Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in BlastPRE Furnace- capFEASIBILITYacity from 1,75,000 to 2,50,000TPA of M/sREPORT Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, .

Addition of Iron Ore Washing & Wet Screening System for Rainy Period 1x 50 TPH (1350 TPD Throughput-for BF feed) & 1x58.3 TPH (1600 TPD Throughput-for DRI feed)

& Increase in Hot Metal production capacity from 175000 TPA to 250000 TPA without change in Size for Existing Blast Furnace

At Industrial Complex, Jajpur, Odisha

Applicant

M/s Visa Steel Limited

Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 1 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER – 1 EXECUTIVE SUMMARY

Presently M/s VISA Steel Limited (VSL) is operating a 0.5 MTPA integrated steel plant at Kalinganagar Industrial Complex in Odisha. The facilities include a 175000 TPA Pig Iron Plant, 300,000 TPA Sponge Iron Plant, 500,000 TPA Steel Melt Shop (with EAF, LRF and VD) & 500,000 TPA Rolling Mill (Bar & Wire Rod Mill).

VISA Steel is also operating 125000 (VISA Steel-50000 & VISA Bao-75,000 TPA) Ferro Chrome Plant and a 75 MW Captive Power Plant.

Previous EC was obtained for 1.5 MTPA integrated steel plant withAn CPPnexure vide– I file no. J- th 11011/33/2007/IA-II(I), dated 12 June 2007 (Copy attached as ) and for expansion of integrated steel plant by addition of Rolling Mill (1.5 MTPA) with CPPAnnexure (256 MW)– rd videII file no. J-11011/1000/2007/IA-II (I), dated 3 July 2008 (Copy attached as th ). Amendment to EC for changeAnnexure in configuration–III of Captive Power Plant was obtained on 5 March 2011 (Copy attached as ). Annexure-IV A detailed statement for existing & proposed is attached as . IRON ORE WASHING & WET SCREENING SYSTEM FOR BLAST FURNACE

The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. These liquid products are drained from the furnace at regular intervals. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions.

Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. The raw ore is removed from the earth and sized into pieces that range from 0.5 to 1.5 inches. This ore is either Hematite (Fe2O3) or Magnetite (Fe3O4) and the iron content ranges from 50% to 70%. This iron rich ore can be charged directly into a blast furnace without any further

M/s VISA STEEL LIMITED Page 2 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. processing. Iron ore that contains a lower iron content must be processed or beneficiated to increase its iron content. The physical quality of Iron ore varies depending upon the season while being excavated from mines, sized as per customer requirement, transportation and handling at RMHS of the steel manufacturing plant. BF requires sized and dry iron ore with no fines attached for quick and healthy reduction to hot metal Iron. During non-monsoon Iron ore remains dry hence fines are easily screened out and requisite sized Iron ore are fed to BF by conveyor means. However screening process becomes a cumbersome task during monsoon season due to sticky nature of Iron ore which comes with fines sticked to it. Hence to obtain Iron ore free from sticky fines, VSL-BF has planned a project for Wet screening of Iron ore and storage of fines generated after wet screening as pollution control measures. This iron ore wet screening system will be in operation only during rainy season to separate out sticky fines from the ore. IRON ORE WASHING & WET SCREENING SYSTEM FOR DIRECT REDUCED IRON

The purpose of a DRI is to chemically reduce and physically solid to solid convert iron oxides into free solid iron called "Sponge Iron". The DRI kilns are horizontal cylindrical steel stack lined with refractory cas table materials lining, where iron ore, non-cocking coal and Dolomite fed to inlet of kiln. The raw materials require 18 to 20 hours to complete the chemical reaction inside kiln & indirect cooling at cooler to discharge as mixture of DRI and Char. This cooled discharged materials passes through magnetic separators where it becomes the final product of DRI Lumps & DRI Fines. These DRI products are keeping bagged ready to dispatch.

Iron oxides can come to the DRI plant in the form of raw ore or pellets. The raw ore is removed from the earth and sized into pieces that range from 0.5 to 1.5 inches. This ore is either 2 3 Hematite (Fe O ) or Magnetite (Fe3O4) and the iron content ranges from 50% to 70%. Only Hematite iron rich ore can be charged by converting to size of 4 mm to 22 mm with Coal & Dolomite to DRI Kiln. Iron ore that contains a lower iron content must be processed or beneficiated to increase its iron content. The physical quality of Iron ore varies depending upon the season while being excavated from mines, sized as per customer requirement; transportation and handling at RMHS of the steel manufacturing plant. For consistent production, sized and dry iron ore with no fines attached required for quick and healthy reduction. During non-monsoon Iron ore remains dry hence fines are easily screened out and requisite sized Iron ore fed to DRI Kilns. However screening process becomes a cumbersome task during monsoon season due to sticky nature of Iron ore which

M/s VISA STEEL LIMITED Page 3 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. comes with fines sticked to it. Hence to obtain Iron ore free from sticky fines, VSL-DRI has planned a modification in existing screening circuit for washing of Iron ore, reuse of water and storage of fines (-4 mm size) generated after washing to complies pollution control measures. This iron ore system will be in operation only during rainy season to separate out sticky fines from the ore.WASHING & WET SCREENING SECTION 1x 50 TPH (1350 TPD Throughput-for BF feed) & 1x58.3 TPH (1600 TPD Throughput-for DRI feed) AIR POLLUTION CONTROL EQUIPMENT

The entire process is a wet process starting from input of raw iron ore to output of washed & screened iron ore. No air pollution envisaged during operation as no ETP DETAIL AND SOLID WASTE MANAGEMENT emission of fines due to rain and high moisture of iron fines.

