operated by
meteorological department. The height of the station is 129 M above
mean sea level which matches closely with the plant at Giridih. Based on
above the region experiences hot summer and cold winter, Strong wind is
experienced in summer and on the eve of Monsoon and during winter
season calm condition prevails. The characteristics of weather are
Average wind speed : 4.05 Km/Hr.
Predominant wind direction : West- Northwest
Mean maximum temperature : 42.5°C
Mean minimum temperature : 15.4°C
Average rain fall : 1100-1200 mm
03.03 Plant Area and Land Acquisition Details
Existing Project site fall Under Jamshedpur Notified Industrial Area, at Bara,
PO- Agrico, Jamshedpur Dist.- East Singhbhum (Jharkhand). No additional
land is required, as proposed expansion through addition of one more Colour
Coating Line will be within the existing plant premises of 24h.
LAND AREA DETAILS
S. No. Particular for Proposed Expansion Area(h)
1. Shaded Area 9.4h
2. Without Shaded Area including green cover 4.4h
3. Infrastructure Area 3.0h
4 Others (Gardening / Rain Harvesting etc) 7.2h
5 Total Plant Area 24h
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‘© 2017 Tata Blue Scope Steel Limited. All rights reserved’
03.04 Logistics
The raw material sources are already connected by road which will require
no further upgradation as the cold rolled coil will be sourced from Tata
cold rolled mill located in nearby of plant.
03.04.01 Road
The proposed plant site is well connected by the state highway between
Ranchi and Jamshedpur.
03.04.02 Railways
Tata Nagar is the nearest railway station from the existing plant site.
03.04.03 Air Connectivity
The nearest airport is Sonari at Jamshedpur.
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‘© 2017 Tata Blue Scope Steel Limited. All rights reserved’
CHAPTER-4: SERVICES, UTILITIES & MANPOWER REQUIREMENT
04.01 General
Besides raw materials, other major requirements of the plant are water,
power, fuel and manpower.
04.02 Water
The process requires de-mineralized water for strip rinsing and quenching
operation. The clarified industrial water supply from the water supply
network of Jamshedpur Utilities & services Company Ltd (JUSCO) is made
available to TBSL. The coating lines would require around 90 m3/h of
industrial water for which a provision of 100m3/h of water supply from
JUSCO is arranged. JUSCO receives water from the existing river water
intake pump houses. Of total requirement of 90 m3/h industrial water, the
DM plant of coating lines would require around 40m3/h for various
process operations.
WATER REQUIREMENT DETAILS
S.No. Particulars Water required (KLD)
1. Existing 2160
2. Proposed 300
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Project is based on Zero effluent discharge hence no process water will be
discharge outside of the plant premises. Waste water from process and
domestic use will go to Treatment Plant and recycled for various secondary
usages including in horticulture.
04.03 Power
The average power demand would be 8 MW therefore a provision of 12 MW
power demand from the existing 33kV switch board of Tata Timken located
at Gol mury Substation 3 km away from the existing plant site is taken. Total
power requirement after proposed expansion will marginally increase. The
additional requirement will be 3 MVA over and above the existing
requirement which will be sourced from existing JUSCO network having
distribution network.
04.04 Other Utility
The other utility and services for the existing coil coating lines are low
pressure steam of 5-6 tph steam at 10 kscg pressure produced in packaged
steam boiler. 100 Nm3/h hydrogen is produced through electrolysis of water.
At present nitrogen 750 nm3/his purchased from third party supplier.
04.05 Manpower
The production process is a continuous one and of programmed operations,
hence there would be requirement of operation and maintenance staff. The
TATA BLUE SCOPE STEEL LIMITED
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total staff strength is around 355 only. This includes production,
maintenance, services and administrative personnel of different categories.
At present the factory employees 355 Persons proposed project will require
another 100 persons. There was large pool of Skilled & Unskilled person
mainly surrounding area from where this requirement will be easily met. This
project will employed good nos. of workmen is direct & indirect job employed
from local area
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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CHAPTER-5: ENVIRONMENTAL MANAGEMENT PALN
05.01 While preparing the feasibility report of the plant, Environmental
consideration have been given due importance. The plant has
incorporated elaborate Pollution Prevention & Control System and ensures
a clean environment all the time.
05.02 AREAS OF CONCERN:
i. AIR POLLUTION:
The sources are furnace fume from MCL and CCL line, boiler operation and
incineration of hazardous waste. Waste gases generated in the furnace,
which may contain fumes, Carbon Dioxide, Sulphur Dioxide and Nitrogen
Oxides after due treatment exhausted to atmosphere.
ii. WATER POLLUTION:
Discharge from process and toilets etc. will cause water pollution in the
discharge body. However, a modern treatment facilities is existing which
treat all waste water and reuse is in horticulture and other areas takes
place
iii. SOLID/HAZARDOUS WASTES:
The major solid/Hazardous wastes generated during operation of metal
coating and paint coating process. As such the plant will be equipped with
appropriate and effective waste handling devices to ensure pollution free
ambience.
iv. NOISE POLLUTION
From the equipment’s, such as metal coating line
TATA BLUE SCOPE STEEL LIMITED
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05.03 ENVIRONMENTAL MANAGEMENT PLAN (EMP):
TBSL is an ISO 14001 EMS accredited company and EMP incorporates an
action plan on some of the vital areas which have bearing on the
environment quality in and around the plant. The following steps are
taken as part of environment management in order to mitigate
environment impacts.
