Status of New Steel Projects in Jharkhand
Brownfield Projects
- Tata Steel, Jamshedpur (Jharkhand) Unit, from 5 million tonnes per annum to 10 million tonnes per annum. 1.8 million tonnes per annum commissioned in May 2008.
- JSW Steel Ltd., Vijayanagar(Karnataka) Unit, from 4 million tonnes per annum to 11 million tonnes per annum. 2.9 million tonnes per annum commissioned in February 2009.
- Essar Steel Ltd., Hazira (Gujarat) Unit, from 4.6 million tonnes per annum to 8.5 million tonnes per annum.
- Jindal Steel & Power Ltd. (JSPL), Raigarh (Chhattisgarh) Unit, from 1.2 million tonnes per annum to 6 million tonnes per annum. 1.2 million tonnes per annum commissioned in 2008.
All brownfield projects of private sector moving as per schedule.
Greenfield Projects
(i) Bhushan Power & Steel Ltd at Jharsuguda (Orissa)
- Proposed capacity 6 million tonnes per annum.
- Proposed investment Rs. 3500 crore.
- 1400 acres of land acquired and 1.2 million tonnes per annum commissioned and operational.
(ii) Bhushan Steel Ltd., Dhenkanal (Orissa)
- Proposed capacity 4 million tonnes per annum.
- Proposed investment Rs. 10000 crore.
- 2000 acres of land acquired in Dhenkanal and Angul 0.8 million tonnes per annum already commissioned and working.
(iii)Tata Steel Ltd., Kalinga Nagar (Orissa)
- Proposed capacity 6 million tonnes per annum in two phases of 3 million tonnes per annum each.
- Proposed investment Rs. 15,400 crores.
- Lease deed for 3040.37 acres of land signed in 2005. However physical possession of site could not be taken due to law and order problem and violent agitation.
(iv) Essar Steel Limited, Paradeep (Orissa)
- Proposed capacity 6 million tonnes per annumin two phase of 3 million tonnes per annum each.
- Proposed investment is Rs. 22,600 crore.
- Land requirement is 1895 acres, out of which 271 acres physically transferred.
- Company is focusing on 6 million tonnes per annum pellet plant.
(v) JSW Steel Ltd., Medinipur (West Bengal)
- Proposed capacity 10 million tonnes per annum.
- Out of 4454 acres of land required, 3800 acres physically transferred to the company.
(vi) Jindal Steel & Power Ltd. (JSPL), angul (Orissa)
- Proposed capacity 6 million tonnes per annum.
- Proposed investment 22500 crores.
- 1725 acres of land in physical possession, out of total requirement of 5750 acres.
- 2 million tonnes per annum capacity likely to be achieved by June 2011.
(vii) Jindal Steel & Power Ltd. (JSPL), Patratu (Jharkhand)
- Proposed capacity 6 million tonnes per annum.
- Proposed investment Rs. 22000 crores.
- Erstwhile Bihar Alloy & Steel company acquired through Debt Recovery Tribunal Auction.
- 600 acres land with original company. 964 acres further acquired. Total land requirement 3114 acres.
- 3 million tonnes per annumlikely to be commissioned by March 2012.
(viii) Posco India Project at Jagatsinghpur district in Orissa
- Proposed capacity 12 million tonnes per annum in 3 phases of 4 million tonnes per annum each. Proposed investment US$ 12 Billion (approx Rs. 51000 crores).
- Mou signed in June 2005.
- Total land required 4004 acres for the project site (Government 3566 acres and private 438 acres).
- Administrative approval has been accorded for transfer of Ac 437.69 of private land.
- Forest Diversion Clearance (Stage – II) was communicated by Ministry of Environment and Forest (MoEF) on 29.12.2009, for diversion of 1253.225 Hectares of forest land.
However, based on reporting of violations of ‘Scheduled Tribes and other Traditional Forests Dwellers (Recognition of Forest Rights) Act 2006, Ministry of Environment and Forest, Government of India, on 05.08.2010, has advised the State Government to suspend all works at Posco site, until further advice in this regard.
(ix) Arcellor Mittal India Ltd.