Iron fines slurry when dumped into slurry tank to be treated with Chemical to avoid contamination of water flowing to the next stage. Clear water is collected at last sump which is to be pumped again for spraying/washing of iron ore at on-line screens. With respect to Iron fines storage tank, very small quantity of water with iron fines is required to be shifted to existing settling tank and its clear water will be sent to existing thickener of GCP. The settled fines will be again shifted to iron fines storage WATER REQUIREMENT & CONSUMPTION tank with the help of JCB/ Excavator.

Initially water requirement is 240 Mᶾ. Above process to be operated with the recirculation of water through the piping & ETP. There is no much water loss in the entireWASTE process WATER, only GENERATION approx. 60 KLD FROM will beEACH the SOURCE,make-up waterTREAT requirement.MENT, RE-USE AND QUANTITY TO BE DISCHARGED WITH DISCHARGE POINTS

Primarily, Water to be collected at following points after washing of Iron ore; 1. At sump S7 from where clean water to be directly reused for spraying at existing on-line screen (Refer process flow chart of iron ore washing). 2. At Pit from where water with slight amount of iron fines to be pumped to sump S11 (Refer process flow chart of iron ore washing). On effluent treatment clean water to be re-used at existing Thickener of GCP and settled fines to be shifted 3. again at sumps S8, S9 and S10. There will be no any discharge of water in the drain and no solid waste 4. generation from the process of iron ore washing system. Total 350 TPD tailings/fines will be generated and will be stored in the fines storage tank of size 21m x 7 m x 2 m. for DRI & 33m x 3 m x 1 m. The solid waste will be further collected at iron ore fines yard.

M/s VISA Steel Limited (VSL) had installed the existing Blast Furnace (BF) Plant in May 2005 and later on forward integration to steel making through the route of Blast Furnace,

M/s VISA STEEL LIMITED Page 4 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Sponge Iron and Electric Arc Furnace using state of art KORF technology. Use of mix of hot metal (liquid) and sponge iron (solid) in the Electric Arc Furnace was the novel and revolutionary concept at the beginning of the New Millennium. It was envisaged that the hot metal obtained from the BF would be used for production of pig iron (pigs) initially till the implementation of the steel making and rolling mill along with associated facilities subsequently. Due to Coking coal crisis and the economical conditions prevailing VSL prudently decided to set up Non Recovery Coke Oven, Ferro Chrome Plant and Power Plant subsequently along with DRI plant, SMS and rolling mill with matching balancing facilities. The installed BF have a working volume of 250 cum and rated production capacity is about 515 tons liquid hot metal per day for steel making and casting pigs in pig casting machine.

Lump iron ore along with coke and fluxes like limestone, dolomite, manganese ore and quartzite are charged in the mini blast furnace, to produce liquid pig iron, commonly known as hot metal. Liquid slag generated in the process is granulated by high pressure jet of water to make it usable for cement manufacturing. Salient Features of Project

Environmental Sl.no Requirement/Status after capacity enhancement Component

There will be no increase in land area 1 Land Area (no physical expansion, no change in BF layout) Water requirement will increase from 1250 KLD to 1370 KLD Required water for the proposed plant is made available 2 Water requirement from the Brahmani / Kharshan river basin for which intake well & water pipe line from river to plant site has been laid. Water for the washing & wet screening unit will be kept in closed circuit and recycled after proper treatment. Entire 3 Water Environment wastewater from BF complex will be recycled & reused for shell cooling and slag granulation Existing Gas Cleaning Plants (GCPs) have adequate capacity for the additional dust load. 4 Air Environment There will be no additional discharge into air environment. Entire dust collected from GCPs will be sold to the sinter plant (100%)

100% BF slag (After expansion 70700 TPA, presently 46000 5 Solid Wastes TPA) will be granulated and sold to cement plants. There will be no dust generated

M/s VISA STEEL LIMITED Page 5 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 6 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER – 2

2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

VISA Steel Limited had installed a 250 m3 Blast Furnace at Kalinga nagar Industrial Complex in Odisha , adopting TATA KORF technology. The plant is located close to village Jakhapura in the Jajpur district of Odhisa. All the plant & machinery were purchased and installed during the years in 2005 and this plant was commissioned in May 2005. As a part of process optimization, thereby aiming to achieve higher productivity. And also operating 2 x 500 TPD Direct Reduced Iron Rotary Kilns for production of 300,000 TPA Sponge Iron at Kalinganagar Industrial Complex, Odisha, using the proven German SL/RN technology provided by Outotec Oyj (formerly Lurgi Metallurgie Gmbh). All the plant & machinery were purchased and installed during the years in 2006-07 and this plant was commissioned in May 2008.

Previous EC was obtained for 1.5 MTPA integrated steel plant withAnnexure CPP vide– I file no. J- th 11011/33/2007/IA-II(I), dated 12 June 2007 (Copy attached as ) and for expansion of integrated steel plant by addition of Rolling Mill (1.5 MTPA) with CPPAnnexure (256 MW)–II rd vide file no. J-11011/1000/2007/IA-II(I), dated 3 July 2008 (Copy attached as ). th Amendment to EC for change Annexure in configuration–III of Captive Power Plant was obtained on 5 March 2011 (Copy attached as ). 2.1 Identification of Project and Project Proponent. In case of mining project, a copy of mining lease/letter / letter of intent should be given.

Project Proposal:

i. Addition of Washing & Wet Screening System for Iron Ore Processing during rainy period 1 each for proper feed to Blast Furnace (BF) and Direct Reduced Iron (DRI). ii. Increase in production capacity of Blast Furnace from 1,75,000 TPA to 2,50,000 TPA without changing the configuration or size of Blast Furnace. Category of Project:

Category “A”. Project Proponent:

Visa Steel Limited.

