Jindal Stainless Limited

EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF

STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

2.6 AUXILIARY AND SERVICE FACILITIES

2.6.1 Oxygen plant

Oxygen will be required for oxygen enrichment in the blast furnaces, blowing in
the chromium-premelter, lancing in the EAF, secondary refining in AOD in steel
melting shop, cutting of slabs in continuous casting plant and for general
purpose use in various units of the steel plant. Nitrogen / argon will be required
for process-gas-refining in AOD, for purging in ladle furnace and also for
shrouding the metal stream from tundish to mould during continuous casting.

The approximate average estimated demands for these gases are given
below.
- Oxygen : 23,500 Nm3/h.
- Nitrogen : 10,000 Nm3/h.
- Argon : 3,200 Nm3/h.

In order to meet the above requirements of oxygen and nitrogen, two oxygen
plants of 425t/d capacity each will be installed in full development of which one
in Phase-I and other in Phase-II. Argon requirement will be met from argon
produced from the two nos 425 tpd capacity of oxygen plants in full development
and balance by procuring from outside agencies.

2.6.2 Acetylene

Acetylene will be required for general maintenance purpose in the ferro-chrome

plant and various other units including repair shops of the steel plant. The total
acetylene requirement is estimated to be about 32,000 Nm3/yr for full
development of the project. Acetylene will be procured from outside agencies in
dissolved acetylene (DA) cylinders.

2.6.3 Captive power plant

The proposed plant will be equipped with its captive power plants (CPPs) to
meet the major demand of electrical energy requirement. The CPP will be based
on waste heat recovery from excess BF gas, flue gas from several Fe-alloy
units.

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

The CPP consists of following facilities.

Sl. Energy source Power generation, MW
No. Phase-I Phase-II
Blast furnace gas 1 x 12 -
Flue gas from Fe-Cr 1 x 13 2 x13
plant
Flue gas from Fe-Mn 1 x 13 1 x 13
plant

2.6.4 Electrics

The estimated power requirement of the proposed steel plant is as follows:-

Description
Maximum Demand : 540MVA
Annual Energy Consumption : 3504 M kWh

Source of power supply

The project shall source its power requirement from the Orissa Power Grid Co
Ltd.. The power shall be received through two double circuit 220 kV lines. The
transmission tower shall however be designed for a double circuit line as a
future provision.

The proposed captive power plant of 1 x 12 MW BF gas based and 5 x 13 MW

flue gas based from ferro-alloy plant under full development will generate power
at 11 kV. The power from CPP shall be synchronized with the Grid power supply
at 33 kV at the 33 kV switchboard located at Power Plant through two number
15 MVA, 11/33 kV step up generator transformers.

2.6.5 Water supply & Requirement

Iron making, steel making and shaping are heat intensive processes wherein a
considerable quantity of cooling water is required for control of metallurgical
processes as well as for dissipation of un-utilised heat. In order to conserve
precious fresh water, water economy has been an underlying criterion for
selection of plant and equipment

The total requirement of fresh water from surface water source to meet process
make-up and drinking needs is estimated as 3029 m3/h for the full development
of the project.

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

The source of water for the plant will be the Brahmani river flowing at a distance
of about 20 kms of the plant site. Raw water, received at the plant boundary, will
be clarified in the raw water treatment plant for use as make-up, drinking water.
Clarified water will be further treated in a demineralised water plant cum water
softening plant to meet the DM and & soft water demand of the plant.

Estimated requirement of water for various plant units and processes under full
development is indicated in table-2.8.
Table – 2.8
Sl Consumer units Water requirement, m3/h
No Circulation water Make-up water
Soft water Industrial water (Soft)/ ((DM)) Industrial
in Primary secondary ckt / water make make-up
ckt open indirect and up water
direct ckt cooling
1a Ferro-alloy plant 6,525 6,525 (34) 458
closed ckt.
b Ferro-alloy plant - 421 - 30
open ckt.
2 BF complex
a BF and stove 4,600 9,800 6 298
b Gas cleaning plant - 1,800 - 212
(GCP)
c Pig casting machine - 1,700 - (-70)
(PCM) Blowdown
from BF ckt.
d Slag granulation - 4,400 - (-110)
plant (SGP) Blowdown
from CPP ckt.
3 Cr-premelter 400 400 (2) 16
4 EAF 3,000 3,000 15 126
5 Ladle Furnace (LF) 800 800 4 34
6 AOD converter 600 600 3 26
(closed circuit)
7 Fume extraction unit - 3,000 - 126
(FEU) for converter/
EAF and LF
8 FEU Unit for AOD - 1,000 42
9 Hot metal pre- 500 36
treatment station
10 Electrode cooling - - - 12
EAF
11 Slag Cooling - - - 50
12 Gas flare station - - - 1
13 Sinter plant - 1300 - 100
14 Laboratory 1

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Sl Consumer units Water requirement, m3/h

