JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

CONTENTS

Chapter - 1 Executive Summary Chapter - 2 Introduction Chapter - 3 Project Description Chapter - 4 Site Analysis Chapter - 5 Planning Brief Chapter - 6 Proposed Infrastructure Chapter - 7 Rehabilitation and Re-settlement (R & R) Plan Chapter - 8 Project Schedule and Cost Estimates Chapter - 9 Analysis of Proposal

Pre-feasibility Report

LIST OF FIGURES

Figure No. Description Fig. 2.1 Production Capacity of JSW Salem Works Fig. 3.1 Location Map of Project Site Fig. 3.2 Satellite Map of Project Site Fig. 4.1 Road Connectivity Map of Salem Fig. 4.2 Wind rose of Sep. to Dec. 2014 at Plant Site Fig. 6.1 Overall layout of the proposed 1.3 MTPA ISP

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

LIST OF TABLES

Table No. Description Table 1.1 Proposed Configuration for 1.3 MTPA Table 3.1 Proposed Changes in the Configuration of the Facilities and Products Table 3.2 List of Raw Material Requirement Table 3.3 Quantity of Solid Waste present and after Expansion Table 4.1 Monthly Rainfall (mm) and Humidity

Table 5.1 Villages Falling within 10 km Radius from the Project Site

Table 8.1 Cost of Pollution Control and Monitoring Measures

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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CHAPTER - 1 EXECUTIVE SUMMARY

M/s. JSW Steel Limited, Salem works is a part of JSW group, leading manufacturer of alloy steels to meet the requirement of auto mobile sectors and engineering applications. The plant is located at M.Kallipatti and Pottaneri Village of Mettur taluk, Salem district, Tamilnadu state. JSW Steel, Salem works is planning to expand the existing capacity from 1 to 1.3 MTPA. In this regard, M/s. JSW Steel Ltd is planned to approach MoEF and obtain environmental clearance from the ministry for the proposal of plant expansion.

To enhance the capacity from 1 to 1.3 MTPA, the following units namely additional sinter plant of 90 m2, Blast furnace 1 & 2 will be enhanced, Energy Optimization Furnace 1 will be enhanced, new bloom caster will be installed by enhancing the capacity of BRM from 0.4 MTPA to 0.48 MTPA and Blooming mill from 0.36 to 0.48 MTPA respectively. Installation of new annealing furnace of 0.06 MT, additional oxygen plant of 250 TPD and additional 30 MW power plant are also planned.

The existing land area is 586.09 acres. This land will be utilized for the expansion of the plant.

The name plate capacity of the plant is 1 MTPA Integrated steel plant. The Proposed configuration for 1.3 MTPA plant is as shown in Table 1.1.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Table 1.1 Proposed configuration for 1.3 MTPA

Total Existing Proposed Capacity Manufacturing Facilities Capacity Expansion after

Expansion

1.0 Coke Oven Plant -1 (Non – Recovery 0.50 0.5 Type ) 2.0 Sinter Plant – 1 (20 Square Meter) 0.175 0.0 2.1 Sinter Plant – 2 (90 Square Meter) 1.06 1.06 2.2 Sinter Plant – 3 (90 Square Meter) 1.06 1.06 4.0 Blast Furnace – 1 (402 to 650 Cubic 0.683 0.367 0.316 Meter)* 4.0 Blast Furnace – 2 (550 to 650 Cubic 0.578 0.105 0.683 Meter) 5.0 Energy Optimising Furnace – 1 (45 T to 0.41 0.23 0.64 65 T) 5.1 Energy Optimising Furnace – 2 (65 T) 0.62 0.62 7.0 Ladle Furnace - 1 with Common VD

(45 T to 65 T) 7.1 Ladle Furnace – 2 (65 T)

7.2 Ladle Furnace - 3 common VD (65 T)

7.3 Ladle Furnace - 4 (65 T)

8.0 Continuous Casting Machine - 1 0.35 0.35 8.1 Continuous Casting Machine - 2 0.5 0.5 8.2 Continuous Casting Machine - 3 0.45 0.45 9.0 Bar & Rod Mill Augmentation 0.4 0.08 0.48 9.1 Blooming Mill Augmentation 0.36 0.12 0.48 10.0 Annealed Steel unit 0.00 0.06 0.06 11.0 peeled and ground 0.00 0.04 0.04 12.0. Air Separation Plant 1 – 150 Ton/Day 12.1 Air Separation Plant 2 – 390 Ton/Day 12.2 Air Separation Plant 3 – 250 Ton/Day 13.0 Captive Power Plant 1 (7 MW) 13.1 Captive Power Plant 2 (2 x 30 MW) 13.2 Captive Power Plant 3 (1 x 30)

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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1.1 Sinter Plant:

Presently, plant is operating two sinter plants with machine size 20 sq. m and 90 sq. m respectively. An additional sinter plant of 90 sq. m has been envisaged with a productivity of 1.45 t/m2/hr for expansion, to cater to the existing two no. blast furnaces after the capacity augmentation with the total capacity of 2.12 MTPA. After commissioning and stabilization of sinter plant- 3, sinter plant-1 will be decommissioned.

1.2 Blast furnace

The plant is presently operating with two blast furnaces with capacities of 402 cum and 550 cum respectively. It is proposed to augment the capacities of both the furnaces to 650 cum each, by replacing the existing refractory lining with the superior quality refractories of lower thickness.

1.3 Steel making shop

The steel melting shop is having two numbers of Energy Optimizing Furnaces (EOF), out of which one will be augmented to higher capacity and thereby ensuring increase in operating capacity of steel melting shop from 0.86 MT to 1.3 MT.

Existing secondary steel refining is having four LRF and two vacuum degaussing units. Three LRFs are having capacity of 65 T each where as LRF1 is of 45 Ton which will be augmented to 65 Tons.

1.4 Continuous Casting Machine (CCM)

Existing casters plant comprising of each three stand billet and bloom caster. In expansion additional bloom caster is envisaged, so as to increase the

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

operating capacity from 1.0 to 1.3 MTPA.