M/s VISA STEEL LIMITED Page 7 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

2.2 Brief Description of Nature of the project

 The objective of the project is to ascertain: Addition of Washing & Wet Screening System for Iron Ore Processing during rainy  period for proper feed to Blast Furnace (BF) and Direct Reduced Iron (DRI). Increase in production capacity of Blast Furnace from 1,75,000 TPA to 2,50,000 TPA without changing the configuration or size of Blast Furnace.

It has been observed from the existing BF that through appropriate process optimization the production capacity could be increased by around 30 % increase in the 3 production of hot metal from 549 t/day to 715 t/day in the same 250 m BF. This could  be achieved by the following steps:  Injection of coal and other fuels to reduce coke rate.  Use of more agglomerated burden (pellets and sinter) – Improved permeability. o Reduction in slag rate and coke rate. o o Mathematical models – burden and heat calculations. Improvements in sinter and pellet quality for BF productivity.  Enhancement in blowing rate of air. o Oxygen Enrichment o Plastic Injection  Improvement in cooling system of the furnace Productivity measures in the form of bell less top, high top pressure, oxygen  improvement, humidity control etc. o Tap hole clay improvement for improved tap hole life.  Multiple tap holes.  Improvement in cast house practices. 2.3 NeedImpro forvement the Projectin opera andting itsand importancemaintenanc toe p therac tCountryices. and/or region.

The existing BF produces foundry grade pig iron for automobile sector. Hot metal is tapped into ladle and poured in the Pig Casting Machine. Productivity rate of foundry grade pig iron using BF is low as compared to productivity of basic grade pig iron using the same blast furnace. This is mainly because of strict process control requirement in making foundry grade pig iron. The automobile sector is experiencing slowdown in as well as in other countries.

M/s VISA STEEL LIMITED Page 8 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Therefore the sale price of foundry grade pig iron is low thereby affecting the sustainability / economic viability of the project. In order to remain competitive in the domestic as well as international market, VISA Steel Limited decided to start making basic grade pig iron from the existing blast furnace. This will make the project sustainable, profitable and socially viable. The general product will meet the demand of India as well as international market. Also for consistent production, sized and dry iron ore with no fines attached required for quick and healthy reduction. During non-monsoon Iron ore remains dry hence fines are easily screened out and requisite sized Iron ore fed to DRI Kilns. However screening process becomes a cumbersome task during monsoon season due to sticky nature of Iron ore which comes with fines sticked to it. Hence to obtain Iron ore free from sticky fines, VSL-DRI has planned a modification in existing screening circuit for washing of Iron ore, reuse of water and storage of fines (-4 mm size) generated after washing to complies pollution control measures. This iron ore system will be in operation only during rainy 2.4 periodDemandto separate & Sup plyout Gapsticky fines from the ore.

The automobile sector is experiencing slowdown in India as well as in other countries. Therefore the demand of foundry grade pig iron for use in automobile sector has reduced. Presently China started dumping low cost foundry grade pig iron in India and other international market. The cost of production of foundry grade pig iron by Indian Producers is more than the sale price of China.

In order to remain sustainable, profitable and socially viable, the company decided to produce basic grade pig iron. The demand of general grade pig iron at competitive cost 2.5 existsImports in the v/sdomestic Indigenous and international Production market.

2.6 ExportImports Possibility are not feasible.

2.7 EmploymentThis will enhance Generation the export (Direct chance & by Indirect) remaining due cost to thecom Project.petitive.

To operate and maintain all the plant facilities, including its technical and general administration needs, the estimated manpower works out to 3869 of which manager and executives constitute 545. For the proposed washing & wet screening unit and enhancement of production capacity of BF following manpower will be required:

M/s VISA STEEL LIMITED Page 9 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Table-01: Category wise break-up of manpower

Sl. No. Category Manpower Requirement

1. Managerial 30

2. Executive 545

3. Skilled 903

4. Semi-skilled 809

5. Unskilled 1457

6. Clerical 125

Total 3869

M/s VISA STEEL LIMITED Page 10 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER - 3

PROJECT DESCRIPTION

3.0 Project Description

The Project is for the following Addition of Washing & Wet Screening System for Iron Ore Processing during rainy  period 1 each for proper feed to Blast Furnace (BF) and Direct Reduced Iron (DRI). Enhancement in production capacity of Blast Furnace from 1,75,000 TPA to 2,50,000 TPA without changing the configuration or size of Blast Furnace. The above proposal is envisaged in the existing integrated steel plant of VISA Steel Ltd. at Kalinganagar Industrial Area, Jajpur, Odisha. 3.1 Type of Project including interlinked and interdependent projects, if any.

The site is located in Kalinganagar Industrial Area of Orissa. The site is at about 110 km from Bhubaneswar. The express highway run’s in the south west direction of the plant. Jakhapura/Sukinda railway station is the serving station for the entire industrial complex located in the south east direction of the plant. The existing Mid east & NINL plant located in the North West direction of the plant. Kalinganagar industrial complex also houses Jindal Stainless and plants situated nearby. The 0.5 MT existing steel plant of VISA steel is located in the east of the proposed expansion project & adequate land is available for the proposed expansion.

The existing plant having an area of 525 Acre (Visa Steel: 476 Acres & Visa Bao: 50 Acre) ~ 212.46 ha. The area requirement for installation of the two washing & wet screening system of 0.74 Acre (0.3 ha.) will be within the existing total area. There is no change in BF area.

M/s VISA STEEL LIMITED Page 11 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Location (map showing general location, specific location, and project boundary & project site layout) with coordinates.