(a) Orissa Greenfield Project
- Proposed capacity 12 million tones per annum in two phases of 6 million tones per annum each.
- Project investment – Rs. 40000 Crores.
- Total land required 7752 acres identified in village Patna, district Keonjhar.
- Land under scheduled ares. Consent of Gram Sabha being obtained.
(b) Jharkhand Greenfield Project
- Proposed capacity 12 million tones per annum in two phases of 6 million tones per annum each.
- Project investment – 40000 Crores.
- Total land requirement 8845 acres. Already inentified in Topra – Kamdara in Ranchi area.
- Land under scheduled area. Law and orders situation not allowing company for further progress.
Shree Radhey Krupa Concast – Ferro Alloy Plant
Ferro Alloy Plant (Unit-I); (2×5 MVA SAF, Fe-Si -7,100 MTPA, Si-Mn -15,900 MTPA Fe-Mn -20,600 MTPA) at Plot No.1, APIIC Gollapuram Industrial Park (Phase-III) Village Gollapuram, Hindupur, District Anantapur in Andhra Pradesh
Shree Radhey Krupa Concast (I) Ltd.- (Unit I) have proposed to set up a Ferro Alloy Plant ; (2×5 MVA SAF, Fe-Si – 7,100 MTPA, Si-Mn -15,900 MTPA, Fe-Mn -20,600 MTPA) at Plot No.1, APIIC Gollapuram Industrial Park (Phase-III), Village Gollapuram, Mandal Hindupur, District Ananthapur in Andhra Pradesh. Total land acquired is 8.0 acres of which 2.7 acres will be developed as green belt. No R & R is involved as proposed site is present in the Notified Industrial area. No National Park / Wildlife Sanctuary / Reserve Forest are located within 10 km radius of the proposed project site. River Pennuru flows at a distance of 2.5 km from the proposed site. Total cost of the proposed project is Rs. 13.30 Crores. Rs. 40 Lakhs and Rs. 70,000 will be earmarked towards total capital cost and recurring cost/annum for environmental pollution control measures.
Following are the details of facilities to be installed and the corresponding products:
| S.No | Facility | Capacity | Product | Production capacity |
| 1 | Submerged Arc Furnace | 2 x 5 MVA | Ferro Manganese
Silico Manganese Ferro Silicon |
20,600 TPA
15,900 TPA 7,100 TPA |
Submerged arc furnace (SAF) will be used for manufacture of ferro alloys. The molten metal and slag will be tapped at regular time intervals into a ladle or onto cast iron pans. The slag will be overflowed to another ladle or in casting pans. Manganese ore, Coke breeze, Quartz, Iron scrap, Pet coke and Dolomite will be used as basic raw materials for Ferro alloy production.
The Committee recommended the project for environmental clearance subject to certain conditions pertaining to environment.
Dudani Fuels – Expansion of Pig Iron Plant
Expansion of Pig Iron Plant (16,500 TPA to 33,000 TPA) by installation of Mini Blast Furnace (1×23 m3, 16,500 TPA) at Mouza Kusumdaha, Village Bagula, P. O. Nagnagar, District Dhanbad, Jharkhand.
Dudani Fuels Pvt. Ltd. have proposed to expand its Pig Iron Plant by installation of Mini Blast Furnace (1×23 m3, 16,500 TPA) at Dag no. 113, 115 and 117, Khatian no. 14, Mouza no. 10, Mouza Kusumdaha, Village Bagula, P.O. Nagnagar, District Dhanbad, Jharkhand. Existing plant has 1×23 m3 Mini Blast Furnace (50 TPD = 16,500 TPA Pig Iron). The total land required for the proposed expansion will be 5.46 acres, which is already acquired and green belt will be developed in 1.80 acres with 15m width along the plant periphery. No R & R is involved. Dhanbad town is at a distance of 7 km from the project site. No national Park/wild life sanctuary/reserve forest is located within 10 km radius of the project site. Total cost of the proposed expansion is Rs. 605.07 Lakhs. Rs. 60.0 Lakhs and Rs. 12.0 Lakhs will be earmarked towards total capital cost and recurring cost / annum for environmental pollution control measures.