1.5 Bar and Rod mill

Bar and Rod Mill is a semi automated rolling mill having a capacity of 4 lakh tone per annum. The mill is designed to roll wide range of mild steel and alloy steel products. Steel billets of size 160 mm x 160 mm x 7m & variety of grades are charged into the reheating furnace. Rolled in three high reversible mill, continuous mill of eighteen stand supplemented by Kocks block to have bar and flat product, additional NTM machine for coil. Mill is having the capacity of 0.4 MTPA which will be augmented to 0.48 MTPA by incorporating two sliding stand/six continuous stand in place of trio in expansion.

1.6 Blooming mill

Blooming Mill is designed to produce heavy Rounds, Round Cornered Square (RCS) in the range of 55 to 240 mm as finished product having a capacity of 0.36 MTPA. The raw material input to the mill is from Bloom caster of sizes 250 x 250 mm and 340 x 400 mm. Blooms are reheated in reheating furnace and rolled in two high reversible mill. The intermediate product is rolled in continuous 8 stand HV mill and required sizes are cut in hot saw. The products are dispatched in dispatch area. The present capacity of 0.36 MTPA is augmented to 0.48 MTPA in expansion by installing additional 2 stands.

1.7 Oxygen plant

Existing plant is having two units of 150 TPD and 390 TPD. In expansion additional pressure swing absorber oxygen plant of a capacity of 250 TPD is envisaged to cater Oxygen enrichment in blast furnace and oxygen requirement of steel.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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1.8 Power plant

Existing captive power plant comprises of;

 1 x 7 MW using BF gas fired boiler  1 x 30 MW using WHR Boilers of COP sensible heat and BF gas  1 x 30 MW using WHR Boilers of COF and supported AFBC boiler.

In expansion, additional 1 X 30 MW using the WHR boilers of COP and BF gas is planned.

The requirement of 210 MW for 1.3 MTPA is met with the above captive generation and the grid support of 40 MW from TANGEDCO

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JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

CHAPTER - 2 INTRODUCTION

2.1 GENERAL

JSW Steel is India’s leading integrated steel producer with a present capacity of 14.3 MTPA. By maintaining exemplary operational efficiencies, the other activity like JSW Energy has grown ten-fold in just three years while, JSW Cement creates the building blocks of India with its environmental benign product. JSW Infrastructure is contributing to the nation’s development by providing world class services to various entrepreneur through state-of-the-art ports, terminals, shipyards and other facilities.

JSW group practices transparent in businesses, strong corporate governance and their dedicated employees have contributed to make every endeavor a great success. Expansions, up-gradations and technological innovations are in built capacity of JSW and focused on individual growth of the company that which has placed India in the business of steel on the global map.

JSW Group has committed to create more smiles at every step of the business journey. JSW Foundation, the group’s CSR and sustainability arm, is in constant pursuit of making life better for communities with its various initiatives in the fields of health, education, livelihood and sports along with art and culture.

The course of the impact on environment has changed as a result of pollution control measures adopted in JSW industries, lush green townships and cheerful employees with spirited growth. JSW group is proud to be house of excellence that creates opportunities for every Indian and leads to the creation of sustainable, dynamic and developed nation.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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While consistently adding values to its business, JSW is well aware to its responsibility, towards environment by implementing best practices in its business operations and contribution to society through various social endeavors.

M/s. JSW Salem works, one of the leading special steel industry in south India located at M.Kallipatti & Pottanneri village, Mettur taluk, Salem district, Tamil Nadu, is planning for expansion of existing integrated steel plant from 1.0 to 1.3 MTPA. M/s. JSW limited had obtained environmental clearance for 1.0 MTPA vide letter no. J-11011/281/2006-IA.II (I) dt. 2nd Jan. 2007, from the MoEF.

2.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

JSW, Salem works, which is India’s one of the largest Integrated Special Steel plant located in Tamilnadu, Salem with designed capacity of 1 MTPA. The production capacity of the plant from the year 2007 to 2014 is shown in Fig. 2.1.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

900000 809525 800000

T 700000 O 600000 531009 N 500000 N 400000 A ASCAST 300000 G AS ROLLED E 200000 100000 0 2007‐08 2008‐09 2009‐10 2010‐11 2011‐12 2012‐13 2013‐14

YEAR OF PRODUCTION

Fig. 2.1 Production Capacity of JSW Salem works

From the above figure, the production capacity of JSW Salem works has achieved the maximum capacity of 0.86 MTPA. In view of this it has been planned for expansion of existing units from 1 to 1.3 MTPA.

2.3 BRIEF DESCRIPTION OF NATURE OF PROJECT

To enhance the capacity from 1 to 1.3 MTPA enhancements of the following units namely sinter plant, blast furnace 1 & 2, Energy Optimization Furnace 1, CCM, Bar & rod mill and Blooming mill are planned.

Additional units Sinter plant, Bloom caster, Annealing furnace, Oxygen plant and Power plant are also envisaged in this expansion plan.

2.4 NEED FOR PROJECT AND ITS IMPORTANCE

Steel is material of choice for industrial application due to its high specific strength and relatively low cost for unit weight. Present per capita steel consumption in India is about 59 kg when compared to per capita steel

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

consumption of 500 to 700 kg in developed countries like Japan, European countries, South Korea, USA etc. The developing countries like Brazil, Mexico, and China have per capital consumption of about 110 kg to 150 kg and the World average is about 150 kg which is also very high when compared to Indian per capita consumption. Hence, there is a large scope in India to improve the per capita consumption and thereby need arise to increase the production of steel.

Automobile sector is growing rapidly in International market and India is considered as one of the global manufacturers in this sector. Every year India's GDP growth is adding on considerably to the automobile sector. Reputed automobile manufactures like Nissan, Hyundai, BMW, Suzuki, Honda, Chevrolet and Renault are expanding their activities in Indian market every year. Recent and past southern part of India has witnessed massive investments in automobile industries. Further, to enable manufacturing processes, energy demand is also in raising trend and hence investment in power sector is also inevitable.

