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TATA BLUE SCOPE STEEL LIMITED

PRE FEASIBILITY REPORT FOR EXPANSION OF THE EXISTING SECONDARY METALLURGICAL UNIT AT BARA,PO AGRICO, JAMSHEDPUR, DIST-EAST SINGHBHUM (JHARKHAND)

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CONTENT

Chapter Description Page No.

1 Introduction 2-9

2 Description of plant 10-20

3 Site details 21-23

4 Services, utilities & manpower requirement 24-26

5 Environmental management 27-32

6 Cost consideration 33

7 Plant Layout 34

8 Google image of 10km Radius surrounding TBSL 35



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CHAPTER-1: Introduction

01.01 Preamble

Capacity, production and processing of steel in India have grown at a frenetic

pace in the last half decade. Growth of this sector is an evidence of the

growing resilience of the Indian steel industry and its ability to adapt its

workings to changing dynamics of the input and products markets. In this

case, rise of the steel processing industry has helped the Indian industry –

especially the hot and cold steel processing – to overcome a crippling

shortage for processed steel. The primary push for the growth of this sector

has come from the rapid expansion of secondary steel processing in India in

the last decade and a half.

Steel being a basic commodity for all industrial activities, quantum of its

consumption is considered as an index of industrial prosperity. Since

independence, there has been a substantial growth in the steel sector in India

from 1.5 MTPA in 1950-51 to more than 80.0 MTPA at present.

Hence, short-term and long-term strategies are necessary in planning the

development of the steel industry in the country to improve the productivity

and level of per capita steel consumption.

The strategies may include setting up of new steel processing plant facilities,

or expansion of the existing steel processing plants, or installation of

upstream / downstream facilities in already existing plants, for production of

semis for processing / finished products.

The National Steel Policy of India has declared a target of producing 110

million tonnes of steel by the year 2020, up from 80.0 million tonnes at



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present. This has given an incentive to all the major steel producers of India

to work out to add capacity.

Tata BlueScope Steel is an equal joint venture between Tata Steel and

BlueScope Steel, Australia. The company operates in the SAARC region in the

field of coated steel, steel building solutions and related building products.

The Company was founded in year 2005 and operates in the South Asian

Association for Regional Cooperation (SAARC) region. Its Coated Steel

Business manufactures and supplies 55% Al-Zn Alloy coated

ZINCALUME® steel and pre-painted COLORBOND® steel for building and

construction industry. The company has a state-of-the-art coated steel

manufacturing plant at Jamshedpur with an annual metal coating capacity of

250,000 t and a paint line capacity of 150,000 t. The plant is accredited with

ISO 9001, ISO 14001 and OHSAS 18001 certifications - a testimony to its

quality and performance.

The demand for coated steel is increasing due expanding steel market and

shift from GC (Galvanized Corrugated) and other conventional roofing and

walling solutions. The coated steel products ZINCALUME® steel and

COLORBOND® steel finds its usage in various applications like Pre-

Engineered Buildings (PEB), colour coated roofing and walling, Solar

structures, silos, LGFS, Pipe cladding etc.

Tata BlueScope Steel Limited manufactures and sells roll-formed roof and

wall-cladding profiles as well as lightweight PEB structures under its 3 brands.

LYSAGHT® brand caters to the B2B segment, DURASHINE® brand is the

flagship retail brand and EZYBUILD® Solutions meets the requirements of

Light Gauge Structural Solutions.



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Tata Blue scope Steel Limited, located under Jamshedpur Notified Industrial

Area at Bara, PO-Agrico, Jamshedpur district East Singhbhum,(JHK) proposing

to expands the capacity of Colour coating line by adding one more CCL

capacity 150,000MT/year in addition to existing CCL of 150,000MT/year. The

expansion would boost up the economy of the backward areas of Jharkhand

State along with boost up the economy of the Jamshedpur, East Singhbhum.

No additional land area is required as the expansion will be executed in the

existing available land. The available land area is 24 h land at Bara Ash pond

owned by Tata steel and the area falls under Jamshedpur Notified Industrial

Area.


BlueScope Steel in the field of coated steel, steel building solutions and

related building products. The Company was founded in year 2005 and

operates in the South Asian Association for Regional Cooperation (SAARC)

region. Tata BlueScope Steel maintains high standards in the area of Safety,

Health and Environment and has been certified by SGS for ISO 9001: 2008,

ISO 14001: 2004 & OHSAS 18001: 2007 certifications.

