Se EIA& EMP FOR THE PROPOSED | jw | EXPANSION FROM 10.0 MTPA TO 16,0 MTPA STEEL PLANT CONTENTS Sion er No. oo _ 1. [INTRODUCTION — Teas |_| prover oescnnon | a-tm2-n 3. | DESCRIPTION OF THE ENVIRONMENT 2-1t03-111 \* ANTICIPATED ENVIRONMENTAL IMPACTS & samaarion 4-1toe 102 «| pwowaaca uowronne Root | sresea oa Jo |enaue erwin “4 |, | ascuosune or consuanrenonoeo | ‘11. | COMMENTS OF THE PROJECT PROPONENT ON THE VARIOUS | 114 to 11-24 | (CONCERNS RAISED IN THE PUBLIC CONSULTATION PROCESS 3 0EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ae LIST OF FIGURES Fig Na. Daxarigion| ‘aptar Na] Zi [LOCATION WAP OF SITE 2 22 | MATERIAL FLOW CHART OF THE PROPOSED EXPANSION 2 PRovecT |3ta | wind-ROSE AT TORANAGALLU DURING WINTER - DAY & 3 NIGHT(OVERALL) 3.1 | WIND-ROSE AT TORANAGALLU DURING WINTER - DAY 3 312 | WIND-ROSE AT TORANAGALLU DURING WINTER - NIGHT 3 41 | ISOPLETHS FOR SPM CONCENTRATION DUE TO PROPOSED ‘4 EXPANSION PROJECT 42 | ISOPLETHs FOR S02 CONCENTRATION DUE TO PROPOSED 4 EXPANSION PROJECT 43 |ISOPLETHS FORNOx CONCENTRATION DUE TO PROPOSED 4 EXPANSION PROJECT 44 |STEPS FOR ASSESSMENT OF SIGNIFICANCE OF 4 ENVIRONMENTAL IMPACTS 81 |ORGANISATION CHART (PROPOSED) OF ENVIRONMENT] 6 MANAGEMENT DEPARTMENT @EIA & EMP FOR THE PROPOSED jaw EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT LIST OF DRAWINGS, _Besciiption 7 —~ praing Wo (GENERAL LAYOUT ross sao |store eyraes wecroesevomn LAND USE_OF STUDY AREA Mec! @6s4/1 1152106 iyl ssw EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT DEX ‘TOR COVERAGE IN THE EIA REPORT | TOR POINTS GIVEN BY NOEEF ‘COVERAGE INEIA REPORT REMARKS ‘Rss Waaion map oF ian map oF ‘310. 00,000 "scale. followed by 4150 000125,000 scale onan AVAZ sheet wah at least next 10 Kms of terrain Le. crcle of 10 kms. ard further 10 kms on ASIAZ sheets with proper lngitudiatudetheights with tin. 100/200 m, contours should Be {included 3-D view Le. DEM (Cigtal | Elevation Model) forthe area in 10 knvadus from the proposal sit. based on satelite Imagery. High- resolution satelite image data having {msm spatial resolution ke quick, “Tkonos, IRS P-6 pan Sharpened ete. forthe. 10K racius ‘area fom proposed site. The same Should be Used for land usedtand ver mapping ofthe area, Present and use should be prepared | ‘Chapter 3 | eter Drawing No MEciassa//S2I02 Chapter 3 page 2-200 Retr Drawing No. Meciassari 18208. “Topoarasty of the area should be ven desl indicating whether the Se requires any filing. s0, dtals of fling, quantity of fil matecal Fequied ts. sourve, transportation it. shoul be lven location of national parks 7 wii sanctuary / reserve forests within 10 fm. Tacs’ ‘should. specicaly be mentioned. A map showing Tancuselandcover,resorved forests, wildfe sanctuaries, natonal parks, tiger fesewe ete in 10 km Of the project Project sto layout pian showing ri material, fy ash and ther storage plane, tore’ well oF water sorage, fiers within 1 km). dumping, ‘waste dsposal, green areas, water bodies, —rverldrainage passing hough the projec ste shoud be included. | Refer Drawing No. Meciass4' 1152102 ‘Ghapier 3 Clause 3.15, St para Refer Drawing No. Meciassa7 1152/02 Refer Drawing No- ‘MEcI085411/52/01 Coordinates oF he plant sie as well Refer Drawing NE wsi | [SH- | TOR POINTS GIVEN BY WOER EXPANSION FROM 10.0 MTPA TO 16.0 EIA & EMP FOR THE PROPOSED (2) MTPAS) STEEL PLANT. ‘COVERAGEINEIA REPORT [REMARKS 35 ash pond ‘sh pond with be inclu, ‘otcnates of tha plat site 35 well ae With topo heat co Topo shoet should also, MECIOSSTTT S27 7. Betas ana Glassiteaion of total and (isentiied and acqured) should be ‘hapier 2, Cause 2.12, age 258, State Govt. and a detailed acton plan should be incised. include. ‘| Proposal should be submited tothe |= "The proposed Moisty for envionment leerence expansion Is within cn after’ scquiing tol land. the existing plant Necessary documents »incating premises and no acquistion of land should be adktional land ie Included. required, 8 | Rehabilitation & Ressilement (Re |= NORE Risse R) should be as per pai of te involve. of forestland be included, 10. | Pormission and approval for tha use of the State Forest Deparment Fegarding impact of proposed expansion on. the surrounding reserve forests, i applicable, should and recommendations ‘sppicable, Tio forest anda Involves and impact is given in Chapter 4, Giause 117, Page 4 3 Incorporated TH. [A lst of ndusties containing name {and type in 25 km radius should be Refer Chapler 6, page 657 106-38 — | inupuin ire transportation TE. | Residential elony shouldbe located WS. [List of raw material required and source ‘alongwith “mode of the tucks for raw mate and friched product transportation must be environmentally compliant. tion, ocated'n wp wind rection should be included. Al Refer Chap? Clause 21, page 2-67 102-66 T Quant of ‘ovement of imported from each port, method of ‘coke and product ‘coking coal 1 be au material including Refor Chapter? Clause 211, page 2-57 10258, 5 | Commitment ‘materials and the Pott Authorities for handling caw ‘and_ parisien fom products We have developing ew Inks in acon to Goa(krshnapatanam, ‘Mangalore, Chena, Gangaveram et) RITES have requests ™EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT Sic [TOR POINTS GIVEN BY NOESF[COVERAGEIN EIA | REWARKS REPORT. {9 examine bo ovr | tis up 18 MTA 16] A chapiar on cing coal avaiabiy, [Retr Chagtor2 source, Boning, utzon Clause 2104, page 2 17 [Undertaking and comment fom | Curery Be coal Autores Australia for suppying|requred is met fom 43 ‘aking coal long wth fa back lan. | suppers. The suppl have adogte recor for supiing the | adcional uattes. || Anata of coal ar Arsene eoiant | Retr Chanter 9, page ‘grneueesar and shoud be insted. | 387 to 2:8 | Peveiogcal ard Chemical anaes [Rel Chapte'S, page and other chanical properties of aw | 650387 imate used (in GPS location of Source of raw Matera) ie. ote, miner ook, 20) coal ‘ron chlorite quate sing. ‘Non {einton and precision insvumers mentoring the detection renge ond mathodlogy such Digtal Analyzer, [AAS with Graphite fumace, ICPMS, IMICRO-WDKRF, EPMA. XRD, Nano sues ofa estas pr 30:10500 {nd WHO noms. These. analysis Should neide Wace eomert nd tata sts ike Cr (V) NI Fe, Ao, Pb, Zn, Hg, 5a, Sete Presence of radioscive dloments (U, Th et. evog'apy, gin size araiyss and | Rafer Chap page Nalor slomont anayois of row | 38510987 || materia and sol rom projet ste Sd aw mater should bo done on {he sare rameter along” wih Banas fr SiO, AsO MgO, MnO, IK, C20, FeO, FeiOs, P10 H.0, CO, Bi | the TOs, or, raw ato! has | Refer Chaar3 page trace elements the perogrphy, ore | 880 $87 micescopy, XRD, elemental mapeing EPMA, XRF is required uanty the amount present and Soro” fee nvored| we Using nd management pan OoEIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ‘SN. | TOR POINTS GIVEN BY MOEEF | COVERAGE INEIA | REMARXS 1 REPORT 22, | Studies for ty ash, musk dleposal [Refer Chapter page sry, sludge material and other | 3-71 103-75, sold waste ganerated should also be Included, ithe raw materials used ae waceslements and management plan 25. Manufacturing process details for alj Refer Chapter? page the plants incluting slaggrinding unt| 2-710 2-10, should be included. A commitment] {hat emission level from al the stact| should not be less than 50 mg/N" 23 A complete table indicating existing, | Refer Chapier 2, Table Yyot to be commissioned, proposed | 2.2, page 2-60 2-7 ‘and cumulative facies and Capacities. Phasing of all the plants shouldbe included Z5_|A chaptor on type and ful detale of | Refer Chapter? coke oven plant including polation | Clause 2.10.4 pago 2- control methods and justification for | 20%0 227 instaling recovery type of coke oven, ‘dy quenching shouldbe included 2B |Mase balance for the raw materi Refer Chapter? Fig? ‘and peoduets shouldbe included | 1, page 2.68 BF. [Energy balance data for all the| Refer Chapter, Tabie components of ste! plant inciuding | 2-4, page 2-57 to 2-68, proposed power plant shoud be Incorporated — A plan forthe lizalion of wasted | Rafer Chapter 2, Table ‘ga8es ffom all the sources including | 28, page 2-71 BF, coke oven in generating power have tobe eat out _ 25. Sto-epocife. — micr-meteorlogical | Reter Chapter ata using temperature, relative | Ciause 3.21, page 3-5 humid, hourly wind speed and | to 38 rection and rainfal should ‘be |__| catectea 30. [One season sit-apoctio miro: | Refer Chapter 3 meteorological "data using | Clause 3.2.1 & 322, temperature, relative humity, hourly | page 3-50 2-18 wind speed and crecon and ran . fand AQ data. (except -monsoon) Should be calleted. The monitoring stations should take info account the re-domnant wind drecton, Population zone" and _sensitve | } ilEIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT [SN | TOR POINTS GIVEN BY MOESF ~[recaptos including reserved forests ‘COVERAGE INEIA | REMARKS REPORT BH [Data generated in the last threo yoars Ve. air wate, raw material Broperios and analysis (major, Wace Sha neawy mata), groundwater fable, seismic history, flood hazard story ete | ristoyete ‘32 | Data on exising ambient i, sack emission, fugitve emissions data, Water Yoqutrement and water Balance "cycle: generation, re. Uslzaten ‘and disposal of solid hazardous ‘waste for the. exstng plant and predicted increase. in palttion load (GLCs) due to Proposed expansion should be Incorporates, aor Chapter 3, Clause 3218922, age 3510 215. Data 2or0. ‘Refer Chapter Sand Chapter 4fEAroport | 1 TAI the environment clearanses ‘corded by the Ministry, Consent to Establish and Operata and. point. wise compliance to the specie and ‘General condtons stipulated in the nvionmontal clearence and |_| Gonsert to Establish and Operte for |_| allthe existing plants ele Ghapier3, Clause 3213 page 3- 86 109-107 Hi [Ambient air-quslty at 8 locations within the study area of 10 km. ‘etal coverage from project ste with fone AAQMS in downwind drecion Should be caried out Rafer Chapter 3 iause 322, page 2.9 tosis |The suspended paricuate mater present in the ambient air must be ‘analyzed tor the presence of poly ‘aromatic hydrocarbons. (PAH), Le. Benzene soluble fraction. Cherical ccaracterzation of SPM and incorporating of RSPM data Refer Chapter 3 page 3-78t0 380 SE [ Determination of atmosphere inversion love atthe project ste and assessment of ground level Concentration of potutants from the Stack emission based on ste MTPA STEEL PLANT. ‘22.Data_ on existing ambient alr, stack emission, fughive emissions data; water requirement and water balance cycle; generation, re-utization and asposal of sal! Razardous waste for the exising plant and predicted increase in palution load (GLCs) dus to propesed expansion shouldbe inco. porated. 33.All the environment clearances accorded by the Ministry, Consent to Establish and ‘Operate and pointwise compliance tothe specie and gonerel condtiors stipulated fn the environmental Gearance and Consant to Establish and Operate for al the ‘isting plans ‘4. Ambient air qualty at 6 locations within the stucy lrea of 10 km. ser coverage ‘rom project ste wath one AAGMS in dourwind direction should be cared out '36.The suspended particulate matter present in the ambient air must be analyzed for ‘he presence of polyaromatic hydrocarbons (PAH), Le. Benzene sake fraction ‘Chemical characterization of RSPM and inoxporaing of RSPM data, 38, Determination of atmospheric inversion level at the project ste and assessment of ‘round level concentration of polutants fom the stack emission based on sie “poste moteorologeal estes. 37.Airqualty modeling for stee! plant for specific polutents needs to be done. Alt ‘polktion contol devices installed and proposed for the contol of emissions fom all {he sources should also be incused, 38, Ambient si quaity monitoring medling along with cumulative impact should be Included forthe day (24 hrs) for maximum GLC along with folowing |) Emissions (leecond) wth and without the air poltion control measures 3) Meteorological inputs (vind speed, m/s), wind direction, ambient ai temperature, cloud cover, relave humity& mixing height) on houry basis |) Model input options fortran, plume ise, deposition et. iv) Prnt-out of model input and output on hourly and dally average basis, 1) A graph of daily averaged concentration (MGLC scenario) with downwind ‘stance at every 600 m terval covering the exact location of GLC, \) Detals of air potion control methods used with percentage efficiency that are sed for eniesion cat estimation with respect o each pollant 1) Applicable air quaity standards as per LULC covered ithe study area and % contibuton of te proposed plan to the applcable Ar qual stander In case of expansion projec, the contibuton should be incusive of both esting and expanded capaci (© 2010 MECON Limited. All rights reserved 6EIA & EMP FOR THE PROPOSED JSw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT \i)No. | to Vil are to be repeated for fugtive emissions and any other source type relevant and Used for industry 2x) Graphs of monthly average daly concentration with dewsind distance 2%) Spesity when and where the ambient air quality standards are exceeded either due to the proposed plant slone or when the plant Cortrbuion is added fo he background air quay x) Fugive dust protein or dust reduction technology fo" workers within 30 m of the plant active areas. '39.Impact of the transport ofthe raw materials and end products on the surrounding {environment should be assessed and provided, The aterats method of aw materia ‘and end product ransportaion shoud alse be studled and deals included 40, One sesson dte for gaseous emissions other han monsoon s2ason in 10 ku aehus Is necessary, 41.An action plan to contol and monitor secondary fughtve emissions from al the Sources as per the latest permissible limits issued by Ine Mirity vice GSR. 414(@) sted 30" May, 2008, 42. nformaten regarding surface hydrclogy and water regime should be incaded. 43.Presenca of on squielaquifers within 1 km of the project boundaties and ‘management pan fr recharging the aquifer should be ineudoa ‘44, Source cf sufacelground water eve, ste (GPS), cation, anlen (lon Chromatograph, ‘metal tece element (as above) chemical analysis for water to be used. I surfaces water's used from river rainfal,dscharge ate, quantiy, drainage and distance rom Project sto should also be inclusea. 45, Ground water analysis with bore well data, lthoJogs, drawdown and recover tests, to quanti the area and vlume of aquifer and ts management. 46.Ground water modeling showing the pathways ofthe polars should be included 47-Colurnn leachate study forall ypes of stockples or waste daposal ses at 20°C- ‘50°C shall be condted and inca, 48,Permisson for the draw of watr from the concerned authority forthe existing as wel a8 proposed plant from the Almatty dam and Tungbnacra dam and woter balance data including quantly of effuent generated, reojled and reused and Gischarged is to be provided. Methods adoptodo be afopted for the water conservaion should be included (© 2010 MECON Limited. All rights reserved ur[ EIA & EMP FOR THE PROPOSED | Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT os 49. note on the impact of craw! of water on the nearby River during lean season, 50, Surface water quality of nearby River (60 m upstream and downstream) and other surface drinsat eight locations must be ascertaned, 51.1 the site is wthin 10 km radius of any malor river, Flood Hezard Zonation Mapping is required at 1°5000 to 1;10,000 scale Incleating the peak and lean river diacharge ‘28 well 9 food occurence frequency. 