At present, JSW Salem works is partially catering to the existing automobile market and is ranked No.1 in special steel sector in India. In order to bridge the demand and supply of special steel. JSW Salem works is planning for expansion from 1 to 1.3 MTPA. Hence, the expansion project is considered as important and required to bridge the gap between demand and supply in special steel market.

2.5 EMPLOYMENT GENERATION

During construction phase of an integrated steel plant, there will be an ample employment opportunities (direct) for local/outside populace during construction work. There are other benefits, too. Important amongst them is

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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the growth of allied steel industries around the plant engaged in supplying equipments etc. to steel plant creates job opportunities (indirectly), and contributes significant economic growth of that area. The living conditions and welfare of people will improve by social welfare schemes which will be implemented with the project commencement.

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JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

Pre-feasibility Report

CHAPTER - 3 PROJECT DESCRIPTION 3.1 TYPE OF PROJECT

M/s. JSW Salem works, is an alloy steel plant with the name plate capacity of 1MTPA for which it has obtained consent to operate from state pollution control board. In view of market demand JSW Salem works is going for capacity addition from 1 to 1.3 MTPA. The configuration of existing integrated steel plant which has obtained environmental clearance and proposed expansion programme are shown in Table 3.1.

Table 3.1 Proposed changes in the configuration of the facilities and products

Total Existing Proposed Capacity Manufacturing Facilities Capacity Expansion after

Expansion

(45 T to 65 T) 7.1 Ladle Furnace – 2 (65 T)

7.2 Ladle Furnace - 3 common VD (65 T)

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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7.3 Ladle Furnace - 4 (65 T)

3.2 LOCATION of JSW PROJECT SITE

The project site of about 586.09 acres is located at M.Kailipatti & Pottenari village of Mettur taluk in Salem district of Tamilnadu state. The proposed project site is about 35 km from the Salem town. The latitude and longitude of the estimated centre point of the project site is as follows:

Latitude: 11o 48’ 16”N to 11o 49’ 2”N Longitude: 77o 54’ 17”E to 77o 55’ 43”E

Map showing the general location, satellite view of project site is shown in Fig. 3.1 and Fig. 3.2.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Fig. 3.1 Location map of project site

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Fig. 3.2 Satellite Map of Project site

3.3 SITE SELECTION BASIS

The land is already available for expansion of the project. The main features of site including environmental considerations make the site suitable for the proposed expansion are given below:

 Existing plant & land with JSW and thus no R&R issues.  Logistic support like availability of raw material, water and power.  Suitable topography for construction of facilities.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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 Good accessibility through road and rail.  Safe from site flooding possibility.  Suitable seismic zone.  No major storage facilities for inflammable and explosive materials.  No archeologically important heritage monuments are located within 10 km radius.  No declared biodiversity parks/sanctuaries are in the surroundings of site.

3.4 SIZE AND MAGNITUDE OF OPERATION

Total available land along with the existing plant is spread over 586.09 acres of land and the proposed expansion would be carried out in the existing plant locations. The magnitude of expansion from 1.0 to 1.3 MTPA.

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS Major Units

The following major technological units have been planned for the proposed expansion and their capacities are indicated in Table 3.1.

(i) Sinter Plant

Sintering is an agglomeration process which converts the iron ore fines into porous mass to make them as feed material for blast furnace iron making. Sinter plant with 1.06 MTPA production capacity is planned with a sinter machine of 90 sq. m size in expansion with necessary accessories like flux and fuel crushing plant, circular cooler, mixing drums, product screening facility, waste gas system, etc.

The sinter plant will consist of the following main technological units.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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 Fuel and flux crushing unit  Flux screening unit  Storage and Proportioning unit  Primary mixing room  Secondary mixing room  Sintering and cooling unit  Waste gas dedusting unit  Main exhaust fan unit  Cold sinter screening unit  Plant dedusting units

The coke breeze generated in coke oven plant and blast furnace will be recycled in sinter plant as solid fuel for sintering. The recycled material from gas cleaning plant of blast furnace is also utilized. Flux materials like limestone and dolomite will be crushed to <3 mm size in crushing plant and stored in the proportioning bins. The coke breeze will be crushed to fines in the range of 0 – 3 mm size using roll crushers and stored in proportioning bins. All the raw materials will be mixed into a homogeneous mixer and nodulised in mixing drums before charging onto sinter machine. Mixed gas will be used as the fuel in ignition furnace in the sinter machine. Sintering will take place in the machine and the hot sinter will be discharged to the circular cooling machine. The cooled sinter will be screened to separate the fines <5 mm from the product sinter. The screened product will be dispatched to blast furnace.

(ii) Blast furnace

The blast furnace is a vertical counter-current heat exchanger as well as a chemical reactor in which burden material charged from the top descend

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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downward and the gasses generated at the tuyere level ascend upward. The inside profile of the furnace from top to bottom is termed furnace throat, shaft, belly, bosh and hearth. The throat is the top part of the furnace and includes the installation necessary for charging coke and burden materials and drawing off the top gasses. The top gas is routed from the furnace top to the gas purifiers and then to the consumption zones. The profile of the furnace widens in the shaft that follows. The widening of the furnace chamber from top to bottom is necessary to avoid hanging and scaffolding of the burden in the blast furnace when the raw material expands during heating. The height of the shaft is about 3/5 of the total height of the furnace. The shaft is followed by the belly and bosh. The profile again narrows in the bosh, as this is the part of the furnace, where the stock column starts to melt the hearth is the lower cylindrical part of the furnace where the fluid slag and the hot metal accumulate. Arranged in the upper part of the hearth are water-cooled tuyeres made of copper. The hot air for combustion is injected through these into the blast furnace. Hot metal is tapped through the tap hole, which is opened by power driven drills into a train of ladles kept below the runner of the cast house. Slag comes along with the metal and is skimmed off with the help of skimmer plate towards slag runner and is granulated and collected in the slag granulation plant. The tap hole is tightly sealed with a mud gun after tapping process is complete.