The plant location is shown in the topographical map attach herewith. The

entire area surrounding the plant is under Jamshedpur Notified industrial area

having population scattered stretched in the area. The existing plant site is

well connected by the Road. Tata Nagar is the nearest railway station from

the existing plant site, which is around 6.2 km away from it in SW direction.



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FIGURE 1.1: STUDY AREA (10 KM RADIUS)



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01.02 METEOROLOGY OF THE AREA:

The nearest meteorology station is located at Jamshedpur operated by

meteorological department. The height of the station is 129 M above mean

sea level which matches closely with the plant at Jamshedpur East

Singhbhum. Based on above the region experiences hot summer and cold

winter, Strong wind is experienced in summer and on the eve of Monsoon

and during winter season calm condition prevails. The characteristics of

weather are

Average wind speed : 4.05 Km/Hr.

Predominant wind direction : West- Northwest

Mean maximum temperature : 42.5°C

Mean minimum temperature : 15.4°C

Average rain fall : 1100-1400 mm

1.2 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

1.2.1 Identification of Project Proponent


BlueScope Steel, Australia. The company operates in the SAARC region in

the field of coated steel, steel building solutions and related building

products. TBSL is among the largest producer of coated and painted steel

strips/coils in India.

TBSL has deployed state – of- the – art technology in its production

processes. Tata BlueScope Steel has won prestigious certifications and

maintains high standards in the area of Safety, Health and Environment

and has been certified by Underwriters Laboratory Inc for ISO 9001: 2008

as well as by M/s. UL MSS India for the ISO 14001 & OHSAS 18001

certifications. Pollution prevention & control systems have been installed



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for the various processes at the factory are of latest design and it

upgraded regularly.

Tata Steel BlueScope Steel is in the field of coated steel, steel building

solutions and related building products and located at Bara, PO Agrico,

Jamshedpur, District East Singhbhum, (Jharkhand). The JSPCB has issued

CTE to this unit vide letter no JA/2655/w/332 dated 1/2/07. (Copy of letter

has been attached). The NOC is granted to TBSL for setting up of plant for

manufacturing of Zinc Aluminum coated steel strip and polyester paint

coated strip at Bara ash pond area, P.O.-Agrico dist.-East Singhbhum

(JHK). The NOC was granted for following production facilities at above

location:

1) Zinc-Aluminium coated steel strip – 100,000 MT/Year

2) Poly Ester paint coated steel strip – 150,000 MT/Year

Consent to Operate for the same has been obtained from Jharkhand State

Pollution Control Board. The latest CTO issued is valid till 2019.

Compliance reports are also submitted regularly.

1.2.2 Project Identification

DETAILS OF THE PROJECT

S. No. Particulars Details

1. Nature of the Project Expansion of capacity by addition of one more

Colour Coated Line capacity

150,000MT/Year(Total capacity of Poly ester

paint coated Strip 300,000MT/Year)

2. Cost of the expansion

project

Rs 300 Cr

3. Cost of EMP a) 12 Cr. – Capital Cost

b) 0.6 Cr – Recurring Cost

4. Total Plot Area 24h

5. Greenbelt Area 7.2h



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6. Project Location Under Jamshedpur Notified Industrial Area

A. Village Bara

B. Tehsil Jamshedpur

C. District Jamshedpur- East Singhbhum

D. State Jharkhand

7. Toposheet No. 73 J/1 & 73 J/2, 73 J/5 & J/6

8. Location co-ordinate The GPS coordinate as observed for the plant

Centre is given below:

NW: 220 49’ 0.07’’N 86◦ 13’ 58.14’’ E

NE : 220 49’ 2.94’’N 86◦ 14’ 15.27’’ E

SE : 220 48’ 49.99’’N 86◦ 14’ 21.50” E

SW: 220 48’ 48.97’’N 86◦ 13’ 59.75” E

Environmental Setting

10. Climatological Data of Study Period :

A. Temperature Max. – 47 °C

B. Relative Humidity 87%

C. Mean Annual Rainfall Avg. 1100-1200 mm

11. Nearest Railway Station Tata Nagar (6.2 km, SW)

12. Nearest Highway NH-33 (2.2 km, N)

13. Nearest Airport Sonari, Jamshedpur (6.3 km, W)

14. Protected forest 3.3 km, N,NE

Wildlife Sanctuary 8.5 km N Dalma

15. Nearest Densely Populated Area Jamshedpur (6.0 km, w)

16. Nearby Water Bodies 3 Subarnarekha River(440m, N)

4 Kharkai River (6.8 km, SW)

5 Dimna Lake (5.2 km, N)

6 Chandil Reservoir (26.5 km, NW)

17. Soil Type Silty loam

18. Seismic Zone Zone II



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1.3 SITE SELECTION

The proposed expansion of existing secondary metallurgical unit is going

to be executed in vacant land in existing plant premises. The plant is

situated at an ideal location, as it is benefited with well-developed road

connectivity to Jamshedpur and to railway station Tata Nagar (6.2 km,

SW) & NH 33 in North direction at a distance of 2.2 km only.

The site has all the necessary infrastructural facilities like electricity, water

distribution system, drainage system, banking, postal services,

communication means, transportation facilities, etc.

Following factors were considered while selecting the site for the existing

plant:

1. Nearness to National Highway (NH-33), which is 2.2 km in North

direction from the plant site, makes it easier to dispatch finished

materials for market. The nearest railway station is Tata Nagar which

is 6.2 km in SW direction from the project site.

2. Environmental considerations such as distance from major roads and

safety distances from nearby villages have been taken into

consideration.

3. There is availability of social infrastructure and man-power.



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CHAPTER-2: DESCRIPTION OF PLANT AND MANUFACTURING PROCESS:

02.01 SCENARIO OF STEEL INDUSTRY:

THE steel industry in the world, which was characterized as a sunset

industry two decades ago, is experiencing a vast change in scenario. The

fast developing Chinese steel industry has far outstripped the world steel

giants. United States, Russia and Japan, which were leading steel

producers, are no more in a position to claim that position.

India is the world’s third-largest producer of crude steel (up from eighth

in 2003) and is expected to become the second-largest producer by the

end of 2016. The growth in the Indian steel sector has been driven by

domestic availability of raw materials such as iron ore and cost-effective

labour. Consequently, the steel sector has been a major contributor to

India’s manufacturing output.

The Indian steel industry is very modern with state-of-the-art steel mills.

It has always strived for continuous modernisation and up-gradation of

older plants and higher energy efficiency levels.

India’s crude steel production grew by 9.4 per cent year-on-year to at

81Million Tonnes (MT) in August 2016. During April-August 2016, crude

steel production in the country grew by 7 per cent year-on-year to 39.98

MT. Over April-August 2016, steel imports fell 34.5 per cent year-on-year

to 3.01 MT, while steel exports rose 23.6 per cent year-on-year to 2.38

MT. Steel consumption in the country is expected to grow 5.3 per cent

year-on-year to 85.8 MT during FY2016-17, led by growth in the

construction and capital goods sector.



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India is expected to become the world's second largest producer of crude

steel in the next 10 years, moving up from the third position, as its

capacity is projected to increase to about 300 MT by 2025. Huge scope

for growth is offered by India’s comparatively low per capita steel

consumption and the expected rise in consumption due to increased

infrastructure construction and the thriving automobile and railways

sectors.

China, producing less than a million tonnes of steel prior to revolution in

1949, has now become the largest steel producer in the world. During

2005 the global steel production stood at 1132 million tonnes, showing a

rise of 6 per cent over the last year. The countries in South America, CIS

(former Soviet Union) Europe and North America have actually shown

negative growth. The Asian continent for the first time produced more

crude steel than the rest of the world combined. Major shift has taken

place because during 2005 with China producing 349 million tonnes of

steel, accounting for 32 per cent of the world steel production. During

2005, Chinese steel production increased by 69 million tonnes i.e. by 25

per cent. Chinese steel output was more than three times that of Japan

and four times of USA during 2005.

Per capita consumption of steel in the world was estimated to be 170 kg

during the year 2005. However in India it stood at only 35 kg during the

same year. Indian steel production was 38 million tonnes, which

accounted for only 3.4 per cent of the world steel output. In view of the

fact that Indian population is 16 per cent of the global population, the

production of steel is much lower in India. Although India is the second



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largest populated country in the world, it ranks eighth in steel

production.