No Circulation water Make-up water
Soft water Industrial water (Soft)/ ((DM)) Industrial
in Primary secondary ckt / water make make-up
ckt open indirect and up water
direct ckt cooling
15 Continuous slab
caster - 1,080 1,080 (5.5) 54
Mould cooling
(closed circuit) 840 840 (4.5) 42
Machine cooling
(closed circuit) - 852 - (-111)
Spray and machine Blow-down
cooling (open circuit) from FEU
units
16 Oxygen plant - 3,720 - 186
18 Compressor unit - 750 - 21
19 DM Plant - - ((70)) 77
20 Hot strip mill (HSM) - 1,080 - 17
direct- intermittent
21 HSM direct- - 855 - 79
continuous
22 HSM closed ckt. 1,212 1,212 6 51
23 HSM – motor cooling - 325 - 14
24 Cold rolling mill 1,336 - 62
(CRM) recirculating
25 CRM – direct - - - 5
26 Service water SMS - - - 10
27 Service water CCP - - - 40
28 Coke oven plant - 200 - 200
29 Misc. service water - - - 20
(AC/Vent, Lab
facilities)
30 Plant drinking water - - - 18
31 Soft water plant - - (80) 88
32 Treatment plant loss - - - 175
33 Losses in the raw - - - 50
water reservoir
34 Transmission loss 228
Total make-up water requirement 3029

Qualitatively compatible process water needs have been segregated in planning

the water recirculation circuits. These are indicated below:

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Water recirculation circuits

Recirculation circuit Process covered
Closed soft water (primary) Converter /EAF, ladle furnace, AOD.
circuit Mould cooling and machine cooling of slab
caster
Ferro alloy plant
HSM
Open Industrial water Secondary side cooling of plate heat exchangers
(clean water cycle) Fume extraction Unit for converter/ EAF & LF
Oxygen plant
Captive power plant & turbo blower
Compressed air station
Blast furnace & stoves
Ferro alloy plant
CRM
Open Industrial water Spray and machine cooling (direct cooling) in
(contaminated water cycle) slab caster.
Spray cooling in HSM
Effluent treatment plant of gas cleaning plant
Slag granulation unit
Sinter plant
Coke oven plant

Water pollution control and conservation

Extensive recycling has been adopted in the design of plant water systems.
Quality of circulating water will be maintained through dosing of conditioning
chemicals for controlling corrosion, scale deposit and microbial growth.

Wastewater from effluent treatment plant, DM plant will be neutralised before

discharge from the plant. The sludge arising out of different circuits will be
recycled / pumped to the sludge pond.

Through cascaded reuse of blow-down, the water scheme ensures practically

zero-discharge from the industrial water circuit.

In order to conserve fresh make-up water use, water required for ash handling
system will be met from blow-down of open cooling water circulation system and
reclaimed water from ash pond. Blow-down water from clean water circuit will
also be used for road sprinkling and gardening purpose.

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

2.6.6 Fuel facilities

Coke Oven Gas (COG): COG will be used as fuel for the walking beam
reheating furnaces, roller hearth annealing furnace, coiler furnaces and the
direct rolling and pickling line (DRAP).

HFO shall be used for preheating of limekilns, ferro-alloy plants, ladle and
tundish in steel melting shop. The annual requirement is estimated as 45,000 t
for full development of the project. The average daily consumption of oil is 162 t /
day. The facilities envisaged include 2 nos. 500 t HFO tanks along with
unloading facilities and transfer pumps. The storage provided is for meeting 7
days requirement of vertical kilns and ferro- alloy plant.

Liquefied Petroleum Gas (LPG): LPG will be required for various units of SMS.
The annual LPG requirement for SMS has been estimated as 12,000 t for full
development of the project. 2 nos. of 100t each (250 m3 water capacity approx.)
LPG bullets will be installed.

2.6.7 Compressed air facilities

The compressed air will be required for various technological units and services
of blast furnace and SMS Complex. To meet industrial quality and instrument
quality compressed air requirement for various consumers of blast furnace and
SMS area and power and blowing station for full development of the project,
compressed air stations have been considered as follows.

Two nos. compressed air stations have been envisaged under full development.
Compressed air station no. 1 will meet the requirement for blast furnace area
and power and blowing station and will be provided with 4 Nos of compressors
(3W +1S), each of 52 Nm3/min. Compressed air station no. 2 will meet the
requirement for SMS, CCP, ferro-chrome, silico-manganese plant and fero-
manganese plant. These will be provided with 5 Nos of compressors (4W + 1S),
each of 80 Nm3/min.

2.6.8 Lime and dolomite plant

A lime and dolomite plant will be set up for production of burnt lime and calcined
dolomite required for steelmaking. The plant will comprise of five (5) Nos. of
vertical shaft kilns of capacity 300 t/day each in full development of which three
in Phase-I and two in Phase-II for calcinations of lime stone and raw dolomite.
Metallurgical lime and calcined dolomite of size + 10mm is proposed to be used

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

as flux in steel melting shop. Lime fines and calcined dolomite fines of size 0-
10mm will be available for sale.

