ADDITIONAL DETAILS SOUGHT BY
EAC (INDUSTRY-1), MOEF&CC, NEW DELHI
FOR
ENVIRONMENTAL CLEARANCE
FOR
THE PROPOSED 10.0 MTPA INTEGRATED STEEL PLANT, 900 MW CAPTIVE
POWER PLANT AND TOWNSHIP NEAR BARENDA VILLAGE, SONAHATU
BLOCK, RANCHI DISTRICT, JHARKHAND STATE
Project Proponent
JSW JHARKHAND STEEL LIMITED
RANCHI, JHARKHAND
Environmental Consultant:
Vimta Labs Limited
142, IDA, Phase-II, Cherlapally, Hyderabad–500 051,
www.vimta.com
(QCI/NABET Accredited EIA Consultancy Organization
NABL/ISO 17025 Certified Laboratory, Recognized by MoEF, New Delhi)
October, 2015
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
I
INTRODUCTION
M/s. JSW Jharkhand Steel Limited proposes to establish 10.0 Million Tonnes
Per Annum (MTPA) capacity Integrated Steel Plant (ISP) along with 900 MW
Captive Power Plant (CPP) and township near Barenda village, Sonahatu block in
Ranchi district of Jharkhand state.
II
PURPOSE OF THE REPORT
The proposed project proposal was considered by the reconstituted Expert
Appraisal Committee (Industry) in its 6th meeting held during 5th- 7th March, 2013
and further reconsidered in its 8th meeting held during 16th and 17th May 2013, for
prescribing TORs vide their letter no. F. No. J-11011/377/2012-IA-II (I) dated 24th
June, 2013 for undertaking detailed EIA/EMP study.
EIA/EMP has been prepared and submitted to state PCB for conducting public
hearing which was held on 21/9/2014 and public concerns and comments were
taken into consideration for preparing the final EIA/EMP report. Final EIA/EMP
report was submitted to MoEF&CC on 18/03/2015.
The project proposal was considered by 37th Expert Appraisal Committee, MoEF&CC
for Environmental Clearance during meeting held on 1st May, 2015 at New Delhi.
After detailed deliberations, the committee sought the following additional
information to be submitted for further consideration.
SR. NO
1
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ADDITIONAL INFORMATION POINTS
Land details provided in the EIA report at page C2-10 should be
resubmitted clearly indicating the type of land and actual land in
possession. The unit should be in Ha
Detailed plan should be submitted for the storage of raw material
with emission mitigation measures
Complete details for the proposed ETP for the Blast Furnace and
Coke oven plant, including design of ETP to meet the cyanide
standards stipulated by MoEF under EPA Act 1986 should be
provided
Details regarding use of SMS and BF slag / flyash in cement
manufacturing should be provided
Revise ash balance and ash equalization plan should be
submitted
Trace element report should be corrected and submitted
Iron ore analysis to be rechecked and submitted
Stamp charging + HPLA commitment in coke oven plant to be
provided
Commitment for the use of CDQ to be submitted
Details regarding Poly aromatic hydro carbon monitoring should
be submitted
SMS slag utilization scheme to be submitted
SMS plant-dog house details for fugitive emission centres should
be submitted
SMS–dry system to be adopted and details should be submitted
VIMTA Labs Limited, Hyderabad
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1
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
14
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Sinter plant–secondary emission mitigation detail should be
provided
Advanced CO monitoring system should be established and
details should be provided
Specific water consumption and water balance should be
submitted
SOx, NOx line emission data used for all the units, including flow
rate taken should be submitted
Revised table for pollution control measures should be submitted
Details on benzol plant as Tar utilisation should be provided
Action plan for waste management for each component should
be submitted
The Committee prescribed an amount of Rs. 700 cr over a period
of 10 years for the CSR related activity. A detailed plan in this
regard should be submitted
Town plan detail should be submitted including the layout of the
buildings, green belt, internal roads, STP, parking plan etc
Details regarding the proposed captive thermal power plant
should be submitted
Commitment to achieve zero effluent discharge in coke oven as
BF to be provided
44
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63
71
73
75
100
The present report includes the replies to the above points sought by EAC,
MoEF&CC, New Delhi.
III
POINT WISE REPLY ON THE QUERIES
1.0
LAND DETAILS PROVIDED IN THE EIA REPORT AT PAGE C2-10 SHOULD BE
RESUBMITTED CLEARLY INDICATING THE TYPE OF LAND AND ACTUAL
LAND IN POSSESSION. THE UNIT SHOULD BE IN HA.
The proposed project will be developed over an area of 1538 ha of land falling in 7
villages. There are mainly 3 types of land involved, (a) Raiyati land (Non-CNT land)
(b) Raiyati land (CNT land) and (c) Government land (GM land). The details of
actual land in possession (land in ha) till date is given below:
VIMTA Labs Limited, Hyderabad
2
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
VIMTA Labs Limited, Hyderabad
3
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW Captive Power Plant and Township near Barenda
Village, Sonahatu Block, Ranchi District, Jharkhand State
VIMTA Labs Limited, Hyderabad
4
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
2.0
DETAILED PLAN SHOULD BE SUBMITTED FOR THE STORAGE OF RAW
MATERIAL WITH EMISSION MITIGATION MEASURES.
Facilities to be provided for receipt, unloading, stacking, reclamation, blending and
distribution of different raw materials have been described below.
2.1
Raw Material Handling Systems (RMHS)
The major raw material include iron ore fines, iron ore lumps, coking coal, non-coking
coal (for CDI), limestone and dolomite. The locations of major raw material storage
and handling facilities shall be planned carefully to have optimum conveyor length
from storage yards and to the wagon tipplers. The annual requirement of major raw
materials required for the proposed steel plant is indicated in TABLE-2.1.
TABLE-2.1
PROJECTED ANNUAL REQUIREMENT OF MAJOR RAW MATERIALS
Sr. No.
Raw Material
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Iron Ore fines for Beneficiation Plant
Iron Ore Lumps
Limestone (BF Grade)
Dolomite (BF Grade)
Quartzite
Limestone (SMS Grade)
Dolomite (SMS Grade)
Coking Coal for Captive Mines
Imported Coking Coal
Non-Coking Coal for PCI
Thermal Coal
Bentonite
Ferro Alloy
Limestone/clinker (Cement/Grinding unit)
Gross Annual
Requirement
(Million Tonnes)
29.00
0.90
1.30
1.10
0.14
1.60
0.70
5.52
4.80
2.30
3.00
0.40
0.20
6.00
Following points have been considered while finalizing the system design concept.
i.
ii.
iii.
iv.
v.
The major raw materials like iron ore fines, iron ore lump, coking coal, fluxes,
limestone and dolomite will be brought to the plant by railway wagons and
unloaded by wagon tipplers.
Transportation of raw materials like iron ore fines, iron ore lump coking coal and
limestone and dolomite from RMHS to respective hoppers/bunkers of consuming
units will be done accordingly. The limestone required for pellet plant, may be
transported from RMHS yard to pellet plant by truck/dumpers since the quantity
is small.
RMHS yard will be designed for minimum storage requirement of all major raw
materials which will be finalised during detailed engineering.
Pellet storage facilities will be provided inside the pellet plant.
The finished product i.e. pellets can either be transported to DR plant or blast
furnace by belt conveyor or may be stored in the pellet storage yard with the help
of a movable tripper. Pellets will be reclaimed from the yard as and when required
and sent to DR plant and blast furnace by the belt conveyor system.
VIMTA Labs Limited, Hyderabad
5
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
vi.
vii.
viii.
ix.
x.
xi.
SMS grade limestone and dolomite will be reclaimed from RMHS yard and sent to
lime calcinations plant (LCP) by belt conveyor.
Burnt lime and calcined dolomite from LCP to SMS will also be transported by belt
conveyors.
Coking coal from RMHS yard to coke oven will be transported by means of belt
conveyor system.
Sinter plant raw material will be transported from RMHS to sinter plant by belt
conveyor system.
The blast furnace will receive its ferrous burden from sinter plant and pellet plant.
Coke will be transported from coke oven to BF by belt conveyor system and the
additives will also be transported from RMHS to stock house by belt conveyor
system
The slag generated from the blast furnace will be transported to slag grinding unit
after granulation.
Design of Raw Material Handling System is indicated in TABLE-2.2.
TABLE-2.2
DESIGN OF RAW MATERIAL HANDLING SYSTEM
Material Req.
for 10.0 Mtpa
Steel Plant
Bulk
Density
t/yr
t/m3
Size
Nos.
Storage
(t)
Days
Iron Ore Fines
29,900,000
2.3
500m x 36m x 11m
4
910,800
10
Iron Ore Concentrate
22,000,000
2.1
500m x 36m x 11m
2
415,800
7
Base Mix
Raw Material
2.2
Longitudinal Covered Storage
Stockpile Size
Storage
Capacity
16,500,000
1.9
500m x 36m x 11m
4
752,400
16
Indigenous Flux
8,540,000
1.5
500m x 36m x 11m
3
445,500
17
Imported Flux
2,300,000
1.5
500m x 36m x 11m
1
148,500
21
PCI Coal
1,600,000
0.8
500m x 36m x 11m
1
79,200
16
Unwashed Coking Coal
7,820,000
0.8
500m x 36m x 11m
3
237,600
10
Washed Coking Coal
3,900,000
0.8
500m x 36m x 11m
1
79,200
7
Imported Coking Coal
4,800,000
0.8
500m x 36m x 11m
5
396,000
26
Thermal Coal
3,000,000
0.8
500m x 36m x 11m
2
158,400
17
Brief Description of RMHS
Wagon tipplers in combination with side arm chargers have been envisaged for
unloading BOX/BOXN and other types of tippable wagons. The track system provided
along with tipplers and track hoppers are adequate to handle a full train consisting
of 45 Nos. of BOBS wagons or 58 Nos. of BOXN wagons and also to cater to the
future increased number of wagons per train.
The incoming materials from wagon tipplers will be conveyed from unloading yard to
the storage yard for stock piling through conveyor systems. Each line of the conveyor
system between raw materials unloading yard and raw materials storage yard are
designed to convey materials at a suitable rate which shall be finalised during
detailed engineering.
VIMTA Labs Limited, Hyderabad
6
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Pellet Handling System
Pellets from the pellet plant can either go to the screen house or stored in the pellet
yard through a stacker-cum-reclaimer. After screening, over size is carried to DR plant
and under size is stored in bunker for evacuation and reuse. Also, pellets will be
transported to BF stock house by conveyor from Pellet plant.
Product Handling System
DRI from product bins of DR plant will be conveyed to the storage bunkers of DRI in
steelmaking shop. Required quantity of DRI, lime and dolomite will be drawn from the
storage bunkers in SMS by belt weigh feeders which will discharge the material on to
another conveyor which can feed the material either to BOF or to the ladle furnace
through movable type vibro feeder and chute. The materials will be dribble fed into
BOF during melting operation.
Ferro Alloy Handling System
Ferro alloys i.e., ferro-manganese, ferro-silicon and other materials like spar, etc. will
be brought to SMS from central stores by trucks in self discharging type containers.
The containers will be lifted crane and materials discharged into the storage bunkers
by placing the containers on the storage bunkers. The empty containers will be sent
back to the central stores for refilling.
Required quantity of ferro alloys and other additives will be drawn from the storage
bunkers by electromagnetic vibro feeders and weigh hoppers which will discharge the
material on to another conveyor which can feed the material either to ladle or to the
ladle furnace on to the RH-TOP through conveyor.
Provision will be kept for programmed charging of bulk materials and ferro alloys in
the BOF, ladle furnace and RH-TOP. Suitable provision of suction of dust through
suitably designed duct network will be kept. The same will be cleaned and discharged
to the atmosphere through tall stacks.
Ore and Flux Supply System to Sinter Plant
Iron ore fines, limestone, dolomite and coke breeze will be reclaimed from the storage
yard by respective stacker–cum-reclaimer and these materials will be transported to
sinter plant bins through a system of conveyors.
Miscellaneous plant arising’s from lime and dolo calcination plant, mill scale, flue dust,
return sinter fines will be transported by belt conveyor to sinter plant bins.
Transportation of Material to Blast Furnace
Sinter from sinter plant and pellet from pellet plant will be conveyed to blast furnace
stock house by belt conveyors. Sized coke will be transported to BF stock house
directly from coke oven battery through a well-developed conveyor system.
Coal Handling System
Coal will be received in railway wagons and unloaded by wagon tippler. Coal will be
conveyed to coal storage yard by belt conveyors and stock pile will be made by
stacker–cum-reclaimer. Reclaimed coal will be sent to coal preparation unit for
processing prior to charging to ovens and also to CPP and Coal Dust injection for Blast
Furnaces.
VIMTA Labs Limited, Hyderabad
7
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
List of Major Equipment in RMHS
Major equipment of Material Handling System are:•
•
•
•
•
•
•
•
•
•
•
•
•
•
Belt Conveyors and related equipment, Belt Feeder, Shuttle Conveyor and
Reversible Shuttle Conveyor System
Vibratory Feeders
Gates
Motorised Diverter Gate
Weigh Hoppers
Belt Weigh Scales (BWS)
Vibration Isolation System
Travelling Tripper and Bunker Sealing Arrangement
In-line Magnetic Separator (ILMS) & Suspended Magnetic Separators
Metal Detectors (MD) & Magnet
Charging hatches
Cranes and Hoists
Transfer Cars
Vulcanising Machine and Mobile Belt Changing units
However for liners in different area such as all storage bins/ bunkers, chutes, skirts,
flap gates etc. shall be provided with suitable wear liners ensuring the flow ability.
The liner schedules are as follows:

Bunkers and wagon tippler hopper
For lump size between 20 mm to 80 mm, Special Steel reinforced rubber liner of 40
mm thick (min) / ceramic impregnated rubber liner shall be used for conical portion
and 1 m vertical height.

Chutes
For lumps of 40 mm thick and above material special Steel reinforced rubber liner of
40 mm thick (min) in secondary impact zone and 60 mm thick special steel reinforced
rubber liner in primary impact zone shall be considered. For material less than 40
mm, 20 mm thick PU liner/SS-409 M (8 mm)/ ceramic impregnated rubber liner min
30 mm thick may be used.

Skirts, Fixed hopper & Gates
SS409M Liner shall be used.

Belt Weigher
The accuracy of belt weigher scale shall be 0.5%.
Any conveyor drives where motor power requirement is more than 200 KW rating
shall be provided with double drives on either side of the conveyor drive pulley.
Other equipment envisaged in this RMHS are:
(a)
Wagon Tippler with Side Arm Charger
Side Arm Charger
The Side Arm Charger mainly consists of the following.
VIMTA Labs Limited, Hyderabad
8
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State







Trolley with wheels and side guide roller, universal coupling arm along with
hydraulic system for lifting.
Travel drive complete with hydraulic motor, brakes, and hydraulic power pack.
Rails with foundation bolts & nuts, racks & pinions.
End stops, Festoon Cable & Trolley with heavy duty carriage and supporting
structures.
Hydraulic Side Arm Charger coupler / decoupler.
Operator's cabin mounted on trolley of Side Arm Charger.
Any other item/ accessory/ fixtures to complete supply of the equipment.
Application
The Side Arm Charger shall be used for wagon positioning at the wagon tippler for
unloading of materials. It shall be used for pushing/pulling a rake of 58 wagons of
110 T gross weight each and locating wagons one by one on tippler. The system shall
be considering future scenario of additional wagons and weight per rake.
Working
A train of 58 loaded wagons shall be brought in by a locomotive pushing/ pulling and
stopped with the leading wagon within range of the side arm charger using track side
marker boards. The loco will be decouple and dispatch and the charger shall be driven
to the leading wagon. Its arm shall be lowered and it shall be coupled to the first
wagon of the train. The train shall be hauled forward by the charger until the front
of the first wagon is about 4 m away from the tippler. The charger shall stop and the
first wagon shall be uncoupled from the train. The charger shall then inch forward to
the leading wagon on to the tippler, automatically decouple itself & arm is raised
before it travels back to the train. The tippler shall rotate for tippling the wagon.
On reaching near the standing train, the charger arm shall be lowered and shall be
coupled to the train ready for repeating the cycle. In the next cycle the train shall be
drawn up by one wagon length, the front wagon will be decoupled & the next cycle
will be repeated. When the next wagon is located on the tippler table the previously
tippled wagon shall be ejected simultaneously.
On the out haul side the empties form a new train ready for collection by a
locomotive.
Wagon Tipplers
Wagon Tippler with hydraulic clamping mainly consists of the following.










Tippler Table with rails, end frame with necessary rack segments, side beam
with rubber pads.
Wagon Tippler hydraulic drive with cylinders, power pack, necessary hoses etc.
Hydraulic clamping system with cylinders, power pack, necessary hoses etc.
Vibrator assembly mounted on tippler.
All foundation bolts.
Control Cabin for the Wagon tippler and Side Arm
Charger can be operated jointly or independently.
Separate water spray system shall be provided for sprinkling water on the
material in the wagon just before entering the wagon tippler.
Any other item / accessory / fixtures to complete supply of the equipment.
Emergency stopper for inhaul wagon rake once it is within operating range of
the side arm charger.
VIMTA Labs Limited, Hyderabad
9
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State


Dust suppression system.
All related electrics and electrical equipment.
Application
Wagon Tippler shall be used for mechanised unloading of broad gauge wagons
carrying raw materials such as lump iron ore, iron ore fines, Mn ore, Quartzite,
limestone, Dolomite, coal etc.
The wagon tippler shall be fed with loaded wagons one by one by Side Arm Charger.
Tippled empty wagons shall be collected on the empty side by ejection while placing
loaded wagons on the tippler. The wagon tippler shall unload the materials into
receiving hoppers for onward transportation to stock yard. The system shall be
considering future scenario of additional wagons and weight per rake.
Typical Technical Parameters
Type
Capacity
No. of tips/hour
Rail gauge
Angle of tippling
Duty
Type of clamping
Type of drive
: Hydraulic indoor type
: 110 T gross
: 20-25
: 1676 mm
: Minimum 175 deg. anti-clockwise looking from wagon entry
side.
: 24 hrs/day (continuous)
: Hydraulic
: Hydraulic motor
(b) Stacker Reclaimer
These equipment are meant to stack the raw material in the yards and also to reclaim
the same for conveying to the consuming departments.
Typical Technical Specification
Stacking rate Coal
Ore
Reclaiming rate Coal/Ore
Long travel speed
No of buckets
Type of drive
:
:
:
:
:
:
1000 TPH
1200 TPH
500 TPH-750 TPH
15 m/min
8
Hydraulic
(c)Twin Boom Stacker:
This equipment is meant to stack iron ore fines/coal in the yards.
Typical Technical Specifications:
Stacking capacity
Rail centers
Boom Luff speed
Boom inclination
Long travel speed
VIMTA Labs Limited, Hyderabad
:
:
:
:
:
1200 TPH
7000 mm
4 m/min
-12 deg to 16 deg
20 m/min
10
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
(d) Barrel Reclaimer
This equipment is meant to reclaim iron ore fines for conveying to pellet plant.
Typical Technical Specification:
Reclaiming capacity
: 1000 TPH
Barrel speed/Cutting speed : 2.4 rpm/41.09 m/min
Bucket volume
: 322 lts
Barrel cutting dia
: 5450 mm
Stock Yard Details
To meet the need of raw materials for 10 MTPA Integrated Steel Plant and 900 MW
Captive Power Plant with 6.0 MTPA Cement/Grinding Plant, a stock yard and related
bulk material handling system will be put up in the designated area in the plant.

Open type Longitudinal Yard
Large quantities of raw materials are handled by following systems.
Wagon tipplers - It is used to unload the cargo from railway wagons
Stacker cum reclaimers - It is used to stack the raw materials and reclaim from
the stack as per the need.
Twin boom stackers
Long conveyor belts
•
•
•
•
Proposed Stockpile Details
Length of stockpiles – 800 m
Width of stockpiles - 36 m
Height of stockpiles - 11 m

Closed Type Circular and Longitudinal Yard
The shed type storage facility is composed with a concrete wall on each side and
divided by sections to store raw material. Raw material is charged by belt conveyor
and tripper installed on top of the wall and discharged by a semi-portal reclaimer.
Shed type storage facility is applied when storing two (2) or more different types of
raw material. Circular dome storage is shown in Figure-2.2.1.
Equipment Description
1. Tipper
Tipper stacks raw materials into the designated place in the shed storage. This is
rail mounted and moves along the rail front and back. Receiving belt is connected
into this tipper.
2. Semi-portal Reclaimer
Semi-portal reclaimers are sorted for ore, coal and sub-material. All of them are
operated automatically in base, remotely at Main Control Room (MCR) and
manually for emergency. They have CCTV that have up and down tilting, right
and left rotating and zooming functions for supervising facilities and automatic
VIMTA Labs Limited, Hyderabad
11
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
remote control. CCTV shall have degree of full visibility that make out the fall of
raw materials through the screen at night.
3. Scraper Boom
The scraper boom's sides shall have proper shapes to eliminate the attached
material on side walls. The attached material on side walls after reclaiming shall
be less than 350 mm.
4. Belt Conveyor
Receiving line
It is conveying belt system which receives iron ore, coal and limestone from yard.
Discharging Line
After raw material is stored, it discharges with certain amount reclaimed into the
conveying system which discharges to the plant respectively as required.
Advantages of Closed Stock Yard
Larger Capacity





Storage capacity increased by 1～2 times
Land reduced by about 50%
Manning reduced over 30%
Transfer process reduced by 40%
Fully-automation
Energy Saving






Compact Layout & small logistic
Reducing over 85% material loss
Reducing consumption in Sintering coking & iron making
Small maintenance of spare parts
Reducing operation cost
Obtain high quality of raw material
Least Disturbance






Wind and rain protection
Thunderstorm protection
Reducing shattering of Lump materials
Stabilizing material features
Prevents contamination of water from bad weather
Moisture content is less affected by rains
The closed yards can be either circular dome type or longitudinal type. The final
selection of open/closed yards would be done during detailed engineering.
VIMTA Labs Limited, Hyderabad
12
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
2.3
Environmental Pollution Control & Mitigation Measures
The main environmental issue relating to raw materials handling and storage is the
fugitive emission of particulate matter arising from material transfers, dumper and
other vehicular traffic, and wind erosion of the piles of the raw material storage. A
secondary concern is the suspended solids and, in some cases, oil contained in the
runoff water from the storage areas.
Fugitive emissions of particulate matter are normally controlled by spraying
stockpiles with water or crusting agents and ensuring that roads and wheels of
dumpers and other vehicles are kept clean. The water runoff is generally directed
to a wastewater treatment plant.
The equipment selected would be adequate to maintain the government stipulated
norms.

Air Pollution Control
The raw material and handling facilities shall include the dust suppression systems
for the wagon tippler, all conveyor transfer points and junction houses from wagon
tippler to existing yard and conveying system and transportation of lump ore in
intermediate building.
Plain water dust suppression system with nozzles shall be provided at wagon tippler
top. Dual fluid (Dry fog) type of dust suppression system (DFDS) shall be provided
for wagon tippler bottom, all conveyor transfer points and junction houses and
receiving and transportation of lump ore in intermediate building. The water
addition in DFDS shall not be more than 0.1% of the weight of material being
handled.
Equipment and System Description
The dual fluid dust suppression (DFDS) works of the principle of agglomeration.
Dust particles released from a material handling or processing plant which becomes
air borne, are made to pass through a blanket of extremely fine fog. The dust
particles and the micron sized fog droplets collide and adhere to each other, thus
increasing their mass.
After a series of such collisions, the mass becomes heavy enough to cause
settlement of the agglomerates on to the larger mass of the material being handled.
The system uses an air driven acoustic oscillator nozzle which is capable of
producing super fine atomization of water droplets that greatly increase the dust
particle to water droplet contact resulting in settlement of dust. The fine droplets
evaporate before wetting anything but the dust. The water addition is 0.1% of the
weight of material being handled.
The DFDS system comprises of main equipment installed at the application points
and auxiliary equipment installed at central water and compressed air supply point.
Plain Water Dust Suppression System for Wagon Tippler Top
Plain water dust suppression system shall be provided at wagon tipper top at the
time of tippling. Necessary pumps with 100% standby, pipes, fittings, valves,
VIMTA Labs Limited, Hyderabad
13
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
nozzles, etc. as required shall be provided. The operation of this dust suppression
system shall be interlocked with the operation of the wagon tippler.