KEY PLAN

M/s VISA STEEL LIMITED Page 12 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

GOOGLE MAP

M/s VISA STEEL LIMITED Page 13 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

TOPO MAP OF PROJECT SITE (10 KM RADIUS)

M/s VISA STEEL LIMITED Page 14 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

PLANT LAYOUT

M/s VISA STEEL LIMITED Page 15 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

3.2.1 Details of alternative site consideration and basis of selecting the proposed site particularly the environmental considerations gone into should be highlighted.

This is an addition proposal in existing plant. Land area and general layout remains unchanged. Also the site is located in an Industrial Area, hence no alternative site was considered. 3.3 Size or magnitude of operation

It is ‘A’ Category Project as per EIA Notification 2006. The present proposal is envisaged in the existing integrated steel plant of VISA Steel Ltd. at Kalinganagar Industrial Area, Jajpur, Odisha for: 1x 50 TPH i. Addition of Washing & Wet Screening System for Iron Ore Processing during rainy period(1350 TPD for properThroughput feed- forto BlastBF feed) Furnace & (BF) and Direct Reduced Iron (DRI). 1 x 58.3 TPH (1600 TPD Throughput-for DRI feed) during rainy period. The net capital investment envisaged for the addition is Rs 68.3. lakhs. ii. Enhancement in production capacity of Blast Furnace from 1,75,000 TPA to 2,50,000 TPA without changing the configuration or size of Blast Furnace. Net Capital Investment or the enhancement is envisaged as Rs. 700 Lakhs. 3.4 Project description with process details i. Iron ore Washing & Wet Screening - Process Details (1 x 50 TPH & 1 x 58.3 TPH)

1. Iron Ore stored at existing day bin (3 Nos.) fed to online screen (3 Nos.). 450 MT x3= 1350 MT per day of Iron ore with fines is screened along with Water spraying on the existing on-line screen. 2. Generation of sludge of iron fines which is diverted to a series of settling tanks where fines getting settled in the sumps and clear water get accumulated in the last sump and again being pumped for spraying on screen. 3. The Process continues as shifting of settled slurry of fines to the fines storage tank  Shifting of fines to DRI. Shifting of accumulated water through storage tanks to existing settling  tank near GCP settling sumps.  After settling of fines, clear water to be pumped to thickener. Settled fines to be evacuated and shifted to fines storage tank. 4. Generation of washed iron ore (+10 mm sized) which goes directly on respective weigh bins for batching and feeding to furnace.

M/s VISA STEEL LIMITED Page 16 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Equipments & configuration/size envisaged for the washing & wet screening section

Sl. No. Equipment Washing & Wet Washing & Wet Screening Screening (Existing) (Proposed)

1. Screens 3 nos. --- 2. Weighing Bin 3 nos. -- 3. Spray nozzles -- Perforated pipe (3 sets each) 4. Water Transfer Pumps -- 2 nos. (1 working+ 1 standing) 5. Settling Tanks (12 m Length x 1 m width x 1 m depth) x 5 nos. ii. Increase in Production Capacity Process Details (175000 to 250000 TPA)

Reduction in the consumption of iron ore, coal and fluxes and the energy required for reducing each tonne of hot metal is at the core of technological research in iron making. To improve the productivity in the Blast Furnace process to over 3t /m3 of furnace volume, while using low grade ore, fines and coal, the following steps are being taken:  Injection of coal and other fuels to reduce coke rate.  Use of more agglomerated burden (pellets and sinter) – Improved permeability.  Reduction in slag rate and coke rate.  Mathematical models – burden and heat calculations.  Improvements in sinter and pellet quality for BF productivity.  Enhancement in blowing rate of air.  Oxygen Enrichment  Plastic Injection  Improvement in cooling system of the furnace Productivity measures in the form of bell less top, high top pressure, oxygen  improvement, humidity control etc.  Tap hole clay improvement for improved tap hole life.  Multiple tap holes.  Improvement in cast house practices. 3.5 ProcessImpro vDescriptionement in operating and maintenance practices.

Process description for 250 m3 Blast Furnace & increaseAnnexure in production-V. capacity of blast furnace from 175000 TPA to 250000 TPA is attached as

M/s VISA STEEL LIMITED Page 17 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. 3.6 Raw Materials required along with estimated quantity, likely source, marketing area of final products. Mode of transport of raw material and finished product

Raw material requirement for the proposed iron ore washing & wet screening system is 2950 TPD envisaged on 2950 TPD (1350 TPD + 1600 TPD) throughput for the system.

Also the raw material requirement for increase in production capacity of blast furnace from 175000 TPA to 250000 TPA is given below:

The main raw materials required for iron making:

Iron bearing material (Iron ore, sinter, pellets etc.) Coke as reluctant Flux materials

The major raw materials to be used for the installed mini blast furnace plant are iron ore lump, coke, limestone, dolomite, manganese ore and quartzite. The project has envisaged use of sinter as iron bearing material in future along with pulverized Coal Dust Injection (PCI) and oxygen enrichment of blast in future. Annual raw materials requirement for 1,75,000 t/a hot metal without considering sinter aAnndnuPCalI i sRshownaw Materin below:ials Requirement Raw Material Requirements RAW SIZE (mm) CONSUMPTION ANNUAL MATERIAL REQUIREMENT

GROSS TONNE TONNE KG/THM Daily

Iron ore 10-30 1850 323,750 1016 Coke- 25-75 780 136,500 Gross 428 Limestone 15-25 105 18,375 58 Dolomite 15-25 100 17,500 55 Manganese 10-30 25 4,375 ore 14 Quartzite 10-25 55 9,625 30 Note: In calculating the annual requirement of raw materials, plant annual production is considered as 1,750,000 Tonne .The consumption norms are based on basic grade pig Iron and a typical ore analysis.

