STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT Modernization-cum-expansion of Bokaro Steel plant by up-gradation of existing SMS-I(1.306 MTPA), debottlenecking of SMS-II (3.35 MTPA) & existing CRM complex (1.66 MTPA), installation of new kiln of 450 TPD in Lime plant, a new Sinter Plant(3.7MTPA) and Oxygen plant (1250 TPD on BOO basis) without increasing the overall production capacity of 5.77 MTPA hot metal. PROJECT SUMMARY 1. INTRODUCTION Bokaro Steel plant (BSL) has already been accorded EC on 16.10.2008 by MoEFCC for expansion of its capacity from 4.0 MTPA to 7.0 MTPA of crude steel vide memo no. J-11011/99/2007-IA II(I). Extension of the EC was accorded for a period of five years w.e.f. 15.10.2013 vide memo no. J- 11011/99/2007-IA.II(I) dtd. 24.01.2014. Further, this earlier EC (valid until 14.10.2018) has been granted an amendment by MoEFCC for modifications in some existing plant facilities of BSL along with reduction of overall plant production capacity to 4.606 MTPA Crude Steel (5.77 hot metal) vide MoEFCC letter F.No J-11011/99/2007-IA.II(I) dated 28.11.2014. The proposed modifications to the project will be carried out within the existing plant premises of Bokaro Steel Plant which is located in vicinity of BIADA industrial estate of Bokaro Steel City, Sub-division Bokaro of Bokaro District in Jharkhand, at longitude 86°02' to 86°10’ E and latitude 23°38' to 23°42' N. The plant is situated 215 to 243m above MSL gently rolling towards River Damodar, flowing west to east. In addition to the above, BSL has been granted EC amendment vide MoEFCC’s letter J-11011/99/2007- IA II(I) dated 13.12.2017 for development of an alternate water pipeline system for drawl of raw water from Damodar river. The existing water source, i.e. Tenu Canal, which is also the only source of water for all plant activities as well as township of BSL, is over 50 years old and requires immediate repair as well as restoration works in view of recent breakdowns. Post EC amendment granted on 28.11.2014, BSL has been progressively installing the different projects of the amended expansion-cum-modernization program, which are presently at an advanced stage of implementation. However, for completion of phase-1 up-gradation of SMS-1 and installation of the new Sinter plant-II of 3.7 MTPA capacity, more time is requested as inordinate delay has occurred because of procedural delays in design & engineering activities as well as site clearance activities necessary for enabling subsequent construction activities for SMS-1 up-gradation as well as installation of Sinter Plant-II. In addition to the above, only (01) one out of the (02) two 1250 TPD Oxygen plants envisaged originally during the expansion of Bokaro Steel plant from 4 MTPA to 7.0 MTPA (reduced to 4.606 MTPA crude steel later) could be installed. The other 1250 TPD Oxygen plant (BOO basis) has been included in the proposed modernization-cum-expansion program. It is also proposed to improve the performance of existing steel-making as well as downstream facilities by execution of some of the debottlenecking facilities which will augment the existing facility of steel making at SMS-II from 3.3 MTPA to 3.35 MTPA resulting in increase overall capacity of crude steel to 4.656 MTPA and existing CRM complex from 1.2 MTPA to 1.66 MTPA. Further, the development of alternate water pipeline system will require more time to complete due to delays in project execution activities. In view of the above, BSL proposes to include the aforementioned activities in the proposed modernization-cum-expansion program. 2. PRESENT PROPOSAL In view of modernizing and improving the existing facilities of Bokaro Steel Plant, BSL has contemplated the up-gradation of existing units, execution of debottlenecking activities as well as addition of some new facilities in the proposed modernization-cum-expansion programme. The overall hot metal production capacity will not change from 5.77 MTPA as per earlier EC and its amendments © 2018 MECON Limited. All rights reserved 1 - 1 STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT Modernization-cum-expansion of Bokaro Steel plant by up-gradation of existing SMS-I(1.306 MTPA), debottlenecking of SMS-II (3.35 MTPA) & existing CRM complex (1.66 MTPA), installation of new kiln of 450 TPD in Lime plant, a new Sinter Plant(3.7MTPA) and Oxygen plant (1250 TPD on BOO basis) without increasing the overall production capacity of 5.77 MTPA hot metal. granted thereof. The modifications, up-gradations and capacity enhancements of various units envisaged in the proposed modernization-cum-expansion program of BSL is mentioned below: Sl. Name of Capacity of units Changes proposed in Total capacity after proposed No. units/products (as per existing EC & all modernization-cum-expansion modernization-cum-expansion amendments thereof) programme programme 1. Hot Metal 5.77 MTPA No change 5.77 MTPA 2. Crude Steel 4.606 MTPA 4.656 MTPA with some proposed 4.656 MTPA debottlenecking projects. 