Raw material (ore, sinter, coke) are screened before being charged into the blast furnace through conveyors or skip. Air for combustion in the blast furnace is blown from turbo blowers which is preheated in hot blast stoves to temperatures around 1200°C, which is then blown through tuyeres.

In to the blast furnace. Each blast furnace is equipped with minimum three stoves which operate alternatively. Preheating of air helps in reducing fuel

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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consumption in the furnace.

The useful volume of the proposed BF’s shall be 650 m3 X 2 No’s with total production of 1.3 MTPA gross hot metal and after considering handling losses the net hot metal available for steel making shall be 1366000 TPA. The feed charge to BF shall consist of 75% sinter, 25% pellet or lump ore.

(iii) Steel making shop

The Energy Optimizing Furnace (EOF) operates as a batch melting process producing batches of molten steel known "heats". The EOF furnace operating cycle is called the tap-to-tap cycle and is made up of the following operations:

 Furnace charging.

 Melting.

 Refining.

 De-slagging.

 Tapping.

 Furnace turn-around.

Modern operations aim for a tap-to-tap time of less than 40 minutes.

EOF shall be equipped with atmospheric injectors, tuyers & supersonic lancers. Hot metal from the blast furnace is poured through launders. Oxygen lances for refining of the liquid bath.

The present EOF- 1 is of capacity 1x45 T/heat and EOF 2 is of capacity 1x65 T/heat. EOF-1 will be augmented to 65 T/heat size in expansion. This

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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will be capable of producing 1260000 TPA of liquid steel. The metallic feed to EOF shall consist of 85% Hot metal and up to 15% solid charges depending on the availability of scrap.

The liquid steel produced from EOF & LD Converter shall be subjected to secondary metallurgy operation in ladle furnace with vacuum degassing.

. (iv) Ladle Refining Furnace (LRF)

Secondary steel treatment in the LRF provides the production of steel with high precision as for chemical composition and temperature, allows desulphuration of metal to be brought up to the specified parameters, the amount of nonmetallic inclusions to be reduced and it also serves as the accumulating and damping facility between a melting unit and steel casting units. Since this is an alloy steel unit, the secondary additions are carried out in this LRF unit to have the required chemical composition. Thus refined steel from LRF is subjected to Vacuum degassing in the common VD unit for 2 LRF. It provides high degree of degassing, de-oxidation, desulphuration, decarburization and nonmetallic inclusions removal. LRF + VD units are equipped with argon lancing or if necessary, with oxygen blowing. Required vacuum is created with the aid of VD boilers.

The liquid steel after secondary metallurgy operation shall be sent to continuous casting machine. A brief description of CCM is as given below:

(v) Continuous Casting Machine (CCM)

During continuous casting, the liquid steel passes from the pouring ladle, with the exclusion of air, via a tundish with an adjustable discharge device

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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into the short, water-cooled copper mould. The shape of the mould defines the shape of the steel. Before casting, the bottom of the mould is sealed with a so-called dummy bar. As soon as the bath reaches its intended steel level, the mould starts to oscillate vertically in order to prevent the strand adhering to its walls. The red hot strand, solidified at the surface zones, is drawn from the mould, first with the aid of a dummy bar, and later by driving rolls. Because of its liquid core, the strand must be carefully sprayed and cooled down with water. Rolls on all sides must also support it until it has completely solidified. This prevents the still thin rim zone from disintegrating. Once it has completely solidified, the strand can be divided by mobile cutting torches or shears. Intensive cooling leads to a homogeneous solidification microstructure with favorable technological properties. High casting speeds are achievable nowadays; depending on dimensions and the number of strands that cast simultaneously, speeds of about 0.6 to 3.5 m/min are possible for slabs.

The existing CCM shop consists of a billet caster & Bloom caster which produces billets & blooms. In expansion, it is planned to install bloom caster 3 to reach the capacity of 1.3 MTPA.

(vi) Bar mill

Bar and Rod mill is a semi automated rolling mill having a capacity of 0.48 MTPA. The mill is designed to roll wide range of mild steel and alloy steel products. Steel billets of size 160 mm x 160 mm x 7m & variety of grades are charged on to the charging grid and fed into the re-heating furnace to heat it to a maximum of 1250 deg C. After attaining the required temperature these hot billets are discharged from the furnace and fed into a three high mill (TRIO) for further reduction to 104 mm x 112 mm. Billet reduced at TRIO will

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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be sent to continuous mill (Train 1, 2 & 3) for further reduction to get the required finishing size at the Kocks Block. Bars/flats, leaving the Kocks Block/Continuous mill are divided by a dividing shear located after the continuous mill, fed into the cooling bed and further cut into 500 T cold shear. Finished product are bundled in the bundling station and stacked in the yard in respective location. In case of coil production for sizes less than 16 mm, bars leaving the Kocks Block are finished at NTM and they are wound in coil shape by the Laying Head which is guided by a pinch roll. The bottom end of the pipe revolves rapidly and forms the rod into rings that overlap in spenserian form on to the stelmor conveyor where it can control the cooling rate of the coil with the help of blowers. The coils are carried through the conveyor and the coils are loaded to the ‘C’ hook conveyor by means of Coil Transfer car and they are cooled to ambient temperature after passing through a conveyor consisting of 100 no’s of ‘C’ hooks. These coils are Inspected, end trimmed, compacted, bound/strapped and unloaded from the conveyor. Coils are then stacked at the stacking yard at the designated places. In case of coil production for sizes more than 16 mm, the finished bar from Kocks travel through water boxes 1 & 2, then it is fed through pinch roll to the Garret Coiler. These hot coils are handled with the help of a plate conveyor.