The product from the proposed expansion will be Pig Iron only (16,500 TPA). Lump Iron ore (24,750 TPA), Coke (11,550 TPA), Limestone (4,125 TPA), Dolomite (2,062 TPA), Manganese ore (247 TPA) and Quartzite (412 TPA) will be used as Raw materials.
In the blast furnace, the hot metal will be produced from iron oxide burden using coke both as reductant and fuel. The hot metal from blast furnace will be cooled and solidified to make Pig Iron. Sinter, Iron ore lumps and pellets are charged from top of blast furnace along with coke, limestone and dolomite. Chemical reaction will start when the preheated high temperature air will be injected at the bottom of Blast Furnace (BF) through the tuners. Coke inside the furnace will burn to produce CO and CO2. CO will help in preheating and reducing iron oxide in successive stages to Iron. Flux materials like Limestone and Dolomite form a molten slag at the furnace operating temperature. Molten iron and slag will accumulate at the bottom of the furnace. Fusible slag being lighter will float above the molten metal and will be removed periodically. The liquid hot metal surges towards Pig Casting Machine (PCM) where it will cool and solidify into Pig Iron.
Dust extraction system will be provided at different material transfer points and dust suppression system will be provided at raw material yard. BF cast stock house and stock house will be fitted with bag filter and BF gas cleaning plant with ESP as per CREP norm. Out of the total BF gas (5,000 Nm3/hr), 2,400 Nm3/hr gas will be used in the BF stove and rest of the BF gas will be used for heating of BF runners, ladle heating and slag granulation.
The Ministry of Environment and Forests have sought following additional information for reconsideration of the project for providing clearance.
1. Compliance to the conditions stipulated in the environmental clearance/NOC of the existing plant
2. Detailed lay out plan of the plant
3. Cumulative impacts due to existing and proposed plant on the ambient air quality
4. Measures for reduction of emissions in the new plant
5. Stack emission data for SOx and NOx
6. Detailed Occupational Health and Safety Plan
Kasturi Ispat – Mini Integrated Steel Plant
Mini Integrated Steel Plant at Village Hirebaganal, Taluka & District Koppal in Karnataka.
Kasturi Ispat Pvt. Ltd. have proposed for Mini Integrated Steel Plant at Village Hirebaganal, Taluka & District Koppal, Karnataka. Total project area is 100 acreswhich is already acquired and green belt will be developed in 33 acres. No R & R is involved. No national Park/wild life sanctuary/reserve forest is located within10 km radius of the project site. Total cost of the project is Rs. 196.25 Crores and Rs. 18.0 Crores and 30-35 lakhs will be earmarked towards capital cost and recurring cost/annum for environmental pollution control measures.
The following facilities will be installed:
|
S.No. |
Plants | Configuration | Capacity |
| 1 | Sponge Iron Unit (Using DRI) | 3×100 TPD | 90,000 TPA |
| 2 | Captive Power Plant – WHRB | 5 MW | 5 MW |
| 3 | Captive Power Plant – AFBC | 5 MW | 5 MW |
| 4 | Steel Melting Facility with IF | 2x15T | 1,00,000 TPA |
| 5 | Billet Casting Facility | 2 strand & 6×11 CCM | 96,000 TPA |
| 6 | Rolling Mill | - | 90,000 TPA |
| 7 | Pelletization Plant | - | 6,00,000 TPA |
Iron ore lumps, coal and dolomite will be used as raw materials in Sponge Iron production. Sponge Iron will be manufactured in DRI kilns and further melted in Induction furnace and rolled in Rolling Mill. Pellet Plant will manufacture pellets. In pellet plant, iron ore fines will be grinded, transferred to pelletizers, dried, pre-heated, roasted and cooled. Hot gases from DRI kiln will be used in waste heat recovery boilers (WHRB)
Hot gases from DRI kiln, will be cooled in gas conditioning tower and dust will be controlled in electrostatic precipitator (ESP) and purified gas will be let off through the chimney. Bag filters will be provided at cooler discharge and conveyor transfer points of Sponge iron plant. Fume extraction system with bag filters will be provided to Induction Furnace. Dust extraction system with bag filters will be installed to collect dust from all transfer points, crushers and screens. ESP will be provided to Power Plant and Pellet Plant. Chemical dust suppression system will be used in coal circuit to suppress the coal fines. Bag filters will be installed in raw material preparation and product separation circuits. A cyclone with venturi scrubber will be used to clean the fumes emanating from the Re-rolling mill. Dust suppression system will be used to suppress dust generated due to vehicular movement, raw material loading, unloading and handling.