Fugitive Emission Control
A typical Fugitive Emission Control system practised in the following areas at similar
steel plants are described below•
•
•
•
•
•
Dust Suppression System
Wind curtains
Paved areas
Vacuum Cleaning
Tyre washing
Cyclones & bag filters
Fig.I: Foam Dust Suppression System
VIMTA Labs Limited, Hyderabad
Fig.II:Dust Suppression System
14
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Fig.III:Spraying of Stockyards with Latex
Fig.IV:Wind Curtain in Coal Yard
Fig.V:Vaccum Sweeping of Roads
Fig.VI:Water Spraying in Coal Yards
Source:-Existing practices at JSW Vijayanagar Steel Plant
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
15
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
3.0
COMPLETE DETAILS FOR THE PROPOSED ETP FOR THE BLAST FURNACE AND
COKE OVEN PLANT, INCLUDING DESIGN OF ETP TO MEET THE CYANIDE
STANDARDS STIPULATED BY MOEF UNDER EP ACT 1986 SHOULD BE
PROVIDED.
3.1
Effluent Treatment Plant – Coke Oven Plant
In the process of treating coke oven gas from the batteries, surplus liquor is
generated. This liquor is treated for removal of ammonia, cyanide in ammonia stills
by distillation and then further treated in a biological oxidation unit called the BOD
unit. The unit comprises aerobic and anaerobic action to reduce phenols, cyanides,
ammonia to the desired levels.

Effluent Treatment Quantity and Water Quality – BOD Treatment
The estimated effluent quantity to be treated shall be 2 x 295 m³/h.
Considering certain fluctuation of the domestic effluent produced in the plant area and
redundancy of the effluent treatment device, 2 x 350 m³/h will be taken as for
biochemical treatment quantity.
Inlet Water Quality (Mixed Water)
Sr. No
1
2
3
4
5
6
7
8

Parameters
COD
BOD3
NH3-N
Phenol
Sulfide
HCN
Oil
SS
Ranges
1500~3000 mg/l
600~1300 mg/l
150~250 mg/l
500~650 mg/l
20 ~ 50 mg/l
8 ~ 20 mg/l
200 ~ 300 mg/l
100~350 mg/l
Effluent Treatment process
As for the high content of COD and ammonia nitrogen in the effluent, which is highly
toxic, biochemical treatment flow shall adopt effective process targeting to coking
effluent water: “pretreatment + anaerobism + pre-SND-Nitration + Bio-oxidization
+ advanced treatment or as commonly referred “Pre-treatment+ A2/O2+ advanced
treatment” . Process Block Diagram of BOD Plant is shown in Figure-3.1.1.
VIMTA Labs Limited, Hyderabad
16
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
FIGURE-3.1.1
PROCESS BLOCK DIAGRAM OF BOD PLANT
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Process Description
The entire effluent treatment flow is divided into 3 stages:
First Stage Treatment
Second Stage Treatment
Third Stage Treatment
Physiochemical treatment/Pre-treatment
Removes Tar, Light Oil & Emulsions
Physiochemical Process
Biological Treatment
• Anaerobic
• Anoxic
• Aerobic
• Contact Oxidation
Final Treatment
• Coagulation
• Filtration
using
The first stage is pre-treatment: including oil separation pool and air floatation
pool;
Firstly, the effluent enters into the oil separation pool for removing light oil and
heavy oil. The collected light oil and heavy oil will be transferred to the
condensing/blowing section for recycling and reusing.
The effluent, which had the light oil and heavy oil removed, will enter air floatation
pool to remove emulsified oil and gelled oil.
The second step is biologic treatment stage: including anaerobic pool, anoxia pool,
aerobic pool and contact oxidization pool;
The effluent is regulated and enters anaerobic pool, in which, polycyclic compounds
can be allosteric and delink by anaerobe, and some stuff that is difficult to be
degraded by aerobic and facultative biology can be converted to substance that is
easy to be degraded. The macro mole organic will be acid fermented and
decomposed into small organic molecules. The effluent biodegradability is further
improved. In anoxia pool, where there’s no O2. The facultative denitrifying bacteria
will utilize the organic substance contained in coking effluent entered into anoxia
pool as carbon source, and use the [O] of NO 3-, NO2- in the returned nitrified
solution to carry out anaerobic respiration and decomposing the COD substance
within the effluent. At the same time, the NO 3-, NO2- ions of the effluent will be
restored into N2 and etc., and the denitrifying of NO3- and NO2- is accomplished. In
the aerobic pool, sufficient air will be blown in and various nutrition stuff needed by
biologic will be added. The cultivated aerobic microorganism is used to remove the
remained COD and etc. pollutant. At the same time, in the aerobic pool, the
nitrifying bacteria and nitrite bacteria are used to oxide the NH3-N in effluent into
NO3-or NO2- ions. Outlet water passing through the intermediate sedimentation
pool will enter into the contact oxidization pool to conduct further nitration
treatment against effluent and reduce the content of ammonia and nitrogen
compound in the water further.
The third stage is of further treatment stage: final sedimentation and filter;
Outlet water will be treated in coagulative sedimentation and lifted into the strainer
to further remove organic substances and turbidities from water; all filtered effluent
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
water will be sent to the coke quenching section for reusing and no water will be
drained outside the plant premises.
This remaining mud will be put into the sludge concentrating pool for concentrating,
and then be conveyed to the pressure filter being pressure filtered; mud cake will
be mixed into coke making coal. In order to ensure biochemical treatment system
proper operating and the quality of outlet water, during operation, the central
control lab shall conduct chemical analysis regularly on water quality of all stages;
the system also will be monitored and measured via level indicators, pressure
meters, flow meters, etc. instruments.
The effluent output shall meet the standards prescribed by CPCB, for integrated
Iron & Steel plants GSR-277(E) dated 31st March, 2012.
Quality of Output Water
Sr. No
1
2
3
4
5
6
7
8
Parameters
Ranges
≤250 mg/l
≤30 mg/l
≤50 mg/l
≤1 mg/l
≤0.2 mg/l
≤10 mg/l
≤100 mg/l
6.0-8.5
COD
BOD3
NH3-N
Phenol
HCN
Oil
SS
pH

Sludge Handling

The excess and waste sludge generated from the sedimentation tanks is pumped
to the sludge concentration pool;
After concentration the sludge dewatered by dosing cationic PAM and pressed
to cake with press filter;
The sludge cake is shifted to mix with the coal in coke plant; and
The water separated during sludge concentration and pressing taken back to
the primary stage of system;




Chemical Addition
Sr. No.
Name of Chemical
1
SPFS (Solid Poly Ferric
Sulphate)
2
Anionic Poly Acrylamide
3
Cationic Polyacrylamide
4
5
Area of Use
Purpose
a) Air floatation pool
b) Coagulation reactor
a) Air floatation pool
b) Coagulation reactor
Filter press unit
De-hydrating the sludge
Mono Sodium Phosphate
a) Regulation pool
b) Aerobic pool
As a “P” source to
maintain C:N:P
Sodium Carbonate
Aerobic pool
To maintain pH between
7 to 7.5
Coagulant
Flocculent
[
VIMTA Labs Limited, Hyderabad
19
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Reusing water system
In order to enhance the re-usage of water thus to reduce the consumption of fresh
water, reusing water system is considered in the project, and it is composed of BOD
water reusing system and regenerated water reusing system.

BOD Water Reusing System
In common operation, the water BOD treatment after being pressurized will be sent
to coke oven battery, coal preparation, coke handling system and flue gas waste
heat recovery system for re-using, and re-using water volume is 2 x 115 m3/h. The
rest of BOD water will be sent to regeneration water plant for deeper and further
treatment. When wet quenching is started, some of BOD water will go directly to
wet quenching instead of going to regeneration water plant. This reusing water
system will be arranged together with BOD system, and the designed water volume
is 2 x 295 m3/h.

Regenerated Water Reusing System
This regenerated water reusing system is to combine some of BOD water with all
the plant clear drainage water and then send it to regeneration water system for
deeper and further treatment, thus the outlet water quality shall be achieved in
such that it could be used as replenish water of water circulation system and sent
to by-product water circulation system and condensing/blowing water circulation
system as replenish water. The recommended designed water system is 2 x 150
m3/h, and this reusing water system shall be planned and supplied in together with
regeneration water system.
The above system parameters will be finalised during detailed engineering.
 Typical RO-Zero Liquid Discharge (ZLD) Plant
JSW proposes to install RO-ZLD unit in phases.
Stages of Treatment
The plant comprises four stages of treatment.

Pre-treatment
•
•

Biological Treatment
•
•
•
•

Pre Anoxic
Aerobic
Post Anoxic
Ultra filtration
Membrane Bio Reactor (MBR)
Reverse Osmosis
•
•

Equalization
Ozonation
Two Stages with Sea Water membranes
Single Pass with Brackish Water membranes
Evaporation
• Crystallizer
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Process flow diagram of RO-ZLD Plant is shown below:
Biological Treatment
First RO System
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Second RO System
ZLD System
VIMTA Labs Limited, Hyderabad
22
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Crystalliser System
Source: JSW Vijayanagar Plant
The mixed salt from centrifuge of Crystallisation System is proposed to dispose to
MoEF approved Hazardous Waste Disposal Company for secured landfilling.
Inlet and outlet water quality parameters are given below:
Sr. No
1
2
3
4
5
6
7
8
9
10
11
12
3.2
Parameters
COD
BOD
pH
Phenols
Ammonical Nitrogen
Cyanide
Oil & grease
Total suspended solids
Total dissolved solids
Alkanity as CaCO3
Total hardness
Reactive silica
Inlet Details
300 ppm
100 ppm
7-8
20 ppm
50 ppm
5 ppm
12 ppm
50-100 ppm
300 ppm
332 ppm
160 ppm
40 ppm
Outlet Details
<5 ppm
50 ppm
7-8
0.05 ppm
<1 ppm
0.05 ppm
BDL
<2 ppm
250 ppm
80 ppm
70 ppm
5 ppm
Effluent Treatment Plant – Blast Furnace
The wastewater is treated in clarifiers and the treated water is recycled to the
process. The blow down from the system is sent to gas cleaning and slag quenching.
The wet gas cleaning plant may be subdivided into the following subsystems:
Axial Cyclone, Scrubber and Demister
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Axial Cyclone
The BF gas from the down comer axially enters the cyclone. A vortex is created in
the separation chamber of the cyclone by means of diverter vanes. The resulting
centrifugal force draws the dust particles contained in the gas to the chamber wall.
The particles slide down the chamber wall into the dust-collecting chamber. The gas
stream is diverted by the cone at the bottom of the separation chamber towards
the top. The clean gas leaves the cyclone via the inner cylinder at the top of the
separation chamber.
Scrubber
The BF gas stream coming from the cyclone enters the scrubber from the top. The
gas enters the spraying zone of the scrubber and passes through the water curtains
emitted by the injecting nozzles.
The coarse dust particles contained in the gas stream are fixed into the water
droplets produced by the spray nozzles. The dust loaded water droplets are
collected in the sump for the spraying chamber and discharged to the water
treatment plant.
After having passed the water curtains, the gas is pre-cleaned. A certain amount of
the pre-cleaned gas can be used for the pressurising of the hoppers of the Bell-Less
Top.
Downstream of the spraying chamber, the gas flows through the annular gap
passage. Here, water is injected on top of the annular gap element before the gas
flows through the annular gap. When entering the annular gap the gas flow is
accelerated. The high gas velocity produces strong turbulence, so that the gas is
mixed with the injected water. During this mixing, even very small dust particles
are fixed by the water droplets and are removed from the gas.
The dust laden water is collected in the annular gap zone sump and recycled to the
spray nozzles at the top of the scrubber via recirculation pumps. The clean gas that
may still contain free water droplets leaves the scrubber in direction of the demister.
Demister
The gas stream entering the demister passes through vanes inducing the gas
stream an angular momentum. Inertia moves the water droplets contained in the
gas stream to the wall. Here the water is collected at the bottom of the demister
and is discharged to the recirculation pumps of the scrubber. The ‘dry’ gas leaves
the demister via the outlet duct.
Water Treatment Plant for the GCP
 Process Description
Gas produced during the operation of the blast furnace is contaminated with
particulate material. The gas cleaned by a wet scrubber producing wash water that
contains the particulate material in suspension. In order to have proper water
recirculation in the scrubbing system, solids must be removed and the water must
be re-cooled to levels that are acceptable for the gas cleaning process.
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Correction of pH is made by addition of ferric chloride or sodium hydroxide in the
carbon steel trough by means of automatic dosing pumps controlled by a pH meter
located in the clarifier outlet pipe.
Polyelectrolyte is also dosed in the inlet clarifier feed pipe to enhance solids
separation in the clarifier.
The water is fed to the clarifier where the solids settle and form sludge. The clarified
water is discharged by gravity into a cooling tower and the cold water pumped back
to the gas clearing unit.
The sludge produced by the clarifiers is pumped to sludge buffer tank and, by piston
diaphragm pumps to the press filters. The cake produced by the press filter is
discharged directly to wheel loaders and trucks.

Sludge Pumps
Suction lines will be provided for the sludge pumps to allow for complete cleaning.





Cooling Tower
The cooling tower composed with three cells, one as stand by, each cell half
flow-rate capacity.
Filling (splash bars) and drop eliminator material will be made of polypropylene
V2 class.
The fan blades will be made of aluminium or fibre reinforced polyester. Bolts,
nuts, and washers will be made of stainless steel.
A platform for maintenance with handrails and an access door in each diffuser
will be provided.
 Chemical Addition Installations
For all chemical dosing stations the necessary pipes, valves and accessories from
the dosing pumps up to the dosing points will be supplied. All chemical dosing
station will be skid mounted type.

Pumping Stations
The above mentioned pumps will be executed according to the following
considerations:



Manifold installation will be foreseen with each suction line equipped with
manual butterfly valve; the head line will be equipped with a mounting joint,
check valve and butterfly pneumatic valve.
Sludge lines will be provided with diaphragm or knife valves. Each pump group
will have a standby unit; the pumps will have automatic failure detection and
protection devices.
Pumps for water containing suspended solids will be of special material,
abrasion resistant, as required.
---------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
25
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
4.
DETAILS REGARDING USE OF SMS AND BF SLAG / FLYASH IN CEMENT
MANUFACTURING SHOULD BE PROVIDED.
4.1
SMS Slag Utilisation
The estimated SMS slag generation is 1.48 MTPA. The proposed BOF process of
steel making leads to generation of following
a) Converter slag
: (160 – 180 kg/tcs) called convertor slag
b) Hot metal pre-treatment slag : (20 kg/tcs) and
c) Ladle furnace slag
: (20 kg/tcs).

Hot Metal Pre-Treatment Slag (HMPT):
This slag is produced in the pre-treatment stage of steel making predominantly in
the desulphurization stage. The composition of HMPT slag is given below;
Particulars
Fe2O3
SiO2
Al2O3
CaO
MgO
SO3
7.4
24.3
9.7
49.9
4.3
1.1
Percentage %
HMPT slag is separately collected, crushed, and the iron bearing materials are
removed. The non-metallic slag, is fed to sinter plant through base mix or through
proportioning bins as a replacement of limestone in sintering.

Converter Slag: (BOF or LD slag or steel slag)
This slag is produced in the process of steel making in BOF convertors. The
composition of steel slag is given below;
Particulars
Percentage %
Fe2O3
SiO2
Al2O3
CaO
MgO
SO3
6.1
24.4
11.9
49.1
4.2
2.2
The molten slag is poured into pits in the slag bay and is allowed to cool.
Water is sprayed on the hot slag to facilitate faster cooling. The slag is then
processed in a series of crushers and screens to separate metallic components. The
metallic component (10% – 15%) is recycled back to the BOF convertors as coolant.
Due to the presence of free lime, the BOF slag cannot be used as an aggregate.
Weathering (natural or accelerated) will ensure the removal of free lime to
acceptable levels (<5%) for use in roads.
JSW has developed the process of accelerated steam ageing which will help in
removal of free lime in about a week. It is proposed to set up this system to produce
aggregates. Further, large portion (approx. 50%) of BOF slag after processing
becomes fines, which are then mixed with BF slag to make cementation roads which
have a longer life.
With the above measures, it is proposed to use 100% of BOF slag generated in the
process.
 Ladle Furnace Slag:
This slag is produced in the secondary metallurgical operations carried out in ladle
furnaces. This slag is essentially in powder form and contains higher amount of
VIMTA Labs Limited, Hyderabad
26
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
alumina and cannot be used internally in steel making. The composition of slag is
given below:
This material is extensively used in manufacture of ladle covering compound and
also in production of high alumina cements. For this, the material will be screened
to remove larger size which is used in convertors for producing steel. Non-metallic
component is sent to produce cement.
Particulars
Fe2O3
SiO2
Al2O3
CaO
MgO
SO3
2.5
22.1
11.6
35.5
13.8
<1.0
Percentage %
a)
Slag of less than 5 mm ( fine steel slag)
(i) Used in producing ordinary portland cement (up to 5% in OPC). The slag is used
as performance improver and also provides the requisite colour to the OPC and
slag cement.
(ii) Used as fine aggregate in civil construction: The fine slag does not contain free
lime, which is one of the reasons for its poor utilization. The BOF slag has been
permitted for use as replacement of river sand by BIS. These material being
heavy can be used in pavements, bricks road making etc.
b) Slag more than 5 mm - 60 mm:
(i) The non-metallic portion of LD slag contains free lime and magnesia. This
advantage has been used in construction of roads / highways as slag bound
materials. In this process, LD slag and granulated BF slag in different
proportions are mixed and rolled to produce a cementations base for roads.
This concept is widely practiced in Europe and Japan. This is being investigated
in Indian steel plants. This has the potential to reduce the thickness of
highways by 25-30% and can help greatly in reducing the use of natural
materials in the construction sector.
This process can also be used for producing gabions, boulders etc., for use in
protection of coastal areas. In Japan, these are called “ferro form”.
(ii) BOF slag as construction aggregates: The BOF steel slag has excellent
properties and is ideally suited for use in the following area.
a) Ballast in railways
b) Aggregates in highways / roads
The preferred application is highways due to higher angle of friction high PSV
heavy weight etc. However, for use as road aggregate, the steel slag needs to
be weathered. Though several options of weathering (natural, accelerated etc.)
are available, it is intended to carryout weathering using steam. This reduces
the weathering time to less than a week. This has been investigated and the
process is established at JSW Vijayanagar.
The proposed utilization of slags will be as below:
a)
HMPT Slag
b) Convertor Slag
VIMTA Labs Limited, Hyderabad
:
:
:
:
:
:
90-95% in sinter making
5-10% metallics to convertor
10% metallics in steel making
10-15% in sinter making
2% in cement plants
70-75% Road construction
27
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
c)
4.2
: 5% Railway ballast
: 95% in cement making
: 5% in steel making
LHF Slag
Blast Furnace Slag Utilisation
The estimated BF slag generation shall be about 3.0 MTPA. It is proposed to set up
6.0 MTPA cement/grinding unit suitable for grinding Granulated Blast Furnace Slag
(GBS) from the steel plant and clinker which would be procured from market
sources. The capacity of the plant is estimated at 6 MTPA which consists of three
finished products viz. GGBS (Ground Granulated Blast Furnace Slag), OPC (Ordinary
Portland Cement) and PSC (Portland Slag Cement).
Raw Material
Slag
Clinker
Gypsum
(Chemical/Mineral)
Specific Power
Consumption
: Generated from blast furnace
: Domestic / International market -China / Vietnam / Thailand
: Domestic/International markets or from fertilizer/chemical
Industries (Paradeep Phosphates / Tata Chemicals), Haldia.
: 34 KWh/ t Clinker Grinding
: 38 KWh/ t Slag Grinding
: Coal/mixed gas is proposed to be used as a fuel.
Fuel for HAG
Product Mix:
Clinker / OPC
Gypsum
GBS / GGBS
IS Standards
PSC
36-51%
4%
45-60%
PSC: IS 455: 1989,
OPC: IS 12269: 1987
OPC
95%
5%
OPC: IS 12269:
1987
GGBS
100%
There is no IS Code for GGBS
and as such the same will be
manufactured as per customer
requirements.
The ingredients in any product may differ based on raw material quality & finished product requirements.
Additives

Gypsum
Gypsum is available from Local Fertilizer Plants. The composition of the gypsum is
as below Quality of Gypsum
Material
Chemical composition (%)
Chemical gypsum

SiO2
Al2O3
Fe2O3
CaO
MgO
SO3
LOI
4.36
1.04
0.30
30.80
0.51
42.51
21.24
Slag
The slag source is inhouse generation from the Blast Furnace.
Material
Blast
furnace
slag
SiO2
30-34
Al2O3
15-19
VIMTA Labs Limited, Hyderabad
Fe2O3
0.31
CaO
30-34
Chemical composition (%)
MgO
SO3
MnO
K2O
8.65
0.86
0.17
0.57
Na2O
0.27
Moisture
8-10
28
Glass
92
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Coal
The properties of coal has been considered as below:
Moisture
: 12 %
Ash
: 18-38%
GCV (Kcal/kg): 3500 – 6500
Utilities

Power
The power demand for the slag/clinker grinding unit at has been estimated as about
50 MVA.

Water
Water is required for equipment cooling, drinking, sanitation, horticulture, etc.,
Approximately 4500 m3/day of water will be required for all the purposes.
Sizing Norms for Main Machinery and StorageThe main machinery and storages shall be sized in accordance to capacities of
similar plants. These norms are summarized as below –
Sr.
No.
1
2
3
4
Department
Coal Mill
Cement Mills (RP)
Packing Plant
Wagon Tippler
Operating
Hrs./day
15
24
16
10
Operating
Days/Year
330
330
365
330
Operating
Hrs./Year
6600
6800
6000
3000
Design
Safety
Factor
1.10
1.10
1.10
1.10
The fuel firing equipment shall comprise of:
The firing system HAG shall include required oil pumps, filters, pipes, valves, safety
instruments, fans, dampers, etc.,

Coal Drying and Grinding
It is recommended to install the VRM for coal grinding.
The brief technical details of the coal mill drying & grinding system are as follows:
Coal Mill Hopper
For mill feeding, 1 No. RCC hopper of mass flow design shall be installed.

Coal mill feeding
Material from the raw coal hopper shall be fed into the coal mill through weigh
feeders beneath the hopper.

Drying
Hot gases from the HAG shall be used for drying of coal in the coal mill.

Mill system
It is recommended to install the VRM for the plant. Mill vent gas shall be transported
to the coal mill bag filter. Fine coal product collected at the bottom of the bag filter
shall be transported to the respective fuel bins through screw conveyors.
VIMTA Labs Limited, Hyderabad
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Product collection
Material collected at the bottom of Bag house (VRM Section) shall be transported
by the dedicated Pumps to respective HAG Bins of RP Section.

Mill dedusting
A bag filter will be used for mill dedusting. Bag filter will be designed to meet the
requirements of prevalent environmental norms.

Cement Grinding System
The brief technical details of the system are as follows:
The plant will adopt either of two kinds of grinding mills viz. Roller Press
Combination Technology (RP) or Vertical Roller Press (VRM) in the whole process of
OPC / GGBS / PSC production line. The salient features of the technology are
highlighted below:
o
o
o
o
o
o
The Roller Press mill or VRM consists of rollers which grind Clinker and Gypsum
to produce Ordinary Portland Cement (OPC).
On the other hand, slag alone is finely ground in Slag Mill RP or VRM to produce
GGBS.
Both the OPC and GGBS are stored in separate silos.
For the production of Portland Slag Cement (PSC), GGBS and OPC are extracted
from the respective silos and blended in definite proportion in a paddle mixer
and stored in PSC silo.
Cement is packed in bags by means of Electronic Roto Packers. Cement as well
as GGBS can also be loaded in bulkers through Bulk loading system.
Modern high technology features will ensure high quality product, high yield in
energy savings, environmental protection, as well as large- scale automation.
Cement Storage
The product will be stored in separate silos. The capacities of the silos will be about
15000 MT each for GGBS, OPC & PSC, however exact silo capacities will be
determined at engineering stage.
From the Storage Silo, cement shall be transported to the packers, with the help of
a set of air slides and bucket elevators.
Provision for bulk loading shall also be provided keeping in view the future demand
for bulk cement.
Cement Packing and Dispatch
Requirement of packing depends upon the market requirements i.e. extent of bulk
and bagged cement sales, by truck / wagon loading.
For cement packing, electronic packing machine of suitable capacity shall be
considered for the proposed plant.
Truck loaders shall be provided for loading of bags.
VIMTA Labs Limited, Hyderabad
30
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Utility Systems
Power System
The details has been provided in subsequent pages. The power requirement shall
be about 50 MVA.

Water Supply
Water demand at the Grinding plant shall be met by pumping water from the system
developed for the steel plant. The requirement of water is about 4500 m3/day.

Compressed Air Supply
It is proposed to install the compressors/ roots blowers, for compressed air
requirements, at one centralized location in the plant suitable for complete plant.