152.4 role on treatment of wastewater fom diferent plans, recycle and reuse for ‘ferent purposes should be included. £53. Provision of taps and veatment plants are to be made, if water Is geting mixed win oll greace ane cleaning agents '54.11the water is mixed wth solid particulates, propeeal for seeiment pond before further \uansport shoud be included. The sediment pond capacity should be 100 tres the twansportcapasiy, 55. Wastewater characteristics (heavy metals, anions and cations, ace metals, PAH) fiom washed /beneficiated plants /washery. '56.The pathways for poltion via seepages, evaporation residual remains are to be studed for surface water (drainage rvs, ponds, lakes), sub-surface and ground ‘water wih @ monitoring and management plans, S51. Ground water nonteing minimum at 8 lecatons and near solid waste dump zone, Geological fesures and Geo-hydroiogical status of th study area are escanial ae ‘also, Ecological status (Terrestnal and nquatc) is via 50. Gevtecticl ats by a bore hole of upto 40 mis. n every One 89. Km area such as, ‘ground wate eve, SPTN values, sol fneness, goology, shear wave velocty ft for luetacton studies and to assoss future Selsmic Hazard. and Earthquake Risk “Manegementin the ree. 59. Aetion plan fot solidMhazardous waste generation, storage, ulization and disposal Particularly slay from all the source, cher and fy ash. Copies of MOU regarding Utlzaton of asa and slag shoul also be ince. 60, Detals of evactation of ash, deals garding ash pond impermeablty and whether itwould be line 50 detals of to lining etc. needs to be adresse. 61. Green batt development plan in 33% area, Details of greenbelt. ond with not iess ‘than 1,500 tress por ha. giving detals of species, width of planation, planning (© 2010 MECON Limited. All rights reserved 1a| EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT schedule ote. Cement manufacturers for ulizing granulated BF stag and fy ash should be inclued. (62. Anote onthe Featment, storage and dsposl ofall ype of stag shoud be included 69. enfifcation and details of land to be used for SMS slag dsposal should be included. 2 (64nd se o sa waste and its composition sua be covered. Toxie metal content inthe waste material and Its composition should also be lnorporated parla of ag, {65.Al stockpiles wll have tobe on top ofa sable ner to avoid leaching of materials to ‘round water. 66. Acton plan for the green belt development plan in $3 9 area should be Inckded. The {gfeen bolt shouldbe around the project boundary and a seheme for greening ofthe Traveling roads should also be Incorporated. Al roofopslterraces should have some: ‘green cover 67.Detats regercng nfestucture facies such as sanitation, ful, cestoom ete. to be ‘Provided fo the labour force during constructon as well as to the casual workers Including tuck vers during operaton phase. 168.4 scheme for rainwater harvesting have to be putin place. Incorporation of water harvesting par for he projets necessary, i source of waters bore wel 69. Detaled desction of the flra and fauna (terrestrial and aquatic) hau be given ‘wi special reference to rare, endemic and endangered species. 70.Socio-economis development activites need to be elaborated upon. Measures of ‘socio economic influence tothe local community proposed to be provided by projet Proponent As far as possible, quantitative clmersion should be given. Provision of ‘schools, colleg, technical initutes, training canes, recreation parks, water suppy to nearby villages ete shouldbe incorporated. “Tlmpact ofthe project on local infrastructure ofthe area such as road network and ‘whether any ational infrastructure would need fo be constricted and the agency responsible forthe same with tine fame 72. A detated disaster management plat inclucing risk assessment and damage contol needs tobe adsreceed 78. Occupational health ofthe workers needs elaboration. Heath elects of ether metals used and heath hazard plans based on monthly correlation ofthese metal related seases and pzople affected and mitigation plans, rsenicosis Management Plan (© 2010 MECON Limited Alrights reserved +eEIA & EMP FOR THE PROPOSED Jaw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT . Arsnic is present in ore, rock, coal, y ash, water, Action Plan for profecting the ‘workers against hazardols chemicals euch au Suiphu acd, pesicdes, soven’s ee, 74, Occupational health ofthe workers needs elaboration Including evaluation of noise, heat, lumination, dust, any other chemicals, meals being suspected in environment and going Into body of workers ether thvough inhalation, ingestion or theugh skin absorption ard steps taken fo avold musculoskeletal disorders (MSD), sackoche, pain in minor end major jonts, fatgue etc. Occupatonal hazarcs specie. pro- Dlacement and periodical monitoring and periodical montoring should be cared out ‘The detaled plan to carryout above mentioned acivly should be mentioned 75.EMP to mitigate the adverse impacts due to the project slong wit tem-wise cost of 1s implementation 76. Pian for the implementation ofthe recommendations made forthe sted pent inthe ‘GREP guidelines must be prepared. TTA note on identification and implementation of Carbon Credit project should be include. 78.Tolal coptal cost and recuing costlannum for environmental polation control "78. Public hearing esuos rised and commitments made by the project propenet onthe ‘same should be nuded separately in EIEMP Report inthe form of tabular chart, £80, Any gation pending against the project and/or any direction / order passed by any Court of Law against he project. so, detais thereof. 4.4 BASIC DATA GENERATION, FIELD STUDIES AND DATA COLLECTION ‘This report has been prepared on the basis of one full season baseline environmental aia monitored and completed during December 2008 to Fabruaty 2010 by Mis Richardson & Cruddas. The data includes motecrologicel condone, ambient sr ual. noi, water quality and soi quay. Site survey has been conducted for studying the Nora Sand fauna, secio-econemie conditions incising puble consultation land use, hysralogy, geology, ecology ee. Adtional information is also collected fom several agencies and ‘depariments, both under State and Central Governments pertaining to above, “The collected data have boon analysed in detl for Mertiyng, predicting and evaluating the environmental impacts ofthe proposed project The maximum anticipated inpacts on ‘environment are assessed and’sutable enueonmental management plan hes been suggested. (© 2010 MECON Limited, llrightsreserved 4-10ae | EIA & EMP FOR THE PROPOSED | FSW | EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT Fig. 11a LOCATION OF SITE (© 2010 MECON Limited. Al rights reservedEIA & EMP FOR THE PROPOSED sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT (Karnataka) Yn ; Ae, oo 2 7 Soe £F : ROL) emmmnine Fig. 1.1b LOCATION OF SITE (©2010 MECON Limited. All rights reserved +n[. EIA & EMP FOR THE PROPOSED jSw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT Le 20 PROJECT DESCRIPTION 24 INTRODUCTION SW Stoel Limted havo plans to enhance the intalied production capacity ofthe plant ftom 10.0 MTPA to 160 MTPA steel products for Techno-Commeral bil The proposed facies are presented in Table 21. lmay be noted that the capacities Indicated aro rated capacities and the facilites will have the flexibility to produce ‘%of the rated capacitas depending on the quality of raw materials, ‘Table 21: Facilities envisaged for the éxpansion project SCN Pant aeiies pas pneficaton Pani | 10.00 mpa of proSueL WA unis oT S00 Th is z 42 mipa peel pant of 44m grt aes a 112 tpa Gorx gas based OR pan of 150TH (TODS DR Plant nected by expert spans, |e Oven Batiany 5.02 miss rosovery pa ovens 489 ovens XT OM [Sai Plant 72 mips stierachne of 700m" rate sa] | et Fursca 123 ripa wih? furraces of 4.078 nner Vie 7 | Siel eting Shop 8.187 mapa stot capacity wit ios 2e1eat 5 Bor somerers | 4x i801 Laaietumace (Le) | a3 160 Roa 2x te0t 1 Conta cating alta [60 wa ot ode seal 2 Blank Caster 2xSerard~22 Miva 2 Blom Caster 2x0 stard-22Moa = aie aster 2x6 svand—19Mbe 3] Fang Was "ite Ro 2x05 Mpa ‘$00 Mi ixoe tea Medium Secon Mls | 21 ies 2_Unvetsal Beam mi | 2 9 | aptve Powor Pant unk ot S00 WW (aaa Wl nary Coal aru Be bowed | ‘unt 300 MW coal based 2unteot 12 Mt TRY Ge MN, 4 Unit 55 Wom COQ (To be executed by expert _ agencies) 70 | Line Gaknaion lant — 8x 300 ted Dele Catenin 25300 pd _| [Tower pant 2x 180 us Toba wrested by ohar Sa ago) ‘The following changes fom the earer proposal considered atthe tie of issue of TOR hhave become necessary due to detaled engineering and changed market conctions, atthough the addtional crude steel capaci remains at 8.0 mipa, (© 2010 MECON Limited. All rights reserved atEIA & EMP FOR THE PROPOSED Jew EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT 1 (Ore benefication plant of 10.3 mtpa produc for utlzing dectning qualtyofiron ore ‘A Pellet pant of 4.2 mip fr uilzng the ultafines present in the ion ore FRocovary typo coko ovens ef 3.08 mipa with 4x89 evens of 7.0 m tal Batteries in place of 65 inipa with 465 ovens of 76 tall bateios 4, Instalation ofa 1.2 mipa DR iron pant usin the corex gas produced in Corex units 5. Enhancing the capac of two Blast furnace of 4013 m3 capacity from 6:0 to 623 rntpa due to use of pele & DRI the burden 6. “Enhancing the capacity of Converter shop fm 6.0 mtpa to 6.187 mtpa due to use of DRI 7. Modification tothe CPP trom two units of 300 MW wth 100% coal based to one unit «f 300 MW wit 100% coal and anether 300 MW wih dual fing fecity of coal and Surplus byproduct gases. {8 Two units of oxygen plant of 1800 tp in pace of one unt Howover, there has been ne change inthe capacities of steel casting and finishing ‘aciest may be noted that the actual crue stel production may vary by 5% ofthe shove rated capacities. ‘The details of products manufactured wil be as flows: ea Prot 55 ToT a Production | 7 — [waits oars renee | "5000000 | meat (| fea Sectors «000000 6 eam sors zap Soiezo chars 3soane _| fu Saar 70000 ‘o| Sean ‘200 {to 300 {0-290 (6) anges {90% 100-2500 1 80-2008 100 (| cranes | tio* 0 _ 3h | ioe B8s-02 908 4) | Spel Bar B8i-0200 00,00 S| fiSemenos pais terme 2 mtpa cae Somes Sine vane Pete (amma ont _ ‘mba 3 by Peas Granite ag Lamba Coa | olism (© 2010 MECON Limited, All rights reserved 22| EIA&EMP FORTHE PROPOSED | | Sw EXPANSION FROM 10.0 MTPA TO 16, MTPA STEEL PLANT dy ree | 22 TYPEOF PROJECT ‘The proposed project fs under Category 'A’ (SNe. 3 (a) of Schedule : “Primary and Secondary Ferrous Metallurgical ind.sties) of th “List of projector activites rectiene prior environmental clearance” of MoEF notication dated 14" Septaniber, 2006 Connection with Enviorment (Protection) Rules 1286. 29. NEEDFOR THE PROvEcT ‘Stoo bing @ basic conmodty fr al industial activites, quantum ofits consumption is considered as an index of industialprosperty. Sines independence, there has bec substantial routh in the steel production in incia om 1.5 Min T9865! to about €0 Mt in 2007-2008, Despite the above growth in tho taal sector, the per capita Tnished stock ‘consumption continues © remain ata level of about 48 4g only, compared to abou Soo kg to 625 kg inthe developed counties and 197 kg as world average, Furher wih early 20% ofthe worle population ind’ contbution is crly of the ander of 3.0 ot word steel production. Hence, short-term an long-term statogios wea necossay a ‘lanning ine developme af the sia industry inthe country to improve the eve! 6 per apla stee! coneumplor. While modemisation ofthe existing steel plants in india may increase steel output marginal, Seting up of new ste! pant facities wil be essential to moet the ncroseing Stee! demand ‘The projects needed toincroase Stee! Production inthe county 28 per Nationa Stel Plcy to bedge the gap tetween demand and soppy. 24 LOCATION ‘The exiting integrated steel plant is situated between 15°10" - 15412" N lattudo and 76°36" - TE'AOE longtule, near Toranagaly wlage of Belary district in the sate of Kamataka. The sts ata distance of 32 km from Bellary, 23 kn from Hoapet and soot 340 km fom Bangalore by road. The site is well connecied by road Shh and Nios ‘The Stato Highway SH-40 passes on tho westside of the plan. fom Tomagaha to Hamapanali via Sencur. National Highway NHS (Gooty- Totanagaletlospet parses on the north side ofthe plat. Nearest ralway station to the ste! plants Torarepet Brood gauge reivay lines between Guntakl and Hub are passing tough the etmon The eastem port of Chemmal is 460 km and westem port ef Gos ls 430 Ken, Musee ‘about 740 km on the Nor West. 25 SIZE ORMAGNITUDE = OPERATION ‘The expansion plants infended to increase tho steel production from 10.0 MTA to 16.0 MPA. The capacties of ferent units are presentod in Table 21. The procees cure ‘material fow forthe exparsion plants gen in Fig. 21. (© 2010 MECON Limited. A rights reserved 2sEIA & EMP FOR THE PROPOSED jw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT 28 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION ‘The expansion ie proposed to be implemented within 48 monte from the date of start of the project (Zero date). 27 TECHNOLOGY & PROCESS DESCRIPTION ‘The nianufacturing process will be of conventional blast fumace (BF)-basic oxygen furnace (BOF) route wth continuous casting of iquid steel 1o Bloomsybiets followed by ste! fishing operations to mest the specie qualty and shape requirements of the consumers. ‘The prnepal process steps involved are (Coke making in byproduct recovery type coke ovens; (i) Siptering of ron ore fines with coke and recycled dusts to make sintr burden of BF, (i Pelitisation of ron or for producing pelts for DRI snd Bias! furace (®) DRL making using Corex gas asthe reducing agent for eed to last fumace and BOF converters (©) ron making in Blast Furnaces (BF) rom lump iron ove and sintered ore (with or without peli), coke and fuxing materials; (¥) Conversion of hot meta to laud ste! by oxygen blowing in BOF followed by refining of Fauld eo! In lade furnaces ‘with addon of alloying materiale for ‘rire adustment of stool chemistry. (ui) Continuous casting of refined iquid steel to biletsloombiank in suitable casters, (i) Hot rollng operations to precuce varius types of shaped steel products of desired size and dimensions. 28 EXISTING PLANT & FACILITIES ‘The major technological & auxiliary faioe at th 10.0 Mtpa sted pant stage for which cleranca from MOEF has been obtained ear are as flows: 1) Raw materials: Coal & ore recehing, storage and handing plant 1) Ore banetciation plant of 19.5 Mpa 1) Patt pant of 10.0 Mtga Iv) Sinter plant of 10.35 Mpa ¥) Coke Ovens(Non recovery type) of 128 Mpa (© 2010 MECON Limited. All rights reserved ayEXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT EIA & EMP FOR THE PROPOSED | (as) ii _ W). Coke Ovens( Recovery typs) of 3.6 Mpa 1) Hot metal production fecives 2 Corexunts of 8 Mipa, “1 Blast furmace of 1250 m of 0.9 mipa capacty 1 Blast furnace of 1650 m”of 2.17 mipa capacty + 2 Blast fumace of 4018 rv of 0 mipa capaci, vip Pig casting mi (1x1200tpa & 23600 tps). 1k) 7 BOF converters of 88 Mipa with soo reining facies 3). Continuous lab castorst of 1600mm, 2 of 1250 mm and 3 of 2200 min) of 8.0 Mpa ‘) Continuous bile cater of 15 mipa 2a) 2 of Hot stip mill of 8.2 Mipa 3i)2 nos of Caldraling mil f 3.0 Mpa 2v)B nos Lie kins (20 fpd each) & 4 nos lime kl (00 tp each). 