Total Power requirement is 22.5 MW and will be met from CPP (10 MW) and Grid of KPTCL (12.5 MW). DG set (1000 KVA) will be installed.
The environment ministry has granted clearance for the project.
Steel Industry News in Brief – This Week
SAIL Plans JV with Kobe Steel
SAIL is planning to set up a 0.5 million tonne tpa iron ore nuggets plant at Durgapur in West Bengal in joint venture with Kobe Steel , Japan. SAIL will use the surplus land available at its Durgapur steel plant. SAIL is currently in the process of preparing a detailed project report. The project is likely to cost Rs.5000 crore.
Essar’s pellet plant to be commissioned shortly.
Essar Steel, which is currently setting up a 8.0 million tpa ore beneficiation plant at Joda and Barbil and a 250 kilometer slurry pipeline from Joda to Paradip is nearing completion. Commercial production is expected in October 2010. The pellets to be produced at Paradip would be exported through the Paradip Port to Essar’s steelmaking unit at Hazira in Gujarat, which is undergoing a capacity expansion to 9.6 million tonne from 4.6 million tonne by 2012.
Lucchini RS, Italy plans new venture in India.
Italian group Lucchini has formed a JV with Bharat Connect to set up a Greenfield plant near Mumbai to manufacture wheels, axles and complete wheel sets for locomotives and main line and metro passenger vehicles. The project is likely to cost 15 million EURO and is expected to go onstream in end 2011.
Shriram EPC bags captive power plant order from Seven Star Steel
Seven Star Steel, has awarded the EPC contract for setting up a 12 MW power plant based on waste heat recovery. The Rs.480 million project will be completed in 18 months.
Land acquisition completed for Monnet Ispat’s Steel Plant in Jharkhand.
Monnet Ispat & Energy which is setting up a 2.5 million tpa steel plant in Jharkhand has acquired about 850 acres of land for the project. The company also needs 450 acres from Dumrada village, under Chandankiyari block. The company officials distributed agreement forms and hope to finalize the deal soon.
Arcelor Mittal to get mining lease for its steel plant in Karnataka.
Arcelor Mittal which is setting up a steel plant in Karnataka is in the process of acquiring land which is expected to be completed by end 2010. The company is also seeking some mining leases in Karnataka.
Gontermann-Peipers signs MoU with Chattisgarh for new plant.
Gontermann-Peipers has signed an MoU with government of Chhattisgarh to set up a 1.2 million tpa pelletization plant at a cost of Rs.300 crore. The implementation of the MoU would be taken up by the Company after obtaining all requisite approvals.
ABB India acquires Bangalore based Steel Consultant.
ABB India has announced plans to acquire Metsys Engineering and Consultancy, based in Bangalore. The Bangalore based company is one of the key technical solution providers to the steel industry in India and other emerging market countries
Green Steel Making – Gas Based Technology for Sponge Iron Industry
This article written by Mr.Prakash Tatia, President of Welspun Maxsteel appeared in the newsletter ( dated April 2010) published by Sponge Iron Manufacturers Association of India.
Worldwide, there is an increasing emphasis on environmental issues. In the area of gaseous emissions, the Kyoto Protocol & recently held Copenhagen summit 2009 has put great pressure on the industrialized countries to reduce emissions and almost all nations are in agreement. This protocol has put tremendous impact on manufacturing industries across the globe and Iron & steel sector is one of the most prominent one.