(vii) Blooming mill

Blooming mill is designed to produce heavy rounds, Round Cornered Square (RCS) in the range of 55 to 240 mm as finished product having a capacity of 0.36 MTPA. The raw material input to the mill is from Bloom caster of sizes i) 250 x 250 mm ii) 340 x 400 mm. It consists of reheating furnace of 100 T capacity of BF gas fired with roller table to feed into two high reversible mill. The Intermediate size from two high reversible mill is fed into 8 stands

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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horizontal and vertical mill for further reduction to required sizes. The products are transferred to hot saw roller table where it is cut into sizes and fed into cooling bed. The end product after cooled is inspected in automatic inspection line, Bundled and stored in stacking area for dispatch. In addition to above another two strands shall be installed and capacity shall be increased from 0.36 to 0.48 MTPA.

(viii) Oxygen plant

Oxygen (99.6% purity) will be consumed in blast furnace for oxygen enrichment of blast and oxygen (99.6% purity) will also be consumed in the steelmaking shop for blowing in the EOF, LD Converter and L RF for steel making, in the continuous casting plant to meet the cutting needs and also to meet the general purpose requirement of various shops of the steel plant. Argon will be required for rinsing in ladles and also to maintain inert atmosphere in the mould/tundish. Nitrogen will be required for purging of gas pipelines, blast furnace top charging equipment, etc.

Oxygen, nitrogen and argon will be produced by air separation process based on low pressure cryogenic cycle and double column rectification system. Oxygen shall be supplied with internal compression with process liquid pumps and nitrogen either internal or external compression.

In expansion existing capacity of Air Separation Plant (ASP) is augmented with 250 TPD Pressure Swing Absorber/cryogenic plant.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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(ix) Power plant

The present captive power generation units are as below

i) 1 x 30 MW – 30 MW (AFBC) coal based power plant ii) 1 x 30 MW – 30 MW BFG and WHR Boilers iii) 1 x 7.5 MW – BFG and FO based

In the proposed power generation plan, additional 1 x 30 MW generation unit will be installed which will be based on BFG and WHR Boiler from expansion.

03.06 RAW MATERIAL REQUIREMENT

The raw material required for the proposed project along with the source is listed in Table 3.2. Table 3.2 List of raw material requirement Sl. Quantity NO. Raw material MMT/Year Source

Indigenous/Imported 1 Iron ore fines 1.378 2 Iron ore pellets 0.5 Indigenous source 3 Lump ore 0.821 Indigenous/Imported 4 Coking coal 0.637 Imported

5 Non coking coal (PCI) 0.407 Imported/

7 Power plant coal 0.198 Indigenous/Imported

8 Coke breeze for SP 0.023 Imported Limestone 9 0.102 Imported/indigenous Dolomite 10 0.148 indigenous

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Sl. Quantity NO. Raw material MMT/Year Source Quartzite 11 0.0224 indigenous Dunite 12 0.021 indigenous Lime powder 13 0.095 Imported/indigenous Mill scale 14 0.095 Indigenous Purchase coke 15 0.2 Imported

03.07 BRIEF OUTLINES FOR RESOURCE UTILIZATION

Existing plant is having the rain water harvesting pond to store the 8000 KL of water.

03.08 AVAILABILITY OF WATER AND ITS SOURCE, ENERGY REQUIREMENT WITH SOURCE

(i) Water

Existing water drawl agreement from PWD source is 5 MGD. The present requirement is about 3.17 MGD including steel plant and captive power plant of 67 MW. Total fresh water requirement after expansion requirement is about 4 . 4 M G D . The present storage capacity is about 20 days. After expansion, including the additional storage will be for the captive consumption for 12 days.)

(ii) Energy

Gas from the BF, will be used in sinter plant, VD boiler and reheating furnaces in the mills. Excess gas would be used in the captive power plant.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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03.09 QUANTITY OF WASTE GENERATED (LIQUID AND SOLID) AND SCHEME OF MANAGEMENT

(i) Wastewater generation

Wastewater generated in individual steel production facilities. It is recommended that each of the production units will be designed to utilize less amount of water and recycle the water to the maximum by cascading use of water. There will be blow downs from each of the systems. It is suggested that the blow down water be collected centrally and treated to make the water usable in less critical applications like slag quenching, green belt development etc.

All efforts will be made to re-use and re-circulate the water and to maintain zero effluent discharge. The following schemes are proposed for wastewater management comprising, treatment, recycling an d disposal systems.

(ii) Gas cleaning plant wastewater

The blast furnace gas cleaning scheme will be of the conventional venturi type which have become the bench mark for similar application. The effluent coming out of the wet scrubber will be contaminated with high concentration of suspended solids. The slurry will b e clarified in the clarifier, to recover clarified water for recycling into the wet gas scrubber after cooling in the cooling tower. The sludge settled in the clarifier will be pumped to the existing sinter plant as a feed material for making sinter. It is suggested that the blow down water from the cooling water circuits will be used as make-up water in the gas cleaning re-circulation systems.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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(iii) Treatment of billet caster effluent and mill effluents

This effluent will be contaminated mainly with suspended solids and traces of oil. The effluent from the mill will be collected first in scale pit which is a large settling basin to separate out the floating oil and settable iron scales. The cleaned water is passed through sand filters to remove finer particles, and then the water is recycled in the process. The backwash from the filters is sent to the settling tank for removal of particulates. The settled sludge is sent to sinter plant for agglomeration. It is planned that the blow down water from the cooling water circuits will be used as make-up in direct contact re- circulation systems.

(iv) Treatment of power plant effluent

The power plant effluent will be the backwash of DM water plant. This effluent will be relatively free from solids and oil and thus the effluent will be treated in a neutralizing pit for pH correction only. The neutralized effluent will be stored in the treated effluent lagoon for reuse along with cooling tower blow down in the direct cooling system.

(v) Use of cooling tower blow downs

It is noted, that the re circulating water in cooling towers gets contaminated with the dust in the atmosphere, necessitating blow down. It is recommended that all cooling towers to be provided with side stream pressure filters to reduce the volume of blow down. The cooling towers are designed to operate at high cycles of concentrations (>8) to conserve water. Further, cooling tower blow downs of indirect cooling

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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water system shall be used for slag quenching, as make up to direct contaminated cooling water circuits and surplus if any, will be stored in the treated wastewater lagoon for in- plant use.