2) 2108 of Gas based captive powerplant of 290 MW 2) 2.06 of Coal based powerplant of 300 KAW each si) Slag coment cushing unis of 42 Mpa xi) 4 units of Oxygen pants totaling 7000 tpd operted by expert agencies 3x) 4fownships of 8000 dweling unts ‘The faces for which the clearance has been obtained and ae sl to be executed are upgrading of BF-1, One lime pant of 600 tod. one oxygen plant of 800 tpd.CAM2 of 2 ‘mip; colour coating ine of 0.5 tpa an galvanizing ine of 10 mie, 23 TECHNOLOGY! PROCESS DESCRIPTION {SW is planing to augment the plant capacty from 10.0 Mtga to 16. Mtpa withthe Bédton ‘of manufactuing facies. The expansion 10 16 Mipa will be similar to the txpansion ofthe plant capacty from 4.0 t0 10 mipa and wil be stand alono unt of 60 Mipa steal making fecilty and wil have minor integration ‘with the existing plant production facies, exceyt for the infastuctural and adminisative actives. The ‘commissioning ofthe 16 Mpa units wil thus be caried out seamlessly. The details of the proposed facies are given inthe Table 2-1. Table 2-2 shows the phasing ofthe facies upto 16 MTPA expansion fom 7.0 Mipa stage. Drg. No, MECIQSS4/11/82I01 (enciosed} presents the lay out f the plant showing the existing and proposed facies, ‘Table 2.2: DETAILS OF EXISTING AND PROPOSED FACILITIES PRODUCTS AND. PRODUCTION CAPACITIES SL] anatactarng “Faailiog Facilites |W cos No, | Facies Inatatod proposed ote | now propoeed urea) ‘netaied | (10to 18 TPA) * (iowTPA 1 [Orebenteaton Pat | aas TPA DOS] —Ixsa MTPA—| RIES MTP | LarPAa vx. uTPA | _| cumatatve 14SMIPA ieguiba | —FoanmPa 7 | Pabat Pare [tnt SMTA 2 TPR Cunutave SOMTPA SOOMTPA 142 MIPA (© 2010 MECON Limited. All rights reserved 28EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT "SE anutatarng Facies Facies |New fsioa ~] No, | Feetives Inatalsd proposed t sow proposed crwrea) Times "| cototeheay >| Sate BE papa ‘9406 m2 00 we Camlab Ena GossuTPA—| Tr ss wTPA : Coke Oven =NR | Two atti af08% | — No edaion Ne sedon Cumulative 7a MTEA, TaamTPA, | Coke Oven Rasovery i245 mtal_| 89, 70 mist , om coke oventateres | "eake oven ‘ZOMTPA coe | bationes of 08 MITA coke Ccumuiatve in A SEMTPA 8 NTPA | Hetmelal-Cowse | 2 Caer unis f8 | No action No aan Leese Cumulative Teun TSMR TEMIPA 7] Het meta ae BETol1250ms. BF | —Ixeo19ma BF | BeadI9 Ma BF Fumace 2atiesoma. ‘at m3 BF | Upgrade BF to 1680 m2 | feumiate Sor MPA Sarai —| ve soMTPA [Ce oar Pint NL NL tZMTPA—] [9] Bs onng Machines | 4X 7200 ward TX | 4 X600%I | — 7X 9600 a cumate se00 I 450083 Bates 000 ws | [70°] Grae aeel= BOF | SRSOT anc 27ST | TE conver |B t converse ‘sumone eonverer | Cieratve BaNTPA wa MPA TEOMA, 7 me ie 83300 oo x00 tod 2200 fp Cunsave 240088 4300 tea “209. 2 | Sia Casi "BETO mm 1XTEOO | 2 2200" —| — No ation ‘nm & 1% 200mm | als caters f3.2 inp cater of 18 MIPA, Sea smut aantea | sonra | sore — WF | BieVBoor coer ‘No aden | Bile castor (7 foe of 10-09 Mpa), 22 -PA ‘a rnd bit | bloom & 22 MPA ae ‘ankeaster L TSMIPA TSMyPA_|—7eMrea | 4 Fant Tam of HSU af 32 | 432000 me widd | No ation IMTpRewecty | SO MTPA HSH _ | cumiat ‘S2MTPA 2 MTPA. Sa, 5 | Wie oa it Tat oO MTPA| No adaon | —2 units of 05 Camas ares TMT oe MTPA TEMIPA (© 2010 MECON Limited. All rights reserved 26EXPANSION FROM 10.0 MTPA TO 16.0 [- is EIA & EMP FOR THE PROPOSED MTPA STEEL PLANT SC Wanufacaring ~Feilifos ——|—Waw ois No, | Facies proposed ta be | now proposed Installed | (foto Ye TPA) (fommPay 6 | Rebar & Secionrat | eT OMA] —hoasant —} Tse aOR] PA, 7 secon m2 TPA) & "beam mil LL rea) | Cumuiowve ioMIPA ToMTPA |e area TF | Gad Rqing mil ——| Tuner 10 TPA | Tmt. 6 MBA] — No aden —| compe anuistve .0mTPA SOMTPA, 20MTPA 75] Gavarizng ines —[ [e025 wrPA—| Wo aiton Cimaiave “SONTPA “LOMTPA 8 | Cove Costing ine i [nos wrpk—|~ Ne adton —) Sumutatve ‘i 05 MTA, OS MTPA. B0 | Power Piantand_——| “Ga bass UPP= | Cia based TH200 | Coal based 13300 ‘ecass seamen: | 100 MW and COP = aw iw Giemaive ‘130 ,Coat based 6 ted 300 ‘S00 a 30 a Bom 70 Traktor Tani of 280 aph| "Tune of 800 ge | Tonio 250 Kg Cumulative 250 gh TSDKahr 000 ge 2 | Gomortplant-Sibg | OZ MIPAS HOS | —x2oMTPA—|—Tunt oF (Grnaing end ming MTPA MIPAGending on Balenoe 14 MTPA ant | nsterecutes cumatve ZaMTPR TEMA SzTER | Ongen Pant BxABLO HCOTTEG | ISOS TABS | —EKTROOTB 1 | camuasve eA “a0 7a00 es | 7080099 —| 2 | Toman ‘imap or 4000} Tiownship er PT Wmsnip of 5000 | 7 woling unis | 4000 dweling units | tings “The following units have been outsourced to other expert agencies as under; ‘Oxygen plant to Praxair, SOC & Bellary oxygen Pipe plentto Jindal Sow pipe and ‘Cement plant to JSW Coment| {mn the proposed expansion to 18 mtpa, It Is also proposed to out source the ORI plant to an expert agency - JSW Projects. ‘Aref description ofeach ofthe steel making process steps is presented below CCoke making: Metallxgcal coke is used as the reducant for reduction of iron ore to produce hot meta. Metallurgical coke Is produced by carbonzing the coking coal at 2 temperature of around 1200"C in absence of oxygen atmosphere m closed door multiple (© 2010 MECON Limited. Al rights reserved 27EIA & EMP FOR THE PROPOSED Jew EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT {all ovens. The volatile matir is Hberated resulthg in formation of coke due to carbonization in the ovens. The energy necessary for the carbonization process 1 ‘Provided by the Blast fumace or the coke oven gaces. Tha coke thus produced n the ‘ven afer 16 10 18 nour of coking ¥s quenched, cooled and sereened fr feeding 0 the Blast fumaces. ‘Te crude coke oven gas, having a potential heat value s cooled, separated fiom ts, napthalones and ammenia to produce deen coke oven gas for use as plart fuel ‘vatious heating applications. ‘Sintering: Sintering is high temperature (1200-1S00°C) process for agglomeration of ion are fines with coke breeze and other fuxes ike limestone, pyrexia and recyclable ‘sold wastes tke me fines, BOF sludge, BF fue dusts ete which are blended in base six yard ‘Tho intored mass known aa Sinter having higher strength is ono ofthe mia metalic ‘bearing burden material for BF. The hot sinter product ‘after coaling is soreened and sted za of sirtered pred! s son to the BF stock hoe for charg tee BF ‘long wih ump iron re Polietisation: Paletising tums very fine-grained ion ore (even low grade Kon or) into balls of certain ameter, which are eutabo for bast furace and det reducton, lon ve i crushed and the imourties ae removed. The ore maxi moistened and a binding agent is adcod. The iror-ich ore is heated wih a binging agent to creste curable marble ‘22d "geen" polls in rotating rune or onfoary lec. These green pellets ae dod and indufated at temperatures of more than 1000 °C. This can take piace in shaft or fotary furnaces or on a Waveling grate. The pelts are wih excellent phystal and ‘etalurgical properties and can be easly transported, due to their high strength and ‘Sutaity for storage, The palliation provess involves twee steps ‘+ Raw material preparation + Forming potets| + Pelt hardening Porto the formation of pelts, waters added to on ore fines to adjust the moisture ‘content io approximately 8% and the ove ls mixed wth smal amounts of binding agents ‘sich as bentonite (approximately 0'5 %) and fluxes such ae fmestone, ime olive and dolomite (15%). Theso give the pelts th proper physical and metallurgical properties ‘needed in further processing, Mixing tates place in contruously operating cum or pan- ‘ype mixers wih of sulable capacty. Pelets aro formed ether n pellaiaing Css OF cums, drums vaualy being connected to role sreens used for soparaing unrated palate. The pelts thus formed have low mechaniel strength; they are hardened “Traveling Grate coupled with ying and furnace. fron making: Sized lon oe, pelt sinter and coke along with other fuking materials {218 charged tothe tall vical BF for production of hot meta in presence of hot bist a ‘The temperature within the furace fs above 1600°C. The gangue minerals present the Iron oe are converted to slag known 26 BF slag and 'F’ content of the axde ore (© 2010 MECON Limited. All rights reserved 28EIA & EMP FOR THE PROPOSED sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT gets converted to molten fon due to reducton of iron oxides of the ore with carbon present in the coke, In order to have adequate carbon for reduction purpose, wel 2s to reduce coke consumption. powdered coal is injected Into he furnate. The hot ron ‘etal alter desulphurizaton with carbide compound's ready for conversion to steal BOF. For balancing the hot metal production, provsion of pigging of the hot metal becomes necessary. The BF slag is granulated by water eting and granulated BF lag Foduced can be used for coment making. The BF gas canlaining mostly Carbon monoxide (CO) is wet leaned inverts sebbers, to bung cown the Gust level the ‘28 to below 5 mgIN cum. The cleaned BF gas is used es plat fuel and for hosting the BF stoves to prodice hot blasts Direct Reduced Iron Making : Dect reduction is an elteratve route ofron making in \which moten ion is produced using coal/ gas asa reducing agent instead of Coke sen conventional Blast Furnaces. it overcomes some ofthe dfieuties of convestinal blast furnaces, The spectic investment and operating cost of direct eduction pants alow compared to integrated toe plats, and are more sulable for developing counties where supplies of coking coal arelimted. DDI is produced by reduction of ran ore (nthe form of lumps, pallets or fines) in rotary ‘ans in the sold phase at 800—1050 °C by using elther sod (non colng coe) of oe (oformes natural gas or coal gasification) as recuctart. Beside supplying the esueng ‘agents, namely carbon monoxide (CO) and hydrogen (H), the energy requirement fer the reduation reaction is also supplied by a part ofthe reductar’ as fuel This process of _drecl reducing the ion ore in so form by reducing gases i caled direct reduction, ‘Reaction mechanism There are two major temperature zones inthe kiln. The fst preheat zone is where the charge is heated to 600 1000°C. Tha second meialization sone fs held fay sores at 1000-1080°C, In the pre-heatng zone, the malsture is deivan off fret and then the hydrocarbons ard hydrogen evolve by thermal decomposition ofthe coal Here, the reduction ef Fon aise proceeds only to ferrous oxide (FeO) (Equation | Fe,0,+00=2Fe0+co, 0 In mealization zone tho final reduction of ferous oxide to metalle kon occurs by reaction cf CO with FeO fo form CO, and metalic ron (Equation I) Fe0+CO=Fe+Co, von @ “Most ofthe CO, reacts wih the exmooe sold ful in the kn end is converted to CO ‘ccording to the Boudouard reacton (Equation il), being an erdothermic reaction this helps in maintaining desire kn temperature by cntvoling ar nection in he hin (© 2019 MECON Limited. All rights reserved 29EIA & EMP FOR THE PROPOSED jew EXPANSION FROM 10.0 MTPA TO 16.0 [ MTPA STEEL PLANT * a ©0,+¢ =200 m Lime calcining: Burt ime (C20) is required for steel making. Limestone Is burt the tall vertical limekins at a temperature of around 1050°C te produce burnt lime, Tne. energy required forthe endothermic reaction Is provided by fel gases. The burnt lime collected atthe bottom ofthe Kins is screened, Lime dusts are recycled to the Sinter Pant Stool making: In the Stoel Melt Shop (SMS), the desulphurised hot metal along with burn ime and fuxing agents is charged tothe BOF. Carbon present in tho hot metal is oxidized by controled blowing of oxygen. The temperature of BOF Is around TTOOC. with the energy gonerased by the combustion of carbon present inthe hot metal. The [BOF gas having carbon monoxide and dust passes through the wet gas cleaning plat. comprising of venturi strubber where the dist in to gas is separated due to nettal Impaction. The water centaining dusts treated in a watr treatment plant and recyeled tothe system. The clean BOF gas depending on ‘CO’ contents recovered and used as ‘fue within the plat. ‘Ate tapping of BF slag, the crude liquid stool is poured and transfered to lad for further refining and chemistry adjustment in the subsequent stoe refining operations In this sperial type of lala crude qui soe s vacuum-degastied and chemistry adjusieg by acdltion of micro alys to produce liquid steel of desired chemisty. Thereafter, the refined lquid steels cortnuousy cast othe bltsbiooms nthe casting machines, Hot roling of billet/tlooms: The billetsbicoms are reheated to @ temperaize of ‘around 1250°C in walkog beam type reheating fumace, Aer descaling of healed biletsfbiooms by high gressure waterjet. the same is hot roled in separate mils to produce shaped products ike wire rods, sections, rebars ee, The products are ready for dopatch. Some of the hlermedates tke blooms and bile are leo sold outside for ‘earying out finishing operations at the customer end. ‘Ar soparation: Steel making in the BOF requles oxygen of high purty. Similar the bast furnaces also requre large quantty of oxygen to facitate coal injection, The ‘oxygen required forthe above processes is produced in Ar soparation plant. This is {xyogenic process to produce quid oxygen, niogen and argon. Oxygen fs consumed in the BOFs for oxygen lancing in the BOFs and in BF blast a for ennetment Nitegen fs used at many locations within the plat for inert gas blanksting and Argon is used for steel refining Incinerator: During the steel manufacturing and fishing process, organic wastes like waste ols, sludge, grease etc sre generated. These wasies are recycled to a large ‘erent, The balance amount wil have to be incinerated in an incinerator, specialy ‘designed fortis purpose. Captive Power Plant: tis proposed to install two 30OMW captive power plants identical to the exsting one withthe folowing conigurations, (© 2010 MECON Limited. All rights reserved 2-10= EIA & EMP FOR THE PROPOSED _JSW | EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT 41. One 300 MW coal based power plant 2 One 300 MW coal an surplus uel gas fred powerplant 240 PROJECTDETAILS ‘The genera layout of the exising and propesed plant \s stown In Deg. No, MEC! 684/1118201. The major plant facies as envisaged for the proposed projec end thelr capactos ae already indicated in Table 21, 2.10.1 BENEFICIATION PLANT SW Stee! Limited plans to sot up 4x 500 Uh benafcation plane complex at Vijayanagar to supply banefciated are to the pelt plant and sinter plant whic in tur wl supely pellets and sinter respectively fo the Bast furnaces and OF Plart. The ifon or in BellryHospet region is fragle In nature and at present it contains around 32% alumina ‘and 4% ‘Silea. The Fe content is aso reducing, ‘Since the avalablty of good qualty lump ore is ited # is expedient te use tho low grade oe fires. The on ore wil be benefciaied tly to upgrade Fe content to 52% and Alumina 4 Stica less than 5% for use Pelt Plant and Sintering Pant Beneficaten Plant Capacity Parameter Value [Feed Input teria aE KO] Capsciy 2000 toh No. of Medes 4 ‘Capacity per modile OPA oduct Recovery 75% ‘Output Product TOO 000 ye ‘Sint: grade product | 5,654,000 tyr [Pellet grace proauet [4.177.000 Uyr Operating Regime 2) Working days: 300 daystyear 1) Working hours: 24 hel day ©) Plant Uteation Efclency 95 4 Raw Materials, Quality and Sources ‘The annual requirements of raw materia forthe proposed beneftiaton plant is fumished © 2010 MECON Lintod, AU rights reserved atEIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16. MTPA STEEL PLANT in tabi below: Raw matorial requirement (Net and dry) Raw Waterais ‘Size ‘Quantity wy ph iron Ore Fines O-zmm— | 15375000} 2000. Quality of Raw Materials ‘The Beneficiaton Plant is designed to handle lowsgrade ror ore fines of the {alloning specication: 2) Size of ROM =-12 mm 8) ROM Bulk density 2.2 ums ©) Specie Gravy : 42 ‘Chemical composition of raw materials. [Raw Material [ron ore ines 38-60 30. — os 04 30 pes [008 Iron ore fines “The ron of es used in Benaficaton plant wil be low-grade ron ore with high alumina tnd si cones. The iron ore fee routed fr the boriaton plant wl ke procure fiom iocal wen ore mines. Product quality ‘Si Ne_ [Parameter ‘Sintor Grade | Peliet Grade —[ 1. | Specie avy 44 44 i 2 [Sas Oi-3mm | WOT-o1Smm_| 3 Fe a Sei (ia [anos + si0z 5% <5 (© 2010 MECON Limited. Al rights reserved 212| EIA & EMP FOR THE PROPOSED jw EXPANSION FROM 10.0 MTPATO 16.0 | L MTPA STEEL PLANT ——w Major Plant Facies ‘Tho beneficiation plant wil comprise the folowing mr faites: + Raw Material Handling Syste, + Sereening, Crushing, Classifeaton & Up gradation (SCCUP) System + Product Handing System * Tang Disposal System Abie description of the plantfacites is urished below Raw Material Handling System (RMHS) ‘The Benoficition Pant wil receive Kon ore fines ether trough track hoppers andlor through muck unioacng