2.7 Environmental Management System

The pollutants in the form of solids, liquids and gases are generated from
various technological units of steel plant and, if let out as such, will have
hazardous effects on the environment. Pollution of the environment not only
adversely affects the human beings, flora and fauna, but also shortens the life of
plant and equipment. This vital aspect, therefore, has been taken into account
while planning the plant and equipment and adequate measures have been
proposed to limit the emission of pollutants within the stipulations of statutory
norms.

To arrest and control different air and water pollutants, the facilities shown in
table 2.8 will be provided in different shops/unit.

Table 2.8
Proposed facilities for control of air and water pollution

Sl. Shop / unit Proposed facilities

No.
1. Coke oven and by Wet scrubber / bag filter, tall chimney
product plant
2. Sinter plant Electrostatic precipitators, bag filters,
tall chimney
3. Blast furnace shop Bag filters, electrostatic precipitators,
thickeners, cooling fans, etc.
4. Ferro-alloy plant Bag filters, cooling fans, etc

5. Steel melting, continuous Bag house, gas coolers, cyclones, tall

casting shop and rolling chimney, etc.
mill complex
6. Material handling system Bag filters, dust suppression system,
cyclones, etc.

The various waste materials arising out of the technological processes would be
reutilised to the extent possible. For example, slag from blast furnaces will be
granulated and sold as a by-product.

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Various measures to reduce noise pollution like reduction of noise at source,

selection of low noise equipment, isolation of noisy equipment, etc. have also
been proposed to bring down the noise level in the plant to an acceptable level.

2.8 MANPOWER PLANNING

In order to operate and maintain the plant facilities, including its technical and
general administration needs, the manpower requirement has been estimated to
be 2,067. This has been arrived at based on development of an organization
structure.

The above estimate covers the top management, middle and junior level
executives and other supporting staff. The estimate, however, does not cover
the personnel for township, medical facilities, etc. The categorywise breakup of
manpower is indicated in table 2.8.

Table-2.8
Category wise breakup of manpower
Sl. Category Requirement
No.
1. Managerial 70
2. Executive 277
3. Highly skilled 426
4. Skilled and semi-skilled 1127
5. Un-skilled and clerical 367
Total 2,237

3.0 SCREENING OF IMPACT

3.1 INTRODUCTION

The first step in environmental impact assessment is to list all the

potentially significant environmental impacts. These are then examined critically and
the major impacts (both negative and positive) are analysed in detail for the EIA.

The existing plant is a green field project, which had been planned out
considering low specific consumption of raw materials and energy and minimum
impact on the environment. In order to ensure comprehensiveness, the various

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

aspects considered in listing of impact during modification-cum-expansion of the

plant are:

• Investigation of project components.

• Investigation of project phases.
• Investigation of Impact generating activities.
• Investigation of types of impacts.

There are various techniques available for listing of impact. These include
checklists, matrices, networks and cause effect diagrams etc.

3.2 LISTING MATRIX

The possible environmental attributes that may be affected by industrial

activities are:
• Air
• Water
• Noise
• Soil / land
• Ecology
• Infrastructure
• Socio-economics.

The various activities which could have significant impact during modification-
cum-expansion of existing plant have been classified under following groups.

• Existing Operations.
• Future Activities

The matrix thus identifies and lists the environmental attributes likely to be
affected and the responsible activities. After listing the potential environmental
aspects, the impacts, whether beneficial or adverse, have been analysed in the
Chapter on Prediction of Impacts

3.2.1 Construction

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EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

In this case, the location of the existing plant is in KALINGANAGAR, Industrial

area, dist Jajpur Road (Orissa). Existing plant site is generally plain with minor
undulation. The existing plant is well connected to state express high way and
nearby railway station Jhakhpura on South Coast railway. Therefore,
construction for infrastructure does not require and hence does not affect the
environment in any way.

The major construction will involve excavation and fabrication work. It will
have marginal impacts on air, water, and noise quality. Socio-economic pattern may be
marginally affected due to generation of employment. However, these impacts will be
for a short duration only.

3.2.2 Operation

The existing plant is partly commissioned. Once existing plant fully

commissioned the operations of plant may affect the quality of air, water, noise
and soil/ land due to emissions, waste disposal, vehicle/automobile movement
etc.

The generation of fugitive and process dust, heat and noise may have
negative impact on health and safety. Marginal impacts are anticipated on water, soil.
Although this impacts will be restricted to within or near the plant premises. The
employment generated for the operation will have positive socio-economic impact.

3.2.3 Future Activities

The future impacts are secondary impacts due to setting up of the plant, which
shall give rise to further industrial and associated developments. This will have a
positive impact on socio-economic structure. The transport activities in the area
shall also get a boost.

3.3 SCREENING OF IMPACTS

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