The major solid waste expected to be generated from the various facilities of integrated steel plant are provided in Table 3 - 13.

Table 3.3 Quantity of solid waste present and after expansion Nature of Quantit Probable Sl. No. Solid waste solid y (t/d) reuse Blast furnace t 1 Sinter BF return Sinter 178 Sinter plant Steel melting shop Road making and 70kg/tonne 1 Slag Slag 732 of crude steel will be used Flume dust Sintering 2 dust 415 from bag filter plant

Continuous casting machine Sintering 1 Scale and muck Scales 110 plant Within the 2 Scrap - 266 steel plant- DRI

Rolling mills Within the 1 Scrap Scrap 103 steel plant- DRI Sintering 2 Scale and muck Scale 8.5 plant

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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To be sold to Oil and Oil and 3 0.3 authorized grease traps grease vendor Broken 4 Reheat furnace refractories - Land filling Coke oven plant 1 Coke breeze Dust 465 coke oven Dust from bag Dust 31 Power plant/ 2 filters coke oven

Captive power plant Cement and Ash including 1 Dust 316 brick fly ash manufacturing Road 2 Bottom ash clinker 80 construction Probable Sl. No. Solid waste Nature of Quantity reuse solid waste (t/d) Sold to Lead acid batteries authorised vendors

(vi) Solid waste management

About 90% of EOF slag will be used within the plant as road making and ballast for railway track. BF slag will be granulated and it will be utilized in captive cement plant.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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CHAPTER- 4 SITE ANALYSIS 4.1 CONNECTIVITY The site is well connected by road and rail. The project site is located about 35 km South-West of Salem city. Mettur town is located at 12 km in SW direction. NH 7 passing at 22 km away from plant site.

The nearest railway station is Salem at a distance of 35 km and nearest airport is Bangalore at a distance of 200 km.

The road connectivity map of Salem is shown in Fig. 4.1.

Fig. 4.1 Road connectivity map of Salem

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed project site is located within the existing facilities of JSW Steel works Salem and the proposed area is plain land. The land earmarked for expansion is neither vegetated nor having any buildings. Hence, site clearing activities like clearing the vegetation or demolition exiting building are not contemplated.

4.3 TOPOGRAPHY

The site is mostly flat. However the surrounding area is undulated with hills and hillocks. The following reserve forests along with the directions with respect to project site are observed in 15 km surrounding area. i) Vanavasi Reserve Forest in SW ii) Gonur and Solappadi reserved forest in NW iii) Parigam reserved forest in N iv) Ramasamy reserved forest in NE v) Elattur reserved forest in ENE

No environmentally sensitive area is located nearby. The Stanley reservoir is located in west direction. The important crops grown are paddy, groundnut, fodder, sugarcane, maize, cholam, ragi, cumbu, cotton, and turmeric. The main source of irrigation is from bore wells and dug wells.

4.4 EXISTING LAND USE PATTERN

The site is located in the interior part of Salem district, which is spread from southwest to northeast and is situated on the eastern side of Tamilnadu state. The district is 11° 14' and 12°53' north latitude and 77° 44' and 78° 50' east

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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longitude. This district is bounded by Dharmapuri district on the north, Erode district on the west, Namakal and Tiruchirapalli districts on the south, and Perambalur and Villupuram districts on the east and the proposed project site is not attracted by any other statutory act like CRZ. No national park, eco- sensitive area are identified within 15 km radius study area.

4.5 EXISTING INFRASTRUCTURE

The site is well connected by road and rail. Presently the site is connected by a metal road. The site is located at about 26 km from NH-7 which is passing in eastern direction. The nearest railway station is Salem situated at about 35 km.

4.6 SOIL CLASSIFICATION

Site geology

Salem is located on the high grade Precambrian terrain of south India with a network of shear zones of Neo to Early Proteorozoic age. The Salem-Attur shear zone, an extension of Moyar-Bhavani shear zone passes through this area. Charnockite, pyroxene granulite, magnetite quartzite, Khondalite, calc granulite and younger granitoidare other rock units exposed in the area.

The district is endowed with rich mineral resources such as Magnesite, Bauxite, Quartz, Felspar, Limestone, Soapstone, Dunite, Roughstone, Granites. (Source-District website of Salem)

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Soil classification

The soils can be broadly classified into 6 major soils types viz., Red insitu, Red Colluvial Soil, Black Soil, Brown Soil, Alluvial and Mixed Soil. Major part of the district is covered by Red insitu and Red Colluvial soils. Block soils are mostly seen in Salem, Attur, Omallur and sankari taluks. Brown Soil occupies major portion of Yercaud and parts of Salem and Omallur taluks and the Alluvial Soil is seen along the river courses in Omallur and Sankari taluks. mixed soil is occurring only in Attur taluk. The proposed site is located on black cotton soil.

4.7 Climatic data from secondary sources

The district receives the rain under the influence of both southwest and northeast monsoons. The northeast monsoon chiefly contributes to the rainfall in the district.

Rainfall data from six stations over the period 1901-2003 were utilized and a perusal of the analysis shows that the normal annual rainfall over the district varies from about 800 mm to 1600 mm. It is the minimum around Sankari (800 mm) in the southwestern part of the district. It gradually increases towards north, northeast and east and attains a maximum around Yercaud (1594.3 mm) in the northern part.

The district enjoys a tropical climate. The weather is pleasant during the period From November to January. Mornings in general are more humid than the afternoons, with the humidity exceeding 75% on an average. In the period June to November the afternoon humidity exceeds 60% on an average. In the rest of the year the afternoons are drier, the summer afternoons being the driest. The

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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hot weather begins early in March, the highest temperature being reached in April and May. Weather cools down progressively from about the middle of June and by December, the mean daily maximum temperature drops to 30.2°C, while the mean daily minimum drops to 19.2°C and 19.6°C in January in Salem and Mettur Dam respectively. The Monthly rainfall (mm) & Humidity details are provided below in Table 4.1.