stator. A conveying system will convey ion or thes ean We lack hopper sysiem to raw material storage yard Raw material recuived at tse taleading system vill be discharged on the above stacking Conveyors for tues conveying tothe raw material rage yard, The recamm conveyer wil less ra eacred to surge bunkers. ‘Screening, Crushing, Classification & Up-gradation (SCCUP) ‘The 600 tph stroam consists of two nos. 250 tph streams. The folowing is the bret escripon of one stream of 259 ph Bolt Feeder Bolt feet at the bottom of surge bunker wl feed raw material to a seraen feed conveyer at 250 teh (max) eapenty Screen The ovat matril (13 rm om the aceon wil be conveyed to crusher & the tuted tol wil be fa bck tthe sean feed convoy The Bee es ervey sal hate a eapciy of 50 tan proved wi’ bl anes Tee AS Se ough ine sent aeany cmeyer ed he te vain Weer (oe epost trough 9 Suny tx Crusher The oversize material fom the screen willbe transferred to a crusher through a {tusher-eeding conveyor. The cusher wil be located outside the main plant busing ‘and near to the surge bins protected by structural sheds, The crushed matsil oa further transfer on tothe screen eeding conveyor (© 2010 MECON Limited. llrightsreserved 213EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 _MTPA STEEL PLANT ® CClassitir (Primary & Secondary) ‘The screen undorsize material (in slurry form) wl be fed tothe primary classfer. The Classier shall nave a capacty of 250 tph, The coarse material (undertow) rom Primary Classier wil be fed to Scubber. The scrubbed material wal be fed to Secondary Cassie whichis also of 250 tph capaci. The fines (overtiow) fom both the dassfars wil be collected in a sump by gravy trough open launder. Density ransmiters has bean envisaged inthe overfw ines of the both the clashes, whieh i used fo contol ‘the speed ofthe spiral Scrubber ‘The coarse mterial(underiow) from Primary Cassi wil be fed to Atriion Scrubber ‘Aton Scrubbers performs beter wth feed materia ess than Sram. The retention time in the scrubber wil be around 4 0 6 minutes. The Scrubber shall have e capacty of 250 ‘eh. De-Watering Screen “The coarse material (undertow) from secondary classe wil be fed to Dewatering Screen for ramoval of moisture. The Dewatering screen shall have a capacty of 900th Sinter Product ‘The final escharge (0.15mm - 3mm) from the Dewatering Sereens (whichis the feed to ‘Site Pant) fom al the fow meds of 500 ih wil be coected on a conveyor. The ‘material vl be further transferred to base blending yard of Sinter Pian (700m) trough conveyor yctones ‘Tho fnae (eve) from beth tho cloccfire & dowatering aereen (100 mesh /-0.46 smn) willbe caected in a sump by gravy trough open launder. The slur wil then be pumped to a batry of eyciones. The overtiow tom tha cyclones (10 mncton) wil ke transfered t talings tickenee, ‘Magnotic Separation (WLIMS & HGWS) ‘Te cyclone undertow wil be fed to Wet Low Intensty Magnetic Separator (WLS) by gravy through launder to recover magnetite ore. From WLIMS, the feebly magnetic fection will ba collected in @ sump located at ground love. The stury willbe pure Io High Gradient Magnetic Separator (HGMS) fr recovering hematite ore. (©2010 MECON Limited. All rights reserved 214eT — | EIA & EMP FOR THE PROPOSED jaw EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT Bolt Fitter ‘The magnetic fection from HGMS and WLIMS wil be transfered to Belt Fiter via \lewaterng cytone for cernoval of moisture. The elscharge from Bek Fiore fom al oe ‘our modules willbe colected on a conveyor to futher transfer the samme inca oe onvoyor to the Pelet Plant Storage Yard. Tne product ef the Bal thee ed oe molsure content of about 810 %. Product Handling System Its envisaged to produce folowing grades of benficiated iron ore concertata nthe beneiiaton plant + Sint product (Size: +0.18 mm to-3 mm) from dewatering seceen + Pelt product (Size: +.01 mm to-0.15 mm) fom bel fers, Sister and pelt feeds wil be further conveyed to sinter plant and pei plant, Tallings Disposal System The Cyclone overiow and the tangs racon from HGMS is transfected to talings ‘Thickener. The talings pumps shall pump the underfow sokds fom the Theckorers is {he existing tangs pond. The overtow from the Thickeners is ciculated back te to Process water reservoir. 210.2 PELLET PLANT {SW Stee! Limited plan to setup 4.2 Mtpa pelt plant comple for ther acional 6.0 ‘Mipa integrated ste! plant at Vjayaneger, Karnataka, The pellet plant wil opsrars oo hasmatit ron re concentrate having about 8S molture, Benefiiated ion ore or iron ore concertvate from benefcation plant, mestone and coke bresze fom local ground storage wil be conveyed to the sos of ron oe ‘concent and additive storage unt within the pale pant From these sos limestone and coke breaze are coleted in preset quantities and cried in ftary kins to reduce the moisture content fo below 1% befor feadng tt the ball nis for co-ginding to get the requisite tneness, Grinding of coarse bertonte wales ‘done separately ina Raymond mil, Then the Iron ore concentrate, ground addves and bentonite are transported to the ‘espeuve as in ground mater storape unt Further, moung it paddle mes soon peli frmaton in peleting discs and heat hardening f geen pets icusing machine willbe cared out One traveling grate indurating machine of 464m? grate ares wi bo installed with ab (© 2010 MECON Limited. Al rights reserved 2.18EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ther associated service tecites, Mixed gae willbe used for drying before grinding and finaly curing induraton of green pellets. However, the exact size ofthe pelt plants wil be naizd after ciscussion with the {echnology supater dung the detaled engineering stage. Design Criteria Capacity 42 Mtpa No.of annual working days: 390 days Induraing macrine area”: 04 m2 Pallet with Zom Useful strand length em Fuel for indurafon ined gas (CV= 2200 kealm3) US & coke breaze additive: Ball il (1n0.) grinding Bantonte grincing Roller mi (1 90) Moxng Pda mee horizontal type (1 no.) Baling Baling discs (7.5m da.)~8 os Feeding greenballs on: By doUbie deck roller screen fornarow size (2- machine: 48 mm) dstibuton onto the indurating machine Inuration ‘Traveling Grate (TG) Indurating Mactine ‘Separation of earth layer: By natural segregation /HL vibrating screen Raw Materials, Quality and Sources, “The annual, daly and hourly raquirements of raw materi forthe proposed pelt plant tre fun'shed i tabla below Raw Material Requirement (Net and dry) Guanity Raw materials se a ae iron Ore Coverite | OSS mech [4.177.000 | 12.6575 627.4 Limestone =20mm | 84000 | 2545 [108 Coke Breeze = 15mm | 64000 _| 2545 [ 108 Bantonte =Smm [30000 | 908 [379 Quality of Raw Materials “The average chemical compaeiion of raw materials to be used for pelt preducton are shown below. (© 2010 MECON Limited. All rights reserved 218EIA & EMP FOR THE PROPOSED sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT | Te _ | (Chemical Composition of Raw Materials (%) Raw Material | Fe(@) [FeO | Fe203 S102 | AOS [C20 [Ngo | TOT [Others] renew cone. {63584 - | 905 [351 20 [oos] tao Limestone [| — 50 | 20 [470] 20 ta10] 30 Goke breeze | 7.55 |= [tos [saa]—28-[ 30 Lor} = oar Bentonte [670 [=| 957 [4601 28.0-[-30 | 30 }20} 04s] ‘Sources of Raw Materials, tron Ore Concentrate Beneficiated iron ore concentrate of size +0.01 to -0.15 mm having about 8% melature ville transported from Benefcition plant tothe pele plan ste Bentonite ‘Tho bentonite requirement ofthe proposed plant wil be met through purchese. Tho ‘ualty of bentonle envisaged for this plants ae follows ‘Swing indox:25-209% pH value 8.08.0 Limestone LUmestone of () 29 mim size required forth plat pant wil be met rom local mines, Coke breeze Coke breeze of) 15 mm size roquive for the pli plant wil be met through internal generation from cake oven plent ‘Operating regime ‘Tho proposed pelet pant wil be operating onthe basle of three shits & day and 390 ays in year afer taking into consideration the ehutdowns rocuired forthe planned maintenance and unschedtled breakdowns, Quality of pellets ‘The expected chemical composton of frished pellets is placed below. ‘Constituents [Vaio Fed) > 64 'Si02 + AROS ot (© 2010 MECON Limited, All rights reserved 27[ EIA 8 EWP FOR THE PROPOSED SW | ®XPANSION FROM 10.0 MTPATO 16.0 MTA STEEL PLANT Lt [Consiiuenis Vata [C20 + MgO Hl FeO. 05, “The expected mechanical and metallurgical properties of finished pales are placed belew SL No. [item value [Sue +Ste 1mm Timm Som SESH max dome i) [Peresiy 210 28%. Ti) — [Cola rushing arena =25TEgip min [iy [ASIN tumble index +635 Re] 94% mi ) — [Abrasion Index 0.8 mm) 496 max ww) [Is swelling index 76% mac vy [is reauctty TO% min vig) [Compression syength aor reduction SD kg Technological factities ‘Te pelet plant proper will comprise the folowing ma) technological unt, = ron ore concentrate and actives torage hin wit Lime sone & coke gfnng unt fal mi) Bevtone storage and grinding unit > Ground meteral(concenvata, Le stone, Coke & Berton) storage and ming unt > Baling unt treatin ut = Poet seoregtion and heat layer separation Firised ple! socks [Apart rom the above units, all major services facies like material handing, water ‘upely systom, compressed ar, mised gas, ventlation and aitoondtioning. plant ‘deausing buldng srucures, cui works and industrial safely, elects, instrumentation ‘and automation have been envisaged forthe proposed pelt plat. 12.1033 DIRECT REDUCTION PLANT Diecteduced iron (ORI), also called sponge iro, is produced from rect reduction of iron of (inthe form of lumps, pales or fines) by a reducing gas produced fom natural ‘986 or coal or gases from Blast Furnace J Corex/ Coke oven pant. The reducing gas is {irmntre of Hysrogen (H2) and Carbon Monoxide (CO) which acts as reducing agent. “This process of directly reducing tho iron ore in sold form by reducing gases is ealod rect reduction. {ISW SB Linited propose to instal Direct Reduction (DR) Plant based on the surplus (© 2010 MECON Limited. All rights reserved 218| EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT | ‘2rex gas produced by the corex plant. The capacty ofthe DR plant wil be about 1.2 Nips ‘The coex gas based DR Process atwactve cost, Since the COREX of gas cortain hyoronen ond carbon manmade te The Direct Reduction (OR) lary shall comprse of one nos. of 150 toh shaft furnace able of producing 1,200,000 Hyr DRI production fom shaft based on 100 % for ave delle asthe charge material, Production program The production program of the drt reduction plant, as envisaged, e given below. Product capacity, aye Direct eduction ron Produced 4,200,000 Blast furnace 143,000. =SMS 557,000 ‘Technological parameters of DR Ps ‘he technlogical paramaters of DR Plat are as flows Nominal Diameter of Shaft (0). ma ‘Surcen Height in reducing zone, m No.of Unit Production, Uh ‘Annual Production, Wiorking hourlvear ‘Shits per day, No. Quality of Sponge ron ‘The ypicalqually of DRI would be as flows: [Degree of metalation. % [2-34 Fe % Feo, (©2010 HECON Limite. All sights reserved 219EIA & EMP FOR THE PROPOSED jaw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT a Major plant facies “The Direct Reduction (OR) Plant wil be equipped wih the folowing fecities forthe production of OR 41. Corex Export Gas Compressor 2. Mist Elminator 3. Vacuum Pressure Swing Absorption Pian CO2 Removal System 4 Gas Heater '5, Paral Combustion System + & MIDREX DR Shaft - 160 toh 7. Scrubber 2406 COKE OVEN AND BY.PRODUCT PLANT ‘The battery willbe of twin fue, underjt, regenerative type slong with provision of recirculation ofa part of waste gas. Oven width of 410 mm is envisaged forthe proposed ‘coke oven plant For the annual production of gross cake of about 3,082,000 tonnes, ‘one coke oven plant with fur batteries of 69 ovens each have been selected, The major {cold eimensions ofthe ovens wil be as fotows. Total length (between buck stays) 48,000 me Total usofl length 15.180 mm Total height 7,000 mm Useful height 8,700 mm Wath at pusher side 385 mm Wath at coke side 435 mm Average Wilh 410mm Taper Somm, set volume of the oven bm ‘ial distance between oven 4,400 mm ‘Number of fues in hating wall 32 Distance between flues 80mm Number of charging holes 3 2 6 Coking time 18h CCoking coal will be the main raw material required for the proposed coke oven plant complex Quality of Coking Coal and Coke ‘The proposed coke oven plant is designed, based on the use of up to 60% imported coking coal and 40% indigenous coking coal to produce metaluxcical coke. The qualty of coal wil be such thatthe coke should be of acceptable quay tothe high capacity (© 2010 MECON Limited, All rights reserved 220a EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT re blast furnaces, and a sutablo blond of indigenous and imported coal would be worked ‘out during detail engineering. The general quaity of imported coal and coke thus produced are given inthe tales below. General Qualty of imported Coking Coal ‘SE No. [ually Barametars Tait [Value 1 [Sue mm [Oto 80 2—[Ash % [9.095% (max) 3 |v % [241026 | Wostare % [Be 10 | Sulphur [05% (ra, 8._| Phosphorous % [0.06% (max) 7.__| Grey king coke type = [65 (mn) 8._| Crile sweting No No. [65 (min) '8_[ Mean max. reflectance (ROma) | - | 1.10101.90 10. | Gieseerfuiity pm | 600-2000 Note: Inaigenous coking coal from captve mines! ether sources will aso be used depending on avalabity and qualy of avaate coal Quality of coke Quality parameters Value ‘Ash, % (ax) 2 VM % (max) 10 ‘M0 (max) 80 (CSR (in) 4 Moisture, % (max) 4 Requirement of coal Based on the design norms adopted and elaborated later i this chapter the annual ‘equirement of coking coal wil be about 4 195,000 Uy. ‘Source of coal ‘The major source of imported coking coal is Australi, which ls the largest exporter of coking coal in the word. Steetmakers in india are also importing coking coal fom ‘Austral However, possiilties can be explored to impor cokang coal from New Zealand, China and South Aca, (© 2010 MECON Limited, All rights reserved 2aEIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT Orde Yield norms Based on the above, assumed blend compesiion, characteristics and three grades of coke sag requiremer, the norms forthe yeld of coke trom 7 m fall ovens with impestod {Coking Coal and Inaigenous Golang coal in the properton ef 60 "40 is taken im ‘consideration ae incleated Inthe table given Below. "Norms for yeld and consumption SC Parieaiars Tait | Guantty No. |_| Dry auivalon Buk dana of coal charge td [07a il | Vie of dr gress coke a5 of cry coal charge % 73 ii)” | Yet of sized coke a8 % of gross coke 25-00 mm 15] W%R | 03479 25mm 0-15 0m. Ta) Wied of coke oven gas par Tonne of dry col Brand Naat] 30 charge TI CV ot enka oven gas Kean |~4500 "W) | Heal consumpion for coke oven atin, bor igatcoal | Keal | 600 “wth mixed ges (BF & CO gas) (Med Gas CV="000 | eosin) Tay | Vil of eter y-prOdUER ws WT Oy eoal, Crate tar | —% | 3B ate 0) ! | Volume of Production and Consumption ‘The volume of production/consumption of various materials and qualty of coa! & coke {or the proposed planton annual basis has been tabulated inthe table below. Siw Ta Tait Guaniiy “| Production [Gross coke (SW Te oe ooo iy] Szed coke ery) 25-50 mm T625mmO76 | Wr vye tyr | 2,520,000, mom 133,000 408,000 Ty [cies caravan ase Tse | 343 iu) | ruta (wat roo) we 25000 2) —| Consumption. 