Entire plant activity is confined to TBSL plant area only and limits to
keep the surrounding areas in undisturbed state.
In a running plant, the fume generating activities will take place and
depending upon the requirement fume extraction measures is adopted
to maintain proper air quality inside the campus, which includes water
scrubber inline.
Present water availability will meet all the water requirements including
drinking water, sanitation etc. Existing toilets and disposal facilities of
waste water will take care of the sanitary requirements of plant staff.
The waste shall be discharged in Septic Tank followed by sock pit.
All existing infrastructural services such as water supply, sewage,
drainage facilities and electrification are available inside the campus.
Existing toilets will be maintained to ensure minimum environmental
impact.
In order to ensure safety to the worker, helmets, safety shoes, safety
belts and dust mask wherever necessary will be provided.
Extensive landscaping programme including trees and flowering plants
in & around the plant are in continuous stage the similar practice shall
be continued for vegetation cover.
TATA BLUE SCOPE STEEL LIMITED
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05.04 MNAGEMENT FOR MITIGATORY MEASURES OF RUNNING PLANT.
05.04.01 MITIGATION MEASURES
Air Pollution Management
Feed coils will be stored in covered sheds
Stack emission will be maintained below 100 mg/Nm3.
CPCB guidelines for control of fugitive emissions will be followed.
Implementation of routine plant schedule maintenance and good
housekeeping to keep small leaks and spills to a minimum will be done.
All the roads inside the plant will be PCC to reduce fugitive emission.
Green belt will be further strengthen along the periphery of the plant
premises & around various plant units to arrest the fugitive emissions if
any.
Water Management
The process is based on closed circuit system; hence there are only
evaporation losses and cooling tower blowdown water which is treated in ETP
and recycled back.
Treated wastewater is used for secondary use & horticulture development.
Rainwater harvesting structures (injection wells with desilting and filter pit) is
existing in the plant premises and used to charge into the underground
resources.
TATA BLUE SCOPE STEEL LIMITED
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Sl.
No.
Description Effluent
Generation
ETP Capacity Remarks
1. TBSL Complex 350-375 m3/day Liquid waste=670m3/day
Chrome waste=24m3/day
Resin waste=12 m3/day
Treated waste
water shall be
used internally
for various
uses
Noise Management
All required noise abatement measures are being provided to keep the noise
levels below permissible limits.
Green belt development helps in minimizing the propagation of noise.
Normally monitoring of noise level will be carried out and corrective measures
will be taken, if required.
Solid Waste Management
Dross are generated in the metal coating line about 15MT/month, this is
being sold to authorize vendors and same practice shall be continue in future
Metal scrap generation from the process is 110 MT/month.
TATA BLUE SCOPE STEEL LIMITED
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Sl.
No.
Solid wastes Generation
Proposed disposal
1. Metal Scrap 1100 t/month Sold to vendors
2. ETP sludge
# chrome sludge
#Non-chrome sludge
400-600kg/quarter
425-450kg/day
Suitably disposed of in SLF
Suitably disposed off
3. Dross generation
from MCL
15MT/month Sold to vendors
05.04.02 GREEN BELT DEVELOPMENT PROGRAMME:
Native diversified species are planted all around the plant boundary and both
sides of roads as per the CPCB guidelines.
Plantation is done by raising plants in the nursery and afterwards planting
saplings at the site.
05.05 OCCUPATIONAL SAFETY AND HEALTH PLAN:
The health of the employees is the wealth of organization. A well-
documented plan is already exist for monitoring the health status of the
employee on regular basis. The existing plan takes care of all the aspect
of safety of equipment for employees.
TATA BLUE SCOPE STEEL LIMITED
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05.06 MONITORING OF ENVIRONMENTAL PARAMETERS: A detailed
monitoring for different environmental parameters is being carried out as
per regulation of state pollution control board.
05.07 ENVIRONMENT AUDIT:
Environment audit shall be carried out on annual basis as per regulatory
requirements. Records of quality of air emissions in term of PM10 are
maintained. As inventory of waste storage area has been maintained
which includes details of the type of waste and the quantity stored,
address of buyers of wastes. Data on stack emission and effluent
monitoring are maintained to ascertain compliance with stipulated
standards.
TATA BLUE SCOPE STEEL LIMITED
PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)
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CHAPTER-6: BLOCK CAPITAL COST
06.01 BLOCK CAPITAL COST
The estimated capital cost for proposed expansion through addition of one more
colour coating line of capacity 150,000MT/year in plant units to enhance
production to 300,000 MT/year Colour Coated Coils and 100,000MT/Year Metal
Coated Line at Jamshedpur Notified industrial area, Bara, PO Agrico, Jamshedpur
district East Singhbhum has been worked out to be Rs 300 Cr.
TATA BLUE SCOPE STEEL LIMITED
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Layout drawing of plant:
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