Fuel Supply
The proposed plant shall be suitably designed on local coal/mixed gas from the
steel plant.
Fire Fighting System
A complete fire fighting system shall be provided comprising of:





4.3
A suitable high-pressure system of fire hydrants consisting of suitable number
of fire hydrants.
A complete separate fire fighting water piping network for feeding the
hydrants.
Heavy-duty ABC powder type fire extinguishers shall be hung at particularly
important electrical equipment areas.
Portable CO2 extinguishers shall be provided throughout the plant.
Automatic fire extinguishing, water system shall be considered for empty bags
store in the packing plant.
Fly Ash Utilisation
The main solid waste from the CPP will be the ash (fly ash and bottom ash). The
equivalent coal consumption in the captive power plant will be 3.0 MTPA thermal
coal and 2 MTPA middlings. The total ash generation will be about 0.75 MTPA. Out
of this, the bottom ash will be about 0.15 MTPA (20% of the total ash) and the
balance fly ash will be 0.6 MTPA.
It is proposed to sell the entire quantity of fly ash to external companies for
cement/brick manufacturing. The following activities will be carried out to comply
as per the new fly ash notification, S.O. 2623 (E) dated on 6 th November 2008
issued by MoEF.
•
•
•
•
The bottom ash will be stored in properly designed ash dykes as per CPCB
guidelines to prevent leaching to the sub-soil and underground aquifer;
The ash disposal area will be lined with HDPE/LDPE impervious lining to prevent
seepage of rain water from the disposal area in the ground and pollute ground
water;
Shall maintain a record of all sale and/ or disposal of the fly ash; and
Shall submit annual compliance report including record of sale and/or disposal
of the fly ash.
VIMTA Labs Limited, Hyderabad
31
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
The Proposed major usage of Ash
 Fly Ash Bricks / Blocks
 Cellular Concrete Products
 Light Weight Aggregates
 Concrete and Mortar
 Cement Manufacturing
 Road Construction
 Embankment/Back Fills/Land Development
 Controlled Low Strength Fill Material (CLSM)
--------------------------------------------------------------------------------------------------5.0
REVISE ASH BALANCE AND ASH EQUALIZATION PLAN SHOULD BE
SUBMITTED
The ash generation details and its utilisation is covered in the Point-4 under section
4.3 and Point -23 under section 23.6.
-------------------------------------------------------------------------------------------------------------------------------------------------
6.0
TRACE ELEMENT REPORT SHOULD BE CORRECTED AND SUBMITTED
The details of trace element in iron ore is given below in Table-6.1.
TABLE-6.1
TRACE ELEMENT
Sr. No
1
2
3
4
5
6
7
8
Trace Elements / Metals
Arsenic (As)
Cadmium (Cd)
Chromium (Cr)
Copper (Cu)
Lead (Pb)
Mercury (Hg)
Nickel (Ni)
Zinc (Zn)
Iron Ore (µg/g)
0.002
0.005
0.03
2.02
1.52
BDL
0.024
0.319
--------------------------------------------------------------------------------------7.0
IRON ORE ANALYSIS TO BE RECHECKED AND SUBMITTED
Iron ore analysis is given in Table-7.1.
TABLE-7.1
IRON ORE ANALYSIS
Sr. No.
1
2
3
4
5
6
7
8
Parameters
Silica (as SiO2)
Aluminium (as Al2O3)
Iron (as Fe2O3)
Calcium (as CaO)
Magnesium (as MgO)
Sodium (as Na2O)
Phosphorous (P)
Loss on ignition
Iron Ore (%)
8.89
4.52
83.18
0.056
2.87
-------------------------------------------------------------------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
32
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
8.0
STAMP CHARGING + HPLA COMMITMENT IN COKE OVEN PLANT TO BE
PROVIDED
JSW commits to install Stamp charging/partial briquetting and High Pressure Liquor
Aspiration (HPLA) system in coke oven plant.
9.0
10.0
------------------------------------------------------------------------------------------COMMITMENT FOR THE USE OF CDQ TO BE SUBMITTED
JSW commits to install CDQ along with wet quenching system for emergency purpose
in phases.
------------------------------------------------------------------------------------------DETAILS REGARDING POLY AROMATIC HYDRO CARBON MONITORING
SHOULD BE SUBMITTED
PAH monitoring will be carried out during post project monitoring stage. The
monitoring will be carried out at coke oven, by product plant of coke oven and
surrounding villages. The PAH test reports of existing JSW- Vijayanagar Plant is
enclosed in Annexure-I.
--------------------------------------------------------------------------------------------
11.0
SMS SLAG UTILIZATION SCHEME TO BE SUBMITTED
Details of SMS slag utilization scheme are provided in point-4 under section-4.1.
---------------------------------------------------------------------------------------------
12.0
SMS PLANT - DOG HOUSE DETAILS FOR FUGITIVE EMISSION CENTRES
SHOULD BE SUBMITTED
Dog House Details for Fugitive Emission Centres – SMS Plant
12.1
Secondary Dedusting Plant comprises the following units

Waste Gas Cooling and Collecting
a. Material Handling Suction
 High level bin fume suction assembly
 Material handling for LF fume suction assembly
 Material handling for RH fume suction assembly
b. Auxiliary Suction Points
 Ladle maintenance area fume suction assembly
c. Furnace secondary suction
 Charging fume suction assembly
 Tapping fume suction assembly
 DeS/Deslagging fume suction assembly
 Ladle furnace fume suction assembly

Waste Gas Cleaning
a. Fabric filter equipment
 Pulse jet filter assembly
 Compressed air station
VIMTA Labs Limited, Hyderabad
33
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Conveying Equipment
a. Uncooled Ducts
 Raw gas collection duct assembly
 Clean Gas Duct
b. Fans
 Radial Low Pressure ID Fan Station
 Raw gas booster fan station
c. Silencer and Stack
 Clean Gas Stack Assembly

12.2
Residual Handling and Recycling
 Dust Handling and Storage
 Mechanical Dust Conveying
 Chain Conveyor
 Feeding screw conveyer
 Bucket elevator
 Discharge screw conveyer
 Silo assembly
 Dust Silo
 Silo top filter unit
 Shut-off device assembly
 Fluidisation unit
 Rotary valve for dust discharge
Secondary Dedusting System
The secondary dedusting system serves to collect the diffuse emissions occurring
during the different operation phases such as converter charging and tapping, DeS, LF, material handling in order to fulfil the environmental and workplace impact
regulations. The dust-laden fumes are collected by fume hoods which are designed
to allow a maximum suction efficiency. The suction volume is controlled for each
suction point by electric driven control dampers according to preset values. All
dampers are of louver type design and equipped with limit switches and position
indication. The dust fumes from the various sources are conveyed via ducts of
appropriate cross section to the mixing duct. Downstream of the mixing duct the
dust cleaning equipment is situated.
The gas is cleaned in a two-row pulse jet filter with raw-and clean gas dampers for
isolation of the individual chambers. The dust collected from the dust cleaning
equipment falls down into the dust hoppers. The collected dust is discharged to the
dust silo through the dust conveying system. The clean gas is conveyed via the
clean gas duct to the exhaust stack and from there to the atmosphere. Two or three
double-inlet radial fans generate the necessary suction. For noise protection, the
ID- fans and the clean gas duct are insulated. A silencer installed in the base of the
stack is further attenuating the noise. The control of the dedusting system will be
done by measurement of the negative pressure in front of the bag-filter. The actual
negative-pressure is following the adjusted set point. Depending on deviations of
the set point of the negative-pressure the ID-fan speed will be adjusted by means
of a VVVF. This will adjust the flow rates on the different suction points depending
on the requirement automatically.
VIMTA Labs Limited, Hyderabad
34
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Depending on the temperature and composition of the dust fines to be cleaned they
run through different conditioning steps.
Very high temperature fines e.g. from converter charging pass through the total
treatment line. Hot gases do not need to go through the static cooler and dust from
suction point with ambient air temperature or directly conducted into the filter. The
highest amounts of dust are generated during converter charging and tapping. For
this reason this area requires the greatest attention.
The individual components of the secondary dedusting line are:
a. Static Cooler
It serves the purpose to absorb the heat energy peaks generated during HM
converter charging. Between the charging operation the cooler releases the heat to
the air sucked through the system. The static coolers are located in each branch of
the charging duct close to the charging hood. The heat storage surface is maximized
by using a multi-plate design with the plates hanging in longitudinal direction in
order to minimize pressure loss and wear. The coolers consist of several individual
packages which are flange connected and can be exchanged individually.
b. Spark Separator
It is used in those areas with the danger that sparks are sucked into the system
and damage the filter bags. The sparks are captured in the special internal
components of the separation chamber.
c. Mixing Chamber
In case a mixing chamber is necessary it is used for temperature adjustment and
homogenisation of the off gas stream before the filter by special guiding/
homogenisation system in the chamber.
d. Pulse Jet Bag-Filter
The fumes captured in the system will be conveyed to the inlet manifold of the pulse
jet filter. The single filter compartments can be isolated from the clean gas side via
pneumatically operated flaps and from the crude gas side via manually operated
dampers. So it is possible to take a filter compartment out of operation for
maintenance. The dust is collected on the outside of the filter bags. The pulse jet
air for cleaning passes through from bag inside. The cleaning of the filter bags is in
off-line mode, that means the section to be cleaned is disconnected from the
filtration process by closing the pneumatic clean gas dampers of the clean gas
channel. To clean the filter bags, short compressed air pulses are injected in certain
intervals into the filter bags. The filter cleaning system is controlled via the central
de-dusting control PLC. On the filter control unit two different automatic modes are
available. One mode is a fixed cycle time based mode and the other one is based
on the filter different pressure. Normally the differential pressure mode shall be
selected on the control unit so the cleaning cycle operates depending on the
measured differential pressure.
Supporting cages in split design prevent collapsing of the bag. The bag material is
polyester needle felt. Into of the filter a penthouse is situated, ventilated by natural
ventilation. To lift the compartment covers manually operated lifting hoists are
provided. The inclination of the walls of the filter hoppers is steep enough to allow
a free flow of the separated dust to the bottom outlet.
VIMTA Labs Limited, Hyderabad
35
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Additionally, compressed air feeding pipes will be provided in the bottom of each
filter hopper. Solenoid valves controlled short air blasts will prevent material hang
up.
e. ID-Fan Station and Clean Gas Duct/ Stack
The necessary suction for the complete dedusting system is produced by three
radial type fans.
The exhaust fans are designed as a double inlet suction type fan. The fans, located
downstream of the bag filter at the clean gas side draws off the cleaned gas via the
clean gas channel of the filter and the clean gas duct and direct it into the
atmosphere via the clean gas stack. The fan is of heavy industrial design.
The fans are driven by electric motors. The suction performance is controlled with
a VVVF for energy saving. The final fan pressure increase will be fixed during the
engineering phase and technical layout clarification. The operation of the bearings
is monitored by a temperature measurement (each fan bearing) and vibration
monitoring (fixed bearing only, radial direction, indication in mm/s). To avoid
excessive under pressure of the equipment upstream the ID-fan, a hardwired
pressure switch is installed for switching off the fan. At the outlet gate plates are
provided to isolate each fan for maintenance. Gas ducts and supporting structures
are foreseen for the transporting of the clean fumes between dust collector and
clean gas stack.
Expansion joints for the compensation due to heat expansion, necessary supports
and inspection openings for the ducts are provided. The stack is of self-supporting
design. A platform with ladders for measurement of the clean gas dust content is
provided. For noise attenuation, the stack base will be designed as casing for the
exhaust silencer.
f.
Dust Conveying System
The dust conveying system comprises:
•
•
•
•
Collecting chain conveyor with drive
Screw conveyor for bucket elevator incl. drive
Feeding bucket elevator with drive
Screw conveyor to dust silo with drive
g. Dust Silo
The silo assembly for dust mainly consists of:
•
•
•
•
•
•
•
•
•
•
Dust silo shell
Access ladder and platforms for dust silo
Supporting structure for dust silo
Top filter unit for dust silo
Fluidisation unit for dust silo
Rotary valve with drive below dust silo
Loading device for dust silo
Cladding for dust silo
Manual slide gate for dust silo
Manual slide for emergency outlet
VIMTA Labs Limited, Hyderabad
36
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
h. Converter Charging/ Tapping Hood
The charging hood is integrated in the doghouse structure and located on the
charging side in the doghouse roof. The hood is designed in welded steel plate
structure with the necessary supports.
The hood is lined with refractory material or hematite for heat protection. Gas ducts
with individual dampers will be connected on both sides of the hood in order to
maintain a uniformly suction of the gases. A static cooler is provided in each branch
of the charging suction duct. The static coolers are buffering the heat generated
during hot metal charging and thus decrease the gas temperature which leads to
an increased suction efficiency. The tapping hood is integrated in the doghouse
structure and located on the tapping side in the doghouse roof. The hood is designed
in welded steel plate structure with the necessary supports. The hood is lined with
refractory material.
i.
Other Suction Hoods
The hoods cover the respective position to be dedusted. If required they have
openings to feed materials. They are generally of welded design and where
necessary protected against overheating.
j.
Raw Gas Ducts
Gas ducts with proper stiffeners and supporting structure are foreseen for the
transporting of the fumes from the fume hoods to the dust collector. Expansion
joints for the compensation due to heat expansion, necessary supports, cleaning
and inspection openings for the ducts are provided.
Dampers in the related gas duct are operated automatically from the related control
rooms via push button for start. In the raw gas collection duct a good mixture of
the gases with different temperatures is achieved by a static mixer.
k. Control Dampers
The dampers are designed as multi-louver damper in a sturdy frame. The damper
blades are overlapping to provide a good sealing in closed position and ensure good
movability also under changing temperature load (tightness approx. 96-98%).
The dampers mainly consist of:
• Damper frame
• Damper blades with shaft and stuffing boxes
• Drive mechanism (levers and rods)
• Actuator (electric or pneumatic)
l.
Compressed Air Station
The pulse jet bag filter requires bone dry compressed air for periodical cleaning of
the filter bags.
Therefore an independent compressed air station is provided consisting of:
• 2 compressors
• 2 adsorption dryers
• 1 buffer vessel
VIMTA Labs Limited, Hyderabad
37
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
12.3
Major Process Equipment Parameters
The proposed major process equipment for 5.0 MTPA SMS shop are given below.

Pulse Jet Filter Assembly
The filter plant is designed as bag filter and subdivided into individual chambers.
The dust-laden gas first enters from the raw gas channel into the dust bin
underneath and then the filter chamber located above, and is filtered to the
admissible clean gas dust content.
The dust accumulates on the outside of the filter bags. Supporting cages prevent
collapsing of the bag. The bag material is polyester needle felt with a special treated
surface.
The filter consists of separate compartments each of which can be completely
isolated from the gas flow during maintenance.
The bags are cleaned periodically with compressed air at an electronically controlled
cycle. The cleaning is at off-line operation; that means single chamber cleaning is
applied. The dust falls into the dust bins of each compartment during the cleaning
cycle.
In order to have additional protection of the filter bags against excessive
temperature in case of emergency, sufficient cooling air can be added through the
emergency air damper located upstream of the filter.
The pulse jet filter assembly comprises:
•
•
•
•
•
•
•
•
•
•
•
•
•
Filter head
Filter bags and cages
Filter supporting structure
Access to filter
Filter casing
Filter penthouse and cladding
Maintenance crane
Raw gas dampers
Clean gas dampers
Filter hoppers
Filter hopper dust transport
Rotary valve below chain conveyor
Filter control unit
Technical Data
No. of Bag Filters
Type of design
Wall thickness casing
Gas volume max.
Gas temperature
Number of chambers
No. of bags in one chamber
VIMTA Labs Limited, Hyderabad
:
:
:
:
:
:
:
1
suction filter with jet cleaning (offline)
4 mm
approx. 2,000,000 m3/h
max. 150° C
16
2 x 170
38
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Dimension of bags
Total filter surface
Air-to-cloth ratio –
offline cleaning
Filter bag material
Differential pressure
(normal)
Compressed air demand

:
:
165 x 8,000 mm
22,274 m²
:
:
approx. 1.53 m³/m2.min
PE 550 g/m2
: max. 25 mbar (inlet-outlet)
: approx. 1600 Nm3/h
6 bar, free of oil, free of solids, dew point -40 °C)
Compressed Air Station
The compressed air station provides compressed air for:
• Cleaning the bags of the pulse jet filter
• Several services of dust handling and storage
Technical Data
Operating pressure
Flow rate
Dew point
Drive type
Motor power
:
:
:
:
:
6 bar g
approx. 1900 Nm³/h
-40 °C
electric
approx. 250 kW
The compressed air station comprises:
•
•
•
•
•
•

Compressor unit
Buffer vessel
Pre filter
Post filter
Oil separator
Refrigerant dryer
Fans
Radial Low Pressure ID Fan Station
The ID fan station provides the required induced draught to overcome the pressure
drop of the gas flow.
The fans, located downstream of the filter plant at the clean gas side draw off the
cleaned gas and direct it into the atmosphere via the clean gas stacks.
The fans are driven via a VVVF, which provides variable speed control by an electric
motor with variable speed.
The fan casing and the ducts between fan station and stack are covered with
acoustic insulation to achieve the specified noise pressure level.
Technical Data
Quantity of fan
Function
Type of design
Impeller type
Mounting
Flow control
VIMTA Labs Limited, Hyderabad
:
:
:
:
:
:
3 set (s)
provide induced draught to overcome gas pressure loss
radial
backward curved
base frame on concrete block
by VVVF
39
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
ID fan data per fan:
Bearing type
Effective conveying capacity
@ 130°C
Design total compression
(estimate)
Noise level max.
Drive type
Motor capacity
Speed of ID-Fan
: roller bearing
: approx. 685,000 Am³/h
:
:
:
:
:
approx. 65 mbar
85 dB (A) in 1 (one) meter distance from the fan
electric
approx. 1,700 kW
max. 1000 RPM
------------------------------------------------------------------------------------------13.0
SMS – DRY SYSTEM TO BE ADOPTED AND DETAILS SHOULD BE SUBMITTED
Dry Type Gas Cleaning System
The Primary Gas Treatment System (PGT-System) is designed for collecting and
treating the gas which is generated during the steel making process in the converter.
The complete plant is sealed gas tight against uncontrolled intake of ambient air.
The actual flow of gas generated inside the vessel is strongly affected by the blowing
rate of oxygen through the lance and the reaction of other oxygen containing
substances charged into the vessel, (suppressed combustion) by controlled intake of
ambient air. The partly combusted gas will be named “LD Gas”.
The flow rate of primary gas and therefore also the total flow rate of LD-gas during
the blowing period is not constant but fluctuates over a wide range. To assure a good
capture efficiency and high LD-gas quality, the flow of LD-gas through the system
has to be carefully and accurately controlled. This is assured by continuously
adjusting the flow rate in such way, that the pressure at the cooling stack inlet varies
only insignificantly around a very low pre-set pressure. It is proposed to adopt a
cascade control concept based on a radial type ID fan (RT IDF) equipped with an inlet
guide van damper (IGVD). Small adjustments of the gas flow rate will be controlled
by the IGVD; larger fluctuations will be controlled by the revolution speed of the RT
IDF by means of a VVVF-control unit (frequency converter).
For the best control results, the measurement probe is to be located as close as
possible to the inlet of the cooling stack. To ensure reliable function, the pressure
probe should not directly be exposed to the off gas.
An accurate control pattern will maintain a good and efficient collection of the Primary
Gas from the converter and further minimizes the risk of inflammable gas mixtures.
Both are the basis for the failsafe operation of the Primary Gas Treatment plant under
all operational conditions.
The Primary Gas Treatment system basically consists of three Sub-Systems:
• Gas Cooling System:
• Gas Cleaning System (DRY type) with:
- Gas Conditioning Tower (GCT)
- 2nd generation dry-type electrostatic precipitator (ESP)
- ID-Fan (IDF)
- Flare Stack (FS)
VIMTA Labs Limited, Hyderabad
40
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
• Gas Recovery System with:
- Switch-Over-Station (SOS)
- Gas cooler (GK)
- Gas-Holder (GH)
- Gas Export Station (BFS)
Gas Cooling System
The inlet cone of the gas conditioning tower will be provided with indirect cooling for
proper gas distribution purposes which results into a lower temperature at inlet Gas
Conditioning Tower (GCT).
Gas Cleaning System (DRY Type)
The BOF waste gas cleaning system is designed as a dry-type electro static precipitator
for high-efficient cleaning the LD-gas. The system is designed for subsequent
converter gas recovery.
The Gas Cleaning System is only in operation with full capacity during blowing time.
After passing through the cooling stack (CS), within that the gas temperature is
reduced, the LD gas enters the adjacent gas conditioning tower (GCT) with a
temperature of approx. 850 - 900°C. The gas is heavily laden with dust particles from
the converter process, mainly with iron, iron oxide but also other particles from slag,
flux charges (lime and others). The range of particles sizes vary from approx. 0.1
micron up to some millimetres.
In the gas conditioning tower (GCT), connected gas tight via a special designed high
temperature compensator, the LD-gas is being cooled and conditioned by evaporation
of injected water. Coarse dust particles are separated in dry state and transported to
the coarse dust silo. The conditioned LD-gas exits the GCT at about 180°C.
By means of the following horizontal cylindrical shaped electrostatic precipitator (ESP),
connected via a gas duct with the Gas Conditioning Tower and located outside The
Steel Shop Building, the remaining fine dust load is further reduced to the requested
clean gas dust content. The dust is also collected in dry state and transported to the
fine dust silo.
The system is capable of reducing the dust content of the clean gas down to ≤ 10
mg/Nm3.
The gas is transported through the Gas Cleaning System to the flare stack (FS) or to
the gas recovery system by means of an induced draft fan (IDF). As explained above
it is recommended to use a radial type IDF (RT IDF).
Advantages of a RT IDF are:





lower temperature increase due to better efficiency (delta to axial fan approx.
10°C)
wider control range than AX IDF
maintenance friendly design of RT IDF
larger tip clearance than AX IDF
short maintenance downtime
Gas Recovery System
Depending on the actual CO content a switch-over station (SOS) will direct the gas
either to the Flare Stack (FS) or with sufficient CO content to the gas holder (GH).
VIMTA Labs Limited, Hyderabad
41
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
At the beginning of the blow, the LD gas is exhausted into the atmosphere and the CO
is burned at the flare stack if burnable, which will be the case usually after few seconds
of the blow subject to a minimum 20 – 30% CO. After a while in the blowing process,
the CO content will rise to a pre-set value and the recovery system will be switched to
a gas holder where the gas is stored for further usage. It can continuously be fed into
the plant LD-Gas-Net via the Gas Export Station (BFS).
The switch-over of the gas from flare mode to recovery mode will be interlocked with
the oxygen level in the off-gas as well as the gas holder level. At the end of the blowing
phase the CO content will decrease, and the system switches back to flare mode.
During flare mode the off-gas will be directed through the flare stack equipped with a
flare burner head and pilot burners. In order to avoid CO being released into
atmosphere it will be ignited by the pilot burners.
A goggle valve is installed downstream of the SOS / recovery valve.
The Gas Cooler can be installed downstream or upstream of the SOS for further cooling
down the LD Gas to temperatures from approx. 150°C -180°C inlet temperature down
to below 70°C appropriate for the gasholder operation. This is vital for a long lifetime
of the gasholder sealing. As a side effect, the cooling reduces the gas volume. The gas
will then be fully saturated.
The Gas Cooler is designed as a counter-flow cooler, which means the gases enter the
cooler in the lower part and leave at the top. Cooling water is injected through nozzlebanks with several individual nozzles. The cooling water is internally circulated by
pumps. At least one pump is in operation, while one is always in stand-by mode.
In order to keep the dust concentration in the re-circulated water on the desired level,
a small amount of water will be continuously exchanged.
Safety Philosophy
BOF steel making plants operating with suppressed combustion require a thoroughly
elaborated safety concept especially with respect to the gas cleaning and recovery
system. Flammable gas mixture of O2, CO and also H2 may develop, and especially the
ESP is a potential source of ignition. Both, formation of combustible gas mixtures, and
sources of ignition cannot completely be avoided. Therefore, the system is designed
to at least minimize the formation of such gas mixtures and sources of ignition.
Furthermore, all necessary measures are taken into consideration to prevent personnel
and the system from damage in case a deflagration occurs.
During non-blowing normal O2 containing air is being sucked into the off-gas system.
During blowing phase the off-gas exiting the BOF mouth contains up to approx. 90%.
At the beginning of blowing the movable skirt is not yet closed, and hence, enough O 2
containing air is being sucked into the system resulting into complete post-combustion
of CO into CO2. Closing down the skirt after start of O2-blowing and ignition takes less
than one minute, this delay in shielding the off-gas system against O2 for CO postcombustion leads to an CO2 /N2 inert gas cushion between O2 and CO containing offgas.
VIMTA Labs Limited, Hyderabad
42
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
The equipment is designed to allow an optimum plug-flow. Transitions from small to
wide diameters (i.e. GCT inlet and ESP inlet) are equipped with gas distribution
internals. Such measures prevent the system from turbulences, and hence, during
normal operation conditions of the converter no combustible mixtures of CO and O 2
will occur.
However, by no means it is possible to fully prevent the system from forming
combustible gas mixtures. For example, it may happen as a consequence of a rapid
stop of blowing.
Also, it is not possible to prevent the system (valid for dry and wet systems) from
developing H2 which strongly influences the critical gas composition. For example, wet
scrap, humid or oily charging material, damages/leakages of the cooling stack and
other reasons may lead to an increased H 2 content. To detect critical a critical gas
composition containing CO, H2 and O2 a redundant gas analyzer is mandatorily installed
in the cooling stack. Measurements beyond the critical values of gas mixtures will
trigger a stop of blowing as well as in case of dry system an immediate earthing of the
ESP high tension.
Gas Cooling System (CS)
The CS will be protected by relief flaps at the top of the deflection bend against
pressure surges due to sudden evaporation inside the BOF vessel (water explosion) or
deflagrations inside the CS.
Gas Cleaning System
Main source of ignition surely is the ESP. Even though being controlled by a highly
sophisticated thyristor control unit the incidence of flash-overs cannot fully be
prevented.
Only the coincidence of combustible gas mixtures and – at the same time – a source
of ignition will lead to a deflagration. The frequency of such incidences cannot be
predicted. It is depending on various factors, such as operating conditions,
maintenance and plant condition, quality of raw materials, etc.
The ESP is equipped with a sufficient number of pressure vent valves which in any case
will reduce the maximum pressure to below 2 bar, for which the ESP casing is designed
for.
Gas Recovery System
Same as in the wet system the plant is equipped with a Nitrogen injection/ purging
system. By purging with Nitrogen through the several duct sections an undesirable
formation of air and gas cushions will be avoided.
The gas analyzing systems (hot gas analyzer and clean gas analyzer) measures the
gas composition and controls the switch-over process.
The main safety features of the cup valve station are:
a)
Nitrogen buffered hydraulic station
VIMTA Labs Limited, Hyderabad
43
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
b)
Gravity driven cup valves in case of black-out in order to switch over to the Flare
Stack(FS)
c) N2 Purging System such as purging of flare stacks when switching over to avoid
air entrance into the clean gas stack during the recovery phase or purging the
gas duct between Gasholder Cup Valve and shut off damper.
d) Emergency N2 purge (thru venturi) to prevent flashback in case of power failure
at the ID fan or break down of the ID fan or during interruption of the oxygen
blowing process.
---------------------------------------------------------------------------------------------------
14.0
SINTER PLANT – SECONDARY EMISSION MITIGATION DETAIL SHOULD BE
PROVIDED.
Plant Dedusting
All transfer stations in the area of the sinter plant (direct vicinity) generating dust
are covered with exhaust hoods. The receiving point and material falling point of
belt conveyor is equipped with local sealing hood, the vibrating screen is equipped
with integrated sealing hood, the movable unloader at top of fuel silo, flux silo and
finished product bin is adopted with the movable ventilation device, all crushers are
sealed strictly and equipped with local sealing hood. The plant is equipped with the
mechanical dedusting system based on above configuration, which is executing
induced draft to form certain negative pressure inside sealing hood, to avoid dust
escape, and to achieve the desired parameters.
The plant adopts high efficiency bag dedusting equipment as purification equipment
of dedusting system. Bag filter removes particulate by straining, impingement,
interception, diffusion, and electrostatic charge. The fabric used in bag filter may be
constructed of any fibrous material, either natural or man-made. The fabric
represents a porous mass through which the gas is passed unidirectional such that
dust particles are retained on the dirty side and the cleaned gas passed on through
to stack. The combination of fabric and collected dust becomes increasingly efficient
as the dust cake accumulates on the fabric surface. The dust-loaded gas/air is
cleaned in the bag filter and is discharged into the open atmosphere through a stack.
The dust separated by the bag filter is withdrawn by chain conveyors and finally
recycled to the sinter process.
The suction required for the proper functioning of the dust collecting system, is
created by the plant dedusting fan. One silencer is provided for noise level
reduction.
The branch pipe for each dust collecting point of system is equipped with manual
or electric regulating valve, to balance the air quantity of each dust collecting point.
The bag filter is designed to achieve dust content in the clean gas at the outlet-end
of the bag filter of 50 mg/Nm³.
The dust collected will be transferred to process belt conveyor through scraper or
transport outside after humidifying by humidifier.
VIMTA Labs Limited, Hyderabad
44
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Typical Plant De-Dusting Bag Filter Parameters
Designation
Quantity
Gas flow rate nominal
Gas flow rate design
Gas temperature, average
Gas temperature, range
Dust load at inlet
Negative pressure
Clean gas dust concentration
Ca(OH)2 Consumption (SO3 removal)
Unit
Set
m³/s
m³/s
°C
°C
mg/Nm³ (dry)
mm WC
mg/Nm³ (dry)
Kg/h
Value
1
290
333
approx. 150
110 - 200
150
160
≤10
Approx.. 100
Dust Handling
Dust transportation from dedusting equipment will be done by pneumatic conveying
system. Dust will be recycled and is charged into the dust bin. Dust will be
conditioned in a granulator, prior to charging into collecting conveyor for raw
material. For pneumatic conveying of dust to the proportioning building two
separates lines for Waste Gas ESP and Plant Dedusting bag filter are envisaged.
The typical parameters of environmental mitigation measures for the Sinter Plant is
given below:
Fan Details
Fan volume, m3/h
Inlet static pressure
Bag filter Details
Filtration area, m2
Bag dimension
Filtering velocity, m/s
ΔP, mm WC
Compressed air
requirement, Nm3/h
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
Typical Bag filter Details
Crusher Bldg
MND Bldg
35000
60000
300
300
Screening Bldg
60000
300
516
152 X 4500
1.14
130
819
152 X 6000
1.22
130
819
152 X 6000
1.22
130
13
20
20
Typical Dedusting ESP details
No. of fields
3
Collecting electrodes in one field
22
Discharge electrodes in one field
21
Total no of collecting electrodes
44
Total no of discharge electrodes
63
Inlet dust load in g/m3
15
Outlet dust emission (mg/nm3)
50
Projected collection area in m2
6214
Specific collection area (m2/m3/sec)
64.65
TR sets
3
Inlet gas temp (°C)
70
Normal operating pressure in Pa
-3500
Gas velocity inside ESP (m/s)
1.15
Gas Flow (m3/hr)
346000
TR sets rating
110kV, 800mA
Retention time in Sec
12.94
No. of Gas pass
19
Source: JSW Vijayanagar Plant: SP-4
-------------------------------------------------------------------------------------VIMTA Labs Limited, Hyderabad
45
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
15.0
ADVANCED CO MONITORING SYSTEM SHOULD BE ESTABLISHED AND
DETAILS SHOULD BE PROVIDED
It is proposed to install advanced CO monitoring system such as Sensepoint XCD.
The Sensepoint XCD range provides comprehensive monitoring of flammable, toxic
and Oxygen gas hazards in potentially explosive atmospheres, both indoors and
outdoors. Users can modify detector operation using the LCD and magnet switches
without ever needing to open the unit. This enables one-man, non-intrusive
operation and reduces routine maintenance time and costs.
A tri-colour backlit LCD clearly indicates the unit’s status at a glance, even from a
distance. A steady green backlight indicates normal operation, flashing yellow
indicates fault and flashing red indicates an alarm. All detectors are supplied preconfigured and include 2 programmable alarm relays, 1 programmable fault relay
as well as an industry standard 4-20 mA output (sink or source selectable) and
MODBUS*.
The scale, range, relay operation, alarm set point and electronic tag number of the
detector can be adjusted using the transmitter's LCD and non-intrusive magnetic
switches. Outputs are automatically inhibited during adjustment, thereby reducing
the risk of false alarm at the control panel during maintenance.
Sensepoint XCD has an integral mounting plate for surface mounting or can be
mounted to a horizontal or vertical pipe using the optional pipe mounting bracket.
Electrical installation can be made using either conduit or cable with suitable
mechanical protection. Two M20 or ¾”NPT entries are provided (depending on
certification). A weatherproof cap is also included for use in the harshest outdoor
Conditions. Other optional accessories include a sunshade/deluge protection, duct
mounting kit, collecting cone and remote mounting sensor socket*.
Sensepoint XCD ensures easy installation and the fastest routine operation by
removing the need for hot work permits in hazardous areas. Using easy to replace
plug-in sensors, downtime is also reduced and on-going costs are minimised
through the use of poison resistant flammable sensors, poison immune infrared
Hydrocarbon sensors and patented Surecell™ toxic sensors.
VIMTA Labs Limited, Hyderabad
46
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
There are three different types of the XCD transmitter for use with three different
families of sensors. The mV type transmitter is for use with the mV family of XCD
sensors including catalytic sensors to detect flammable gases in the range 0-100%
LEL and infrared (IR) sensors for detection of Hydrocarbon gases in the range 0100% LEL and 0-100% Vol, as well as Carbon Dioxide (CO2) in the range 0-2% Vol.
The EC type transmitter is for use with the EC family of XCD sensors including
Carbon Monoxide (CO), Hydrogen Sulphide, (H2S) and Hydrogen (H2). The Oxygen
transmitter is for use with the Oxygen (O2) XCD sensors.
A transmitter can auto-recognise any sensor from within its sensor family. The
sensor simply plugs into the bottom of the transmitter and the transmitter
automatically configures itself accordingly.
VIMTA Labs Limited, Hyderabad
47
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
---------------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
48
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
16.0
SPECIFIC WATER CONSUMPTION AND WATER BALANCE SHOULD BE
SUBMITTED
The water consumption details for various units are given below:
Sl. No.
Plant Facilities
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Main Steel Plant Facilities
RMHS
Pellet Plant
Coke Oven Plant
Sinter Plant
Blast Furnace with PCM
Direct Reduction Plant
SMS & Casters
Wire Rod Mill
Medium Section Mill
Heavy Section Mill
Hot Strip Mill
Bar Mill
Cold Rolling Mill Complex
Oxygen plant
Lime & Dolo Calcination Plant
16
17
18
19
20
20
21
22
Township
Additional Units
Miscellaneous
Drinking water to plant
Total Process Water (Main
Plant)
Iron Ore Beneficiation Plant
Captive Power Plant
Cement Plant
Coking & Non-Coking Coal
Washery
Sub Total
Treatment Loss
Total Raw Water required
VIMTA Labs Limited, Hyderabad
Capacity
2 x 4.0 Mt/yr
3 x 2.0 Mt/yr
3 x 7.8 Mt/yr
2 x 4.9 Mt/yr
1.2 Mt/yr
10.4 Mt/yr
1.0 Mt/yr
1.2 Mt/yr
2 x 1.1 Mt/yr
4.5 Mt/yr
1.0 Mt/yr
2.3 Mt/yr
3 x 2500 tpd
5 x 600 tpd
2 x 600 tpd
TPA
Sp. Cons.
(m3/unit)
53737429
8000000
6000000
15600000
9800000
1200000
10400000
1000000
1200000
2200000
4500000
1000000
2300000
1750000
1386000
0.02
0.04
1.24
0.07
0.7
1
0.7
0.4
0.4
0.4
0.37
0.4
0.45
0.5
0.12
Total Water
Consumption
(m3/annum)
10,74,749
3,20,000
74,40,000
10,92,000
68,60,000
12,00,000
72,80,000
4,00,000
4,80,000
8,80,000
16,65,000
4,00,000
10,35,000
8,75,000
1,66,320
4,20,000
24,00,000
32,00,000
22,40,000
3,71,88,069
29.0 Mt/yr
3 x 300 MW
6.0 Mt/yr
5.52 Mt/yr
2.30 Mt/yr
29000000
900
6000000
7820000
0.25
2.5
0.25
0.047
72,50,000
1,80,00,000
15,00,000
3,67,540
2,71,17,540
32,15,280
6,75,20,889
8,440
45
49
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW Captive Power Plant and Township near Barenda
Village, Sonahatu Block, Ranchi District, Jharkhand State
------------------------------------------------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
50
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
17.0
SOX, NOX LINE EMISSION DATA USED FOR ALL THE UNITS, INCLUDING
FLOW RATE TAKEN SHOULD BE SUBMITTED
The details of stack emissions are provided in Annexure-II. Calculation for one
stack is described below:
General Calculations

Area Calculations
3.14 x (Top Stack Diameter ) 2
= 3.14 X (5)2/4 = 19.625 m2
Area (m ) 
4
2

Temperature Correction
Temperature correction is calculated based on standard ambient temperature of
25 C.
Temperature Correction 

273  25 0 C
= 298/388 = 0.76
273  StackTemperature 0 C
Particulate Matter Emissions
Emission rate = 50 mg/Nm3 X 15,00,000 /3600/1000 = 20.8 g/s

Emission Calculations Sulphurdioxide
Emission rate = 30 mg/Nm3 X 15,00,000 /3600/1000 = 12.5 g/s

NOx Emissions
Emission rate = 140 mg/Nm3 X 15,00,000 /3600/1000 = 58.33 g/s
--------------------------------------------------------------------------------------------18.0
REVISED TABLE FOR POLLUTION CONTROL MEASURES SHOULD BE
SUBMITTED
Sources of Emission & Pollution Control Measures
The sources of emissions from the proposed steel plant and the control measures
adopted are given below. In addition to the measures taken to control pollution, it is
also proposed to limit the design emission norms to a maximum of 50 mg/Nm3 of
particulates.
VIMTA Labs Limited, Hyderabad
51
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr.
No
1
2
Area of Operations
Raw material
handling
Fugitive emissions in
material handling
Coke ovens
Coal & Coke handling
Coal charging
Carbonization
Coke pushing
Coke quenching
3
7
8
Sinter Plant
Sintering process
Raw material
preparation and
handling
Sinter screening and
transport
Pellet Plant
Raw material
preparation and handling
Mixed material drying
unit
In-duration unit system
(grate-kiln-cooler)
Blast Furnaces
Sinter, coke and flux
handling in stock
house
BF processes
Cast house
Stoves heating
BOF
Material handling
operations
Converters
Desulphurisation,
RHFs, LHFs etc
Billet/bloom casters
Rolling mills
9
Incinerator
4
5
6
10
11
Cement grinding unit
Power Plant
Air Pollution Control Measures Proposed
to be Adopted
Design Limits
• Dust suppression systems
(chemical and dry fog type)
• Water sprinklers
• DE systems with bag filters in
case of conveyors, lime handling
• Work area 5.0
mg/Nm3
• Stack: 50
mg/Nm3
• DE systems
• On main charging with HPLA aspiration
• CGT car for aspirating gas into adjacent
ovens
• Leaking of doors, lids etc.
• Use of lean gas for under firing
• Low NOx burners
• Land based pushing emission
control
• Stack: 50 mg/Nm
As per MOEF norms
applicable for coke
ovens
As per MOEF norms
applicable for coke
ovens
As per MOEF norms
applicable for coke
ovens
As per MOEF norms
applicable for coke
ovens
• Dry quenching with stand by wet
quenching facility
• ESP for collected waste gases
• Centralised De-dusting system with bag
filiter common for both areas
50 mg/Nm3
50 mg/Nm3
• Dust suppression system
• Multicyclone-scrubber based de-dusting
Work
area
mg/m3
50 mg/Nm3
• ESP
50 mg/Nm3
• Bag filters
50 mg/NM3
• Gas cleaning in venture Scrubbers
• FE systems with ESP/Bag filter
• Use of lean gas• Use of lean gas
5 mg/NM3
50 mg/NM3
50 mg/NM3
• Bag filters
50mg/NM3
• Secondary fume extraction system
• Spark arresters followed by Bag filters
50mg/NM3
•
•
•
•
Use of low sulphur gases for SO2 control
Use of low sulphur gases for SO2 control
Low NOx burner
Scrubber and alkali treatment
• Bag filters
• ESP/Bag filters
• Low NOx burners
5.0
50 mg/NM3
As per CPCB
regulations
50 mg/NM3
50 mg/NM3
--------------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
52
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
19.0
DETAILS ON BENZOL PLANT AND TAR UTILISATION SHOULD BE PROVIDED
Benzol & BTX Plant
Process Technology
It is proposed to install Benzol Recovery Plant and BTX plant of 90,000 t/yr capacity
for the coke oven plants to produce value added products like Benzol, Benzene,
Toluene & Xylene.
Block Diagram of the Proposed Plant
COG from CO
Benzol
Recovery
CO gas back to
Steel Plant Network
COG from Steel Plant Network
PSA H2
Recovery
To Steel Plant
Network
H2 Gas
COG after Benzol
Recovery
Aromatics
Recovery &
Separation
Benzol Hydro
Refining
Raffinates
Xylene
Toluene
Benzene
The flow and composition of coke oven gas before and after benzol recovery plant
is given below:
Description
Gas before Benzol Recovery
Plant
Gas after Benzol
Recovery Plant
330,000 Nm3/h
330,000 Nm3/h
Ammonia
3
0.1 g/Nm
0.1 g/Nm3
H2S
0.3 g/Nm3
0.3 g/Nm3
HCN
0.28 g/Nm
0.28 g/Nm3
32-35 g/Nm3
2-5 g/Nm3
0.4 g/Nm3
0.2 g/Nm3
Gas Flow of coke oven plant
Benzol
Naphthalene
Tar
Temperature
Pressure
VIMTA Labs Limited, Hyderabad
3
Traces
Traces
30-35 °C
25-27 °C
0.0085 Mpa
0.0075 MPa
53
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Benzol Recovery Plant
The Benzol Recovery Plant will consists of three sections 1. Cooling section
2. Benzol scrubbing
3. Benzol recovery
Process Description
Coke Oven Gas (COG) after the existing ammonia removal & recovery unit is
pressure boosted by the exhauster and fed to Benzol Scrubbing unit.
COG is cooled from 35oC to 22-25oC in the cooling towers in heat exchanger with
chilled water. After heat exchanger, the gas is passed into benzol scrubbing tower
from the bottom and comes in contact in counter flow with the circulating scrubbing
oil which is sprayed from top of tower. The benzol in the gas is absorbed by the
circulating wash oil, and is then sent through the fog precipitator for the removal
of fog.
The rich oil at the bottom of benzol scrubbing tower is pressurized by lean and rich
pumps and delivered to crude benzol condenser for heat exchange with crude
benzol from top of benzol removal tower to be preheated upto 60°C. It is then sent
to oil-oil heat exchangers for heat exchange with lean oil from bottom of benzol
removal tower, wherein the temp increased from 60°C to 140°C. Finally, it enters
into tube type heat furnace for heating upto 180°C and then passes into benzol
removal tower. The crude benzol oil-water gas which is distilled from top of benzol
removal tower enters into crude benzol condenser wherein its temperature is
lowered down to 30°C by rich oil from bottom of benzol scrubbing tower and 16°C
chilled water, and then it enters into crude benzol oil-water separator. The
separated crude benzol enters into crude benzol backflow tank, and part of crude
benzol is sent to benzol removal tower for back flowing by crude benzol backflow
pumps. The balance part is sent to crude benzol storage tank and is delivered to
tanks area by crude benzol delivery pumps for storage. The separated oil-water
compound enters into control separator, wherein the scrubbing oil is separated and
sent to underground emptying tank.
From there it is further delivered to lean oil tank by submerged pump, and the
separated water self flows into condensation liquid storage tank.
The hot lean oil after benzol removal flows out of the bottom of benzol removal
tower, and self-flows to oil-oil heat exchangers for heat exchange with rich oil,
lowing down its temperature to ~90°C, and enters to lean oil tank. After that, it is
pressurized by rich and lean oil pumps and delivered to lean oil coolers to be cooled
down to 30°C respectively by 35°C circulating water and 16°C chilled water. Then
it is sent to benzol scrubbing tower for spraying and scrubbing gas. The new
scrubbing oil, as make-up for circulating scrubbing oil, is delivered from tanks area
into lean oil tank. The 0.5 MPa (gauge) steam is heated upto 400°C by tube type
heat furnace. One part is used as heat source for scrubbing oil regenerator, and
the other enters as heat source into the bottom of benzol removal tower. The fuel
of tube type heat furnace is supplied by the gas after benzol scrubbing and filtered
by gas filter. During the operation of benzol scrubbing and removal, the quality of
circulating scrubbing oil deteriorates gradually. In order to ensure the quality of
scrubbing oil, part of scrubbing oil will be regenerated by scrubbing oil regenerator.
VIMTA Labs Limited, Hyderabad
54
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
It is heated by hot steam, and the oil vapors thus distilled enters into benzol
removal tower. The residue could be discharged to residue oil tank and delivered
to coal storage yard periodically, or it could be used as fuel.
In order to reduce naphthalene contents in scrubbing oil, there are baffle plates at
the top of benzol removal tower, for capturing naphthalene. The naphthalene oil
flows into naphthalene liquid tank and pressurized by steam to be sent to the tar
tanks in the tanks area.
The condensation liquid which is produced from final cooling tower enters into water
sealing tanks of final cooling tower, and then over-flows into condensation liquid
storage tanks, wherein it is circled via condensation liquid pump to final cooling
tower for spraying. The redundant part is delivered to condensation/blowing
section.
The process flow diagram for obtaining Crude benzol is shown below.
Benzol Hydro-Refining Unit
Benzol hydro-refining unit will utilize the crude benzol as raw material and remove
the harmful impurities such as hydrocarbon, hydrogen sulfide, ammonia and water
etc. containing the sulfur, nitrogen, oxygen through chemical and physical
methods, in order to get high purity benzene, toluene, xylene. The process diagram
is shown below with process description.
VIMTA Labs Limited, Hyderabad
55
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Process Description
Hydro-refining unit removes the impurities from the crude benzol through twostage hydrogenation reaction, including de-heavy component of raw material,
hydrogenation reaction, hydrogenation oil stabilization and the hydrogenation oil
pre-distilling part.
Typical benzol feed to hydro refining unit is as below.
Component
Benzene
Toluene
Olefins/ Aromatics
Thiophene
CS2
Pyridine
Others
Total
VIMTA Labs Limited, Hyderabad
wt %
73.80
11.40
8.50
0.56
0.08
0.40
5.26
100
56
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Pre-fractionation of Benzol (Deoctanizer)
The crude benzol from tank area pump enters the de-octanisation column. This
column operates under slight vacuum. The column separates the light and heavy
components from benzol.
The overhead vapour (C8 aromatics & below) are condensed in air cooled
condenser and are ready to be hydro treated.
1st Stage Hydro-Refining
The C8- cut from Deoctanizer is pumped to the reactor by the high-pressure reactor
feed pump. Make-up hydrogen is pressure boosted by the makeup hydrogen
compressor and then combined with the reactor feed and heated to the required
inlet temperature of the 1st stage hydro-refining (HDT) reactor by exchanging heat
with the 2nd stage reactor effluent. The combined feed stream is then passed
through the 1st stage reactor, where saturation takes place. The reactor operates
in mixed phase with a high liquid content to prevent reactor plugging caused by
potential polymer by-products.
2nd Stage Hydro-Refining
The effluent from 1st stage hydro-refining is heated through exchanger with hot 2nd
stage reactor effluent before being sent to Vaporizer for full vaporization. Recycled
hydrogen is preheated with high pressure (HP) steam and then combined with 1st
stage reactor effluent. The 1 st stage reactor effluent – hot hydrogen mixture is
brought at the outlet of exchangers in full vapor phase conditions. Any polymeric
material present in the full vaporized stream, is separated in vaporizer and drawn
off the bottom of the vaporizer. This liquid draw is eventually recycled back to the
Deoctanizer for polymer removal with the C9+ material. Vapor is further pre-heated
in fired heater to the required reactor inlet temperature and then sent to the 2 nd
stage HDT reactor. In the 2nd stage HDT reactor, desulfurization, denitrogenation,
and mono-olefin saturation occur.
The 2nd stage reactor effluent is cooled/ condensed by preheating the feed to the
2nd stage reactor followed by preheating the feed to the 1 st stage HDT reactor, and
then preheating the feed to Deoctanizer. The reactor effluent is finally cooled in
2nd stage reactor effluent air-cooler and finally by a water-cooled exchanger and
supplied to the 2nd stage HDT separator. In the separator the hydrogen and light
hydrocarbon gases are separated from the hydrotreated product. Separator offgas
is routed to the MEA system, for H2S and NH3 removal, before being recycled to
the vaporizer by the recycle gas compressor. A small purge stream is purged out
of the system to control the level of impurities in the recycled gas. Water is recycled
around the last cooler and separator in order to prevent plugging. The liquid
product from the separator drum is sent to the stabilizer to remove the light ends,
remaining dissolved H2S and water.
Stabilizer
The hydrotreated liquid from the separator is introduced into the stabilizer. Feed is
preheated by exchanging heat with the stabilizer bottom stream. Overhead vapors
from the stabilizer is condensed in water-cooled condenser and collected in
overhead receiver. The stabilizer removes the light ends, hydrogen, H 2S as noncondensable vapor and water as liquid. The water is purged out of the system while
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
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the offgas is sent to the BL. Remaining overhead liquid is sent back to the stabilizer
as reflux. The bottom product is sent to Deheptanizer for further processing. MP
steam is used for reboiling Stabilizer in reboiler.
Deheptanizer
The stabilized product is sent to Deheptanizer, where C8 aromatics are separated
to the bottom of the column. Overhead vapors, mostly C6-C7 hydrocarbons, are
condensed in air-cooled condenser and collected in overhead receiver. Overhead
liquid is then sent to extraction unit for aromatics production by deheptanizer
overhead pump. Deheptanizer bottoms is cooled down to storage temperature
using cooling water and sent to the BL by deheptanizer bottom pump. Deheptanizer
is reboiled using MP steam in reboiler.
Recycle Gas H2S Removal
Methyl diethanolamine (MDEA) is used for H2S absorption from recycle gas. The
absorption takes place in H2S absorption column. Recycle gas is supplied at the
bottom of the column while lean MDEA is supplied at the top of the column. The
vapor stream leaving the top of the absorber is free of H 2S and can be recycled
back to the hydro-refining reactor. The bottom liquid represents the rich MDEA
which is sent to the amine regenerator column. Overhead vapor is condensed and
collected in overhead receiver. The sour water is returned as reflux; a small slip
stream is purged to the BL, to the sour water stripper. The non-condensable
consisting mainly in H2S vapor is supplied to the sulfuric acid unit for recovery and
further processing.
The bottom product of the amine regenerator represents the lean solvent which
will be returned in a close circulating loop to the top of the H 2S absorber. The lean
MDEA is cooled down by preheating the rich MDEA feed to the column and finally
cooled down to the H2S absorber feed temperature by using an air-cooled heat
exchanger. The lean MDEA is passed through a series of filters for removing any
solid particles which can build up in the system and affect the operation of the
absorber
PSA Hydrogen Unit
The hydrogen used for this device is produced by PSA hydrogen producing unit.
PSA hydrogen producing device uses the plant COG gas for hydrogen production.
The COG gas composition is complex, and product hydrogen purity requirement is
high, so, the process of this device is composed of the compressing process,
pretreatment process, the pressure swing adsorption process and purification
process. Process is briefly described as follows:
Compression
Compressing process is composed of 2 sets (1 in operation and 1 in standby) of
3/4-stage reciprocating compressors. The COG gas is compressed by first stage of
the compressor to ~ 0.22 MPa (G), then enters pretreatment system to remove
the naphthalene, tar, NH3, H2S, organic sulfur and other aromatic chemical
compound (s). After the treated COG gas is compressed by the second, third or
fourth stages of compressor to ~ 2.7 MPa(G), it enters the pre-treatment system.
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
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Pre-treatment Process
The pre-treatment system is composed of mist separator, 2 pre-absorbers and one
set of superfine filter. The two absorbers are working alternately to realize the gas
purification. The working process of pretreatment column includes: Adsorption
process, pressure-reducing process, heating and impurities desorbing, cooling
adsorbent and pressure boosting process.
Pressure Swing Adsorption Process
The pressure swing adsorbing process is designed as 5-1-3 PSA configuration.
Sometimes 6-1-4 configuration is also adopted.
The technological process consists of adsorption, boosting and pressure reducing,
pathwise pressure releasing, reverse pressure releasing, washing, pressure
equalizing and boosting and the final boosting of the product etc.
Purification Process
The 99.9% hydrogen, still containing some oxygen, needs to be purified further.
The crude hydrogen first enters the normal temperature deoxidizing column and
under Pallidium (Pd) based catalyst. Oxygen reacts with hydrogen to form water.
The gas is then cooled to normal temperature in the cooler, enters pressureequalized TSA drying system composed of two drying column, one pre-drying
column, one liquid separating tank and two heat exchangers etc. The product
hydrogen can reach requirement with purity of 99.99% and oxygen content is
guaranteed to be less than 10ppm (usually less than 1ppm) and dew point that is
lower than – 60 °C.
The process flow of PSA hydrogen generation unit is given below:
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Control Philosophy
The complete complex shall be monitored, controlled and protected using a new
state of the art control system. The control system shall houses the substation
switchgear equipment, the control system equipment / operator room and the
administration area.
The safeguarding system will incorporate the following systems:



Basic Process Control Systems / Distributed Control System (DCS)
Emergency Shutdown system (ESD)
Fire & Gas System (F&G System)
In general, the first layer of protection is from DCS. The DCS will perform basic
control functions by regulating process variables such as pressure, temperature,
flow, level etc. Many of the products that this facility processes are inherently
hazardous. Therefore and ESD system is being employed to provide a second layer
of protection to help mitigate many of the risks associated with the process.
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
The main operator interface shall be through DCS which consists of operator
consoles, engineering consoles, alarm management, history and reporting,
control, sequence, logic and monitoring functions.
The ESD system shall be programmable Logic Controller which can automatically
detect any abnormal operation or equipment conditions and alert the operator and
also take automatic safety action to protect personnel, plant facilities and
environment.
The F&G system shall continuously monitor and detect fire, heat, smoke and
flammable and toxic gases in the pant area. The F&G system which on detection
shall initiate audible and visual alarms to alert personnel and initialize the fire
protection system as desired.
The control room shall be segregated in to two main sections - The rack room and
the operator room. The rack room shall consist of all the control system cabinets,
racks etc. The operator room shall consist of the Human Machine Interface (HMI)
graphics displays, hardwired matrix panels that have critical alarm annunciators,
push buttons and lamps, printers etc.
Product Mix
The expected quantity of products from the Hydro-Refining plant is given below:
Description
Benzene
Toluene
Mixed Xylene
Raffinates
Unit
63,000 t/yr
11,700 t/yr
5,400 t/yr
9,900 t/yr
Percentage
70.0%
13.0%
6.0%
11%
Crude Benzol Specification
Specifications of crude benzol are given below.
Item
Appearance
Density
(20oC)
Unit
g/ml
Specification
Yellow Transparent Liquid
0.871 - 0.900
Distillation range
Distillation capacity below 75 oC (volume), % not
more than
-
Distillation capacity below 180 oC (volume), %
not more than
93
Temperature at 96% distillation volume, oC not
more than
-
Water Content
No visible insoluble water at
ambient temperature (18-25 oC)
by visual method.
Benzene Specification
The main product of the proposed plant is Benzene. Its output from crude benzol
is 65-70%. Benzene is an organic chemical compound. It is composed of six carbon
atoms in a ring, with one hydrogen atom attached to each carbon atom, with the
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
molecular formula C6H6. Specifications of pure benzene for export grade are given
below.
Chemical and Physical Analysis
Item
Appearance
Sp.Gr (20oC)
Benzene Purity
Non-aromatics hydrocarbons &
Toluene
Total Sulfur
Thiophene wt
Crystallization point
Evaporation residue
Acid wash colorimetry
Residual Solvent
Moisture
Test for Neutrality
Unit
wt%
Specification
Colourless Transparent Liquid
0.878 - 0.881
99.95 min
wppm
500 max
wppm
wppm
o
C
100 ml
0.5 max
0.5 max
5.5 min
5 mg max
0.05 g/K2Cr2O7/L
1.0 max
400 max
Neutral
wppm
wppm
Toluene
Toluene, also known as Methylbenzene, is a clear, water-insoluble liquid with the
typical smell of paint thinners. It is a mono-substituted benzene derivative, i.e.,
one in which a single hydrogen atom from the benzene molecule has been replaced
by a univalent group. The molecular formula of toluene is C7H8 or C6H5CH3.
Toluene is used:




In the manufacture of foam mattresses e.g. polyurethanes.
For making dyes, plasticiser, pharmaceuticals, phenol, benzoic acid, diisocyanate (used in polyurethane manufacture), benzene etc.
As a solvent and diluent in coatings.
For making the explosive 'Trinitrotoluene' (TNT).
The chemical analysis of Toluene is indicated below:
Item
Appearance
Sp.Gr (15.6/15.6oC)
Pt-Co color
Toluene Purity
Benzene
Non-aromatics
Total Sulfur
C8 Aromatics
Basic Nitrogen
Residual Solvent
VIMTA Labs Limited, Hyderabad
Unit
wt%
wppm
wppm
wppm
wppm
wppm
wppm
Specification
Clear, White
0.869 - 0.873
20 max
99 min
200 max
9600 max
1 max
200 max
0.2 max
1 max
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Xylene Specification
Xylene, also known as Dimethyl benzene is used as a solvent for paints
pharmaceuticals etc. It can be converted to toluene and benzene for subsequent
uses.
The chemical analysis of Xylene is indicated below:
Item
Appearance
Sp.Gr (20 °C)
Pt-Co color
Total Sulfur
Distillation range
Evaporated residues
Unit
wppm
°C
mg/100ml
Specification
Clear, White
0.860 - 0.870
20 max
3 max
10
5 max
Tar Utilisation
20.0
Tar generated from coke oven plants will be about 3,00,000 T/annum, which is
proposed to sold in the open market.
------------------------------------------------------------------------------------------ACTION PLAN FOR WASTE MANAGEMENT FOR EACH COMPONENT SHOULD
BE SUBMITTED
The details of waste generated from the proposed integrated steel plant are
presented in the following sections.
20.1 Non-Hazardous Waste
The main solid waste generated in the proposed steel plant will be BF slag, BOF
slag and slime which is non-hazardous waste. Other solid waste includes gas
cleaning plant sludge, dust from ESP, bag filter and dust extraction system and
refractory debris etc. this solid waste except refractory will be completely reused
in sinter plant and coal fines will be used in the power plant. Further, oil soaked
cotton waste; organic wastes from steel plant, paper, plastics and waste bag filters
will be generated. The details of solid waste generated from the proposed steel
plant is given in Table-20.1.
TABLE–20.1
SOLID WASTE GENERATION AND DISPOSAL
Sr. No.
Solid Waste
Generation
(TPA)
Proposed Disposal
1
Slag
a
Iron Making slag
3,000,000
98% granulated and sold to cement plants, 2%
treated in dry pits and used for land fill
b
Steel making slag
1,480,000
BOF slag is granulated, metallic separated and
used in construction
2
Sludge
a
Iron making sludge
129,000
Used in pellet plant after dewatering
b
Steel making sludge
151,000
Used in sinter plants after dewatering
3
Slimes
from
Beneficiation Plant
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5,800,000
Stored in secured land fill
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr. No.
4
Mill scales
a
Steel making shop
b
Rolling mills
5
Dusts
A
Generation
(TPA)
Proposed Disposal
38,000
Used in sinter plants
149,000
Used in sinter plants
Flue dust from Blast
furnace
106,572
Used in sinter plants
B
Dust from bag filter
343,428
Used in sinter plants
6
Lime / Dolo dusts
38,000
Used in sinter plants
7
Ash
8
Reject
from
Coal
Washery (Middling’s)
9
20.2
Solid Waste
750,000
Refractory waste
1,600,000
50,000100,000
Sold to cement plants and
manufacturing fly ash bricks
used
for
Will be used in power plant
Will be disposed in secured land field
Hazardous Waste
The hazardous waste such as waste oil, lead acid batteries and oil soaked cotton
waste will be generated. The waste oil generated will be utilized in recovery coke
oven for process improvements. Lead acid batteries will be sold to authorized
users/recyclers approved by JSPCB. The oil soaked cotton waste will be incinerated
in BOF. The hazardous waste generated from the proposed steel plant is given in
Table-20.2.
TABLE-20.2
HAZARDOUS WASTE GENERATION AND ITS DISPOSAL
Sr.
No.
1
Category
Waste oil & Used oil
Quantity kl or
t/yr @10 MTPA
2750 KL / Year
2
3
4
Acid and alkali residue from CRM
Waste pickled liquor from CRM
Tar sludge from coke oven
5
Water treatment sludge
8172 t
6
Spent activated carbon, catalyst
& Oil soaked filter
Sludge from hazardous waste
treatment process, incinerator &
Waste sulphur
8.7 t/y
7
450 t
73216000 KL
315 t
59 t/y
Proposed Disposal
Sold to authorised
parties
Regenerated in ARP
Regenerated in ARP
Used back in Coke
oven
Sent to hazardous
waste land fill
Incinerated
Sent to hazardous
waste disposal site
The utilisation schemes for BF, SMS and fly ash are covered under point no.4.
20.3
Utilization (Recycle & Reuse) of Solid Waste
Different types of solid wastes are generated from integrated steel plant. The
source of solid waste generation along with their re-use, re-cycle, utilization and
disposal methodology are given in Table-20.3.
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
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TABLE-20.3
SOLID WASTE GENERATION ALONG WITH THEIR RE-USE,
RE-CYCLE, UTILIZATION AND DISPOSAL
Sr.
No.
Type of
Solid Waste
Recycle
1
BF slag
2
BOF Slag
3
BOF Scales & Reused in
Scrap
sinter plant
as sinter
mix.
Mill Scrap
Used in BF
Fly ash
4
5
6
7
8
9
10
11
-
Re-utilization
Dump for
Future
Re-use
Use
Within Plant
Sold
Cement plant
Sold
to
cement
manufacturer/glass
manufacturers
 Granulated and  Will be sold to parties
partly used in
for building roads
plant
(aggregate for road
 Balance will be
making, rail track
crushed & used
ballast, land filling,
for making
after conditioning as
roads, civil
it contains lime which
works, etc.
if
used
before
conditioning then it
swells),
civil
engineering works,
etc.
 Used in sinter plant
-
Sold
to
cement
manufacturers/road
making/brick making
Bottom Ash
Ash
Waste
-Used in plant for Sold as material for
Refractory
making
making
road
refractory mortars embankment or for filling
in captive
low lying areas
mortar shops
- Making /
repairing plant
roads
Lime/dolomite
Re-used in sinter
Fines
plant
Mill scale
-Reused in sinter
plant
- Reused as a
reductant input
material in BF
BF flue dust Reused in Used
in
pellet
sinter plant plant
as sinter
mix.
BF GCP
Reused in Used in sinter
sludge
sinter plant plant after
as sinter
pelletisation
mix after
pelletisation
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dump
-
-
-
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr.
No.
•
•