1 paraingenon oa OW Ge aeT | Gr FIRED toovers) Ty | Mixed gas GF + CO gaa for under fing of | — Goalie BTS ovens & oter htemal use ‘Coke Dry Quenching Plant “Two coke dry quenching plants (CDQP) of 175 th capacty consisting of thee cooling (© 2010 MECON Limited. Allright reserved 22EIA & EMP FOR THE PROPOSED Jw EXPANSION FROM 10.0 MIPA TO 16.0 MTPA STEEL PLANT chambers each wil be nsaled to cool coke produced in the batteries. Technological parameters ‘The technological parameters/ features of coke dy quenching plant will be ss Indicated in table below. Features of Coke Dry Quenching Plant (CDP) Description Capacly of COM unt Quarsy of C00 unt. “Temperature of coke charged inthe chariber [Temperature of coke afer cooing Temperature of creulsting gas beter ening cooing chamber [170-1005 “Temperature of culating gas before wasie heat boler B00 = 10200" “Thermal fein 80-85% Pressure of steam generaied 93 MPa [Temperature of steam generaiod 7 5a0°C. “Temperature of Food water Ta0°C. “Generation of steamvboier 105 0h (ye Time of Coke Charging Bd see, Process description Hot coke pushed from ovens will be recelved in a special type of coke car which has a Setachable bucket wth mechanism fr bottom dscharge. The coke car with hot coke wil be brounht o coke dy quencring instalation. The coke bucket wal be ited fo the top of ‘eating chamber with the help of coke bucket ier. Each chamber willbe provided with ‘en independni coke Luckett. The Bucket during ting wl be covered wa spt ‘ype of screen. This wil lp in rotaining tho heat 28 well as prolect the working area {fom emission of heat. Hot coke willbe charged into the chamber through coke charging dave. As the coke travels down the chamber, It gets cooled by the counter cuert stream of inert goses, which wil be recrculated by a mil fn provided for each chamber, Cooled coke wil be discharged on the conveyer tuning below the chamoer through he cxkeclischarging device. The entre eperaton from ling of the hot ‘coke tthe The by-product plant wil be designed for recovery of orly essential by-products lke ‘ammonia and crude ter. In ation to that, naphthalone scrubbing urt wil fe istsed to emove and recover naphthalene ftom ‘coke oven ‘gas. Naphthalene ich solar of generated in naphthalene scrubbing unt wil be sold io eiteide pares for recovery of naphthalene from solar ol. This regenerated solar oll (etipped off naphihalons) wil be ‘reused in the scrubbing unit with action of make-up fresh solr ol Facitios proposed inthe by-products plant have been summarized below. Technological Units of By-product Plant 3 Prat ‘Fieites proposed "| Gas condensation plan fr cling of gas, | Pimary gos coolers, eactosale removal of tat fo, separation of tar and|precbtator ETP), evhoustr (cece Neverby cooing water and chile wator | giver), Sect wit tar anit _| hanging fase 2 | Ramana eiphate par er rent of | Saute, canctogs, Furoa, eat Ging fanmonia inthe form” of arenonium | and bagging syste aman clu and Suipate ‘ssxonated eaipmont Fis gas og {Final gas coor Naphtelons senig aE ‘aphihalne rubber ark, pumps 6 Characteristics of coke oven gas after leaning in by-product plant [Nivogen [ Residual inparies Taga, gS Tae Hos ‘maa ‘Nahr Berzol nyo zarbane FFL PPA (© 2010 MECON Limited. A rights reserved 225EIA & EMP FOR THE PROPOSED sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ‘Air Pollution Gontro! Measures ‘As emissions from coke oven operations atthe proposed plant wil be controled by ‘smokeless charging techniques, such as High Pressure Liquor Ammonia (HPLA) system, Pushing Emssion Control (PEC), leak proof doors ete, as described below: 'b) Leak Proof Oven Doors and Hydro-ot door cleaners Doors wil be of leek proof oven doors wih flexbie sealing strips. The door design ‘wil provide flexle sealing stip and other moded features to ensure leak proof Sealing, The door wil ba of heat resistant cat iron provided witnspringoaced fetches and spring loaded sealing stips. Hydro-jet door cleaner system wil bo provided to reduce the poluton and Improved working environment. The system {nil'be_ completo wit high-pressure wator pump, tank, hose, nazzies ete. with pressure and volume contrat arrangement The hydro jet clearing system wll be {sed for door anc the dorfame leering ©) Charging Lids (Holes) Each Oven wil be provided with 3 numbers of charging holes. These will bo of ‘modied type to sut magnetic idling and provided with proper insulaton to Fecuce i op temperature. Sodium siicate marr wil be used for luting of the lids. ‘The charging hoe frames and bds wil be of heat resistant cast ron. 4) Screw Feeders with Hydroulically Pressed Sleeves as Part of Charging Cars {Goal charging car wil be designed for single spot operation of opening and ‘Scrow feed charging ovens. Feeding of coal ito ovens vill be carted out with Contl speed by serew feaders, During charging hydraulicaly pressed sleeves wil be helping fo eliminate leakage around charging holes. The charging cars wl be of modern single spot type wit hydraule dives to cater tothe needs. The charging Cars willbe proved with PLC and ai-condttoned operators cabin, ©) High Preseure Ammonia Liquor Aspiration (HPALA) System: ‘To contol charging emissions fom Coke Oven Battory, water sealed ascension pipe covers and righ pressure armenia iquor aspiration (HPALA) system wil be Provided. It wil consist of high presstre booster pumps for ammonia liquor, spay Pozzes and pipaines, The low pressure ammerical iquor wil be drawn fom the liquor mains and ijacted Into tNe gooseneck while charging. The charging gasos fvolved wl be sucked n othe gae caleatng mains, prevertieg emission of dust ‘and smoke into the aimosphere. HPLA system will be provided with pumps, HP nozzle, LP nozzles, goosenecks, pipes, valves and fitings, elects, instrumentation, Pumps wil be housed in a Separate room near the pusher car track. Required MCC and instruments wl also be provided. {) Water Sealed Ascension Pipe (AP) Covers “Toe gas oftake eystom wil comprise base castings, acconsion pipes (AP), wator {Sealed AP covers, gocsenecks, iolaton valves, gas colecing mains, necessary (© 2010 MECON Limited. All sights reserved 228sjsu MTPA STEEL PLANT ° » ” EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 a flushing kquor spraying and injection devices. Te system wil be complete with inlt and outet water pipe network, water sealed AP covers, etum trough, ete Proper sealing of gos wil be obtained wih the help of water in the covers. Leveler Muffs as Part of Coke Pusher Machines New modern single spot coke pusher machines with laveler mut and hydraulic vos will bo provided. Lovelor muff will Map to eliminate gas leakage during leveling operation. The pusher machines wil be provided with PLO and a ‘conitoned operator's catin. igh Pressure Water Jet Door and Frame Cleaners It's proposed to provide a water et door and treme cleaner on the oven machines [leon pusher cars and door extractor care. Thisvil ensue proper cleaning of door frames and doors which in um vl ensure less erno leakage from the doors, High Pressure Wator Jet Goose Neck Cleaners as Part of Charging Cars ‘The charging cars as proposed above wl be prvided with High Presaure water et (yerojet) gooseneck cleaners. This wil ensure proper flow of gas to. gos colectng mains. This wil contol the buling of pressure inthe ovens, which wil ‘gain prevent leakage trough doors. Oven Top Vacuum Cleaners as Part of Charghg Cars “Ths Is essential for proper upkeep of oven top. Ths system wil be provided in coal ‘charging cars. Spillage Chain Conveyor on Service Platforms ‘The spllage coke conveyer wil be provided fer removing the hot coke epilage likely fo fall during opening ofthe cake oven doors and pushing of oven pusher ‘ide service platform. The foal system wil consst of special chain conveyer ited with drag plates running inside a lined trough a the service platform. The chain ‘conveyor will scharge the material on be eomtayor which wil cary the same fo Stuctural "storage hopper Yor disposal be tucks. Proper water spraying arrangement before bet conveyor will be provied inthe system to take care of temperature of coke to be tansported onto belt conveyor. Pushing Emission Control (PEC) System Pushing emission contol system has been considered forthe coke oven plant ‘This system wil consist of a duct runing along te lene of Battory en coke side (away from the quencting car track), a traveling hood with one side connected t9 ‘dor extracting machine and other running on a 3d all supported onthe Weslo of the duet, spark arrester, bag filer house, fans and stack. (© 2010 MECON Limited. All rights reserved 227EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT 2.40.5 SINTER PLANT “The proposed sinter plant complex wil consist of one sinter machine of 700 né grate area along wih associated services feces. The plant capacty has bean sele:ted as 7.2 Mipa for charging about 70-75% sinter in BF burden ata ated produetivy of 13 th The proposed sinter plant wll be of state-of-the-art technology and will operate on blended mi. The basic design parameters envisaged areas given below. [am deseripiion [tae Value Sinir machine afea a. 7oOme Produciviy umem 13 Annual sinter requement (gross) tye] 7798000 “Annual sip str requirement ar T5000 ‘Size of finished sinter ne 0 ‘Annual working regime: days 330 No.of working Rours/y i 2. ‘Gaseous energy consumptan Tar gniion por tonne of Gzszous keat | 2000 ‘Gok breeze consunplon per tones ap aier Tat 7 Mang and nedilsing rum (fa x length mem | 46x04 ‘Under-grate suction of sinter machine Tam wo|— 1600 Sintr machine bed height (ching ATE rem ReaD |g 65) layor depth) Cooler typo, Cra Gooler bad height Tmt [400-1600 “Temperature of cooled Star deg. —|Below 100 “Exhavsler (no ard capaciy) Tx mah [2 x 14400 ‘Dust content in exhaust go ‘gins | "Below 50 Operating regime ‘Tho sinter pant wil be operating onthe basis of 3 shits day and 330 days in a year, taking into consideration the shutdowns requied for the planned maintenance end Unscheduled breakdowns as indcated below, Si Tem uration Th dayal yr No. “| Scheduled epare 7510 shutdowns 735 hours each yea) 2 [Untoreseen downine ard 15 maintenance [opis repairs 5 (0 days every wo eae] Total 36 (© 2010 MECON Limited. Allright reservedEIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT a Modern features ‘The folowing state-ofthe-att features are envisaged for the proposed sinter plant complex. 1 Use of blended mix + Electronic weighing and proportioning system * Combined mang and baling drum * Improved sealing system (spring loaded pale cas) and higher under-gate suction, + SG iron pallets wth high chrome (28-30%) cast ste! grate bars + Energy efficient gntonturace with top fred sit bumners + Deep bed dip ral circular sinter cooler + Eimintion of aintonance Inteneve hat sinter seen, + Process gas ag pant dedusing systems using dry ESPs + Process contol and automaton * Cooler wast heat utlization in ignition furace Quality of Raw Materias ‘The physical and chemical characterstes of various raw materials to be used in the proposed sinter plant are given below. ‘Gonstitvent, % | Wor oreTines | Limestone | Dolomite | Coke breeze (Ash) ‘Size, nm 08, O38 Os OS: Fei 3854 0. +0 35) Si02, eT 361 | 38 B28 ‘A2OS i8z 72 | 495 26:22 ‘Cad 5 248 | 8-06 1535 Mg0. = 48 | 1821 OrAZ Na20 + R20, 308, 305, = s 0.008 na. ha. o8. LOT [1530 ao-as—[“35-a7 a7 ‘Sintor quality “The expected quality of snteris projected below. Constant % FeZ03 W337 FeO. 5.00, SiOz 4.58 “AzOs 225, a0 331 ‘Mgo- 188 ©2010 MECON Limited, All rights reserved 2.29EIA & EMP FOR THE PROPOSED JSW | ®*PANSION FROM 10 9MTPATO 160 | MTPA STEEL PLANT Constituent %—— S. Boone 205 012 Mano. Dota Others 196. Basicty 18H Main plant facilities ‘The sinter plant complex wil consis of theflowing main technological uns Proportioning Unit Suitable capacity of storage and proportioning bins have been envisaged for the proposed sinter plant. The Blended mix, corective adctons and in-plant returns wil be ‘edo the common collecting conveyor by eletonic bet weigh feeders, whereas, lime ‘il be fed fo common collating bet conveyor by loss n weigh feeder and ESP dust from ESP dustin, ‘Combined Mixing and Nodulising Unit Material fom belt weigh feeders below respectve proportioning bins wil be transported to a combined ring and nodulzing drum by @ bel conveyor where the various caw ‘materials wil be moistened and mixed by 46m dia, X 21m length crum mixer installed in the bulls, ‘A fied quently of water of about 60% of requrement wil be added inthe mixing part fand the rest variable quantity. will be added in. the nodulsing pert depending on Fequiement. ‘The raw mix dscharged from mixing and. nodusing drum wil bo transported f sinter plant main building by abet conveyor. ‘Sintor Plant Main Building ‘The sinter plant main bulking will mainly consists of heath layer and raw mix feeding Un, gniton furnace, sinter mactine proper, ht sinter breaker etc Hearth Layer Storage Unit Sinter of size 15 to 25 mm as heath layer wil be brought fom sinter screen building to sinter mactine building and stored in a hearth layer bin located atthe feed end of he Sinter machine wih sutable feeding facty and fed on tothe string machine sand. Raw Material Feeding Unit, “The raw sinter mic wil be fe rom raw material hopper fo the sintaing machine strand through drum feoder and deflector plata T's loested at the feeding end ofthe sintering (© 2010 MECON Limite, All rights reserved 230EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ei machine after the heart ayer hopper. The eum ol feeder sutace wl be sultably ied ‘The raw material feeding unit wil be designed to change the feed rato instantly according tothe requirements ofthe sintering process \e. according tothe Increase ot ecroase in the speed of the sintering process. Sector! sub gatos wil be inetlitsiog the with at the dum feoder discharge for sutable adustnent of the bed. hoot Wiethwise. After the raw mic drum feeder, a cut off pate is nsaled to level and smoothen the top surface ofthe charge to Tacitate a batter and uniform ignitin ofthe top surface when the strand passes under gniionfumace. Ignition Furnace ‘The ignition furnace with post heat hood ane pre heating (before ignton furnace) wil be insted just after the sinter mix drum feeder. The lgiton furnace wi have suitably located energy efficient type gas fring burner designed for 2000 Keal/ Ne? of mixed ae (CO gas + BF gas), Gas mixing staton and gas boosting sition (f gas pressure is ot Sucient fr igntion burners) wil be located outsise sinter pant battery int Hat ir rom waste Reat recovery system of siter cooler wil also be uses for preheating of raw Material before igntan furnace and past hast hood ltr ign fumase. Sintoring machine proper Siterng machine having 700m effective sintering area with associated facies have been envisaged for rew sinter plant complex. Siner raw mix willbe fad uniformly onthe pallets over the hearh layer materia. The height of te mix wil be 650 mm max ‘ncluding 40-60 mm near layer height. Ignition Rood wil be provided for grivon of tho ‘mx o ensue ignitor temperature of 1200 to 300°C, Th wil be achieved by means ot mixed 92s (CV 2000 KcalNr) fod heat ecient burers. A post ignition hood wil iso be provided to avoid chilling of top layer of sinter bed. The recovered waste heat from ‘cooker wil be utizedorigniton, post Igtien and preheating of raw-ma Hot Sinter Brosker Hot sinter breaker of suitable size wll be provided atthe discharge end of sinter machine aiong with trolley mounted grizzly assemy. Hot sinter passing through hot sinter breaker wil be crushed to 150 mm size before feeding to sinter cost. ‘Sintor Cooling Unit CCcuiar sinter coole wil bo used to cool the sinter fo fess than 100°C after iis sscharged from hat sinter breaker at approximately 800°C upto -150 mm size, co that t ‘can be transported tough conventional conveyer system, Three numbers of forced ‘raught fans of adequate capacty for each size of c2oer wil be provided fo coo! the ‘itr sinter cooler” Screening Unit ‘The sinter after being cocied in the sinter cooler i transperted tothe sereering house. (© 2010 MECON Limited. Alright reserved 23EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT ee ‘The sie fraction +25 mm, 15-28 mmm, 6 15 mm and -8 mm wil be Separated out from {old sinter screens. Tha eae fraction of +3 mm to 13 mm, +25 mm and the excess ‘mount of +15 mm to -25 mm wil be dspatched to bast furnace and mm faction wil be transported back to proportioning bulcing tough belt con-eyers and fexo-vell conveyors, Emergency Sinter Storage Unit [An emergency storage has been envisaged to hald axcund 6,000 tonnes of product sinter, in order to meat any eventuality inser pan bas furnaces, Waste Gas Dedusting Unit Dry type electrostatic preciptators of suitable capacty at 160°C - 250°C wil be ‘envisaged for dedusting of waste gases before entering the main exhausters. The unt tl have high efficiency to ensure less than £0 maiNn of dust ir the outgoing gases from the stack, Main Exhaustor Unit Cleaned gas from ESP willbe exhaust by means of two exhausters, each of capacty 14,400 min at 160 deg C and 1600 mmiAC at fan et Plant Dedusting Unit ESPs wil be uted for plant dedusting and dedusted clean awit be let nto atmosphere ‘through stack of sutable height. In adaliton to above, sanice facies ike power, water, ‘compressed air, electrics, inerumentaton and aulomation, material handling ett: have bbeon envisaged for emoot functioning ofthe sinter plant, BLAST FURNACE “The blast furnace compex wil comprise of two blast furaces of 4019 m? Inner velume each along wih fs auxilaries, These are simiar to the edting BF# and BF #4 at ‘Wayanagar. ‘The bast fumaceis envisaged to operate with pelt, sinter, DR, coke, coal dust, faxes and adctives. ‘The hot metal produced wil be charged in BOFS. The liquid slag wil be granulated at ‘asthouse slag granulation unt. The BF top ges wil be cleaned in dust catcher and gas ‘Geening system, and detibuted to the stoves, runner ‘aeete Ty “Trunnion wih Cater “rough ina = 10m [Dnwe Hicraulc power Waal ve at Fiyaralc Equipmant wit ol pup and iting runeer main ough cover | va stan, pumping vt mmanpustor [Main rough evar menipdar asets, Cig seis [ype Fiore omar pe Cy baal Zor Prems on an 20 bar [Fores on aiming pion aust oting fees sot erg ange 10° arming speed S08 Lier persion Led te DSTO system Tapa ae Tipe = ae Stoke 500 (al persion eal sil pana Freauie Eup — Pug nk vn aR Soa —| Dalam [ss aes 4 Main trough cover manipuator Ths aging Typ Dive yer power Ca Capeciy at (© 2010 MECON Limited Al rights reserved 237EIA & EMP FOR THE PROPOSED jaw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT Cast house slag granulation ‘The various cast house granvation systems are the PWINBA, VALRASA, NSC- ALO. ‘The PWINBA has besn considered forthe Tepart with cold water system, detals of which are furished below [No.ofaystems— 2 (For Srcular east Rouge wih Tour ta> holes) —] Molen slag production 7000 ted Slag flow rate vg. 5 Un [Transient excess: 7 tin Design maximum “0 unin n Spay box Perforated plates wit Soramis ncaa ‘Granulation Tari ‘Overiow ype Materia Stes! pate Accessories hi, outotchanal, wearing Tnor, Band connected to stack, expansion aps. SeckDia 45m Height ‘0m Material Steel pats [Dewatering dram INBA ype. Sis. “To be finalized dung Stal engineering Drive Speed — - Drive unit of dewatering drum || Hyeraule motor “Transmission chain ‘hain wheats - Pillow bios. Tobreaton speci Lubrication of unit for dive chain [Support evuctue, chain over, heed fer do-watering drum Hot watertanke Steal plato ‘Cooling tower [Tree = Fydraulc equipment | | Comprising main pump a tank Greuon Bump and accessories. Paps. ‘Granulation pump ‘Cooling tower pup Booster pump. Drain pumps Valves and age, siping Bell conveyor inside dewatering Gran Capacity = aOR ~ B05 Uh wah OTT Bet 7200 mm Slop Length xem (© 2010 MECON Limited, AU rights reserved 238EIA & EMP FOR THE PROPOSED -— —_— Sw EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT a Coal dust injection system for blast furnace {Goal dust injection system with dense phase conveying of pulverized coal with nitrogen for fuidzing and inerisation and nivoganfa for injacon vith static datrbuors for Uniform distribution of pulverized coal acess tuyere is proposed fr incorporation in BE, Basic parametors of CDI systom + Daily hot metal production - 29041 approx. = Coslinjection rate @ 125 kati (Norma) and 160 kgithm (Max for Design) © Coal Ash ~ 10% (rmported coal) Moisture ~ 10 6 (Max) ‘Size of pulverized coal - 0.075 mm (80 % Min) (100% < tm) Moisture of pulverized coal <1 at aulp of grinding ml. ‘The system of pulverized coal injection can be divided mainly in the folowing three units |. Raw coal handing and storage secton(outsige battery iit) Ti. Coal drying and puverising section |i Coal injectonsetion For the bast furnace, the PCI system wil have two feed tanks, one distributor and one Injecton system. The pulverised coals fed trom the puver'sed coal bin tothe feed tare In batch mode, where eacn tank operated inthe following sequence ane repeated at the end of each cycle filing, pressursing, holding, inectng. and depressuring. Automatic contol offing, injecting and change-over vall bo ineoporsied imo fe system. After leaving the food tank, the coalitrogen murs Is mixed with transport Iitogen in the mixing tee, and the resulting midure 1s proportioned sullaby the stnbutr (sted near the lop ofthe furnace) before being Injected Into the nid tuyeres ‘The entre PCI system may be operated by a suitablyintegrated PLC aystem, resulting In ahighly automated system requiring minimum manual inputs. BF gas cleaning plant ‘The dust laden blast fumace gas afer dust catcher shal be clezned in the gas cleaning plant. The raw gas main wll connect scrubber to gravity cust catcher. The systom wit bbe completed with external demistor arranged In cian gas main immediatey. down stream of the scrubber vessel. Provision of atop gas recovery turbine (TRT) wl De made in the clean gas system down steam tom the mist sereratar The turbine wat Provide blast furnace top gas pressure control. When the TRI is cut of seve, the scrubber wl ke over the pressure contra function. (© 2019 MECON Limited, AU rights reserved 239EIA & EMP FOR THE PROPOSED yéw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT | Design data of the biast furnace gas cleaning plant 1) Medium to be handled Blast furnace gas 1), GV. of gas 908 Kea ii) Type ‘Two = stage leaning in preseubber and RS suber 1) No.of units One. ¥) Volume of BF gas ‘510,700 Nev (max) Pressure of th gas at inlet 25 koloma () ‘i Dust content ofthe inlet gasto GCP = 17.0 gmayNm’ (max) 8.0~ 10.0 gman’ (normal) vi)Moistue contentofinietgas te GCP: 7.5% by yolume: 1s) Outet pressure ofthe gas 22 kalem'a) 1) Dust content ofthe gas at ‘SmgiNer(max) the out 3) Outlet temp. of the gas 40-45°C (ev9) Pigcasting machine (PCM) ‘Two nos. of double strand pig casting machine of adequate capacty have been Cemisaged for production of pig iron. The PCM will consist of the following units / facies, = POM proper + Lime preparation unit Setting tank and pump house -Pouring end and discharge end sprocket Gentraised grease lubrication system 2 PCM contol oom and substation. Pig storage yard witn magnet cane, BF gas fares stack BF gas fae eystom is provided to contol the pressure of BF gas network by faring the texcese gas to atmosphere, The excess gas released through the bleeder willbe burt in the bumer located a the top ofthe stack The height of stack wil be 45 metres. ‘Teignta the AF gas atthe main burner tio ad to maintain the Name. @ system of pilot tbumere end ignton device wil be provided. The pt bumers wil be ignited by CO gas. Pilot bumers wil be ignited through automate ignition system from the local contol panel a8 weil as fom BF canto oom. Indcation with alas shal be provided at the main BF conta room fer the operating Condon of the fare system. Remote operation ofthe ignition system for plot burner Shull be provided from BF corral room. (© 2010 MECON Limited. All rights reserved 240EXPANSION FROM 10.0 MTPA TO 16.0 cA EIA & EMP FOR THE PROPOSED ~e) MTPA STEEL PLANT rei - seal) Operating parameters and location = Capacty £14,900 mm (a) Pressure in BF gas header 800 mm WE 2 Temperate 45500 2 cane value 1204 kcal? 2 Steck reign 45m ‘The fave stack wil bo located by the side of intorplant pipeline route near to the blast umace [BF gas holder of 100000 ms 2.10.7 STEEL MELTING AND CONTINUOUS CASTING SHOP. A state otsho-at steel meting faites to produce 6,187,000 Uyr of quid steeL The ‘Production of ste! has been envisaged though BOF — LF ~RH-TOP degasser route. In onder to achieve the quid steel production of 6,187,000 tyr, four (4) basic oxygen fumaces of 180 t nominal capacity each have been envisaged. Steel melting shop (GMS) wit un based on four auto four converter concept ‘There wil be four (4) 180 t ladle furnaces (LF) of 35 MVA transformer rating each and ‘wo (2) RH-TOP degasser unt of 180 t capacity for degassing of high grade stes! Products. However, te actual size of he converters il be alized before placement of ‘exder and afer discussion wit the technology supplier during the dealed engineering stage. ‘Steelmaking facies ‘Te steelmaking shop wil consttute the folowing malor plant fates. 2 x 180 t Het ‘etal desuphurisstion (HN) units 4 x 180 Basic oxygen furances (BOFS) 4x 180 {Ladle furnaces (LF) 2x 180 t RH-TOP degasser unt Bie! technclogcal parameters of major steeimaleng production units envisaged are givens flows, Hot metal desutphurization “Two (2) twin hot metal desulphursation stations of 180 { lade capacity have been ‘envisaged to bring down the sulphur content in hot metal received from blast fumases. Desuihurisation of hot metal wil be cared out in the hot meta! charging ladies of seelmeling. shop por to charging into BOFS. Hot metal from blast furnace 10 steelmeting shop wil bo received by torpedo ladles and will be readied at relading ps Hot metal wil be pretesied in desuphwsisaion statone before beng used for steelmaking, The desulphurcation facts wil be based on lance injection process Desulphurisaton facies are planned in hot metal reeeiptcum charging bay. Caloum carbide and magnesium based reagents Wl be used for desuihursaton of hot metal, (© 2010 MECON Limited. All rights reserved aadEIA & EMP FOR THE PROPOSED Jaw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT trogen vi be used a the cartier gas during injection. Hot metal desulphursation stations will have the folowing facies + Reogent storage faites * Reagent injecion system * Desiogaing faites * Decusting system “The techniocloporating parameters ofthe desulphurestion statlon are a8 given in the following table , ‘Technieal parameters ofthe desulphurisation station ‘Description Paramotors Type of deacbutenton | Cea cmc ae magneton based Tamountafhatmetlio betwee |g 9.900 for dosuphutsation —___ [Sp. consumgion of ara = Caleium Carbide Digitcf AM = Magnesium granules B75 kai of HN 12 consumion, max (per dato 3.12 Nena of HN [Nominal eapsciy of ot metal idle 60 Ladle type, Open tos “Type of desiphursaton sation i" Tocjecton ype: [Conveying and ijection medium Bry nitrogen 93s. “Typical incon rato T ecact | 49-504giin ‘eamant na izvemn Hott tonpaat, oC so Supt conn ht eta =Baloe eaten % a5 “Rie teens % (a ans Basic oxygen furnaces (BOFs) ‘The BOF shoo is envisaged to produce 6,167,000 tof auld stel per annum for which four (4) Nos. of 180 t capacity each converters will be installed. The shape of the Converter wil be symmetrical top with fxed converter bottom. Facies for inert gas jpurging fom converter btfom have been envisaged. Medium fr inert gas blowing wil be argon’ nivogen depending upon the grade of stel, Top conical portion of converter ‘vessel wil be of water-cooled (© 2010 MECON Limite. All rights reserved 22EIA & EMP FOR THE PROPOSED jaw EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT ‘The shop willbe provid with folowing major design features, -Aldconverte operation practice Combined blowing fies in converters Nitrogen slag splashing facity “Toprelring facies in converter Converter top cone cooing systom : Faces for minimising sig caryover Into steel adie during tapping Emergency lance iting facies n cae of power faire Hot metal temperature measurement in charging lade Slag sensing device in steel lle , ‘Automatic and dynamic process control model based on BOF gas analysis Secondary emission contol aces. Technological parameters of BOF ‘The major technological parameters of basic oxygen furnaces are given in the table below Si tem Gi ‘Guanity No. _ 1. [Liga stot production Ty | 6 ier a0 2—| Wo. of converter netted Nos 4 ‘3 [No.of converters in operation Nos. 4 ou 04 operation 4 Nomina! hest weight t 160 5 | Working volume of converer, (wi new | aS "180 fining) “6 | Tap to-ap ime, average ct wy, Z| Oxygen blowing rate, NmBlmnin = Average =| = 300 785 Maximum 7 | Specie consurapion of oxygen far Bowing | NAT & ‘9 Converter ining life, approx Heats 2,000) 40_| Converter ening tine. —p 768 (7 aay) 71. | No.of heats /day/ conver, ae os. 268 12 Avalabity of esch OF. @ 330 13. No.of days BOF shop operating at 360 Lae furnace (LF) Four (4) nos. of lacie furnaces of 180 t capacity each have been envisaged for refning of 6,187,000 Uy of gud seo. Ladle funace is widely Used as secondary refining unt for carrying out heating, deoxidtion, desuphursaton, alloying and homogenisaion of temperature and chemical compostion of steel tapped ino ladle rom steelmaking vessels (© 2010 MECON Limited. All rights reserved 2437 —_ EIA & EMP FOR THE PROPOSED: | EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT | we The ladle furnace wil help to produze various ste! grade, improve producti, steal ually and operating indices ofthe meting uni In addiion, the ladle fumace Wal be Used 28 a holding fursace when casters are nat ready fo recelve heat or during ‘emergency situations, ‘Tecinclogical parameters of the ladle furnace are given balow. ‘Technological parameters of ladle furnace fx Parameter Tait] Valle Feature No. Liguidsteaito be weated —| tyr 87 000, | Heats to be teated por day) — No 75 | as) 3 [Ladle capaci z a = [Treatment ime — ri B00 | Type of ladle fumaea ~ — | Sing Staion wih water-zooled oof 6. [Transformer capacty TVA ed 7 Heating rate “Cini 34 [Method of charging Machenised | | easiives _ | Metnes of argon purging. =| Porous plug th ase Bator [Main functions of ladle] —- |= Aloying fumace | + Heating | Homegecisstion of chemical Composition and temperature |- Desulphursaton Holding of baud steel in case of | emergency Tr ‘olecion and] —~ | Bag titers wih TO Yan, chimney, te RH-TOP degasser In vow of the envisaged product mix. two RH-TOP degassing units of 180+ capacity tach have been considered. The degassing system fs used extensively for removal of gases such es hycrogen, orygen, et. I also helps assist In producton of low carbon ‘ioe grades. Oxygen and fuel gas mix aro used to provide heating of vessel eracones, {at Fgh temperature. The main technological parameters of the R-TOP vacuum degassing unt are given below. (© 2040 MECON Limited. All rights reserved 2aEIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ‘Major technological parameters of RH-TOP degassing unit ‘SEN Tam Thi ‘Value feature ‘| Type of dagaseer unt Fbied Beaten stator vassal 2 | Heat weight et 80 3. Cireulaton speed nin 100 “| Hydrogen level in sleet betore treatment bem 510 = ater treatment _| ben <15 [Minimum vacuum level] torr O4 achiovable [No.of working davai a 300. 