Iron & Steel industry is growing globally & so are its related environmental issues. This industry is now under intense scrutiny because it emits about 7% of global anthropogenic carbon dioxide. Iron making and steelmaking are energy intensive and essentially all the carbon entering a steel complex leaves as CO2. Although the steel industry has reduced energy consumption and emissions significantly, much more will be required.
Worldwide steel is manufactured by two routes namely Primary and Secondary Route
Primary Route uses Blast Furnace / Basic Oxygen Furnace for steel making, which is a traditional route of steel making. Iron Ore and Coke is main raw material in this process, leading to high Carbon emission in environment. While on the other side Secondary route uses Electric Arc Furnace / Induction furnace for steel making and uses Scrap, Pig Iron and Sponge Iron (HBI /DRI) as key raw materials. Steel produced by Primary route accounted for around 70% of global production and the rest through Secondary route, however after realizing the environmental impact and stringent guidelines laid by Kyoto protocol question arises of “How To Lower Iron and Steel making Carbon Emission”
On a macro basis, there are three ways to lower CO2 emissions from iron and steel making production
- Reduce energy consumption so that less energy (and carbon) is required per ton of steel produced,
- sequester the CO2 produced underground, either in storage or for enhanced oil recovery,
- use an energy source with less carbon than coal.
Option 1) has been a serious focus for many years. Since 1980, the USA steel industry has reduced energy consumption per ton of steel 45 percent. However, further gains are increasingly difficult as the processes become more and more efficient. Option 2) is being studied and there is promise, but it does nothing to reduce emissions from the iron and steel making processes, it just reduces the CO2 emitted to the atmosphere. Also, there are significant practical limitations . Option 3) hold the most promise for significantly reducing carbon emissions. An attractive energy source is natural gas.
Natural gas is primarily methane, with a chemical formula of CH4. Thus, there are four hydrogen atoms for each carbon atom. Coal is a diverse mixture of compounds, but it has a higher proportion of carbon to hydrogen than does natural gas. Since almost all the carbon and hydrogen used in an iron and steelmaking facility are eventually converted to CO2 and H2O (water), natural gas produces much less carbon dioxide than does coal. Table below shows the CO2 emission rates for combusting methane versus two types of coal.
Carbon Di Oixde emissions for iron and steel making energy sources.
Natural Gas – 49 (t/TJ) or 115 (lbs/MMBtu)
Bituminous metallurgical coal – 90 (t/TJ) or 212 (lbs/MMBtu)
Bituminous Steam Coal – 94 (t/TJ) or 220 ((lbs/MMBtu)
(* Source : Midrex Tech)
As the table shows, natural gas emits only about one-half the CO2 per unit of energy as does coal. This characteristic makes natural gas an ideal energy source for steel making. The DR/EAF combination has much lower carbon emissions per ton of steel than does the BF/BOF process.
To highlight the significant emissions advantage of the DR/EAF steelmaking route versus the BF/BOF route, A detailed analysis of various steelmaking methods, including the blast furnace/BOF and the EAF fed with various mixes of scrap plus alternate iron (DRI, HBI, and pig iron) as shown in graph below
From graph it is evident that, the lowest carbon emissions result from the use of 100 percent scrap steel in an EAF, however scrap being generated commodity, has quality issues and scarcely available the metalliks to be used for steel making is Gas Based Sponge Iron (DRI/HBI) in combination with steel scrap.
The Liquid steel produced by using Gas Based Sponge Iron along with steel scrap reduces CO2 emission to the extent of 61% compare to BF-BOF route – Substantial Reduction
The Green Solution
World steel industry is required to reduce CO2 emissions. The reduction quantities have been set for all countries. Use of Natural gas for direct reduction, combined with EAF steel making is environment friendly. In EAF, CO2 emission is less than 50% of that in BF.
Regions such as the, Middle East, South America, Russia and India have already discovered the benefits of the natural gas-based DR/EAF steel making route. This will result in promising growth of secondary route of steel making. Gas Based sponge iron (DRI / HBI) is the perfect replacement of scrap and key metallic to “Green Steel Making”
SAIL Plans New TMT Bar Mill in HP
Steel Authority of India Limited (SAIL) has planned to set up one TMT Bar Mill at Steel Processing Unit (SPU) at Kandrori District Kangra in Himachal Pradesh with a capacity of 1,00, 000 tonnes per annum. The project is under execution and the expected date of completion is by first quarter of 2012. The possibility of setting up an additional SPU in Himachal Pradesh is being explored.