Table 4.1 Monthly rainfall (mm) & Humidity

Name of the Station: Salem Year: 2010-2011 Mean Maximum Mean Minimum Humidity % Normal Actual Normal Actual 8.30 17.30 Months (2) (3) (4) (5) hrs. hrs (6) (7) April 2010 36.9 39.1 25.1 26.8 67 38 May 36.8 37.7 25.5 25.8 72 45 June 34.9 34.2 24.4 24.6 78 54 July 33.4 32.5 23.6 23.4 80 58 August 33.2 31.9 23.4 23.3 83 61 September 33.1 32.0 23.3 23.2 82 63 October 31.9 32.9 22.8 23.3 81 61 November 30.5 29.1 21.2 22.1 89 75 December 30.1 28.3 19.6 20.6 84 64 Jan 2011 33.1 31.3 19.2 19.7 78 43 February 33.7 32.4 20.2 20.3 73 40 March 33.7 35.5 22.5 22.2 71 30 Climatic data from secondary sources Annual rainfall – 1185.4 mm Temperature Winter – 15.60C to 32.10C Summer – 22.30C to 430C Monsoon – 25.30C to 32.50C Post monsoon – 19.30C to 32.40C Average wind speed – 6.4 km/hr

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Humidity Winter – 46 to 78% Summer – 47 to 74% Monsoon – 68 to 84% Post Monsoon – 60 to 79% Source: IMD

Fig. 4.2 Wind rose of Sep. to Dec. 2014 at plant site

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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4.8 Social infrastructure available

Population

The total population of Salem dist. As on 2001 is about 30.16 lakh and Mechieri block constitute about 10.87 lakh. The population growth rate during 2001 – 2011 is about 15.44% of salem district. The density of the population of Salem is i.e., 665/sq. km The literacy rate of Salem is about 72.86 % as per 2001 census. The Salem district is well supported with social infrastructure facilities like Hospital (10 No’s), Dispensaries (14 No’s), Primary health centers (75 No’s), Health sub-centers (348 No’s) and other medical institutions (20 No’s).

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JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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CHAPTER - 5 PLANNING BRIEF 5.1 Planning concept

The plant will be located interior part of Salem district in Tamilnadu. Already M/s. JSW has installed a steel plant of capacity 1.0 MTPA in the proposed project site. The proposed project is an expansion project.

5.2 Population projection

Project will be creating considerable employment opportunities for local people during construction phase. During recruitment preference will be given to local as per employment guideline of the State. However, priority will be given to the nearby village people after testing their skills and abilities. The villages falling in the study area of 10 km radius are shown in the Table 5.1. Table 5.1 Villages falling within 10km radius from the project site

Sl. No. Name of the Village 1. Mecheri 2. Karappatti 3. Pudu Kuttappatti 4. Kuttappatti 5. Ervadi 6. Palakkaranur 7. Kanakkappatti 8. Nangavalli 9. Malamanur 10. Kuvundanur 11. Amarattanur

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12. Errappareddiyur 13. Malaiyanur 14. Kudiraikkaranur 15. Mallamooppampatti 16. Chinna Seeragapadi

Source: Census of India 2011

5.3 Land use planning The proposed site is admeasuring about 586.09 acres. The proposed land use is as follows:

 Plant facilities – 42.9 acres  Material handling conveyors – 2.7 acres  Green belt – 29.7 acres  Miscellaneous (Settling tank, Rain water harvesting) – 1.5 acres  Open barren land for future use – 7.0 acres  Approach roads inside plant boundary – 6.2 acres Seismology The site is located in zone II of seismic zoning map of India as per IS 1893- 2012 which associated with low seismic potential The detailed geological and seismological investigations revealed that the site is outside the range of capable fault within 5 km from the project site. The design basis seismic parameters are evaluated based on geological seismological information.

5.4 Assessment of infrastructure demand

The proposed plant will be located near to Mecheri village. The project site is fenced with compound wall. Inside the plant all the required infrastructure like internal roads, water supply, storm water drains are already developed and

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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the same will be expanded further to meet the expansion requirement.

5.5 Amenities/facilities

The site is well connected by road and rail. Presently the site is connected by a metal road from NH-7. The site will be made physically isolated from the surroundings by rubble masonry wall on all sides. Other physical protection measures (security) have also been adopted for the site.

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JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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CHAPTER - 6 PROPOSED INFRASTRUCTURE

6.1 Industrial area (Processing area)- Plant Site

The layout already shown will be spread over the acquired land of 586.09 acres in Mecheri block. The following are the existing/proposed construction within the plant site. . Coke oven . Sinter plant . Blast furnace . Energy optimization furnace . Laddle refining furnace & VD . Continuous casting machines . Rolling mills (Non flat) . Oxygen and calcining plant . Power plant . Fire Station

Other Facilities: This includes Sewage Treatment Plants (STP), Effluent Treatment Plant (ETP), Raw Water Treatment Plant (RWTP), Rainwater Harvesting Pond, First Aid Centre, Diesel Storage yard, Security towers, Chemical storage yard, all roads and storm water drains etc.

Overall layout of the proposed 1.3 MTPA ISP is shown in Fig. 6.1.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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Fig. 6.1 Overall layout of the proposed 1.3 MTPA ISP

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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6.2 Residential area- township site

Township is not being planned for the proposed project.

6.3 Green belt

Under plantation programme, green belt will be developed around the plant boundary. About 33% of the total land (193.4 acres) is proposed for green belt plantation during the initial five years. The species to be grown in the areas should be dust tolerant and fast growing species so that a permanent green belt is created. The plants having following characteristics are chosen for plantation.

 Ability to tolerate and remove air pollutants.  Ability to grow in the area.  Rapid rate of growth.  Evergreen habit  Large crown volume  Small leaves with smooth surface  Should not have adverse effects on soil chemistry and ground water.  Have aesthetic value.