The requirements of raw materials owning to increase in the capacity of furnace from 549 t/d to 715 t/d corresponding to 2,50, 000 tpa production is estimated as shown in table below: Raw Material Size (Mm) Consumption Annual Daily Requirement Requirement

M/s VISA STEEL LIMITED Page 18 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. KG/THM TONNE TONNE

Iron ore 10-30 1850 462,500 Coke (Gross) 20-60 680 170000 1490350 Limestone 15-25 105 26,250 80 Dolomite 15-25 100 25,000 75 Manganese ore 10-30 25 6,250 Quartzite 10-25 55 13,750 4020

Note: In calculating the annual requirement of raw materials, plant annual production is considered as 250,000 Tonne .The consumption norms are based on basic grade pig Iron and a typical ore analysis. 3.7 Resource Optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined.

Entire dust collected in Gas Cleaning Plant of Blast Furnaces and Scales of Cast House / PCM will be recycled in Sinter Plant.

Slag generated from BF will be granulated and 100% sold to cement making plants. Wastewater generated from BFs will be treated and reused. BF gas shall be partially reused in stoves for making hot blast and balance shall be used along with coke oven gas to generate power using Waste Heat Recovery Boiler based Power Plant . 3.8 Availability of water its source, energy /power requirement and source

3.8.1 Water Requirement and Source:

WaterI. RequirementFor Iron Ore forWashing the Project & Wet is describedScreening below: system

The one time water requirement for the system is envisaged as 240 KL, while the make- up water requirement for the evaporation and process losses is envisaged as 60 KLD.

Initially water consumption is 240 Mᶾ. Above process to be operated with the recirculation of water through the piping. There is no water much loss in the entire process, only approx.. 60 KLD will be the make-up water requirement. II. Increase in Blast Furnace production Capacity from 175000 TPA to 250000 TPA

There is no change in source of water and its quantity. Required water for the Integrated system is made available from the Brahmani / Kharshan river basin for which intake well & water pipe line from river to plant site has been laid. The make-up water requirement of the plant BF is estimated as 750Kl/day. However there is no extra requirement of water.

M/s VISA STEEL LIMITED Page 19 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

3.8.2 Power Requirement and Source

Power requirement for washing & wet screening plant is envisaged as 150KWH/THM and for enhancement of production from BF there are no more power will be required. There is no change in source of power. Power is made available for the existing VISA Steel Limited plant connected from the 220 kV New Duburi sub station located in the south west direction of the plant as well as 75 MW Captive Power Plant. Quantity of waste to be generated (liquid and solid) and scheme for their management / disposal

I. For Iron Ore Washing & Wet Screening system

Iron fines slurry to be treated with chemical at Iron fines slurry sumps to avoid contamination of water and there will be no waste water generation after treatment. Treated clean water will be re-circulated for washing.

ETP Detail & Solid Waste management

Iron fines slurry when dumped into slurry tank to be treated with Chemical to avoid contamination of water following which clear water is collected at last sump which is to be pumped again for spraying/washing of iron ore at on-line screens. With respect to Iron fines storage tank, very small quantity of water with iron fines is required to be shifted to existing settling tank and its clear water will be sent to existing thickener of GCP. The settled fines will be again be shifted to iron fines storage tank with the help of JCB/Poclain. Total 350 TPD tailings/fines will be generated and will be stored in the fines storage tank of size 21m x 7 m x 2 m. for DRI & 33m x 3 m x 1 m. The solid waste will be further accumulate at iron ore fines yard. II. Increase in Blast Furnace production from 175000 TPA to 250000 TPA 

 Slag generation will increase from 46000 TPA to 70700 TPA  Existing earmarked area for storage of slag generated is sufficient.  Slag from blast furnace will be granulated and sold as a by-product. The spent oil and lubricants will be given to authorized recyclers, as per approval of CPCB.

M/s VISA STEEL LIMITED Page 20 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER-4

SITE ANALYSIS

4.0 Site Analysis

4.1 Connectivity

The site is located in Kalinganagar Industrial Area of Orissa. The site is at about 110 km from Bhubaneswar. The Paradeep - Daitari Express highway (NH200) runs in the south west direction of the plant. Jakhapura railway station is the serving station for the entire industrial complex located in the south east direction of the plant. The Paradip port is located in the south west direction of the plant, which is about 120 km away from the plant. The existing Mideast & NINL plant located in the North West direction of the plant. Kalinganagar industrial complex also houses Jindal Stainless and Tata Steel plants situated nearby. 4.2 Land form, Land use and Land ownership

TheLandproposed Usage for project 1 x 50 will TPH be washing installed &within wet screening the existing plant premises of VISA Steel Ltd. a) Near Blast Furnace Land Usage- 1915 M²

 Break up:-  Iron ore fines storage = 1800 M²  Iron ore washing tank = 99 M² Water Pit = 16 M² Land Usage for 1 x 58.3 TPH washing & wet screening plant b) Near DRI Land Usage- 1207 M²

 Break up:-  Iron ore fines storage = 350 M²  Iron ore washing tank = 57 M² c) WaterIncrea soakingse in Blast Pit Furnace production= 800 Capacity M² from 175000 TPA to 250000 TPA

No additional land will be required.

M/s VISA STEEL LIMITED Page 21 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. 4.3 Topography

The project area form a part of land locked area and characterized by flat terrain and hillocks. The terrain of the land gradually slopes down from west to east and south-east direction. The difference between the maximum & minimum contour levels is approximately 20 m. The drainage pattern is dendritic type. Brahmani river flows on the south of the project area at a 4.4distanceExisting of 6km. Land Use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive area, water bodies (distance from the HFL of the river), CRZ, in case of notified industrial area, a copy of the Gazette notification should be given.