7 Treatrent time min, 20.25 ‘8 | Heats tobe treated a Nos. 2A (max) ‘9 [Preheaing temperature —af| "c 7350-1 400 degassing vessel Continuous Casting Shop ‘A casting shop has been envisaged for JSW Stee! Lid in Vjayanagar, Kamatake, The Casting shop is designed to produce about 6,187,000 tyt af iqud steel and east the ‘same it 6 032 300 Vr of bles, blanks and blooms. Continuous Casting Facile - Blank Caster, Bilet Caster and Bloom Caster In order to produce wire rods, special bars, medium sections and heavy sections fike ‘beams, channels and anges, bile, Bank and bloom casters ae the present exces. The technoiogy of continuous casing of stel into bilet/blanks hae beon fly mastered today for any grade of steal. The continuous casting process has gained words acceptance, mainly because of high yell, good product qually and good eccnemies of ‘operation. In order to cast 6,187,000 Vr gud steel nto ong products, blank ile and boom casters wil be Instaled in the steel meling shop along with necessary auxiliary and service facies. ‘Two nos. Three Strand Blank Caster for heavy sectons, Two nos. Six Strand Bloom aster for medium sections, One no. Si Svand Bilet Caster for wire rods and One na, ‘Ste Strand Billet Caster for special bars wil be insaled the stee! meting shop along with necessary usiiary and sence facies. Technological parameters of continuous casters “The main technological parameters of continuous casters are fused below. (© 2010 MECON Limited. All rights reserved 245x EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT » [en a] rae Parameter | —Paramster | Parameter = | i [Bian Caner Bie Cast | Bet Castor] 2 haat Ras "1005400 |" 804.900 Proaicton |_| - 3] aus soe tobe | “Oy | 2500 Zie5a00 | Tatas | — esa | {east , TN Simathice | Na | 2x Satend | 2 e-aend —| Txsatand | xeon 5 Type of machine Facial win curve] Radial wth cave | Radial win | Radal wih raul aula curvemgud | eure mods | Basgnrange mmx | WO0x 520x100] TEOX 180 5a ~33E | 100% 100 sa, | 10x 130 a | mmx | 10x 520% 100, x00 400% 16089 | 16031609 ra {ren —|"Ganaraar 000 | einorapeorzano” | sono, pono | 6060 000. | Type of bending ‘Mul pomt ‘Contnucus | Continuous | Contowous Unventing! | etaigttenng | etaightening | staigtenng Contos L seagoing 7 _ 3 Banding ries — | “a 20. a 30 = 70°] Nominal neat] —t 70 10 180 00 TT [Hest —ebvey | mi =O @ a TE | Besa caning | am | 02-20 T5-60 Oe=60 | 08-88 spat - | Casing tine [min [ao @ 50-60 —| 60-66 “A Casing proctbe | - | Saquonce caving | Seausnce casing | Sequence |~Sequenes casting ‘easing 5 Prepare tna a ae 25-30 25-30 E-[ Ne of Rete day | Nos. 28 28-27 2 226 TE Coser avabi | aye = 30 a0 co) e[ Mould ype 7 | Carved, pte —| Cures mail| Curved Curved movi adnate | caridgstype’ | maul, mou, ‘wa deagn | saridgetyee | carga desg | ypedesgn 7E | taale toting | =| Tare “Tomat way | “Ture win | Turret wth ores Mower Rowers | mowers | ter weighing acts | ‘waiting wanting | ‘woihing ‘ach fecitas_| tac 7 Tonsah foie | >| Tara carts” | Turon ear wii | Tunas car | Tunssh car dotce TWiower& TMiowor 8 | win tower & | wih ower weighing fecties | weihng weohng | “8 weghng ‘ocites fecties_| “tection i, [casing pseico Ties ‘Cosed |" Ghose Closed 22 [Mud ect Fiiaucteacto | Fyauictescio | Wyeraulctee | Fyaulet mechani ‘mectoncal ‘mechanical | remechancal | ero esranat [Mand ever Tana aire | ~ Automate [Automate (© 2010 MECON Limited. All rights reserved 2.48ir EIA & EMP FOR THE PROPOSED. Jaw EXPANSION FROM 10.0 MTPA TO 16.0 — MTPA STEEL PLANT _| = Stanton] ta Parametar | Paramntir No. - antler a | Sirend cooing — |=) Byram aims | Drama, armist | yma a) Oyama a rey ap ie ope | Taroko Het Het Het 26 | Product cating Rate ay ~~ Auimatis oye “aomate epenetech | propane rch oxerane tin sng rch extn | Pramict =| Tivouan reat | Thzough vou) Though na | Though rane ‘Secnarge rofing abe cross | rtingtana, cose | "out rling | “outing tneter ‘ere table, ceoss | Sie cogs | ee ae sraferee | vendor ste BOF Gas Cleaning Plant Ie ls proposed to install 4 Nos. of 180% nominal capaci LO converters along with ‘suppressed conbuston ges clearing plan (GCP) for each ofthe converter of the BOF hop. The functon of BOF GCP isto collect, coo, lean, discharge and ether recover or flare the gas, released at convertor mouth during sto! making. Gas cleaning plant for {ch converte nil have the folowing systems + Gas collecton system comprising skit, hood and cooling stack as its main equipment = Gas cooing system comprising crculaing water pumps, expansion vessel, fefan ‘ole, ass main equipment alongwith izer connecting piping network. = Gas cleaning system comprising of satrator, venturi scrubber unt 1 and 2 and water Aropet separator fr each stage ater vertu 1 and 2 (thee are self contained in we Stage scrubbing tower), recyeing fark recireulation pump. emergency water supply system and ntereonacing piping, = Gas discharge system (for gas recovery and as wel as for go faring system) ‘compfsing, LD fan, change-over valve, fare system ee its man equipment slong ‘wih ntoreernesing dusting ana pling new Gas recovery system commen for gas cleaning pants wit have the following systens/ ecuipment. Dry seal gas helder of adequate capacity (approx. 40,000 mh) to store the BOF gas recovered from sech ofthe converter as and when avaiable, atthe eame tre ensuing _valabity of suiticient volume of gas for the required detvery tothe consumes. Electrostatic preiitators (ESP) to futher clean the gas to meet the maximum emissiie dust content of the ges. as requred by the consumers along. wth Interconnecting ducting and piping network Booster-fans to increase the discharge pressure of gas to mest the minimum required ‘Pressure by the consumer(s/gas network along with inter connecting ducting and piping (© 2010 MECON Limited. Al rights reserved 241___MTPASTEEL PLANT EIA & EMP FOR THE PROPOSED sSu |» EXPANSION FROM 10.0 MTPA TO 16.0 network 2408 ROLLING MILLS Based onthe product-nx, two universal beam mils, two medium section mil, two wie ‘od mills and one Special Bar Quay mil of suitable capacty has been proposed forthe Drojoct Tho continuous cast baam blanks, bilets and blooms wil be rolled Ito heavy Soclons Ike H-beams and channels in universal beam mil, mecum sections Ike angles, channels, beams in medium section mil, wie rods in wire rod mal and special bar in 'SBQ mil. The Mis shall produce about 1,000,000 yr wire rods, 800,000 tyr special bars, 2,100,000 uyr medium sections & 2,100,000 Ur of heany sections, Universal Beam Mil 24 Mpa Mediu Section Mi 21 Mpa Wire rod Mt 1.0Mtpa Special Qualty Yar at os Mpa Wire Rod mit ‘A continuous wir rod mils proposed to be installed to produce 1,000,000 tons pe year of ods. The input material wil be bits. “The wire rod mil wit produce 1,000,000 tons per year of wire rods in cols Inthe ize range of §5 mm to 22 mm ameter. The reference size of Input bits forthe wire rod till be 109 me x 100 mm = 160 mm x 160 mm x 12 m long, Bilt for roling wil be inspected and condoned before charging to the biletreheating ‘umacs of wie rad il. Bile inspection and contioning fectves wil incude bile ing device, searing torches, auto bet grinding machine, et. Bilets wil be charged tothe ‘umace by bilet charging ekid and bilt charging conveyer. A bet discord eka will be provided fr rjec iets. Bilt reheating furnace wil reheat the incoming bles to an tit tomperatire of 1 160°C to 1250"C. Fumace dlecharge mechanism wil elscharge the billets fom furmace for rating though the mil ‘A teggl shear wil be provided on the enty side of roughing stand No.1 for emergency tating of cobbles, et. The bits wil be rlled through a continuous roughing mil Wai Comprising of soven 2-Hi stands flloned by an intermediate mil train combpraing of tight 241 stands. A crop and cobble shear wil be installed after each rling tain for t70p and eabble cutting. Following the intermediate tra, @ No-vist frishing block wi ten roling stands wil be provided to rish rol the eds te the required sizes. “The fished wir rods wil passthrough a watorzoaling section and wil thoreafir enter a lying head which wil form col loaps ofthe wire rod (© 2010 MECON Limited. Al rights reserved 2.48[ EIA & EMP FOR THE PROPOSED | ] sw EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT A | ‘The wire rod loops wil be air cooled ina Stotmor convayot. col reform tub wil futher {orm the wire red cols and the fished calle wil be delivered al unloading stations {through a hook conveyor comprising of compacting, stepping and woighingfactince For reginding of mil rls, ther ros and shear knives and for disassembly, clearing, inspecton and assembly of bearings and chock, a fll and bearing shop fs envisaged {he wire rod mi. This shop wil alsa serve the equements ofthe rebar Fil ‘Auntor faites ike direct & indect water closed circuits with trostment fecities and ‘nalng towers are envisaged. Compassed al, hydraulic end lurieston facies serve ‘varus mi equprmentin ther operaton, Wie Rods are stored in closed area stacks and in open areas as per importance of frisned procuet quaites. A maximum of 7 days storage's only planned, Finished products are dispatched through rail and road ways. Lot of care ts being Planned for preventing handling damages Ike floors, Talon liners fo prevent metal contacts, nylon lashings et, ‘The basle data ofthe mil are a8 folows [Annual eapsety p00, 900 99° rade to be produced |= Carbon steels and iow alloy stews Input materia: Type Cencaat bit Ses 100 mm x 100 me — 180 am x TOA, a | | square length uo 12m Finished orodut— T= LIT Rosato Sen Ss nmto 2mm ae in st=gh eras wo Sem (eauvatrt tat saute heagore and oiogone ae a edt as Na Sey ST TT feet er Seogh | Ha Special Quality Bar Mi ‘A Special Quality Bar (SAB) mil is proposed tobe installed to produce 800.000 tons por year of special bas. The input material wil be ifets. The 0.8 Mipa mil wil may Produce a wide vary of higher-quality carbon and alloy bers that are used in the forging, machining and colddrawing indusrie forthe proaicion of automate pati, hand tools, electric motor shafts and valves. SBQ generally contains more alloys thn merchant quality and commodiy grades of soe bars, ands reduced wth mare preese dimensions and chemist. (© 2010 MECON Limited. All rights reserved 249EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 oe MTPA STEEL PLANT Input Reference bilet size: 130 mmx 130mm 480 mmx 180 mm = Bilt length About 12m Bilt weight ‘About 1800 kg Output Spocial Quality Bars 980-250 To maintain tigher productivity even in cases of smaller rounds st achnology comtined with high speed bar delivery to cooling bed Is used. For bigger secions brake sider are Used for tansfering cut length bars on to walking type rake cooling beds 180 Uhr walking beam typo. wih, moved gas fring is planned for heatng bile to roling Temperatures uslo 1160 °C. Hot charg is also placed to save teat energy by good production panning between steel making and rong. Billets are transported tough Fole tabis fom casters to mil reheating faces ‘The mil woking level is planned at elevated | floor love (+5.0 mY). Hot blots fom furnace past through high pressure water descalr on roller talies for entering ito Teughing group of stands. 6 stand roughing and 6 sland intermediate group and 6 pre- finishing statds are planed with shears In between for oling billet ino ral product 2s pase design Arrangement is single stand rling normaly with Horzortal Vertical stana Srrangemeni For cartsin products where requied with help of convertible stands 3 Vertical using Is Used as a horizontal housing as por pass rong schedule. Shears do ‘ropeutingsand chopping of sock incase of problems. For smaller siz upto 922 mm bars sit in @ power siter and further reduction as done in tao separte lines in 6 stand no tourist block mil. Bigger sizes which are fished rolled by peefrishing group passthrough a cena line of enarnels, water boxes, ole fables and dvcing shears be fore shifing onto sake type cooing beds. Smaller sizes foled afer sting sien pase theaugh water boxes. rane tables and ving, shear before deectd fo rteing channels where these ar siowed down by pinch rol ives. Slowed dows bere are guided onto same coclng bed for cooling. Lue to controlled use of water in water boxes the product outer is formed martensite layer with central perite stucure. Ths method helps in actleving good properties from ordinary stee! saving in ‘aly adstors in steal making. ‘Bars from czoling bod while cooling re transerrd to cold shear ‘or cuting to market ‘order lengths. Cut pieces are transfered to two bundling areas for sorting, segregating Shon pisces, courting and bundling as er order plan. Tring machines provide tes with labeing detals to bundles for futher handing. EOT cranes colect ready bundles to ‘assigned staxks of {0 dispatch vehices. Duing inprocess sampes are checkod for ‘weight or moter, nich profile on bars, mechanical properties et, (© 2010 MECON Limite. Al rights reserved 250EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT | Medium Section Mill This 21 Mtpa mill will produce medium sections lke angles, channels and beams required in stuctural works. [ieee 1 4 Beam TSO LTS aa -395x 900% | ITT SOO] '5000/8000/12000 utp | ‘Nadim Secon 2.700706 (ay | Beane: 120-500 +100 300 } 100-220 (| Arges 100 x 100 ~ 250 «250 +120 180~ 200 x 100 (@)| Chamate 140-400 Diferent input materals are used as per end product size and its pass design 160 th walkng beam fuer with mixed gas fring is planned ‘or heating of input ‘materials up 1250°O. Input material travel through role tables fom bloom caster to reheat fumace Heated bloom pass through high pressure descaler to breakdown stand. This is 2 high eawy duty trque stand. Stock i olen revering made for 810 7 passes to get rough finishing shaoe. Gap adjustment is done by AGC system as per pass schedule programmed n automation Masel form breakdown mil ater cropping at hot sheer is fed to universal reversible tandem mill On each end universe stanés with edger stand sandwthed between are 3 stands to rol the semi shaped product to final product. Roling is dane in to & fom reversible forn a8 per pass echesule each tme closing the ral gap a per predicied Plan, Final 3 passes are done from universal rougher, edger through universal fisher. Reling is done wih XH form in each pass schedule. Roling Is done as per production planning requrement. Roll changes, pass changes and ‘stand changes and eafbide changes are dono 9s per pass if of groves. Used rls and Carbide rings are redressed for feeh ute in rol turning shop, De’ & Indirect water is Used in the nil with treatment feces, cooling towers and pump rouses just outside mil. Hydrauit& lubrcaton fies are planned for various equipment movements and bearing lubrcstions. Fished products are stored pat in covered area and partyin open area Dispatches are planned by both rll nd road, (© 2010 MECON Limited. All rights reserved 2681| EIA & EMP FOR THE PROPOSED aw EXPANSION FROM 10.0 MTPA TO 16. MTPA STEEL PLANT Universal Beam mill ‘Thi 2.1 Mpa mil wil produce Heavy Sectors Ike channels and beams required in sutra works Tipu ——_ | 1 Blank 400x320 700 2.117,300 1810 x 320 x 100 x €000/8000/12000 ‘Output "1. | Heayy Seaions , 2,700,000 (@| Beams 350-750 200-1000 _|crame's | 200-400 _| ‘The Universal Beam Mil wil be @ modem mil with the state ofthe art facies for ‘rodueton of beams and channels, Tha input material for the mil wil be continuous cast beam blanks. The mil shall be designed fo achieve higher yields, superior surface fish, close tolerances. The Beam Blanks coming fom the storage yard ae charged onto the ‘cold charging table by means of crane for cold charge orcrealy from the COM run-out Follertable and chargea drecty to the Furnace In case of hot charge. The startng Materia! aro loaded into re-neaing funace, heated up to the. required fling Aemperature, decharged one a atime and Wransierred tothe rong mil. Before entering the roughing mil, ve staring materials ae deseales by means of high prossure (250 bor max) water descaler. Products are continuously ofed in (15) igen stands in H, V and U configuration. The roling mil is completely arranged over SHS. Howsingless Cattidge stands, five In the rougher and ten In the Intermediateinishing. mil. The roughing mil fs composed of (5) five stands atenged in H-V-H-H+V, where tne vertical ‘lands have the funcion of edging and shaping the rolled stock eides so that several beams sizes can be rolled with the same roughing fll ee. A roller table i installed between the roughing stands and intemmesiatafeising stands foreseen to fee the bar for