A three member Committee had been constituted comprising of representatives from SAIL, Government of Himachal Pradesh and Confederation of Indian Industry to examine inter-alia activities towards expanding the manufacturing base of steel products in the State of Himachal Pradesh
Ogun Steel Commissions Phase I Steel Project
Ogun Steel Rolling Mills, a Coimabatore based company has commissioned first phase of its upcoming steel rolling mill project at Selakkaraichal village near Coimbatore.
The first phase involved setting up a facility for making TMT rods ( for construction industry) with a capacity of 250 tonnes per day. The project was implemented at a cost of Rs.35 crore.
The company plans to take up the Phase II expansion that involves setting up a facility for MS Structurals ( for fabrication industry) with an outlay of Rs. 20 crore. Necessary approvals were being got and clearances, such as environmental, financial and power supply tie up, were expected in another two months and the project is expected to be completed in seven months.
The third phase comprises setting up a facility for making billets continuous casting etc, work on which would commence in approximately ten months and entail an investment of about Rs 45 crore.
New Steel Projects in Jharkhand
List of New Steel Plant Projects for which MoUs have been signed with state government of Jharkhand since 2007
|
|
Name of the
|
Location |
Capacity in MTPA |
Project cost Rs. in |
DateMoU |
Present status &
|
|
1 |
M/s.
|
Nandpur/ Manoharpur |
|
6750 |
12.01.07 |
Production not started |
|
2 |
M/s.
|
Nala Block Jamtara |
|
1500 |
09.02.07 |
Production not started |
|
3 |
M/s.
|
Raneshwar, Sikaripara, |
|
1500 |
09.02.07 |
Production not started |
|
4 |
M/s.
|
Afjalpur, Balablock, |
|
1500 |
09.02.07 |
Production not started |
|
5 |
M/s.
|
Kumrabad, Dumka |
|
1500 |
09.02.07 |
Production not started |
|
6 |
M/s.
|
Pathanmara |
|
300 |
14.02.07 |
Production not started |
|
7 |
M/s.
|
Barlanga |
|
1830 |
23.02.07 |
Production not started |
|
8 |
M/s.
|
Goridih and Rugri new |
|
361 |
24.02.07 |
Production not started |
|
9 |
M/s.
|
Rajkharswan |
|
6300 |
26.02.07 |
Production not started |
|
10 |
M/s |
Patratu |
Steel Plant - 6.0 |
18560 |
08.11.07 |
Production not started |
|
11 |
|
Galudih, E. Singhbhum |
Integrated Steel |
7000 |
- |
Production not started |
|
12 |
|
Ramgarh |
Integrated Steel |
1840 |
- |
Partially commissioned |
|
13 |
|
Ramgarh |
Integrated Steel |
353.53 |
- |
Partially commissioned |
|
14 |
|
Ghatishila |
Integrated Mini |
847 |
- |
Production not started |
|
15 |
|
Hosir, Hazaribagh |
Steel Plant – |
785 |
- |
Partially commissioned |
|
16 |
|
Kanchi Bundu, Ranchi |
Steel Plant – 1.3 |
655 |
- |
Production not started |
|
17 |
|
Ramgarh |
Steel Plant – |
655 |
- |
Production not started |
New Steel Projects in Orissa
List of New Steel Plant Projects for which MoUs have been signed with state government of Orissa since 2007.
|
|
|
|
|
|
|
|
|
1 |
|
|
4.0 (Pelletation |
1485.00 |
15.03.2008 |
Production not |
|
2 |
|
|
0.50 |
606.00 |
29.01.2008 |
Production not |
|
3 |
|
|
0.25 |
291.00 |
29.01.2008 |
Production not |
|
4 |
|
|
0.25 |
227.13 |
29.01.2008 |
Production not |