Table 4.1 Environmental Setting of the area

Aerial distance (within Name/ 15 km.) Proposed Sl.No. Areas Identit project location y boundary

Areas protected under international 1 conventions, national or local legislation for their No ecological, landscape, cultural or other related value

Areas which are important or sensitive for ecological 2 reasons - Wetlands, watercourses or other water No Not found bodies, coastal zone, biospheres, mountains, forests Areas used by protected, important or sensitive 3 species of flora or fauna for breeding, nesting, No Not found foraging, resting, over wintering, migration 4 Inland, coastal, marine or underground waters No Nil 5 State, National boundaries No Routes or facilities used by the public for 6 access to recreation or other tourist, No Not applicable pilgrim areas 7 Defence installations No Not existing 8 Densely populated or built-up area No Not existing (hospitals, schools, places of worship, coArmeamunitys occupifacileditiesby) sensitive man-made land 9 uses No Not existing

A(groundreas conwatertainingresources,important,surfacehighrequasources,lity or Only minerals like scarce resources coal and limestone 10 forestry, agriculture, fisheries, tourism, minerals) Yes are available nearby.

M/s VISA STEEL LIMITED Page 22 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

(those where existing legal eAnrveiaronmes alreantdayl subjstanedardscted to arepolleuxtcioneedeord) 11 environmental damage. No

Aearreatshqsuausckees,ptisubsideble to nace,turallandslihazarddes, erosion,which cofluoldoding cause the project to present environmental problems 12 or extreme or adverse climatic conditions No Not applicable ( ) 4.5 Existing Infrastructure

The site is located in Kalinganagar Industrial Area of Orissa. The site is at about 110 km from Bhubaneswar. The express highway run’s in the south west direction of the plant. Jakhapura railway station is the serving station for the entire industrial complex located in the south east direction of the plant. . The existing Mid east & NINL plant located in the North West direction of the plant. Kalinganagar industrial complex also houses Jindal Stainless and Tata Steel plants situated nearby. The 0.5 MT existing steel plant of VISA steel is located in the east of the proposed expansion project & adequate land is available for the proposed expansion. Soil Classification

The soil of the study area is generally sandy loam fine to coarse grained angular or granular, permeability is poor to moderate. 4.6 Climatic data from secondary sources

The climate is characterized by hot summer with high humidity throughout the year. May 0 month is usually the hottest with daily maximum of 47 C and mean daily on yearly basis is 0 27.15 C. Average annual rainfall is 1487 mm. 4.7 Social Infrastructure available

Hospitals, schools, places of worship, community facilities are present within 15 km radius.

M/s VISA STEEL LIMITED Page 23 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER-5 PLANNING BRIEF 5.0 Planning Brief 5.1 Planning concept (type of industries, facilities, transportation etc.,) town and country planning/development authority classification

5.2 ThisPopulation is ‘A’ Category Projection Project as per EIA Notification 14-9-2006 and requires EC.

To operate and maintain the plant facilities, including its technical and general administration needs, the Categoryestimated wise manpower break -worksup of manpowerout to 3869

Sl. No. Category Manpower Requirement 1. Managerial 30 2. Executive 545 3. Skilled 903 4. Semi-skilled 809 5. Unskilled 1457 6. Clerical 125 5.3 Land Use Planning (breakup along with greenbelt etc.,) Total 3869 Facilities Area allocation in acre

Plant Facilities 241 Storage (Fuel) 4 Water Storage & Treatment 15 Rain water harvesting pond 4 Raw material Storage 42 Solid waste Disposal 35 TotalInternal Roads 52511 Green belt 173

5.4 Assessment of Infrastructure Demand (physical & social)

5.5 NoAmenities/Facilitiesadditional infrastructure is required for capacity enhancement.

No additional amenities / facilities is required for capacity enhancement. The existing amenities / facilities are adequate for the BF production enhancement.

M/s VISA STEEL LIMITED Page 24 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER-6

PROPOSED INFRASTRUCTURE 6.0 PROPOSED INFRASTRUCTURE

There is no change in the land area, greenbelt area and general layout plan of the project. 6.1 Industrial Area (processing area) The expansion of capacity will be within existing area. There is no change in the plant area of 241 acres, Raw material storage 42 acres and solid waste disposal/storage area of 35 acres. The 0.74 acres for the washing and wet screening section will be part of the existing plant area.

6.2 Residential area (Non-processing area)

No change. The facilities like water storage and treatment – 15 acres, rain water harvesting – 4 acres and internal roads – 11 acres will remain same. 6.3 Green Belt

Greenbelt / plantation already have done over 33% (i.e. 173 acre) of the total plant area. In the future the gap filling will be done as required to enhance the tree density . 6.4 Social Infrastructure Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure.

6.5 Connectivity (traffic and transportation road/rail/ metro/water ways etc.,)

The plant is located in Kalinganagar Industrial Area of Orissa. The site is at about 110 km from Bhubaneswar. The Paradeep - Daitari Express highway (NH200) runs in the south west direction of the plant. Jakhapura railway station is the serving station for the entire industrial complex located in the south east direction of the plant. The Paradip port is located in the south west direction of the plant, which is about 120 km away from the plant. The existing Mideast & NINL plant located in the North West direction of the plant. Kalinganagar industrial complex also houses Jindal Stainless and Tata Steel plants situated nearby.