Type of
Solid Waste
Re-utilization
Dump for
Future
Re-use
Use
Within Plant
Sold
12
BOF sludge
Reused in Used
in
sinter
sinter plant plant
& BF
13
Sinter
ESP Recycled in
dust
sinter plant
Recycle of waste means utilization of waste in the same process from which it has been
generated
Reuse of waste means utilization of the waste in any process other than the process from
which the waste has been generated. The process utilizing the waste may be within the plant
or outside the plant. In case of utilization outside plant, the waste is sold to firm utilizing the
waste
• Disposal means dumping of waste in designated areas.
Recycle
The following shop wise specific management measures will be adopted for solid
waste:
Sinter Plants
 100% recycling of LD sludge, mill scale, lime and dolomite dust, SP sludge, and
ESP dust;
• 100% recycling of return sinter fines;
• Utilization of 10 mm LD slag; and
• BF flue dust utilization in Sinter Plant.
DR Plant
•
•
DRI process dust 100% used - reused in sinter plant as sinter mix. Unused
quantity sold to parties for brick making, land filling and to oil refineries as
replacement of activated carbon; and
DRI de-dusting dust 100% used - reused in sinter plant as sinter mix. Unused
quantity sold to parties for brick making & land filling.
Blast Furnaces
•
•
•
•
•
100% cast house slag granulation for sale to cement plants;
Recovery of iron scraps at BF slag dump;
Use of cast-able material in cast house runners, in place of ramming mass, which
will reduce scrap generation by 1%;
Recycling of BF flue dust in sinter plant and sold; and
Recycling of used refractory.
Steel Melting Shops
•
•
Recycling of LD sludge will be explored; and
LD slag – after granulation partly used in sinter plants, blast furnaces and steel
melting shop for conserving limestone & dolomite. Balance used for making
roads, civil works etc.
Refractory Material Plant
•
•
•
Under size limestone, dolomite & lime fines recycled 100% to sinter plant;
Utilisation of refractory grog made from used refractory bricks for mortar
manufacturing of different grades (25% raw material input is from grog);
Ladle covering compound in SMS using LD slag;
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
•
Waste Mg-C bricks for production of new bricks for converter bottom, coating and
patching materials for converter vessels; and
Rolling Mills
• 100% recycling of mill scales.
Coal Based Power Plant
• 100% used in Fly-ash brick making plant and sold to cement plants.
20.4
Solid Waste Management at JSW Steel-Vijayanagar Plant
The following practices were started in JSW Vijayanagar Plant, to effectively utilise the
micro fine dusts and mill scale dusts in Sinter Plant and SMS Plant after agglomeration.
A. Micro Pelletizing Plant
During iron and steel making a wide range of by-products are produced. Among these
large amounts of micro fine dust and sludge are generated from the air and water
pollution control equipment. These non-iron/steel by-products are often termed
wastes. This has been especially true in the past when large quantity of these materials
were land filled. In today’s green manufacturing world it is becoming increasingly
difficult and costly to continue with land filling. To term these materials as waste
ignores the potential value that exists in them and the benefits that they can have on
the iron and steel making process. Correct management of these by-products can
recover their value and reduce existing cost of land filling.
Micro-Pelletization is a process that converts individual by-products into a homogenized
agglomerated form that can be handled in conventional iron and steel making units i.e.
blending of BOF Sludge from Steel Melting Shop, Blast Furnace sludge from Gas
cleaning plant slurry, Bag filter dust, ESP dust, Lime & dolomite dust, Blast Furnace
Flue Dust and LD Slag (<6mm) from steel melting shop, to produce a blend suitable for
micro-pelletization. The aim of the process is to produce a consistent blend in terms of
‘handleability’, temperature and moisture content that can then be used to produce
micro-pellets of the desired quality, which can be used in sinter making in conventional
Iron & steel making.
Application
Large amount of iron ore fines and micro fine dust are utilized for sinter making, Earlier
at JSW Steel, there micro fines dust were used in sinter making routing through the
basemix( Raw material pile). Since these micro fine dusts wholly do not take part in the
process of sinter making, the inlet dust concentration increases due to which there is
high emission from the sinter plants are observed. Use of these micro pellets in sinter
making reduces emission level.
Working Philosophy
The micro pellet plant converts the input materials into useable agglomerated products.
The plant comprises a mixing, micro pelletizing and discharge circuit. A 0.6 MTPA micro
pellet plant has been commissioned in Aug 2013 at JSW Steel Vijayanagar works.
Micro pellets are produced using the dust, sludge and slag as mentioned above and
water is added to create the micro pellet feed mix. Micro pellet production is made in
to a predetermined recipe with a moisture content of 10%. The recipe specifies the
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
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amount of each component that is used within the batch, the moisture content and the
mixing time to be used and the settings to be used for the pelletising disk.
Process Description
The mix will be discharged from the mixer and conveyed to a pelletizing disc and this
will agglomerate the mix to produce micro pellet of the desired size ( 6 mm by
adjusting, speed and angle of inclination of the disc). The micro pellets will be
discharged from the disc onto a conveyer. Micro pelletizing plant is shown in Figure20.1.
Any fines or spillages generated by the process will be conveyed back to the front end
of the plant and combined with the mix such that they are fully recycled at the facility.
The micro pellets are released from the pelletizing disc onto a series of discharge
conveyers. From the conveyer, the micro pellets pass down a discharge chute onto a
rotary stacking conveyer. It stacks the micro pellets into one of four 2500 tonne
stockpiles. Micro pellets are left to cure in their initial stockpiles from 48 to 72 hours or
depending on production and then sent to base mix for further use in sinter making.
Micro Pellet Typical Composition
By-products
BOF
sludge
Bag
filter
dust
Flue
dust
<6mm
slag
Lime &
Dolomite
dust
Burnt
lime
Water
Total
% of byproduct Used
30
14
30
17
6
2
1
100
Product Quality
The Fe (T) in micro pellets is about 38%
Benefits
1. Increased consumption of waste material in the base mix. It has been observed
that the waste utilization has increased from 45 to 70 kg/ton of base mix.
2. Reduction in Stack Emission in Sinter Plants.
3. Reduction of -100 mesh in base mix by 2.5% is expected to increase sinter
productivity by 0.5 T/Sq.m/Day.
4. Regular Disposal of Dust from Bag Filters leading to improved performance.
5. Increase in solid waste utilization.
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Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
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FIGURE-20.1
MICRO PELLETIZING PLANT
B. Mill Scale Briquetting Plant:- 0.2 MTPA
In an integrated steel plant during iron and steel making, large amount mill scales from
mills, iron bearing dusts are generated from the blast furnace cast house and secondary
fume extraction system of steel melting shop.
Conventionally the mill scale consisting of > 72% Fe (total) is used for sinter making in
steel making. Due to the high iron content of these kinds of dust and waste materials,
an innovative technique of briquetting these kind of wastes was implemented at JSW
Steel for better and gainful utilization in LD converters in steel melting shop.
Mill scale briquetting plant converts individual by-products into a homogenized
agglomerated form that can be handled in steel making facilities.
Application
LD converters in Steel Melting Shop (SMS) requires large amount of iron fines as coolant
in the process. These briquetting can be used as alternative source of these iron ore.
Where in it reduces iron ore input to steel making. Earlier at JSW Steel, there iron fines
were used in steel making as coolant.
Since these iron fines wholly do not take part in the process of steel making (as blowing
oxygen will carry away the dust particles) the inlet dust concentration increases due to
which there is high emission from the roofs of steel making shops are observed. Use of
mill scale briquettes in steel making as drastically reduced emission.
Working Philosophy
Mill scale briquetting is a process that converts individual by-products into a
homogenized agglomerated form that can be handled in conventional steel making units
i.e. blending of Mill scale, CRM dust, Hydrated lime and molasses, in required quantity
VIMTA Labs Limited, Hyderabad
69
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
to produce a blend suitable for Mill scale briquetting. The aim of process is to produce
a consistent blend in terms of ‘handle ability’, temperature, density and moisture
content that can then be used in steel making.
Proposed Technology
About 500 TPD of the mill scale and iron bearing dust from blast furnace, CRM and steel
melting shops. is generated from the various sources is briquetted to further directly
used as coolant in LD converter. Mill scale is mixed with required proportion of hydrated
lime, molasses, CRM pickling dust and bag filter dust to produce briquettes of size 75 x
50 x 25 mm, having adequate strength and chemical properties suitable for LD
converter to be used as a coolant.
Environment Friendly Product
The mill scale briquettes produced contains high Fe content, which can be directly used
in the LD converter as a coolant, there by replacing equivalent amount of Iron ore/DRI
or Scrap. This is an environment friendly product as it usage in LD converter in steel
melting shops would considerably reduce usage of raw material (Iron ore) or Direct
reduced Iron produced from the DRI plant or metal scraps.
MILL SCALE BRIQUETTE TYPICAL COMPOSITION
Consumption
Mill Scale
Bag Filter
Dust
CRM Dust
Hydrated
lime
Molasses
%
77.97
7.97
4.05
2.02
8.00
Product Quality
The Fe (T) in mill scale briquettes is about 65%
Benefits
1. The mill scale briquettes produced contains high Fe content, which can be directly
used in the LD converter as a coolant, there by replacing equivalent amount of Iron &
ore/DRI or Scrap.
2. This is an environment friendly product as it usage in LD converter in steel melting
strips would considerably reduce usage of raw material (Iron ore) or Direct reduced
Iron produced from the DRI plant or metal scraps.
3. Lime consumption is marginally reduced.
4. Yield is marginally increased
5. Re-blow is reduced
----------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
70
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
21.0
THE COMMITTEE PRESCRIBED AN AMOUNT OF RS. 700 CR OVER A PERIOD
OF 10 YEARS FOR THE CSR RELATED ACTIVITY. A DETAILED PLAN IN THIS
REGARD SHOULD BE SUBMITTED.
JSW conducted need based survey of sustainable development in the study area
(10 km radius) and identified needs of the local peoples including valid concerns
expressed during public consultation, mitigation issues merging from social impact
assessment and R&R plan. It is therefore, total Rs. 175 corers (capital & recurring
cost) is proposed towards CSR related activities and also detailed plan covering the
activity wise cost involved is submitted below:
PROPOSED CSR BUDGET
Sr.
No.
1
2
3
4
5
6
7
8
Category
Health programs
Water and sanitation
Education programs
Sports and culture
Livelihoods
Community
infrastructure
development
including green belt
development
Supporting vulnerable
persons
Management cost (Rs.
in Crores)
Grand Total
Capital
Expenses
(Rs. In Crores)
Recurring
Expenses
(Rs. In Crores)
Total
25.00
18.00
06.28
04.00
10.00
20.33
10.35
04.00
04.40
05.25
(Rs. In
Crores)
45.33
28.35
10.28
08.40
15.25
25.00
08.98
33.98
0
03.41
05.00
25.00
93.28
81.72
03.41
30.00
175
DETAILED CSR BUDGET AND ACTION PLAN
Sr.
No.
1
CSR Programs
Health
Programme
VIMTA Labs Limited, Hyderabad
Action Plan
Mobile medical unit (MMU) with doctor, pharmacist, lab
technician, community health worker and diagnostic
facilities in collaboration with technical support
agencies like Help-age India (Best Practice)
Partnership with government primary health center for
supplementing national health programs like polio, TB,
and malaria etc.
Health camps for family planning HIV/aids and other
communicable diseases
Promoting rural health insurance by creating
awareness and subsidy
Training and awareness programs for health, hygiene
and sanitation volunteers
Total
Approx.
Budget
in
Crores
16.5
10
7
7
4.83
71
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr.
No.
2
CSR Programs
Water and
Sanitation
Programme
Action Plan
Establishing water treatment and distribution system in
periphery villages @ 20 lts. to each family (Tata trust
model of drinking water treatment plant can be
adopted)
Ensuring supplying of drinking water to the periphery
villages in summer by providing tankers, wherever is
required.
Providing proper sanitation facilities to the villages and
developing nirmal gram puraskar villages (national
program)
Total
Approx.
Budget
in
Crores
45.33
20
7
1.35
28.35
3
4
5
Education
Programme
Sports &
Cultural
Livelihoods
Development
Programme
Strengthening of school buildings/ establishing model
Aganwadies/ Balwadies in collaboration with ICDS and
adult education centers drinking water supply and
toilets in schools
Setting up of village school, library ,computer training,
ITI's
Strengthening of mid - day meal program by improving
quality of food, kitchen in the school, plates and
tumblers etc.
Sponsorship of bright students of adjoining villages
Promoting rural sports through coaching and sports
material support in project periphery villages
Facilitation and sponsorship to local talent for
competitions and state, national & international level
coaching
Organizing local and district level sports meets
Developing play grounds in each affected village
Short term courses for employability skill training in
collaboration with Rajiv Gandhi youth employability
skill development program
Sponsorship and promotion of full time vocational
training course
Promoting micro-enterprises and small business
Agriculture, horticulture and animal husbandry
development program
0.94
1.54
6.3
1.5
10.28
2.1
1.4
1.4
3.5
8.4
2
1.25
7
5
15.25
6
Community
Infrastructure
VIMTA Labs Limited, Hyderabad
Construction of roads, public utilities, bus shelters,
religious places etc. in all project affected villages and
the study area as per requirement.
Laying of drainage system, improving sanitation
facilities, construction of toilets.
Construction of community center in project periphery
villages
28
3.5
0.7
72
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr.
No.
CSR Programs
Action Plan
Construction of health center
Veterinary service center
Developing grazing lands
7
8
Supporting
Vulnerable
Persons
Management
Cost
Ensuring
life-long
pension
to
vulnerable
(elderly/widows/special
disabilities)
from
the
government schemes through community facilitation
services
Gainful engagement on priority to vulnerable persons
and creation/adoption of old age homes
Human resource and establishment of foundation and
administration
Total (Rs in Crores)
Total
Approx.
Budget
in
Crores
1
0.3
0.48
33.98
2.71
0.7
3.41
30
175
--------------------------------------------------------------------------------------------22.0
TOWN PLAN DETAIL SHOULD BE SUBMITTED INCLUDING THE LAYOUT OF THE
BUILDINGS, GREEN BELT, INTERNAL ROADS, STP, AND PARKING PLAN ETC.
The township is to serve a large steel plant of 10 MTPA capacity and CPP of 900
MW capacity. The proposed township is planned over an area of 121.41 ha in
Barenda village and may have up to 9620 dwellings of various categories. Adequate
green belt/green cover will be developed in the township.
The township will be located in the northeast direction to the plant and falls in the
cross-wind direction to the proposed plant site.
The existing layout of JSW-Vidyanagar township is shown below.
The township will be developed with all facilities including green belt, open spaces
for car parking, community centre, school, temple, health centre, STP and water
treatment plant etc. The township layout will be finalised during the detailed
engineering stage.
JSW has already constructed townships at the following locations
1)
2)
3)
4)
5)
Vijayanagar, Karnataka
Barmer, Rajasthan
Jaigarh, Maharashtra
Salem, Tamil Nadu
Vasild, Maharashtra
The proposed township at Barenda village shall also be in the same lines as
described above.
VIMTA Labs Limited, Hyderabad
73
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
VIDYANAGAR TOWNSHIP LAYOUT PLAN
-------------------------------------------------------------------------------------------------
VIMTA Labs Limited, Hyderabad
74
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
23.0
DETAILS REGARDING THE PROPOSED CAPTIVE THERMAL POWER PLANT
SHOULD BE SUBMITTED.
It is proposed to install a 900 MW CPP for the proposed plant for which 3.0 MTPA of
thermal coal and 2.0 MTPA of middling’s generated from the captive coal washery of
the plant will be required. Thermal coal would be replaced by the surplus plant gas
to the extent possible. The configuration of the CPP shall be 3 x 300 MW. The plant
and equipment for captive power plant of capacity 300 MW (1 unit) are enumerated
below. The typical flow diagram of captive power plant is shown in Figure -23.1.
 Steam Boiler & Accessories
The steam boiler (SB) would be designed for firing 100% imported coal and would
be natural circulation drum type. The SB would be of two pass design, radiant, single
reheat, balanced draft, semi-outdoor type, rated to deliver 1015 t/hr of superheated
steam at 173 ata, 541 0C when supplied with feed water at a temperature of 2790C
at the economiser inlet. The reheat steam temperature would also be 5410C.
The steam boiler would be provided with coal mills along with individual raw coal
gravimetric feeders and coalbunkers. Sampling arrangement at mill outlet would be
provided for purpose of establishing the average gross calorific value of coal as well
as coal fineness. The coal mills would be provided with steam blanketing system for
the purpose of fire protection. The SB would be designed to handle and burn HFO as
secondary fuel up to 22.5% MCR capacity for start-up and for flame stabilisation
during low-load operation. For unit light up and warm up purposes LDO shall be fired.
The required fuel oil pressurising units and fuel oil heating equipment would be
provided. High-energy electric arc ignitors would be provided to ignite the fuel oil
guns.
The steam boiler would consist of water cooled furnace, radiant and convection
super-heaters, re-heaters, economiser, regenerative air heaters, steam coil air preheaters, etc. Soot blowers would be provided at strategic locations and would be
designed for sequential fully automatic operation from the unit control room.
The plant would comprise of primary air fans, forced draft fans, and induced draft
fans. Electrostatic precipitator (ESP) and fly ash hoppers would be provided for the
collection of fly ash. The ESP shall be designed to achieve an outlet dust
concentration of 50 mg/Nm³.
 Steam Turbine Generator & Accessories
The selected steam turbine generator (STG) would be rated for 300 MW maximum
continuous output at the generator terminals, with throttle steam conditions of 165
ata and 538OC / 538OC steam temperature and 0.1 bar (a) back pressure. The steam
turbine would be a reheat extraction-condensing turbine.
The turbine-generator would be complete with all accessories such as protection
system, lube and control oil systems, seal oil system, jacking oil system, seal steam
system, turbine drain system, 60% MCR HP/LP bypass system, electro-hydraulic
control system, automatic turbine run-up system, on-line automatic turbine test
system and turbine supervisory instrumentation. The turbine-generator would also
have all necessary indicating and control devices to permit the unit to be placed on
turning gear, rolled, accelerated and synchronized automatically from the control
room. Other accessories of the turbine-generator would include an oil purification
unit with transfer pumps and clean and dirty oil storage tanks of adequate capacity.
VIMTA Labs Limited, Hyderabad
75
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Feed Cycle Equipment
 Condensate Extraction Pumps
2 x 100% capacity condensate extraction pumps, one working and one standby,
would be provided. The pumps would be vertical, canister type, and multistage
centrifugal pumps driven by AC motors.
Generator
Water
Treatment
Raw Water
Turbine
D.M Makeup
Deaerator
LP Heater
Boiler
Reservoir
C.W
Pump
Neut Pit
BFP
H P Heater
Mill
CEP
Intake Pump
RIVER
Economisar
Condenser
Coal
Bunker
Makeup
Cooling
Tower
Ash Water
Pump House
Central
Monitoring Basin
Air
Preheater
FD
Fan
To Ash Handling
System
Dust Supression/
Sanitation/
Green Belt Dev.
PA
Fan
Electrostatic
Precipitator
Bottom Ash
ID
Fan
Chimney
Fly Ash Collection/
Disposal
FIGURE -23.1
TYPICAL FLOW DIAGRAM OF CAPTIVE POWER PLANT
VIMTA Labs Limited, Hyderabad
76
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
 Boiler Feed Pumps
3 x 50% capacity boiler feed pumps would be provided to pump the feed water from
the de-aerator to the steam generator through the high pressure heaters. The boiler
feed pumps would be horizontal, multistage, AC motor driven centrifugal pumps of
barrel type with variable speed hydraulic coupling.
 Low Pressure Heaters
The low-pressure heaters would be of shell & tube type with U-shaped carbon steel
tubes, with their ends rolled in carbon steel tube sheets.
 De-Aerator
The de-aerating feed water heater would be a direct contact, variable pressure type
heater with spray-tray type or spray type of de-aeration arrangement. The feed
water storage tank would have a storage capacity adequate to feed the steamgenerator for 6 minutes when operating at MCR conditions.
 High Pressure Heaters
The high-pressure heaters would be of shell & tube type with carbon steel U-tubes
welded into carbon steel tube sheets. The HP heaters would be provided with a desuperheating zone and a drain-cooling zone in addition to the condensing zone.
 Gland Steam Condenser
A surface type gland steam condenser would be used to condense the gland steam
exhausted from the turbine glands. The gland steam condenser would be of singlepass type with the main condensate flowing through the tubes to condense the
steam. Exhausters would be provided to evacuate the air from the shell side and
maintain the shell at the required negative pressure.
 Turbine Lube Oil Purification System
In the lubrication cycle for the turbine-generator, the lube oil comes in contact with
water, air and metal particles, which cause deterioration of the lube oil. In order to
prolong the life of the lubricating oil and the parts served by the lube oil, suitable
purification equipment is required to be provided to remove the contamination and
restore the oil to acceptable conditions.
 Fuel Oil System
The fuel oil system would be designed for the use of heavy fuel oil (HFO) for startup and flame stabilisation purposes. Light diesel oil (LDO) shall be used as fuel for
light up and warm up purposes. The peak requirement of LDO would be during light
up and commissioning whereas the peak requirement of HFO would be during the
trial operation.
 Chemical Dosing System
Phosphate dosing system would be provided to ensure chemical conditioning of the
steam generator drum water so as to prevent scale formation. In addition,
ammonia/hydrazine-dosing system would be provided to ensure chemical
conditioning of the feed water by removing the dissolved oxygen and carbon dioxide
present in the feed water.
VIMTA Labs Limited, Hyderabad
77
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Instrumentation And Control System

 Distributed Microprocessor Based Instrumentation
Microprocessor based distributed control system with state of art Man - Machine
Interface (MMI) is proposed to provide a comprehensive integrated instrumentation
and control system including the functions of Data Acquisition System (DAS) to
operate, control and monitor the steam generator and auxiliaries, steam turbine
generator and auxiliaries and the balance of plant systems with a hierarchically
distributed structure.
 Utility Packages
Utility packages are proposed with dedicated stand-alone I&C system. However,
these panels are proposed to be located in the unit control room.
 Unit Control Desk
The unit, functional group / drive level control and operation of all main plant
equipment including generator, transformers and auxiliaries would be from a set of
monitors mounted on a control desk.
 Control Room
A common control room is proposed with all the facilities of main control room,
electronic cubicle room, Shift Charge Engineer’s room, auxiliary electronics room &
UPS room.
 Auxiliary Systems

Compressed Air System
Two (2) (one operating & one standby) screw would be provided for the proposed
unit.

Air Conditioning System
It is proposed to air-condition the unit control room, electronic cubicle room, shift
charge engineer’s room, ESP control room, SWAS, analyzer panel room, coal
handling control room, DM plant control room and switchyard control room.

Ventilation System
For the ventilation of the station building, evaporative cooling system (Air washer
type) is envisaged. For ventilation of other buildings, supply air fans, exhaust air
fans, roof extractors or a suitable combination of these would be provided.

Hydrogen Gas System
Hydrogen gas with a purity of 99.9% (by volume) is required for cooling of the
generator. It would be required for the initial filling and continuous make-up during
normal operation for maintaining the required purity in the generator.

Cranes and Hoists
Station Building Cranes
Two nos. Overhead, cabin / pendent operated electric overhead traveling (EOT)
VIMTA Labs Limited, Hyderabad
78
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
cranes, of 125 / 20 tons capacity would be provided for the proposed Unit also for
handling of various main plant equipment. Turbine & generator erection would also
be carried out by using the above cranes.
CW Pump House EOT Crane
Mobile crane would be provided to facilitate erection and maintenance of pump
components and drive motors.
EOT Crane for Lifting Boiler Feed Pumps (BFP)
An EOT crane of 12 tons capacity crane is proposed to be provided for maintenance
of BFPs for the proposed Unit.
Miscellaneous Lifting Tackles / Hoists
For the equipment, which weighs above 1000 kg, electrically operated type of hoists
and trolleys would be provided. For the equipment weighing less than 1000 kg,
manually operated hoists and trolleys would be provided.
Workshop Equipment
It is proposed to utilize the work shop equipment available in the existing power
plant and no separate work shop equipment are proposed to be procured for the
expansion plant.
 Electrical Systems
 Generator
The generator would be rated to deliver 300 MW, at 20 kV, 50 Hz, 0.85-power
factor, at 3000 rpm. The generator winding would be star connected with the phase
and neutral terminals brought out to an accessible point. The generator will deliver
rated MVA output under ± 5% variation in voltage and +3 to -5% variations in
frequency. The star point of the generator would be connected to earth through an
earthing transformer, the secondary of which will be loaded by a resistance.
The generator Stator winding and terminal bushing are water inner-cooled, rotor
winding is hydrogen inner-cooled and stator core hydrogen cooled. Hydrogen
coolers would be built into the stator frame of the generator and would be sized to
ensure at least 80% of the rated output when one hydrogen cooler is taken out for
maintenance.
The generator would be provided with either brush-less or static excitation system.
Suitable fast acting non-dead band type continuous acting voltage regulator would
be provided and mounted in sheet steel clad cubicles. The excitation cubicles will
have necessary sections to house the apparatus and accessories required for field
flashing and control.
The generator would be provided with Class – F insulation. However, temperature
rise would be limited to Class – B.

Generator Bus Duct
The terminals of the generator will be connected to the generator transformer
through Isolated Phase Bus Duct (IPBD) of adequate short circuit withstand
capability with suitably rated tap-offs to the unit auxiliary transformers. The bus
VIMTA Labs Limited, Hyderabad
79
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
duct will be natural air-cooled and will run partly indoors and partly outdoor. The
rating of the generator bus duct will be as furnished in table below.
GENERATOR ISOLATED PHASE BUS DUCT (IPBD)
Sr. No.
1
2
3
4
5
6
7
Particulars
Type of Bus Duct
Nominal Service Voltage / frequency
Rated voltage
Continuous current rating
Basic impulse insulation level (1.2/ 50
micro-sec)
Bus bar conductor material
VT & SP cubicle
Voltage transformer
Lightning Arrestor
8

Bus duct material
Rating
IPBD / Natural air cooled
20 kV / 50 Hz
24 kV
12,500 A
125 kV peak.
Aluminium / as per IS 5082
20 /
3
kV / 110 /
3
V / 110 /
3
V, 3
nos., 100 VA / ph.
24 kV Metal oxide type, with nominal discharge
current of 10 kA.
Aluminium / as per IS 5082
Generator Transformer
The generator will be connected to the 400 kV switchyard through the generator
transformer (GT). The GT will be 355 MVA, 3 phase ONAN / ONAF / OFAF cooled
and will be provided with on-load taps in steps of 2.5%. The BIL of the transformer
will be 1300 kV. The rating and details of the generator transformer are as in table
below.
GENERATOR TRANSFORMER
Sr. No.
1
2
3
4
5
6
7
8
9
Particulars
Type of cooling
Rating
No load voltage ratio
Vector group
Percentage impedance
Type of tap changer
Tap range
Impulse voltage withstand (1.2/ 50
micro-sec)
Terminal connection
LV Side
10.

Applicable standard
Rating
ONAN / ONAF / OFAF
355 MVA, 3 phase
20 kV / 420 kV
Ynd1
14.5%
On-load
+ 5% to –10% in steps of 1.25%
1300 kV peak.
HV side Terminals on bushings for
overhead line connection.
Throat type with matching flanges for
connection to IPBD.
IS 2026.
Station Transformer
One Station transformer of three – winding, three phase, 50 / 25 /25 MVA, 220 kV
/ 6.9/6.9 kV, with on load tap changer +5% to -15% in steps of 1.25% will be
provided. The ST-6 shall be connected to the existing 220 kV switchyard. The
ratings and details of the station transformer are as in table below.
Station Transformer
Sr. No.
1
2
Particulars
Type of cooling
Rating
VIMTA Labs Limited, Hyderabad
Station Transformer
ONAN / ONAF
50/25/25 MVA
80
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
3
4
5
6
7
8
No load voltage ratio
Vector group
Type of tap changer
Tap range
Impulse voltage withstand (1.2/ 50
micro-sec)
Terminal connection
LV Side
9

Applicable standard
220 kV / 6.9/6.9 kV
YN yno (yno)
on-load
+5% to –15% in steps of 1.25%
950 kV peak.
HV side Terminals on bushings for
overhead line connection.
Throat type with matching flanges for
connection to SPBD.
IS 2026
Steel Plant Transformers
Two transformers of three – winding, three phase, 210/ 150 /60 MVA, 400 kV
/34.5/11.5 kV, would be connected to 400 KV to evacuate power to the steel plant.
The ratings and details of the transformers are as in table below.
400 KV Transformers
Sr. No.
1
2
3
4
Particulars
Type of cooling
Rating
No load voltage ratio
Percentage
of
Impendence
Transformer-1
ONAN / ONAF/ OFOF
210/ 150 /60 MVA
400 kV /34.5/11.5 Kv
10% on 50 MVA base for 50
MVA rating
Transformer-2
ONAN / ONAF/ OFOF
210/ 150 /60 MVA
400 kV /34.5/11.5 Kv
12% on 150 MVA base for
150 MVA rating
 400 KV Switchyard
The technical parameters of the switchyard are indicated in table below.
400 KV Switchyard
Sr. No.
Parameters
1.0
1.1
(a)
(b)
(c)
(d)
1.2
(a)
(b)
(c)
(d)
2.3
3.0
3.1
Technical Data for Switchyard
Design Voltage Levels
Nominal Voltage
Highest system voltage
Basic impulse level
Fault level
Minimum Clearances
Phase to Phase
Phase to Earth
Section Clearance
Minimum height of live point above
finished grade
Minimum creepage distance
Circuit Breakers
Type of breaker
Short circuit breaking and making
current
Applicable standards
Isolators
Type of mounting and execution of poles
3.2
4.0
Applicable Standards
Current transformers
1.3
2.0
2.1
2.2
VIMTA Labs Limited, Hyderabad
Ratings, 400 kV
Switchyard
Ratings, 220 kV
Switchyard
400 kV
420 kV
1425 kV peak.
40 kA rms for 1 sec.
220 kV
245 kV
1050 kV peak.
40 kA rms for 1 sec.
4100
3400
6500
2440
2400
2100
4000
2440
mm
mm
mm
mm
mm
mm
mm
mm
31 mm /kV
31 mm / kV
SF6
40 kA rms / 100 kA
peak.
IEC - 56
SF6
40 kA rms / 100 kA
peak.
IEC - 56
Centre
break,
horizontal upright
IS 9721
Centre
break,
horizontal upright
IS 9721
81
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr. No.
Parameters
4.1
Type
4.2
Accuracy class for metering cores
4.3
4.4
No. of cores per CT
Applicable standards
5.0
5.1
Capacitive voltage transformer
Type
5.2
Rated voltage factor
5.3
5.4
5.5
6.0
6.1
6.2
6.3
6.4
6.5
6.6
7.0
7.1
7.2
Method of connection
Accuracy class for metering cores
Applicable standards
Lightning Arrestor
Type
Rated voltage
Nominal discharge current
Low current / long duration class
Pressure relief class
Applicable standards
Line traps
Continuous current rating
Quantity
7.3
8.0
8.1
Applicable standards
Coupling devices
Applicable standards

Ratings, 400 kV
Switchyard
Outdoor,
oil
immersed.
0.2
for
revenue
metering
and
0.5 for other
5/6
IS 2705
Ratings, 220 kV
Switchyard
Outdoor,
oil
immersed.
0.2
for
revenue
metering
and
0.5 for other
5/6
IS 2705
Capacitor, outdoor,
oil immersed
1.2 continuous
1.5 for 30 secs.
Star
0.2
IS 3156
Capacitor, outdoor,
oil immersed
1.2 continuous
1.5 for 30 secs.
Star
0.2
IS 3156
Zinc oxide, gap less
360 kV
10 kA
III
A
IEC – 99
Zinc oxide, gap less
198 kV
10 kA
III
A
IEC – 99
2000A
Two (2) for each line
circuit.
IEC 353
2000A
Two (2) for each line
circuit.
IEC 353
IEC 481
IEC 481
Auxiliary Power Supply System
Various auxiliaries will be supplied at the following nominal voltages depending
upon their ratings and functions:
a)
6600 V,  10%, 50 Hz  5%, 3 phase, 3 wire, non-effectively grounded AC
supply for motors rated above 175 kW
b)
415 V,  10%, 50 Hz  5%, 3 phase, 3 wire, solidly grounded AC supply for
motors rated 175 kW and below and other L.T. services
c)
240 V,  10%, 50 Hz  5%, 1 phase AC supply for lighting, space heating of
motors and panels, single phase motors, etc.
d)
220 V, ungrounded DC supply for protection, control and indication
e)
220 V, 1 phase AC uninterruptible power supply for panel-mounted
instruments, CRT units, printers, analysers, etc., forming a part of the plant
instrumentation and control system.