All these traits are difficult to get in a single species. Therefore a combination of several species with all these traits is sought while planning a plantation. The plantation should be planted close to the source or close to the area to be protected to optimize attenuation within physical limits. The areas that need special attention under plantation development are:

 Along plant boundary  Along the side of roads

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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 Around offices and other buildings  Stretches of open land at project site complex

The following species are having a better chance of survival in this region. Plantations are done at a spacing of 2 x 2 m. The expected rate of survival will be around 75%. The efforts to improve the survival of the saplings and their healthy growth will be taken up like watering, fencing, keeping watch and ward and seeking guidance from the local Forest Dept.

6.4 Drinking water management (source and supply of water)

Total fresh water requirement is 5 MGD. The source of the raw water is down stream of river Cauvery. Water supply will be from the main supply line of about 16 km.

6.5 Sewerage system

All effluent will be treated to meet the statutory norms and reused in the plant to ensure zero discharge. About 3.3 m3/hr of treated sewage will be generated from STP, and the same will be used for green belt development.

6.6 Solid waste management

SMS slag will be initially dumped suitably and then will be used for road/paver block, making/ballast for railway track after granulation. BF slag will be utilized in cement plant.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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6.7 Power requirement and supply/ source

The average power demand of the plant is estimated to be 90 MW. Power to the tune of 97 MW will be generated. It is proposed to meet the entire requirement of electric power from the captive sources taking the support of state electricity grid for stability. Provision will be made to sell the surplus power if any through the grid.

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JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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CHAPTER - 7 REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 Rehabilitation and Resettlement (R & R) Plan

The project site of about 586.09 acres, which is located at Village M.Kallipatti P.O, Pottaneri, Mecheri, Mettur-Taluk, Salem District, Tamilnadu state. The plant site is already under the possession of JSW and no habitation exist in the proposed plant site hence no R & R issues. The land area required for the plant with associated common facilities with adequate screening distance between the plant and the site boundary is available and hence land acquisition or displacement of public is not envisaged. As a social commitment from the company the R & R policy as mentioned in the earlier EIA/EMP report is being followed.

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JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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CHAPTER- 8 PROJECT SCHEDULE AND COST ESTIMATE

8.1 Project schedule

The construction work is expected to commence in year 2015 on obtaining statutory clearance and commissioning of the plant to reach the ultimate capacity is expected in 2016.

8.2 Cost Estimate

The cost envisaged for pollution control and monitoring measures like ventilation, air conditioning, are included in the capital cost. Cost towards environmental monitoring facilities is additionally included. In the analysis of capital cost, recurring cost is also included to know the yearly expenditure. Other features which forms an integral part of the plant design like stacks, ash handling equipment are not included in the analysis. Hence, constructions of STP and other environmental measures like collection pits are included in the analysis.

The estimated capital cost of the project is about Rs. 800 crores. A good fraction of this expenditure goes towards pollution control measures. Table 8.1 gives the breakup of the cost for various control measures.

 In addition to those indicated in the table, there are a number of other features, which forms an integral part of the plant design and contribute to either save energy or to decrease the energy consumption.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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 Likewise, the costs of fire protection and physical protection measures are not considered, although there may be secondary environmental consequences due to fires or security lapses.  The estimates of recurring costs include only the revenue expenses for operating the respective facilities. The salary of staff and capital depreciation are not included.

Table 8.1 Cost of pollution control and monitoring measures

Recurring Cost Capital cost Item per annum (Rs. in Crores) (Rs. in Crores) Environmental Pollution Control  Air pollution Control 10 1  Water Pollution Control 20 2 (ETP & STP)  Solid Waste Management 10 1  Noise pollution 2 0.2  Occupational health 3 0.3

Environmental and Pollution Monitoring  Environmental Survey and 5 0.5 Sampling  Social corporate 2 0.2 responsibilities  Green belt development 0.5 0.05 Green belt development 52.5 5.25

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CHAPTER - 9 ANALYSIS OF PROPOSAL 9.1 GENERAL Development of industrial projects does not necessarily have adverse impact on the environment. There is always an associated beneficial impact. The proposed project will fulfill the demand of nation’s special steel. The major benefits that can be anticipated are in terms of (i) employment for the locals, both in the skilled and the semi skilled category, (ii) increased opportunities for education, (iii) development of infrastructure such as schools, hospitals and roads and (iv) growth of small scale industries. Impacts from these are generally difficult to quantify in a precise manner. Since the proposed project is an expansion project there will not be any negative impact instead there will be an infrastructural development of the area which will benefit the people livelihood.

9.2 EMPLOYMENT AND ECONOMIC BENEFITS

The plant will provide substantial job opportunities for the locals and persons from Mecheri and Salem. People belonging to nearby villages are likely to be engaged everyday for outsourced works as contract labour in the project activities.

In total, it is expected that indirectely around 2000 people will get benefited due to this project. However, this numbers will be reached over a period of time as per the progress of project. Needless to mention that, during the construction phase of about 1 year, more number of people will get employment.

JSW STEEL LIMITED 1.3 MTPA Integrated Steel Plant at Pottaneri, Salem, Tamilnadu

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One can expect growth in the commercial activities commensurate with the anticipated increase in population. Migration and urbanization of adjoining areas also adds to the opportunities.

Transport and communication facilities will vastly improve. Besides the mass transport by state run buses, availability of taxis and autos will grow appreciably.

9.3 BENEFITS FROM WELFARE ACTIVITIES

As and when the proposed project is approved and the construction begins, M/s. JSW would commit itself to spend Rs. 2.0 crores per annum for social welfare projects. The amount would be spent for essential purposes like Schools, medical aid, parks, shopping complex, training facility, supporting water supply scheme to the nearby villages, roads and other amenities . 9.4 RECOMMENDATION

The proposed project is likely to bring in additional benefits to the areas surrounding the plant in terms of increase in the educational, health, infrastructure and employment potential.

Like in any other project increase in the employment potential both direct as well as through contractual labour would bring in additional income for the people living around the project area.

Proposed project of JSW would also join and strengthen the ongoing social welfare activities, contributing in terms of resource and manpower.

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