M/s VISA STEEL LIMITED Page 25 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. 6.6 Drinking water management (source & supply of water)

Water requirement will increase from 1250 KLD to 1370 KLD. Required water for the proposed plant is made available from the Brahmani / Kharshan river basin for

6.7 Seweragewhich intake system well & water pipe line from river to plant site has been laid.

The domestic waste water is collected in respective section collection sump and transferred to collection tank of STP. From collection tank the waste water is pumped to FAB reactors where the BOD reduction takes place with the help of air and media in suspension. From the reactor the treated water along with sludge goes to tube settler where sludge is removed and sent to sludge drying beds. The clear treated water is collected in filter feed tank from where it is pumped through Pressure Sand Filter and activated carbon Filter where sodium hypochloride solution is dosed for disinfection. The final treated water is re-used for various purposes.

PROCESS BLOCK DIAGRAM

Screen Oil & Grease Equalization Chamber Trap Tank

FAB-2 FAB-1

Sludge drying bed Tube settler

RAW WATER Storage 90 m3

Chlorination

M/s VISA STEEL LIMITED Page 26 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

DMF 15m3/hr

ACF 15m3/hr

TREATED WATER TANK For Distribution 90m3

6.8 Industrial waste management I. For Iron Ore Washing & Wet Screening system

Iron fines slurry to be treated with chemical X at Iron fines slurry sumps to avoid contamination of water and there will be no waste water generation after treatment. Treated clean water will be re-circulated for washing.

Total 350 TPD tailings/fines will be generated and will be stored in the fines storage tank of size 21m x 7 m x 2 m and for DRI & 33m x 3 m x 1 m. The solid waste will be II. furtherIncrease collected in Blast at Furnace iron ore productionfines yard. from 175000 TPA to 250000 TPA 

 Slag generation will increase from 46000. TPA to 70700 TPA  Existing earmarked area for storage of slag generated is sufficient. Slag from blast furnace will be granulated and sold as a by-product. The spent oil and lubricants will be given to authorized recyclers, as per approval of SPCB. 6.9 Power requirement & supply/ source

Power is made available for the existing VISA Steel Limited plant connected from the 220 kV New Duburi sub station located in the south west direction of the plant as well as 75 MW Captive Power Plant.

M/s VISA STEEL LIMITED Page 27 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER-7

REHABILATION & RESETTLEMENT (R&R) PLAN

7.0 Rehabilation & Resettlement (R&R) Plan

7.1 Policy to be adopted (central/state) in respect of the project affected persons including home oustees, land oustees and landless laboureres (a brief out line to be given).

Not applicable. As the entire land area of 525 Acre (Visa Steel-476 & Visa Bao-50 Acre) is in possession of the company and no additional land is required for this project. The proposed project will be installed within the existing premises, hence no question of Rehabilitation & Resettlement.

M/s VISA STEEL LIMITED Page 28 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER-8

PROJECT SCHEDULE & COST ESTIMATES

8.0 Project Schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion (time schedule for the project to be given).

It is planned that the preparatory work for the project like financial tie-up, appointment of project consultant, clearance from statutory authorities, etc. will be completed prior to8.2 zero Estimated date. project cost along with analysis in terms of economic viability of the project

a) Investment for 1 x 50 TPH washing & wet screening plant for BF The net capital Investment is Rs.385,000/- The details of net capital Investment is given below: only) Net Capital Investment- INR 385,000 (Rupees Three lakhs eighty five thousand Break up:-  Pump with motor = INR 250,000  Pipes and fittings = INR 100,000 Solenoid operated valve = INR 35,000 TOTAL = INR 385,000

b) Investment for 1 x 58.3 TPH washing & wet screening plant for DRI Capital Investment on Machineries- INR 1,000,000 (Rupees Ten lakhs only) Break up:-  Slurry Pump with motor = INR 750,000  Water recirculation pump with motor = INR 150,000 Pipes and fittings = INR 100,000 TOTAL= INR 1,000,000 c) Increase in production capacity of blast furnace from 175000 TPA to 250000 TPA

The cost envisaged for enhancement of capacity for blast furnace from 175000 TPA to 250000 TPA each is Rs. 7.0 Crores.

M/s VISA STEEL LIMITED Page 29 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CHAPTER-9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.0 Analysis of Proposal (final recommendations)

The state of Odisha will get revenues in terms of taxes, local people will get opportunity in terms of indirect employment, business opportunity, in short nearby people will get opportunity to improve their livelihood.

9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area.

Details of the CSR Expenses is given in the table below: CSR EXPENDITURE UPTO FEB,2018 (FY 2017-18)

Projects or 1 2 3 Programmes4 7 carried out in Sector in Local Area or Cumulatative Sl. which the Other (Specify expenditure CSR Project or activity Undertaken No. Project is the State or upto (Feb Covered District where '2018) the Projects or programme was undertaken

Jakhapura or 1 Conduct Mega Health Camp at Jakhapura Nearby Villages Conduct Awareness Camp on Hygiene in neraby School Health 2 Nearby Villages and Villages Awareness Campaign for preventive measure against 1,89,561 3 Dengue, Malaria etc and necessary medication in Rainy Nearby villages Season 4 Conduct Monthly camp Nearby Villages Boring, installation of overhead tank for supply of drinking Jakhapura & 5 water Drinking nearby villages Water Installation of overhead tank & connect the same to Mantira 6 existing borewell 5,08,731 Military Chhak Jal Chhatri at "Military chhak & Gopanandhu Chhak" in 7 and Gopabandhu Summer Sports & Chhak culture 8 Sports training program to the youth of nearby villages 9 Conducting cultural programm in nearby villages Infrastructure 1,36,600 10 Construction of Anganwadi building in Trijanga village