Unit Auxiliary Transformers (UAT)
Two unit auxiliary transformer will be provided for the unit to feed auxiliary unit
loads. This will be 16/20 MVA, 20 / 6.9 kV, 3 phase, 50 Hz, with + 5% off-circuit
taps in steps of 2.5% on the HV side. The unit auxiliary transformers will be ONAN
cooled with a vector group of Dyn11.The LV neutral will be earthed through a
resistance loaded single phase transformer.
VIMTA Labs Limited, Hyderabad
82
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Service Transformers
The details of service transformers are indicated in table below:
Unit Auxiliary Transformer / Service Transformers
Sr.
No

Particulars
Unit
Auxiliary
Transformer
Unit
Service
Transformer
Other Service
Transformer
1
MVA rating
20
2.5
1.6
2
Type of cooling
ONAN /ONAF
ONAN
ONAN
3
No load
ratio
20 kV / 6.9 kV
6.6 kV / 433 V
6.6 kV / 433 V
4
Vector group
Dyn 11
Dyn 11
Dyn 11
5
Type
of
changer
Off load
Off-circuit
Off-circuit
6
Tap range & Steps.
+/-5% in steps of
2.5%
+/-5% in steps of
2.5%
+/-5% in steps
of 2.5%
7
Impulse withstand
(1.2/50 micro-sec.)
125 kV peak / 60
kV peak
60 kV peak
60 kV peak
8
Power
frequency
withstand HV/LV
50 kV rms / 20 kV
rms
20 kV rms / 3 kV
rms
20 kV rms / 3 kV
rms
9
Applicable
standards
voltage
tap
IS 2026
6.6 KV Switchgear
Technical parameters of 6.6 kV switchgear are given in table below:
6.6 KV Switch Gear
Sr. No.
1.0
1.1
1.2
1.3
1.4
1.5
2.0
2.1
2.2
2.3
2.4
2.5
2.6
3.0
3.1
3.2
4.0
4.1
Particulars
Switch gear
Nominal system voltage, phases &
frequency
System Neutral Earthing
Power frequency with stand / impulse
withstand (1.2 / 50 micro-sec).
Short time withstand / dynamic rating
Applicable standards
Circuit breaker
Type
Operating duty
Rated current
Rated breaking / making current
Short time rating
Mechanism
Contactors
Type
Application
HRC Fuses
Type
VIMTA Labs Limited, Hyderabad
Rating
6600 V, 3 Phase, 50 Hz
Non-effectively earthed
27 kV rms / 60 kV peak.
40 kA for 1.0 sec / 100 kA peak.
IS 3427
Vacuum / SF6, drawout type
0 – 3 min - CO-3 min-CO.
As required
40 kA rms / 100 kA peak.
40 kA for 1.0 sec.
Motor charged spring closing
Vacuum
For motors in CH & AH system
Current limiting HRC fuses
83
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sr. No.
4.2
4.3
4.4

Particulars
Application
Symmetrical Breaking capacity
Applicable standards
Rating
Short-circuit protection of 6.6 kV
motor feeders with vacuum
contactors
40 kA rms
IS 9224.
415 V System
The technical particulars of 415V switch gear are as given in table below.
415 V SWITCH GEAR
Sr. No.
1.0
1.1
1.2
1.3
Particulars
1.4
1.5
1.6
2.0
2.1
Switch gear & Bus bar rating
Rated voltage/No. of phases/frequency
System neutral earthing
One minute power frequency withstand voltage
(a)
Power circuit
(b)
Control circuit
(c)
Aux. circuits connected to CTs
Maximum allowable Temperature of Bus bars
Short circuit withstand of Bus bars
Dynamic rating of busbars
Circuit breakers
Type
2.2
2.3
Operating duty
Rated breaking current / Making current
2.4
3.0
3.1
3.2
3.3
4.0
Short circuit withstand current
Starters
Type
Contactor rated duty as per IS 2959 & IS 8544
Utilisation categories as per IS 2959
Applicable standards
Rating
415V / 3 Ph / 50 Hz
Solidly earthed
2500 V
1500 V
2000 V
900C
50 kA for 1 sec.
100 kA peak
Air break, motor charged
spring closing mechanism
0 – 3 min – CO-3 min – CO
50 kA at 415V AC & 0.25 pf
/ 84 kAP
50 kA for 1 sec.
DOL & Reversible.
Continuous & Intermittent
AC 3 & AC 4
IS 2516
 DC System
The unit will be provided with a 1x100% capacity 220 V battery bank with
associated 1x100% capacity chargers with separate float & boost units which will
feed a DC switchboard.
The incoming and outgoing feeder circuits in DC
switchboard will be provided with switch-fuse units, which will have suitable
supervisory devices against, fuse failure.
 Emergency Power Supply
To enable the unit to shut down safely during complete A.C supply failure in the
station, certain important plant auxiliaries will be provided with a reliable A.C power
supply through a separate source. For this purpose, one (1) 415V quick starting
diesel generator set with automatic mains failure (AMF) will be provided for the
unit. The rating of the DG set will be 630 kVA.
VIMTA Labs Limited, Hyderabad
84
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
 Un-Interruptible Power Supply System
For panel-mounted instruments, CRTs, printers, analysers, recorder, etc., 220 V
single phase A.C un-interruptible power supply will be made available.
 Generator And 400 KV Switchyard Protections And Control
The details of the protections that will be provided for the various electrical
equipment viz., Generator, generator transformer (GT), station transformers (ST),
unit auxiliary transformer (UAT), service transformers, 400 kV switching equipment
& transformers, 400 kV lines, motors, switch gear, etc., are indicated below.
 Generator Protections
One generator relay panel (GRP) will be provided for the unit. This panel will be
located in the unit control room. The following protection schemes will be provided
in the GRP and the protections will be divided into two groups; each group being
100% redundant and on separate DC supply, so that even if one group of
protections is not available or under maintenance, the generator is protected by
the other group
a) Generator differential protection (87G1)
b) Generator stator 0 – 95% earth fault protection (64 GI)
c) Generator stator earth fault (95 – 100%) protection (64G2)
d) Generator back-up stator earth fault (0-95%) protection (64G3)
e) Rotor earth fault protection (2 stage) (64F)
f) Generator negative phase sequence protection (46GI & 46G2)
g) Generator reverse power protection (32G1 & 32G2)
h) Generator loss of excitation protection (40G1 & 40G2)
i) Generator pole slipping protection (78G) & Directional pole slip unit 78G (32)
j) Generator under frequency protection (81G & 81G2)
k) Generator over-voltage protection (59G)
l) Generator backup impedence protection (21G)
m) Generator stator overload protection (50GS)
n) Generator VT fuse failure protection (60G)
o) Dead machine protection (61B)
p) Generator field over-voltage protection (59F)
q) Generator, Generator Transformer and Unit Auxiliary Transformers overfluxing protection (99G1 & 99G2)
r) Stator Inter turn protection
s) Over frequency protection
 Generator Transformer Protections
The following protections will be provided for the Generator Transformer:
a) Generator transformer HV winding restricted earth fault protection (64 GT)
b) Generator, generator transformer and unit auxiliary transformers overall
differential protection (870A)
c) Generator transformer differential protection (87GT)
d) Generator transformer over-current protection (51GT)
e) Buchholz (63), winding temperature (49WT) and oil temperature (490T)
protections
f) Generator transformer pressure relief protection (63PTX)
VIMTA Labs Limited, Hyderabad
85
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
g) Generator transformers fire protection trip
 Unit Auxiliary Transformer Protections
The protections that will be provided for the unit auxiliary transformers:
a) UAT differential protection (87UAT) and short circuit protection (50UAT)
b) UAT back-up over current protection on HV and LV sides (51)
c) Neutral displacement relay on LV side (64N2)
d) Buchholz (63), winding temperature (49WT) and oil temperature (490T)
protection
e) UAT pressure relief protection (63PTX)
f) UAT fire protection and trip (63 RTX)
 6600 V / 433 V Service Transformer Protections
The following protections will be provided for service transformers:
a) Over current protection on HV and LV sides (51) and short circuit protection
(50) on HV side
b) Earth fault current protection on HV and LV sides (50N & 5IN).
c) Buchholz (63), winding temperature (49WT) and oil temperature (490T)
protections
 400 KV Lines Protection
The 400 kV lines will have the following protections:
a) Distance protection (21-1)
b) Distance protection (21-2) or Directional inverse time phase over current
with high set unit (67 / 50)
c) Fuse fail relay (FFR) for each secondary of CVT
d) Directional inverse time earth fault protection (67N)
e) Under voltage relays for live – line / dead bus and dead – line / live bus
closing and safe grid establishment (27-1, 27-2, 27S)
f) Fault locator (FL)
g) Neutral impedance replica of distance relay (21NTR)
h) Fault recorder (FR).
 400 KV Bus Bar Protections
Tuned high-impedance high-speed bus fault relay is proposed for detecting the
fault on 400 kV buses. The bus bar protection scheme will have detecting
elements for each of the main buses and one check zone element. The main and
check zone elements will be connected to two different secondaries of CTs and
tripping will be initiated only when respective bus element and check zone
elements operate. Bus wire supervision relays to guard against faults in the CT
secondary wiring and bus wire shorting relay to short CT secondary bus wires
on fault are also proposed.
 Steel Plant Transformer Protections
The Steel plant transformer bays will have the following protections:
a) The transformer HV winding restricted earth fault protection (64)
b) Transformer differential protection (87)
VIMTA Labs Limited, Hyderabad
86
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
c) Transformer over-current protection (51)
d) Buchholz (63), winding temperature (49WT) and oil temperature (490T)
protections
e) Transformer pressure relief protection (63PTX)
f) Transformers fire protection trip
 Local Breaker Back-Up (50 LBB)
All 400 kV circuit breakers including generator transformer breaker will be
provided with local breaker back-up protection. For generator transformer
breaker, an additional relay will be provided to detect breaker failure for ground
and phase fault in the generator circuit and other low magnitude faults also.
The local breaker back-up protection relay will be a triple pole over-current relay
with high drop-off to pick-up ratio with fast acting feature. This will provide
protection against stuck breaker condition for the 400 kV systems. This
protection will be initiated by primary fault detecting relays and time delayed to
permit the breaker to trip.
 Circuit Breaker Protection
All the trip coils of the circuit breakers will be supervised.
protections will also be included:
a) Pole discrepancy protection
b) Trip coil supervision relay for each trip coil (98L1 to L6).
c) Anti pumping device for breaker closing (94).
The following
 Protection Of 6.6 KV Motors
All 6.6 kV motors will be provided with the following protections:
a) Thermal overload protection
b) Overload alarm protection
c) Instantaneous over current protection
d) Locked rotor protection
e) Negative sequence protection
f) Differential protection (For motor ratings of 1000 kW and above)
g) Earth fault
h) Bus under voltage
i) Bearing temperature monitor
j) Water flow monitor for CACW motors
k) Lube oil pressure monitor
l) Winding temperature monitor
 Protection Of 415 V Motors
Motors rated below 100 kW will have bi-metallic relays for thermal overload
protection and HRC fuses for short circuit protection. Motors rated 100 kW to
175 kW will be provided with locked rotor protection in addition to above.
VIMTA Labs Limited, Hyderabad
87
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
 Power Supply And Lightning Circuits
The power supply feeders will have properly rated HRC fuses for short-circuit
protection. Lighting circuits will be protected by miniature circuit breakers.
 400 kV / 220 kV Switchyard Control
All breakers will be controlled from switchyard mimic control panels (SCP)
located in main control room. All control operations like closing and opening of
circuit breakers and isolators will be performed from the respective control
panels. Discrepancy type control switches will be provided on the control panel.
In addition to the control switches, the control panels shall consists of the
following:
a.
b.
c.
d.
e.
Mimic of bay layout
Metering
Facia annunciation
Indicating and monitoring lamps
Synchronising facilities, etc.
 Cabling System
Power cables would be selected based on the following criteria:
a) Continuous circuit current rating
b) De-rating factors for ambient temperature and grouping
c) Short circuit rating of the circuit
d) Voltage dip
e) Standardisation of cable sizes to reduce inventory.
 Lighting System
Suitable illumination necessary to facilitate normal operation and maintenance
activities and to ensure safety of working personnel would be provided.
 Safety Earthing And Lightning Protection
A safety earthing system comprising buried steel conductor earthing grid would
be provided for the switchyard and other outlying areas.
 Communication System
For effective communication in the plant, public address system, private
automatic branch exchange system (EPABX), radio paging system and P&T
telephone system will be provided.
 Fire Detection / Alarm And Fire Proof Sealing System
A fire alarm system would be provided to facilitate visual and audible fire
detection at the incipient stage of fire in the power station.
VIMTA Labs Limited, Hyderabad
88
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
 Evacuation of Power
The power generated from proposed 1x 300 MW captive plant would be
connected to 400 KV switchyard and power will be evacuated to the steel plant
through two Nos. of 210MVA 400/33KV transformers and through two numbers
of 315 MVA - 400KV/220KV inter connecting transformers.

Services, Utilities & Manpower Requirement

General
Besides raw materials i.e. coal, other major requirements of the plant are water,
power and fuel.

Water System
The requirement of make-up for the proposed power plant (3X300 MW) is about
2250 m3/hr. The source of raw water would be clarified water from the existing
steel plant.
Water would be used for condenser cooling, cooling of Steam Generator &
Turbine Generator auxiliaries and various other requirements like Steam
Generator make-up, service and potable water. The water systems consist of
various sub-systems are listed below:
a)
b)
c)
d)
e)
f)
g)
h)
Raw water system
Condenser cooling water (CW) system
Make up water system
Auxiliary cooling water (ACW) system
Water treatment (WT) system
Service & potable water system
Fire protection system
Effluent Reuse and Recycling System
Clarified Water (CW) would be directly fed into the CW fore bay as make-up to
CW System and a part of it to the Clarified Water Storage Tank (CWST) to meet
the other water requirements of the plant like service water and fire protection
system. CWST will be provided in 2 compartments with a common sump to
facilitate cleaning and maintenance. CWST would be sized for storing water for
plant service water requirements plus reserve storage for fire protection system.
The CWST is a closed structure.
The total plant make-up water requirement is summarised in table below.
Plant Make-up Water Requirements
Item
Make-up water for condenser
and other auxiliaries
Plant service water and fire
water make- up
For DM plant input
Air washer make-up & misc.
Plant potable water
Net
amount
of
water
required
VIMTA Labs Limited, Hyderabad
Estimated Qty (m3/hr)
2010
Quality
Clarified water
54
Clarified water
78
105
3
2250
Filtered water
89
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Clarified Water Chemical Dosing System
About 1.5% of the total CW flow is considered to be treated through side stream
filters. Water to these filters will be fed directly from the discharge of CW pump
header. The treated water from side stream filters is fed back to the CW fore bay.
Backwash for the filters is from the CW header itself. The back wash effluent from
the back wash filters would be led to the cooling pond.
Chemical dosing system would comprise of chemicals with anti-scalant / anticorrosive and dispersant properties. For each type of chemical the dosing system
would consist of 2 x 100% dosing pumps with PP / SS material of construction
with one dosing tank. Acid dosing system with 1 No. bulk acid storage tank and
dosing pumps would be provided to control the alkalinity in the system.
To prevent / control algae growth in the CW system, chlorine dosing would be
provided. 1x100% capacity evaporator type chlorinator of capacity 60 kg/hr would
be provided to dose chlorine in the CW system. 5 chlorine cylinders, each of 1
tonne capacity would be provided to cater to about 8 days of chlorine demand.
Chlorinator system proposed for this unit will be located in the separate
chlorination room. Continuous dosing would be done at the rate of 1 ppm and
shock dosing would be done at a rate of 3 ppm. Chlorine leak detection and
absorption system would be provided to trap chlorine leakages from chlorine
tonners.

Water Treatment Plant
The water treatment plant broadly consists of a filtration plant, DM plant and an
Ultra Filtration plant.
The Filtration plant consists of pressure sand filter of capacity 2 x 70 m 3 / hr, to
remove turbidity and suspended solids. Alum would be dosed at the inlet to filters
to aid filtration process.

Demineralisation (DM) Plant
The Demineralisation (DM) plant meets the requirement of steam boiler (SB) feed
water make-up and Auxiliary Cooling Water (ACW) system make-up. From DM
water storage tank, three (3) nos. of DM water transfer pumps will cater to the
DM water transfer requirements of all the units. The condensate storage tank
would be sized to meet maximum requirement of DM water when the unit is under
start-up.

Service and Potable Water Systems
The service water system supplies water required for air washer system and
miscellaneous services like cleaning, washing etc. One (1) no. service water pump
would pump water from the CWST to a service water overhead tank. This tank
will be located on the de-aerator floor from where further distribution to other
customers will be gravity. For distribution to the boiler platforms at higher
elevations, 2 x 100% capacity service water booster pumps will be provided.
Requirements of the plant potable water system would be met from the filtered
water storage tank. A tap off will be provided to a potable water overhead tank
located de-aerator floor from where further distribution to other customers in the
plant will be gravity.
VIMTA Labs Limited, Hyderabad
90
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State

Chemical Laboratory Equipment
The existing quality control laboratory, with modern equipment, shall be utilized
for the proposed Captive Power Plant. The main functions of the laboratory will be
to analysis the coal, water and steam samples from the plant.

Fire Protection System
Fire protection system would be provided covering all the buildings of the
proposed power plant boundary. The water would be drawn from the CWST in
which a reserve storage capacity will be earmarked for the system. The following
fire protection systems are proposed:
a) Hydrant system
b) Automatic High Velocity Water Spray (HVWS) system for the protection of
transformers and manual HVWS system for the protection of turbine oil tanks.
c) Automatic Deluge/ Medium Velocity Water Spray (MVWS) system for the
protection of cable vaults and overhead conveyors.
d) Heavy duty portable or trolley mounted fire extinguishers for the protection
of control rooms.
e) Portable fire extinguishers for different areas.
Adequate number of pumps will be provided and system would be designed
to conform to the rules and regulations of fire safety standards as per TAC.

Power System
The total annual power consumption for the 300 MW Captive Power Plant is 28
MW considering 8% auxiliary power consumption.
The power generated from proposed 300 MW captive power plant would be
connected to 400 KV switchyard and power will be evacuated to the Steel Plant
through transformers.
The loads will be segregated as unit loads and common service loads. The unit
auxiliary loads will be supplied through unit auxiliary transformers connected
directly to the generator through isolated phase bus ducts. Start-up for the
auxiliaries will be supplied through station transformer with GT breaker kept open.
Once the unit is started and the generator picks up rated speed & voltage, GT
breaker is closed after synchronising with grid. Tie feeder will be provided from
6.6 kV station switch gear to 6.6 kV unit switch gears of the unit so that during
non availability of one unit auxiliary transformer, the station transformer will feed
the loads connected to that unit auxiliary transformer.
An uninterrupted power supply (UPS) system would be provided to cater to 220V
AC, single phase, 50 Hz, 2 wire power supply requirements of instrumentation
and control systems viz. man-machine interface equipment, analysers, receiver
instruments, Closed loop controls, sequence controls, protection and interlock
system, annunciation system and sequence of events recording system.
To enable the unit to shutdown safely during complete A.C supply failure in the
station, certain important plant auxiliaries will be provided with a reliable A.C
power supply through a separate source. For this purpose, one (1) 415V quick
starting diesel generator set with automatic mains failure (AMF) will be provided
for the unit. The rating of the DG set will be 630 kVA.
VIMTA Labs Limited, Hyderabad
91
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
The diesel generator will feed an emergency 415V switch gear, to which all the
essential loads such as the A.C emergency bearing lube oil and seal oil pumps,
turning gear motor, battery chargers, emergency lights, and essential instrument
power supply feeders will be connected. When the station A.C supply is healthy,
the emergency switchgear will be fed from the unit service switchgear. When the
station A.C supply fails, the DG set will start automatically and will feed the loads
connected to the emergency switchgear. When the normal A.C supply is restored,
these essential loads will be manually changed over to the normal power supply.

Instrumentation and Control System
The Automation, Instrumentation and Control System (I&C) shall be sufficient to
monitor and control all significant variables in accordance with the process
requirement, provide all operating requirements and necessary sequencing,
interlocking and safety functions including alarms for abnormal conditions of the
proposed Captive Power Plant.

Process Automation System
The automation system for process control and monitoring will be based on a
modern Distributed Control System latest version (hereafter referred to as DCS).
The DCS system structure is based on an integrated distribution system with
inherent open type architecture. The system will have mainly two functional
levels.

Communication System
The existing telephone system will cater the requirement of the communication
inside as well as outside the power plant.

Repair and Maintenance Facilities
The existing steel plant repair and maintenance facilities will take care of routine
repair and periodical maintenance work of the captive power plant. Major repairing
works involving machining, fabrication and assembly of heavy and critical jobs of
specialized nature are envisaged to be contracted to outside agencies.

Warehouse
The existing warehouse will be utilised to keep spares of equipment, hardwares
and consumables. A Part of the building will be utilised for easy manual loading
and unloading of the materials from trucks. Forklifts will be used for movement of
materials inside the stores building.

Ancillary Facilities
Existing ancillary facilities such as administrative building, canteen, car park, cycle
and scooter stand, first-aid station etc. shall take care of the proposed plant
manpower.

Drainage and Sewerage System
Open type drain has been envisaged for the plant storm water drainage. The
drains will be laid generally by the side of the roads. Storm water run-off, collected
through arterial and trunk drain, will be discharged suitably for minimum
pollution.
VIMTA Labs Limited, Hyderabad
92
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Sanitary faecal sewage will be collected from the ablution blocks through pipeline
and the same will be connected to a sewage treatment plant. The effluent from
the sewage treatment plant will be utilized for the development and maintenance
of greenery

Roads
Adequate plant road system will be provided. The road system will be integrated
with the existing roads.

Ash Handling System
Ash formed due to combustion of pulverized coal in the steam generator will be
collected as bottom ash in the bottom ash hopper, coarse ash in economizer APH
and duct hoppers and fly ash in ESP and stack hoppers. Bottom ash will be
collected in the water impounded bottom ash hopper and conveyed to ash slurry
sump through jet pumps. The ash slurry conveyed to ash slurry sump will be
further conveyed to ash disposal area by means of ash slurry pumps. Coarse ash
will be automatically extracted and conveyed to the feeder ejectors located below
each hopper. Necessary vacuum/momentum required for extracting the ash from
the hoppers shall be created by the feeder ejectors. The coarse ash slurry thus
produced shall be routed to coarse ash tank located in boiler area. The slurry
collected in the coarse ash tank shall be conveyed to the proposed ash slurry sump
through coarse ash slurry pumps. The fly ash from electrostatic precipitator and
stack hoppers will be extracted through vacuum and conveyed to fly ash silos
through pressure conveying system. The fly ash will be further disposed in dry
form through trucks or in wet form to ash disposal area through HCSD system.
Bottom Ash Handling System
Bottom Ash (BA) will be collected continuously in a W-shaped, water impounded,
storage type, water cooled refractory lined, bottom ash hopper. BA hopper will be
located directly below the bottom water wall header of boiler and will have an
effective storage capacity of 8 hours bottom ash and coarse ash generated while
firing worst coal. The bottom ash of unit collected in BA hopper will be removed
in two (2) hours once in a shift of 8 hours. To unload contents of the BA hopper,
its feed gates will be opened by a remotely controlled/ operated four way solenoid
valve and air water converter unit. It will be ensured that full quantity of ash slurry
is removed during de-ashing cycle. BA hopper will consist of two sections; each
section provided with two clinker grinders with electric drives installed directly
below the feed gate assembly to limit the size of clinkers to maximum 25 mm.
Out of two clinker grinders provided for each V section of BA hopper, one grinder
will operate while the other will be standby. Operation of the grinder motor will be
electrically interlocked with the grinder seal water pressure, jet pump water
pressure and BA disposal line discharge pressure. The slurry (mixture of bottom
ash and water) from the clinker grinder will be conveyed to ash slurry sump by
jet pumps through cast iron to IS 1536 Class D. Bottom Ash hopper overflow will
be routed through overflow seal box to a drain sump. The contents of this drain
sump will be discharged to ash slurry system clarifier.
VIMTA Labs Limited, Hyderabad
93
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Coarse Ash Handling System
Coarse ash will be automatically extracted and conveyed to the feeder ejectors
located below each hopper. Necessary vacuum/momentum required for extracting
the ash from the hoppers shall be created by the feeder ejectors. The coarse ash
slurry thus produced shall be routed to coarse ash tank located in boiler area. The
slurry collected in the coarse ash tank shall be conveyed to the proposed ash
slurry sump through coarse ash slurry pumps.
The water required for feeder ejectors will be drawn from HP Water Pumps. The
coarse ash slurry collected in the coarse tank will be removed in 45 minutes once
in a shift of 8 hours.
Fly Ash Handling System
Fly ash collected in various ESP and stack hoppers will be extracted and conveyed
to buffer hoppers automatically and sequentially by means of vacuum generated
by mechanical exhauster and will be transported to fly ash silos by means of
pressure conveying system. Adequately rated oil free rotary screw type Conveying
Air Compressors will be provided to supply compressed air required for conveying
fly ash from buffer hoppers to fly ash silos. One (1) buffer hopper will be provided
for each vacuum stream. Adequately sized bag filters will be mounted on buffer
hopper. Four (4) streams are proposed for evacuating the fly ash from fly ash
hoppers to fly ash silos. Below each buffer hopper, two ash vessels will be provided
to convey ash to fly ash silos. One (1) fly ash storage silo in RCC construction will
be provided, each having an effective storage capacity of storing 16 hours. Fly
ash silo will be provided with four outlets; one for unloading ash in dry form into
closed trucks through telescopic chute; one for unloading ash in conditioned form
into open trucks through ash conditioner, one for unloading ash to mixing tanks
and fourth outlet blind flanged for future use. Fly ash storage silo will be provided
with adequately rated vent filter on silo roof. The silo will be located adjacent to
the existing silos.
Two (2) adequately rated low speed, oil free, lobe type fluidizing air blowers with
heaters will be provided for fluidizing ESP Hoppers. Two adequately rated low
speed, oil free, lobe type fluidizing air blowers with heaters will be provided for fly
ash silo; one working and one standby. Two adequately rated oil free screw
compressors with refrigerant type air driers and air receivers will be provided for
supplying instrument air for various valves and cleaning of pulse jet type bag
filters.
Ash Disposal System
The bottom and coarse ash slurry collected in the ash slurry sump will be pumped
to ash disposal area. Two (2) ash slurry pumps with associated pipes and valves
will be installed to dispose ash slurry to the ash disposal area. Existing ash water
recovery system will be used for recovering the decanted water for re-use in ash
disposal system. Out of the two series, one series will normally operate and other
will be standby.
VIMTA Labs Limited, Hyderabad
94
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Fly Ash Slurry Disposal System
The ash from fly ash silos will be fed by rotary feeders and ash conditioners into
the slurry mixing tank, the level of which will be controlled. The conditioned dry
fly ash will be wetted out by water to be added in the mixing tank and the entire
ash will blended to a uniform consistency by mixer.
One mixing tank and one (1) ash slurry pump (HCSD type) will be provided for fly
ash silo. Each slurry pump discharge piping will be provided up to the disposal
area with all necessary isolation valves, line flushing valves etc. The ash slurry
pump will be suitably designed for high concentration slurry disposal (HCSD)
system and necessary pulsation dampeners/accumulator immediately after slurry
pump discharge and/or on discharge lines. The mixing tank will be sufficiently
large to provide a reasonable residence time so that short terms fluctuations in
concentration can largely be blended out. The ash mixing and pumping process
will operate in cyclic mode and automatically dispose of ash so as to accommodate
changes in ash production caused by fluctuating boiler loads or other variables.
Ash disposal pipelines will be installed above ground with flange joints wherever
necessary and it will suit the maximum pressure encountered in the pipeline or
otherwise pipelines will be welded. The ash slurry disposal will be designed for 6570% concentration (solids by weight). The disposal area will be filled in such a
way that the deposits can reach the required height within the area and suitable
the engineering of the ash pond will be done.
23.7
Environmental Management
The proposed plant would result in air, water and land pollution of varying nature
and degree. The following sections briefly outlines the nature and sources of
pollution and also suggests broad environmental protection measures to be
adopted for limiting pollution within permissible levels.