3. Coke Oven 3.442 MTPA coke No change 3.442 MTPA Complex 4. Blast Furnace 5.77 MTPA Hot metal No change 5.77 MTPA Complex 5. Sinter Plant 8.7 MTPA (5 MTPA + 3.7 MTPA) -1 new sinter plant of 360 m2 grate 8.7 MTPA Complex area of 3.7 MTPA (included in new (5 MTPA + 3.7 MTPA) proposal due to delay in installation activities) No change in overall sinter production (8.7 MTPA) as per earlier EC amendment granted. 6. SMS Complex SMS-I - SMS-I up-gradation to 1.306 4.656 MTPA (1.306 MTPA + 3.35 [upgraded from 1.5 MTPA to Stage- MTPA included in new proposal due MTPA) 1: 1.306 MTPA] to delay in installation activities. No change in capacity of 1.306 MTPA as per earlier EC amendment granted. SMS-II (with capacity augmentation - Execution of some to 3.30 MTPA) debottlenecking facilities of SMS-II Tot. Capacity: 4.606 MTPA (1.306 will augment the capacity to 3.35 MTPA + 3.30 MTPA) MTPA. 7. Slabbing Mill - Universal Slabbing Mill with 7 no. No change - soaking pit batteries 8. Hot Strip Mill 4.5 MTPA No change 4.5 MTPA 9. CRM complex Existing CRM Complex: 1.2 - Execution of some 2.86 MTPA (1.66 MTPA + 1.2 MTPA debottlenecking facilities at existing MTPA) New CRM Complex: 1.2 MTPA CRM complex will augment the Tot. Capacity: 2.4 MTPA (1.2 capacity to 1.66 MTPA. MTPA + 1.2 MTPA) 10. Lime-Dolo Kiln - 6 x 270 TPD (4 kiln in operation: - New kiln of 450 TPD will be added 6 x 270 TPD (existing) + 1 x 450 (Existing Rotary 3 for lime + 1 for dolomite) TPD (new) Kiln for SMS-II) 11. Oxygen Plant Tot. Capacity: 3950 TPD No change. Installation of earlier 3950 TPD (1450 TPD captive plant + 2x1250 envisaged of 1250 TPD Oxygen [1450 TPD (existing plant) + TPD BOO plant) plant (BOO) 1250 TPD (existing BOO Plant) + 1250 TPD (new)] 12. Water supply Tenu Canal along with alternate No change. Alternate water Tenu Canal along with alternate system water pipeline system pipeline system included due to water pipeline system delay in project execution activities. © 2018 MECON Limited. All rights reserved 1 - 2 STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT Modernization-cum-expansion of Bokaro Steel plant by up-gradation of existing SMS-I(1.306 MTPA), debottlenecking of SMS-II (3.35 MTPA) & existing CRM complex (1.66 MTPA), installation of new kiln of 450 TPD in Lime plant, a new Sinter Plant(3.7MTPA) and Oxygen plant (1250 TPD on BOO basis) without increasing the overall production capacity of 5.77 MTPA hot metal. 3. PROJECT DESCRIPTION 3.1 Site Location The proposed modernization-cum-expansion of existing Bokaro steel plant will be carried out within the plant premises of existing Bokaro Steel (BSL) plant which is located at Bokaro Steel city, Sub-division Bokaro of Bokaro District in Jharkhand, between longitude 86° 02’ to 86°10’E and latitude 23°38’ to 23°42’ N near River Damodar. 3.2 Land & R&R Issues No additional land acquisition is required for the proposed modernization-cum-expansion programme of BSL as the proposed modernization-cum-expansion of existing Bokaro steel plant will be carried out within the plant premises of existing Bokaro Steel (BSL) plant. Consequently, no R&R issues are involved. 3.3 Water Water demand shall be met from the existing water allocated to BSL and no additional water source will be required for the proposed modernization-cum-expansion program. An alternate system of drawl of raw water from Damodar River through pipelines will be developed along with existing Tenu Canal. 3.4 Pollution load, effluent and solid waste generation and utilization The proposed modernization-cum-expansion of existing Bokaro steel plant will be carried out without increasing the overall production capacity of 5.77 MTPA of hot metal as per earlier EC and its amendments granted thereof. The solid waste generation, effluent generation and the total pollution load will marginally increase due to ~1% increase in overall crude steel production from 4.606 MTPA (CS) as envisaged at EC stage to 4.656 MTPA (CS) as proposed now. The re-utilization/disposal pattern of solid waste as well as effluent management will be done as per applicable rules and statutory guidelines.