M/s VISA STEEL LIMITED Page 30 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

11 Development of park near factory main gate (JCDL Land) - Conveyance to school-going children of Kudmisahi to 12 Kudmisahi Jakhapura and Nearby areas Korei & Jajpur 13 Construction of Toilet in Schools Road One time Sponsor for Meritorious Students (03 Nos) for 14 enhanching knowldege for Competitive Exams Providing transport facility once in a year for educational Education 15 visit Plantation Expenses(Gardening and Plantation near 95,905 16 Hostel, Staff Quarters) and its Maintenance 17 Development of Playground

18 Main Gate with Aesthetic Desgn along with sign board

19 Computer Training including Study Material Cost Computer Training including Study Material Cost in other 20 Nearby Villages Tailoring training institute at Jakhapura 21 Women ( including House rent and The salary for teaching staff) Jakhapura Empowerment 22 Motivational training lto women Nearby villages 23 Training to different types of recepies Nearby villages 2,10,909 24 Awareness program for health care of ladies Nearby villages 25 Yoga training to ladies Nearby villages Garden Island at 26 Maintenance of Garden Island and Electricity Charges Miliatry Chhak Jakhapura, Kudmisahi, 27 Distribution of Fruit Plants in Nearby Villages(1000 nos) Environmental Balungabandi etc Protection & 28 Maintenance of Kadam Garden near Jakhapura Beautification Jakhapura Distribution of Plants in Vivekananda Sikshya Kendra, Jakhapura, 7,82,681 Jakhapura, Balungandi Upper Primary School, Kudmisahi Kudmisahi & 29 Pre-School Edcation Centre & Other Nearby school and Balungabandi villages (Jakhapura, Balungabandi, Kudmisahi, Aulapal), RIET International School Military Chhak to 30 Watering of Roads from Military Chhak to Jakhapura Jakhapura 31 Aahar Scheme Jajpur Other Projects 32 Any Local Project Jajpur 33 Jajpur Zilla Mahotsav Jajpur 1,03,280 34 Vyasasarovar Utsav/Industrial Trade Fair Jajpur 35 District Red Cross Society Jajpur TOTAL 20,27,667

M/s VISA STEEL LIMITED Page 31 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

CONCLUSION:

As enumerated in the foregoing paragraphs, the designed capacity of the MBF plant was 2.5 Mt / year. This could not be achieved due to numerous reasons cited in the report. Subsequently with the modifications carried out during the capital repair of the MBF plant in 2016, the capacity has been restored to 2,50,000 t / year. Now the plant has been stabilized and giving the daily hot metal production of 700-715 tpd. M/s VSL had taken appropriate measures to debottleneck upstream and downstream facilities and properly augmented them to match with the increased production of hot metal. No adverse effect on environment is envisaged as proper mitigation measure will be taken up for the same.

M/s VISA STEEL LIMITED Page 32 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha. Annexure-I

M/s VISA STEEL LIMITED Page 33 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 34 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 35 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 36 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 37 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Annexure-II

M/s VISA STEEL LIMITED Page 38 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 39 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 40 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 41 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 42 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Annexure-III

M/s VISA STEEL LIMITED Page 43 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

M/s VISA STEEL LIMITED Page 44 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Annexure-IV

Statement

Sl. No. Existing Proposed

1. Rolling Mill (0.5 MTPA) -- 2. DRI Kiln (I & II) 2x500 TPD -- 3. CPP -75 MW (50 MW WHRB+25 MW CFBC) -- 4. Ferro Chrome Plant (FAP) 2x16.5 MVA (50,000 --- TPA) 5. Blast Furnace -1x250m3 (1,75,000 TPA Pig Iron) 1,75,000 TPA to 2,50,000 TPA 6. SMS (0.5 MTPA) -- Electric Arc Furnace (EAF)-1x80 T -- Ladle Refinery Furnace (LRF)-1x80 T -- Bilet Caster (1x3/4 Strand -- Dry Screening of Iron Ore Iron Ore Washing & Wet 1x 50 TPH (1350 TPD Throughput-for BF feed) & Screening System 1x58.3 TPH (1600 TPD Throughput-for DRI feed) 1x 50 TPH (1350 TPD Throughput-for BF feed) & 1x58.3 TPH (1600 TPD Throughput-for DRI feed)

M/s VISA STEEL LIMITED Page 45 Pre-feasibility Report for addition of Wet Screening System to Blast Furnace & DRI for Iron Ore Processing. Increase in Blast Furnace capacity from 1,75,000 to 2,50,000TPA of M/s Visa Steel Limited At- Kalinga nagar Industrial Complex, Jajpur, Odisha.

Annexure-V

Increase in Production Capacity Process Details (175000 to 250000 TPA)

Reduction in the consumption of iron ore, coal and fluxes and the energy required for reducing each tonne of hot metal is at the core of technological research in iron making. To improve the productivity in the Blast Furnace process to over 3t /m3 of furnace volume, while using low grade ore, fines and coal, the following steps are being taken:  Injection of coal and other fuels to reduce coke rate.  Use of more agglomerated burden (pellets and sinter) – Improved permeability.  Reduction in slag rate and coke rate.  Mathematical models – burden and heat calculations.  Improvements in sinter and pellet quality for BF productivity.  Enhancement in blowing rate of air.  Oxygen Enrichment  Plastic Injection  Improvement in cooling system of the furnace Productivity measures in the form of bell less top, high top pressure, oxygen  improvement, humidity control etc.  Tap hole clay improvement for improved tap hole life.  Multiple tap holes.  Improvement in cast house practices. Improvement in operating and maintenance practices.

M/s VISA STEEL LIMITED Page 46 -

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