Nature of Pollution
The inputs to the Power Plant will comprise raw materials i.e. coal along with water,
fuel and power. These would therefore lead to release of emissions to the air,
generation of wastewater and solid wastes. The Process would not be generating
any Hazardous Waste, as there is no Hazardous Chemical involved in the process.
The sources of pollution from the proposed project and the types of environmental
pollution likely to occur are summarized as below.
Section / Units
Materials
Operation
Pollutants
Recipient
Form of
Pollution
Air
Pollution
Air
Pollution
Coal
conveyors/Transfer
Coal
Conveying
Dust
Air
Coal mill
Coal
Crushing
Dust
Air
Flue gas
Combustion
of coal and
steam
generation
Dust , SO2,
NOx
Air
Air
pollution
Ash handling
Dust
Work zone
Air
pollution
Discharges
Thermal
pollution
Water
environment
Water
pollution
Stack emissions
Bottom and fly
ash
Ash handling
Boiler section
cooling water
and
Boiler blow
downs/cooling
VIMTA Labs Limited, Hyderabad
95
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
tower blow
down
DM plant
Acids / alkalies
Plant operation
Spent
regenerate
---
---
H2SO4 and
NaOH
Noise, Heat
Water
environment
Work zone
Water
pollution
Noise
pollution
and
thermal
stress
Pollution Prevention and Control Measures
In consideration of the above stated pollution potential of the power plant, the
following mitigation schemes are envisaged in order to control environmental
pollution within the permissible norms and keep the environment fairly clean.
Ambient Air Quality Stations will be installed for monitoring the continuous Ambient
Air Quality based on meteorological conditions, wind direction pattern, etc. for
measurement of following parameters in the ambient air.
•
•
•
•
•
•
Suspended Particulate Matter
Respirable Particulate Matter
SO2
NOx
CO2
CO
Provision for checking Ambient Air Quality outside the plant boundary will also be
made. High volume samplers with attachments for gaseous sampling and
particulate matter sampler will be envisaged for this purpose.

Air Environment Protection
The air polluting emission from the power plant are as follows:





Dust particulates from fly ash in flue gas
Sulphur dioxide (SO2) in flue gas
Nitrogen oxides (NOx) in flue gas
Coal dust particles due to handling of coal
Fly ash dust particles from ash silos and ash disposal area
Dust particulates from Fly Ash in Flue Gas
The standard for particulate emission applicable to this project is 50 mg/ Nm3. The
electrostatic precipitators (ESP) proposed to be installed in this project would be
designed to limit the emission level of the particulate matter to 50 mg/N m3.
Sulphur dioxide (SO2) in Flue Gas
One stack (chimney) of height 275 M is proposed to be constructed.
Nitrogen oxides (NOx) in Flue Gas
To reduce NOx emissions, over-fire air system equipment with air ports would be
installed for the furnace. Further, the steam generators would be fitted with
VIMTA Labs Limited, Hyderabad
96
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
advanced low NOx burners. The NOx emissions would be checked for ground level
concentrations (GLC) as per the above indicated Indian Emission Regulations.
Coal dust particles due to handling of coal
Coal dust would be generated generally at the conveyor transfer points. Hence,
coal transfer points would be provided with dust suppression / dust extraction
facilities. Further, in order to arrest the coal dust generation, all conveyors would
be provided with enclosed galleries. Dust collection system would also be provided
in coal bunkers to evacuate dust from the coal bunkers. Collected dust would be
returned to either the associated belt conveyor or to the coal bunker. The dust
collector outlet emission would be restricted to 50 mg/Nm³.
Fly ash dust particles from ash silos and ash disposal area
One fly ash storage silo for the unit is proposed to be provided. Fly ash evacuated
from the ESP collecting hoppers would be transported in closed pipe lines by
pneumatic means. At the time of unloading fly ash in to the silo, some ash laden
air would get vented out. In order to restrict the fly ash dust particles to the limits
of 50 mg/Nm3, a vent filter would be installed on top of the fly ash silo at the vents.
The following pollution control measures would be installed for ash disposal:
a) To reduce the dust nuisance while loading the ash into the trucks from fly ash
silo, the fly ash would be conditioned with water spray.
b) It is proposed to cover the ash in the open trucks with tarpaulin to prevent
flying of fine ash during transportation.
c) Water sprinkling system would be provided in the ash disposal area to restrain
flying of fine ash due to wind.
d) The ash disposal area would be lined with impervious lining to prevent seepage
of rain water from the disposal area in to the ground and pollute ground water

Noise environment protection
The plant is expected to increase the noise level in the surrounding due to operation
of plant and machinery.
The main sources of noise in a power plant are:





Steam turbine generator
Other rotating equipment
Combustion induced noises
Flow induced noises
Steam safety valves
Necessary noise control and abatement measurers will be adopted to minimize the
noise level from the plant during construction and operation phase to a maximum
of 85 db (A) as per the requirement of OSHA (Occupational Safety and Health
Administration) Standards.
All rotary equipment like fans, blowers, pumps & compressors would be of low noise
design. The grouting of these equipment’s will be made free from vibrations. Noise
absorbing cladding around drying ball mill will be provided to reduce the noise level.
VIMTA Labs Limited, Hyderabad
97
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
The work zone noise exposure of the operating personnel would be avoided by
remote operation from the control rooms by using required safety equipments.

Water Environment Protection
The water pollutants are:









Cooling tower blow down water
Boiler blow down water
Water treatment plant effluent
Effluent from Bottom ash handling system
Air pre-heater wash water effluent
Plant wash down water
Floor and Equipment drainage effluent
Rain water drainage
Sewage from various buildings in the plant
The cooling tower blow down water would be used for ash handling system
purposes and the excess blow down would be led to the existing cooling pond.
The boiler blow down does not require treatment to achieve the limits but relies
on operating at sufficient blow down levels to prevent the build-up of
contaminants. The boiler blow down is also directed to the existing cooling pond.
The effluent from the regeneration of the cation resin units in the water treatment
plant (DM Plant) are generally acidic in nature and from the anion resin units are
alkaline in nature. The combined wastewater from the DM plant would be
neutralised in an existing neutralising pit. The neutralised effluent is expected to
have suspended solids less than 5 ppm and pH in the range of 6.5 to 8.5. This
would also be led to the existing cooling pond.
The drain and overflow water from the bottom ash handling system would be
collected at the bottom ash sump where the ash would be settled and clarified
ash water overflows to clear well section of the basin. This would be sent to the
existing cooling pond.
Frequently, the air pre heaters of the boilers need to be washed. The washed
water would be led to the nearest drains. These drains would also be led to the
existing cooling pond.
In the power plant, some specific locations require washing to maintain good plant
housekeeping and prevent build-up of dirt and waste material. The waste water
would be led to the bottom ash sump.
The function of this system is to provide a means for collecting and draining water
from floors in process areas of the plant and collecting and disposing of water and
other liquids from process equipment, discharged fire protection water and oil
storage tanks. In the turbine building, the ground floor slabs would be sloped to
drain out floor drains. The equipment drains are piped directly to the drain system.
Drains are collected and directed to the sumps inside the buildings from where it
would be pumped to the oil – water separator. Oily effluent if any would be
collected and disposed while clear water would be led to drains.
The rain (storm) water removed from the building roofs and yard area grade level
VIMTA Labs Limited, Hyderabad
98
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
surfaces would be directed through the open ditches and culverts to the storm
drainage piping.
All drain would be concrete lined and located along the roads. All drainage ditches
would be located to provide the shortest practical drainage path while providing
efficient drainage for the yard. Grade level would be contoured such that storm
water runoff is directed on the ground by sheet flow, to well defined drainage
paths leading to the ditches.
Sewage from various buildings in the power plant area would be conveyed through
separate drains to septic tanks. The effluent from septic tanks would be disposed
off in the soil by providing dispersion trenches. There would be no ground pollution
because of leaching. Sludge shall have to be removed and disposed off in landfill.
The waste water generated from the indirect cooling circuit would be routed
through the cooling tower and pressure filter for recycling purpose.
The plant sanitary wastewater will be treated in sewage treatment plant and the
treated whole water will be used for dust suppression and maintenance of plant
green belt.

Solid Waste
1. During construction phase, solid waste such as excavated soil, debris, some
metal waste and very small amount of oil & grease from construction machines
will be generated. This waste may contaminate soil at plant site temporarily
and would be restricted to a small area.
2. Used/Spent oil and grease will be generated during maintenance of equipment
and machine.
3. Solid waste consisting of coal fine particles, fly ash and bottom ash will be
generated in the plant. Coal fine particles will be reused in the plant, fly ash
will be sold to the cement plant.
Fly Ash Utilisation
The main solid waste from the CPP will be the ash (fly ash and bottom ash). The
total ash generation will be about 0.75 MTPA. Out of this, the bottom ash will be
about 0.15 MTPA (20% of the total ash) and the balance fly ash will be 0.6 MTPA.
It is proposed to sell the entire quantity of fly ash to external companies for
cement/brick manufacturing. The following activities will be carried out to comply
as per the new fly ash notification, S.O. 2623 (E) dated on 6 th November 2008
issued by MoEF.
•
•
•
•
The bottom ash will be stored in properly designed ash dykes as per CPCB
guidelines to prevent leaching to the sub-soil and underground aquifer;
The ash disposal area will be lined with HDPE/LDPE impervious lining to
prevent seepage of rain water from the disposal area in the ground and
pollute ground water;
Shall maintain a record of all sale and/ or disposal of the fly ash; and
Shall submit annual compliance report including record of sale and/or disposal
of the fly ash.
VIMTA Labs Limited, Hyderabad
99
Additional Details for the Proposed 10.0 MTPA Integrated Steel Plant, 900 MW
Captive Power Plant and Township near Barenda Village, Sonahatu Block,
Ranchi District, Jharkhand State
Plant Safety
Plant safety measures would form an integral part of the environment protection
plan of the proposed plant. Workers’ safety would be of highest degree of concern
so as to avoid any form of personal injury or untoward accident. In-build safety
features of the plant and machinery would be made adequate in order to avoid
hazardous events causing damage to the life and property.
Efforts would be made to afford the best safety measures and health services with
a view to keep the workplace free of hazards to the extent possible. Standard
programs will be framed and followed for regular medical check-up, lung function
test, audiometry, vision test, etc. for the workers on a regular basis so as to prevent
and to detect occupational diseases and to promote their general well-being.

Greenbelt and Landscaping
Adequate space would be reserved for gardening and tree plantations at the site.
This would improve the plant aesthetics as well as prevent the fugitive dust
emissions. Unpaved areas, if any, within the plant boundary would be provided
with grass cover. This would not only act as ‘lung space’ but would also improve
the plant aesthetics.
------------------------------------------------------------------------------------------24.0
COMMITMENT TO ACHIEVE ZERO EFFLUENT DISCHARGE IN COKE OVEN
AND BF TO BE PROVIDED.
JSW will make all efforts to attain Zero Effluent Discharge in coke oven and blast
furnace units in phases.
-------------------------------------------------------------------------------------****
VIMTA Labs Limited, Hyderabad
100
Annexure-II
Stack Emission Calculations
Final
Sr. No.
Plant Name
Pellet Plant
1
Pellet Plant-1
2
Pellet Plant-1
3
Pellet Plant-2
4
Pellet Plant-2
Sinter Plant
1
Sinter Plant-1A
2
Sinter Plant-1A
3
Sinter Plant-1A+B
4
Sinter Plant-1B
5
Sinter Plant-1B
6
Sinter Plant-2A
7
Sinter Plant-2A
8
Sinter Plant-2A+B
9
Sinter Plant-2B
10
Sinter Plant-2B
DR Plant
1
DR Plant-1
2
DR Plant-1
3
DR Plant-1
Blast Furnace
1
Blast Furnace-1
2
Blast Furnace-1
3
Blast Furnace-1
4
Blast Furnace-1
5
Blast Furnace-2
6
Blast Furnace-2
7
Blast Furnace-2
8
Blast Furnace-2
Coke Oven
1
Coke Oven-1
2
Coke Oven-1
3
Coke Oven-1
4
Coke Oven-1
5
Coke Oven-1
6
Coke Oven-2
7
Coke Oven-2
8
Coke Oven-2
9
Coke Oven-2
10
Coke Oven-2
Steel Melting Shop
1
SMS-1
2
SMS-1
3
SMS-1
4
SMS-1
5
SMS-1
6
SMS-1
7
SMS-2
8
SMS-2
9
SMS-2
10
SMS-2
11
SMS-2
Reheating Furance
1
HSM
2
Wire Rod Mill
3
Bar Mill
4
Medium Section Mill
5
Heavy Section Mill-1
6
Heavy Section Mill-2
7
Plate Mill
8
Tin Plate Mill
Stack attached to
Pollution Control
Equipment
Final
Norms
Norms
Norms
Emission Rate
Emission
Rate
Emission Rate
Nox
Height
Dia.
Temp.
Velocity
Temp. Correction
Flow rate
PM
SO2
Nox
PM
SO2
m
m
oC
m/s
oC
Nm3/hr
mg/Nm3
mg/Nm3
mg/Nm3
g/s
g/s
g/s
Pellet ESP
Machine Discharge
Pellet ESP
Machine Discharge
ESP
Bag Filter
ESP
Bag Filter
100
30
100
30
5
1.5
5
1.5
115
45
115
45
27.63
18.66
27.63
18.66
0.77
0.94
0.77
0.94
15,00,000.0
1,11,220.0
15,00,000.0
1,11,220.0
50
50
50
50
30
30
-
140
140
-
20.83
1.54
20.83
1.54
12.5
12.5
-
58.3
58.3
-
Sinter Machine
Dedusting
Sinter Storage Dedusting
Sinter Machine
Dedusting
Sinter Machine
Dedusting
Sinter Storage Dedusting
Sinter Machine
Dedusting
ESP
Bag Filter
Bag Filter
ESP
Bag Filter
ESP
Bag Filter
Bag Filter
ESP
Bag Filter
130
65
65
130
65
130
65
65
130
65
7.7
4.5
4
7.7
4.5
7.7
4.5
4
7.7
4.5
190
60
30
190
60
190
60
30
190
60
20.15
7.73
4.45
20.15
7.73
20.15
7.73
4.45
20.15
7.73
0.64
0.89
0.98
0.64
0.89
0.64
0.89
0.98
0.64
0.89
21,74,400.0
3,96,000.0
1,98,000.0
21,74,400.0
3,96,000.0
21,74,400.0
3,96,000.0
1,98,000.0
21,74,400.0
3,96,000.0
50
50
50
50
50
50
50
50
50
50
150
150
150
150
-
150
150
150
150
-
30.20
5.50
2.75
30.20
5.50
30.20
5.50
2.75
30.20
5.50
90.6
90.6
90.6
90.6
-
90.6
90.6
90.6
90.6
-
Flue gas ejector
Reduction Furnace
Product Silo Dust Collector
Reformer
Bag Filter
40
30
30
4.5
0.9
0.9
180
65
55
32.60
10.68
12.69
0.66
0.88
0.91
12,28,034.0
21,562.0
26,411.0
1.48
47.67
40.32
-
281
21
-
0.50
0.29
0.30
-
95.9
0.1
-
Stove
Casthouse East
Casthouse West
Stockhouse
Stove
Casthouse East
Casthouse West
Stockhouse
ESP
Bag Filter
Bag Filter
Bag Filter
ESP
Bag Filter
Bag Filter
Bag Filter
60
40
40
40
60
40
40
40
3.5
5
5
3.5
3.5
5
5
3.5
200
40
40
40
200
40
40
40
20.62
24.52
24.52
19.71
20.62
24.52
24.52
19.71
0.63
0.95
0.95
0.95
0.63
0.95
0.95
0.95
4,50,000.0
16,50,000.0
16,50,000.0
6,50,000.0
4,50,000.0
16,50,000.0
16,50,000.0
6,50,000.0
30
30
30
30
30
30
30
30
30
30
-
50
50
-
3.75
13.75
13.75
5.42
3.75
13.75
13.75
5.42
3.8
3.8
-
6.3
6.3
-
Coke Oven Battery-1&2
Coke Oven Battery-3&4
CO Pushing Emission-1
CO Pushing Emission-2
Ammonia Cracker-1
Coke Oven Battery-1&2
Coke Oven Battery-3&4
CO Pushing Emission-1
CO Pushing Emission-2
Ammonia Cracker-1
ESP
ESP
Bag Filter
Bag Filter
ESP
ESP
ESP
Bag Filter
Bag Filter
ESP
165
165
40
40
50
165
165
40
40
50
4.2
4.2
3
3
2
4.2
4.2
3
3
2
200
200
55
55
150
200
200
55
55
150
11.93
11.93
20.76
20.76
15.06
11.93
11.93
20.76
20.76
15.06
0.63
0.63
0.91
0.91
0.70
0.63
0.63
0.91
0.91
0.70
3,75,000.0
3,75,000.0
4,80,000.0
4,80,000.0
1,20,000.0
3,75,000.0
3,75,000.0
4,80,000.0
4,80,000.0
1,20,000.0
50
50
50
50
50
50
50
50
-
400
400
60
60
400
400
60
60
-
350
350
50
50
350
350
50
50
-
5.21
5.21
6.67
6.67
5.21
5.21
6.67
6.67
-
41.7
41.7
8.0
8.0
41.7
41.7
8.0
8.0
-
36.5
36.5
6.67
6.67
36.5
36.5
6.67
6.67
-
BOF-1
BOF-2
BOF-3
Fume Extraction System
LHF - 3 Nos.
RH - 1
BOF-1
BOF-2
Fume Extraction System
LHF - 2 Nos.
RH - 1
ESP
ESP
ESP
Bag Filter
Bag Filter
Bag Filter
ESP
ESP
Bag Filter
Bag Filter
Bag Filter
60
60
60
40
60
30
60
60
40
60
30
2
2
2
5.5
3
0.6
2.5
2.5
5.5
3
0.8
60
60
60
60
50
60
60
60
60
50
60
14.82
14.82
14.82
20.90
12.78
10.98
15.81
15.81
20.90
12.78
12.35
0.89
0.89
0.89
0.89
0.92
0.89
0.89
0.89
0.89
0.92
0.89
1,50,000.0
1,50,000.0
1,50,000.0
16,00,000.0
3,00,000.0
10,000.0
2,50,000.0
2,50,000.0
16,00,000.0
3,00,000.0
20,000.0
50
50
50
30
30
30
50
50
30
30
30
100
100
100
100
100
-
200
200
200
200
200
-
2.08
2.08
2.08
13.33
2.50
0.08
3.47
3.47
13.33
2.50
0.17
4.17
4.17
4.17
6.94
6.94
-
8.33
8.33
8.33
13.89
13.89
-
Reheating Furnace-3 Nos.
Reheating Furnace
Reheating Furnace
Reheating Furnace
Reheating Furnace
Reheating Furnace
Reheating Furnace
Reheating Furnace
ESP
ESP
ESP
ESP
ESP
ESP
Bag Filter
Bag Filter
100
80
80
80
80
80
65
47
4.2
3
3
3
3
3
4.5
1.5
293
318
318
325
320
320
300
150
9.52
5.85
5.85
7.10
6.26
6.26
5.04
22.31
0.53
0.50
0.50
0.50
0.50
0.50
0.52
0.70
2,50,000.0
75,000.0
75,000.0
90,000.0
80,000.0
80,000.0
1,50,000.0
1,00,000.0
30
30
30
30
30
30
15
40
50
50
50
50
50
50
50
40
100
100
100
100
100
100
150
70
2.08
0.63
0.63
0.75
0.67
0.67
0.63
1.11
3.5
1.0
1.0
1.3
1.1
1.1
2.1
1.1
6.94
2.08
2.08
2.50
2.22
2.22
6.3
1.9
Annexure-II
Stack Emission Calculations
Cold Rolling Mill
1
Cold Rolling Mill
2
Cold Rolling Mill
3
Galvanizing Line
4
Colour Coating Line
5
Electrical Steel
Lime Plant
1
Lime Plant-1
2
Lime Plant-2
3
Lime Plant-3
4
Lime Plant-4
5
Lime Plant-5
Dolo Plant
1
Dolo Plant-1
2
Dolo Plant-2
Cement Plant
1
Slag Cement Plant
2
Raw mill/Kiln
3
Cement Mill
4
coal mill
5
cooler
6
Packer-I
7
Packer-II
8
Packer-III
Captive Power Plant
1
Power Plant-1
2
Power Plant-2
3
Power Plant-3
Incinerator
1
Incinerator-1
2
Incinerator-2
Pickling Line
Annealing Furnace
Annealing Furnace
CCL
HDGL Stack
Bag Filter
Bag Filter
Bag Filter
Bag Filter
Bag Filter
30
40
40
40
65
1.2
1.5
1.5
1
2
45
120
120
40
150
9.44
9.54
4.15
18.57
12.55
0.94
0.76
0.76
0.95
0.70
36,000.0
46,000.0
20,000.0
50,000.0
1,00,000.0
25
40
40
50
40
40
20
80
80
40
0.25
0.51
0.22
1.39
0.5
0.2
0.6
1.0
0.4
1.1
Kiln
Kiln
Kiln
Kiln
Kiln
Bag Filter
Bag Filter
Bag Filter
Bag Filter
Bag Filter
55
55
55
55
55
2
2
2
2
2
130
130
130
130
130
14.35
14.35
14.35
14.35
14.35
0.74
0.74
0.74
0.74
0.74
1,20,000.0
1,20,000.0
1,20,000.0
1,20,000.0
1,20,000.0
30
30
30
30
30
9
9
9
9
9
5
5
5
5
5
1.00
1.00
1.00
1.00
1.00
0.30
0.30
0.30
0.30
0.30
0.17
0.17
0.17
0.17
0.17
Kiln
Kiln
Bag Filter
Bag Filter
55
55
2
2
130
130
14.35
14.35
0.74
0.74
1,20,000.0
1,20,000.0
30
30
9
9
5
5
1.00
1.00
0.30
0.30
0.17
0.17
ESP
ESP/Bag House
ESP/Bag House
ESP/Bag House
ESP/Bag House
ESP/Bag House
ESP/Bag House
ESP/Bag House
40
100
35
62
62
30
30
30
1.5
5
1.4
2.3
4.5
0.8
0.8
0.8
60
140
90
40
230
40
40
40
10.54
15.00
7.00
7.00
12.00
7.00
7.00
7.00
0.89
0.72
0.82
0.95
0.59
0.95
0.95
0.95
60,000.0
212.0
8.8
27.6
112.6
3.3
3.3
3.3
50
50
50
50
50
50
50
50
-
750
0.83
10.60
0.44
1.38
5.63
0.17
0.17
0.17
69.4
-
159.00
-
CPP-1
CPP-2
CPP-3
ESP
ESP
ESP
275
275
275
5.5
5.5
5.5
150
150
150
24.89
24.89
24.89
0.70
0.70
0.70
15,00,000.0
15,00,000.0
15,00,000.0
100
100
100
1,200
1,200
1,200
800
800
800
41.67
41.67
41.67
500.0
500.0
500.0
333.3
333.3
333.3
Incinerator-1
Incinerator-2
ESP
ESP
30
30
0.5
0.5
50
50
9.20
9.20
0.92
0.92
6,000.0
6,000.0
50
50
120
120
200
200
0.08
0.08
0.20
0.20
0.33
0.33
SCP
Kiln
Cement mill
coal mill
cooler cooler
Packer i
Packer ii
Packer iii