high speed roughing. At sermedite/nishing mil entry side a Crop shear for head ‘cropping and emergency is proved. The oll pass Sequence Is based on a symmetrical Shape throughout the mil and provides stable rollag condtions, "Tho. frst Informediatefirishing stand is 2-high horizontal and has the function of controling the ‘songation ratio between roled-stock web and fang, thus seting the fal besmangs: height Inthe Itormecitefinishing stands the Horizontal stands have a function fo contol the web and flange, with very sti tolerances on the dimensional shape ofthe ‘nished beam. A roll table with Ring aprons conveys brakes and alscharges the rmutiple bar lengths onto the mechanically driven cooing bed. This I ao fied with Tining-up grooved rolls and a hot saw for head eropping and sampling. To achieve the target temperature for straightening, the necessay time of cooling is dusted fm the automate systom roling schedule table, (On the ext side ofthe cooing bed an exit caring transfer I provided for smooth take off of the sectons from the cooing bed. After the cooing bed, the bars are automatically {ed into the staightening machine for simultaneaus inne of one or two profes. The (© 2010 MECON Limited. All rights reserved 282EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT straightening machine performs the “Full Length in Line” straightening of the multiple length bars. fer straightening, the bars are grouped in reguiar layers ai transfered to te cold cutingto-ength area. The provided cold saw withthe associated overhoad beam type gauges provides max. exblty in cuting pattems ws wel os hghost ‘roouctvtes. Here the ar layers ere cut atthe same time which also performs Head ‘nd tail cuting. The saws are equipped with automatic Camping devices ensuing a bration ree saw cutting procedure, Special care has boon taken to sold ary oetoct on the fishing sections. Saws are equipped wih 9 special fast changing mandiis for {Quick changing tines. This is important. sinc usualy the saw blades must be changed ‘uring the operation of the mil. To aved remaining water nthe top chamber a he beamslsections an air spray systom is provided afer the cuting presecure, Ata the ‘uting, bar layers are aviomatcaly conveyed to the two independent inpecton beds, where the bars are tited and inspected and after checking transferod fo the to ‘magnetic stacers. The stacking stabons consist of one + one independent steckng systems of 24m. Layer of bars are automaticaly separated in the chain transfer sack according to the required numberof pieces and conveyed to the magnetic heads waere they are automaticaly stacked. Afr pling the stacke wil be trantered fougy the lscharging area, which consists of two Sund Tying Machine designed fo compan and strong bindings. Prior to the last strapping procecure the packs are welghed and the weight is printed on a label that i tagged fo te strap and then fnally Sallcse and Stored ina callectng bed. The frished products are then loaded into the vale / alway ‘wagon by EOT cranes and cspatehed rom the Yar, 2.40.9 LIME AND DOLOMITE PLANT The lime and dolamite plant wil comprice of 6 nos, vertical ime shaft kin and 2 no. Vetical dolomite shaft kin of capacity 300 tp. each to meet the requirement of sof lime ‘and calcined dolonte for steelmaking process. ‘Theme and dolorite pla wil have the following production capacity as given below. [Sto [itenr Quantity xe) _] 4, | Sie ine for SMS 353,000 | (Galcned dolomite for SUS "12,000. Technological paremeters Lime and dolomite callnation unt Nos offime kin 6 1) Capac atime kn -300 tpt each Ii) Notof dott -2 iv) Capacy of oiomite kin -900 pd each ¥)— Kinfeod size, mm -25-55, W) —Calcinatontemp, “C-050-1160 Wi) Specie consumption of uel -820 (kcallkg of burt ime and dolomite) (© 2010 MECON Limited. Al rights reserved 253EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT | il) Working schedule of th plant 290 dayaiyr (Sehitsdoy) ‘Operating condition Limestone / aw dolomite of ize 25-SSmm wil be charged into shat in for ealchation, ‘The undersze limestone! dolomite of size O-25mm shall be separated out by the screen before feeding tothe fle Limestone snd dolomite wil be subjected for calcination at 8 temperature $50-1180°C to achieve éoft bumt reactive ime / dolore for steelmaking Mec gas will be used as fue. Limestone and dolomite of size 25.55mm wil be rocsived from mines and storedin raw material storage yard. From there these materials wil be conveyed fo raw rateil storage bunker. The Imestone and raw dolomite from storage bunkers wil be fod tothe ‘scroon by bolt conveyor and undesize me stone and dolomite of ze O-25mm wil be Serooned out and siored In anather bunker which i meant to store the uncersize rmateral There willbe 1 no, storage bunker for each kn and tno, undersize bunker foreach kh The undersie Ummestone and raw dolomite wil be stored for onward spose to othar consuring units. Screened materials of size 25-55mm wil be fad to shaft kins by means of skip hoist through a weigh hopper. Limestone and raw dolomite wil be calcined at temperature of 950-1150°C. ‘The line and calcined dolomte from the kins will be discharged to two diferent convejors which are placed below te kins. The ime ang calcined colomita wil then be fea Yo single dock screen to separate out undereze (026mm) material The Undrsize (025m) Ime and dolomite material wil be stored in two separate bunkers. The sized Time ard calcined dolomite of 25-S5mm willbe stored in ine nos of burkers (sires. of bunks’ for lime and tee nos. of bunkers for aleined dolomite). Lime and acid dolomite of size 25-55im wil be conveyed to SMS trough belt conveyor and undersize lime (0-25 rim) will be wansported through Wucksleement tanker to other Consuming uns. ‘The waste gas which s coming out trom the kn is having 5-10 gnvNm’ dust. This gas willbe loaned in waste gas cleaning system to vert out the clean ges to atmoschere, ‘The dst iad at claan gas willbe as per noms of county ‘The dedusting system wil be proved for raw material storage bung, serven tous bul and ime covery bin bung to keep dust free atmosphere in the ie Kin area, ‘To, passenger-cumfraght i has been proved for ease of movemert to diferent floors. 2.10.40 OXYGEN PLANT ‘Oxygen wal be required for oxygen enrichment in the blast furnace, injection inthe DR Plant, blowing in the BOF, heating of BOF ling, secondary refining in RH-TOP, cating (© 2010 MECON Limited. All rights reserved 254EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT Oe of bianks, beams and bilets In continuous casting plant, and fr general purpose use in ‘arous units ofthe steel pant. The average demand of the oxygen is estimated fo be ‘out 2.12 MN Vd. Nitrogen will be mainly required 2 carrie gain de-sulphursation Lait, DR plant, slag splashing in BOF, strting in BOF, cokd cust injacion system, bell less top equipment for blast furnace, purging In GCP of BOF and sso for occasional purging of fuel gas pipalines and equipment Argon will bo recived for shrousing inthe {undish and mould in the continuous casting plant, tiring in BOF and ladle. Argon wil ‘so be requred fo laboratory purpose. In order to meet the above requirement of exygen, nipgen and argon, 2 (two) air ‘Separation unit af 1800 Ud capaci each wil be installed Based on BOO concept Argon requirement wil be met from argon produced frm the oxygen plantas envisaged for he proposed project. Requirement of Various Gases SI.No. [Product [Puri] | Gaseous sagen] 99.6 2 [ Gaseous nitrogen | 00.005, 3—_[avgon 20,005. Cxjg2n, nitrogen and argon will be produced by sir separation process based on low pressure cryogenic cyce and double column rectfcaion syster. Tho unt wil be able to Produce gaseous es well 2 quid products Gaseous products from the oxygen plant wil be astibutes trough pipeline network ‘system conelting of prosaue rogulathg ond metering ston to varcus consumers, 2:10.11 POWER & BLOWING STATION 4. Power and biowing station = S.os of BFICOlconvetar gas fred boilers. “a ns of Steam tisbine driven turbo Blowers 2. 2unts of Top pressure recovery turbine 13 unitof Coke Bry Quenching Plant (CDAP) Power and blowing station Based on the above, following facies have been envisaged for power and bowing Station, + Mbced gas fed boilers and ausaies 3 x 300 th + Steam turbine ven tbo Blowers - 8x 100% (4W+ 188) 12010 MECON Limited. All ights reserved 295EIA & EMP FOR THE PROPOSED i [J EXPANSION FROM 10.0 MTPA TO 16.0 | a MTPA STEEL PLANT é | Deserator-2 Nos. + Bole feed pumps 9 Nos (2W +188) Requirement of input materials and services. Requirement of input materials and services forthe power and blowing sation are given below. > ‘Requirement of input materials and services Taput Materials Services Tait] — Quant Mixed gas {BF gas 2 CO gas 3. BOF gaa eal | 831.43 105 DM water as make up for BF gas fred boiers | -mah | 216 wa] 34700 ZL (caring iar up and fare alabisaton) | aa) ‘Steam balance he steam belance of te turbo blower station is given below. A Steam Generation SL No. | Description — TTHP steam, 0h “L_[ Evaporated cooing fr Converter 60 2. Evaporated cooling fr steeoling reheating Tunace 130) 3 | Sos. mixed 98 fred overs (P € 85) 735, 4 eoae 210 "TOTAL Steam Generation (max) 530 (ma ‘Consumption ‘Sieam turbine ven tab Blower sat ra Process steam forsee plant 2001 ‘Apiary steam Te nas ‘TOTAL Steam Consumption "1130 0h ‘Top pressure recovery turbine “Top pressure recovery turbine (TRT) recovers pressure energy from outlet gases of blast furace which was clhervise lost by the gas cleaning plant and converts into clectoiy. Blast fumace gas after wet type gas clearing plant and upsteam of BF outlet {988 man stop vale Is fed trough inlet main stop valve (Goggle valve), quick shutoff ‘atve and gover valve toa turbo expander to work to dive 8 generator for generating lect for feeding to power net. The expanded gas is discharged into main BF gas StS sel se = tet te a w= | ; {ae ee (© 2010 MECON Limite. All rights reserved 2.67EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 | MTPA STEEL PLANT [St [Units —]Specitie | Power Power Power No. | CConsumpti | requirement | requirement | requirement at fon units) atiOmpa |“ 46mipa Prods’) MW Produc | 7 tion tion way widay | Oayaen Pant | cD 78 SPOCL 182 Baper Pant | 7 7 7 —| er | —, Sager Pat # ¥ % Boor | , Oger Pani [F New Pit ‘xsl = z = = [tr 3s TOTAL | ORF aE Tr] (© 2010 MECONLimmted. All rights reserved 268Sw EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ‘Table 2-5 : WATER CONSUMPTION AT DIFFERENT STAGES OF STEEL PLANT EXPANSION - an oe som z =| a a = = pepe wo PR Be rs sr a |--fa a — son Bs — oma wee arf ef as ee a ater sitet — [8 bt a a =| Sete aor — Pee ee pei 6b af oe St eae — ee ear aaa = ates fer tr wrt ar scarp ee tt monte ss [ut a treme [ tr tor fa| a eter tas he eb ar ara oer tba oes a ‘er [a SEs eee eee = = terete ‘ear — fa |b ae ‘artes ar Bae Pet to oar ‘3 Se ter oes oe ScccmsPots[ Ee | 1 Sea oe v= roy va] — er rts ese 5a} — He oe = = sa er} — er pee tae afer a He PS apes | oe fort er tro 0 MON A tard 28EIA & EMP FOR THE PROPOSED Sw EXPANSION FROM 10.0 MTPA TO 16.0 MTPA STEEL PLANT ‘i ‘Spclie | —— wr we War —[ ear to, kz | roruonete | rasemeret | wane | Hane [Product | Wat" Prea] Wale | Pde fon | mas) | don | ¢mat) | ton | (mata) sey sap say | Gagen Pane spook [oe [ewe | aeto_[aeou [250 “Sond [aa ‘rysen nt GoC | 1 ~[Twoo | Teo] S600 | ae00 | ~Pa00— 1300 a [Oar isis 00 Teo 000 | —o00 5 [Dirk Wir sr 70 00 | 0000 Sips Voges [Rava ure 7 oc RE | aT [esses Bepartan 1a ez TOBE | HEE semen ° ° ib Siese) Teal ay | re aan amare GD | 74.8670 (©2010 MECON Limited. Al rights reserved 270EIA & EMP FOR THE PROPOSED Jjsw EXPANSION FROM 10.0 MTPA TO 16.0 Ll MTPA STEEL PLANT Table 26 Hourly ful aa balance =] sem | [Sees ae 22/2 orton | on’ | ty ~ os Sastre | Hamel | SET | BO] Fa arp ete Taare | BaTeaT [as | BT] TS o[eaa to Tala sao TE BT Fess TP eeseeret | era age | parma re [arpa er ea = aa cl Bcc Medea 3 [Basar | eer TaYrea|—ar aaaTpe Paaaro 7] Raat | Pa ew | roar [ons | af waar fa eae] | siegretra | aaa | “aaa oe] waa a | os | z a a aaa ar re pa] $ Bem —[ sey | tee | ato ee ooo co O[Biwtaeen | Woes a0 [ries | tome] tou] fr af S| ae | Rea Taa aa io rea aro oe {sam | Bin | tee ree | gett [oar rt [Tae aene | Ue [fee] eas | cat | eo Pate | ot ater ye ae 77 ee 3 eee | gin Tr a Power & ~ + ‘see ‘sai - | (© 2010 MECON Limited. All rights reserved 2m__—_— EIA & EMP FOR THE PROPOSED | JS | EXPANSION FROM 10.0 MISA Sone ct MTPA STEEL PLANT 430 DESCRIPTION OF Tie ENVIRONMENT 34 tRoeveTION 384 genet Siaaninrg eet ctoerentemrantre tng ges pote raet For studyngiheexsing basine onerrralcoas tne oomgeere pet rates Delosaten of rjc st nd say ao. Doloatn of antenatal consonants and mehotay. Daineaten of oy poe Deiratn sh ean ts Plat ond descents uncurins bases second et ‘Ate deste fh bow fr he rato ee te loving hss were conducng + atin sas of oun SH Sal Pat pee cs 342 Priests and Sut Ar Fert pupetoo ntonmarllpat sear, sara nas bonded in two 2)zores, any () ocr so na exes Sa ‘odin fen beast, anne bates Soto aa mononuclear mn os Rian sesereoston sdeeimsacs Teimeacothe pjesama bocroaenr ee = Se meas Trosmarmeralcongonents ue aha pois lower partion FR sa aogier Table 38, © 210 MecoW nia ee toed 2EIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPATO 80 | (#) IMTPA STEEL PLANT ‘a: tmnt Consent ods bea Fr Sy =| os aa 7 7 are au [+ Aen ir Oat rer pain By = a a = sa a — aa ee at a > rs —| Tat = Se Wa eR [5 Sek Eas c Pe ‘fxrmnee ie a wos toe a uty ares — war] cr em Saleen aes 9 es Se ei | ee ace ee ere SES aeae ee 204 seca ee ee ee Sues somping and ona ur carted outyEmreynonal troneeey saree, ECON eal and osng tty of IS to rd sal abo sod {ereamishrg totus ns 315 Locatinaf 0 Plant and ts Suroundings ‘The expansion pln of JSW i proposedto eae whine wing pant roniss. (© 2010MECONLntes Arg rend aEin EP ron THe RoroseD DeANSON PROM oa MTORTS oo ineastee ser | ts me wea ty ne aaa, Te gues ge ofr yo fam Yee macoart “The tty rain calenOaovy amedby Sanat on gou,copoer mova: resol Se dst af mel Darian be nore, The woe plat se 2 ‘Shes non gnon 03 ruang tom olay ot Thee abou {fim te Tarn Raeny Son, Tho ae oer tral reahgi!pans ee ‘areas sponge won pat Poort vero sje, sh Steed Ls of 24 hs POEL omer pan sTPCL Bowe pen) sho! wie! 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Tha Nest etn he eeroselpeiaterepand pera ins cebnoan tonsa one Drlnge: To prsosed ta scoot any er tm, Howovr he ae edared by ert on hw not sb end Kangana on hess iu: Norhata and {€270MECON Lined Ate sees aaEIA & EMP FOR THE PROPOSED EXPANSION FROM 10.0 MTPA TO 16.0 { MTPA STEEL PLANT “eee carla a carota {35cm neces ssf unger hgh carl hgoer ee SReticote peteerceneranaes enn Sere ee eteneeier raya tee SE Goin cman ; ‘Thee a saver goun at butainsne att aa. Tho proposals ue Gana ground war bam The mai souoe che a gee nero ne mio Sroahtaten aannnoe Tho Nahant se wsartobace punta ge WeteorslogyAprIMO tina HetccogclDepatmary crea dts rented ‘eg 05105 Sory wns apport abl om noe fee ho yar» fom Novambr ts af Fenty In Dosa ae he mesh [Srpemure b loves be mean dy nin 377°C By te an of Peta {Srperoure bop fib rep 8 AML whch ab htt eh amas Gh, [Iintess wo mart th heats opraehe Win th ae ncnan fe, fe ‘tut bncancs sigh coc a cote lobe so ugh ou be merecon ee ‘Hemaerumompenreosords Onan 49 fre 49°C unverceacn BES ‘Sunoranscltroasone ae het par fn ya nnn late ny ev oy foms52/#kinmomngand 3's so nto shears Relate usaly weene Woe To awsage sal fat ssroseodebotye Spam Oe Sou EasiresandEatries vor predate seaten Seth Exetaty omponetkpsorare sar Oren We raoon aes, he eS ann fer Vos nN Soyo imetogoay cata rove a Store ony tng wet’ ad mone Dung hepa om yt Nownbe yeni madera hoa Side Rest Tnoyeat oye gueray doo oy ced onan rodonicant nd decors 2 shownla Table 346 fie} (emer {© 210 WecOM Dna Ape mse aedX EIA. 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