TBSL proposed to expand the existing Colour Coating Line Product

capacity from 150,000MT/year to at existing location by adding another

Colour Coated Line with similar capacity of 150,000MT/Year at Bara, PO

Agrico, Jamshedpur district East Singhbhum(JHK). No additional land area

required as the proposed capacity of CCL will come up in exist plant

premises. The total land area is 24h, as per EIA notification 14th Sep’2006

this project falls in category ‘A’ and therefore this project required

Environment clearance from MOEF&CC.

THE PROJECT

The existing plant production capacity is not sufficient to meet the

domestic requirement of Colour coated Steel Strip. To meet the domestic

requirement and demand of construction industry, this expansion is

essential. It is also essential to sustain in the market product quality

demand on modern equipment.

The project is expected to have a high development impact, as it aims at

Enabling a company to become more globally competitive.

Efficiency increases to support cost optimization.

Speciality steel niche product catering to growing construction

marketing nationally & internationally.

Attain global leadership in coated steel business.

02.02 Existing Plant

The existing plant have production facilities for value addition of cold

rolled hard coil by metal alloy coating and further Polyester Paint



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Coating of the cold rolled steel strips for improved corrosion

protection properties and aesthetic appeal.

The production plan of existing plant as follows:

Zinc-Aluminium(Galvalume/Zinc alum) -100,000 TPY

Polyester Paint coated strip – 150,000 TPY

The strips will be varying from 600 mm to 1270mm wide and 0.25mm

to 1.3 mm thick as being produce from Cold Rolling Mill of Tata Steel

Plant at Jamshedpur. The metal coating thickness on both sides would

be of 300 to 500 gm/sq. m and paint coating thickness would be of 15

to 35 microns.

Manufacturing Process:

The manufacturing process is a mechanical one. The feed stock for both the

line is hard cold rolled strips in coil form.

Metal Coating Line: the MCL is a continuous process line as illustrated in

Figure 2.1. The line would have sequential operations like (i) alkali

degreasing followed by rinsing and hot air drying (ii) last trace of oil removal

in a non-oxidizing furnace having 95% N2 and 5%H2 atmosphere (iii)

continuous annealing at a temperature of around 8000C (iv) cooling the strip

to a temperature of around 6000C prior to passing through molten zinc and

aluminum bath. The metal thus coated on the strip would be water quenched,

air dried and finally passed through dilute chromic acid bath for passivation of

the coated metal surface. The coated metal strip is mechanically coiled for

dispatch.



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Paint Coated Line: this line is shown in fig-2.2 is similar to metal coating

having process steps as alkali cleaning, chromate passivation, polyester based

primer paint coating, followed by baking, quenching, drying and final paint

coating followed by baking again, quenched, dried, embossed and sizing of

painted coil strips for dispatch.

02.03 RAW MATERIALS REQUIREMENT:

The requirement of principal raw materials and chemicals, other than cold

rolled steel strips as feed stock would be caustic soda for preparation of

alkaline degreasing solution, chromic acid for passivation, zinc ingots,

Aluminum ingots and polyester paint products.

The estimated monthly consumption of these raw materials and chemicals is

indicated in the Table-2.1:

Table-2.1: Average monthly Consumption of Raw Material and Chemicals

S.

No.

Raw Materials/

Chemicals

Forms &

Composition

Quantity

t/month

Source

1. Cold Rolled Coils Thin steel strip 21,000 Tata Steel Plant

2. Zinc Ingots Solid Zinc 99.8% 400 Indigenous

3. Aluminum Ingots Solid Al 99% 500 Indigenous

4. Caustic Soda Caustic Lye

NaOH=30-35%(w/w)

16-17 Indigenous

5. Chromic Acid Aq. SolutionCr2O3=2 to

3 %(w/w)

6-7 Indigenous

6. Paint Products and

thinner

Polyester, Epoxy, Kynar

etc

500 Indigenous



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Fig-2.1A: indicative Illustration of metal coating line (MCL)

welder

cold rolled coil

cleaning &

degreasing

section

heat treatment

furnace

zinc bath

air "knives" (adjust

zine coating thickness)

chromate spray

skinpassing /

leveling mill

galvanised steel

Fig. - 2.2 : Schematic Diagram of the Galvanising Process



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FIGURE 2.1 PROCESS FLOW DIAGRAM METAL COATING LINE



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Fig. 2.2A: Schematic Diagram of the Paint/Colour Coating Line

2.04 Fuel:

The furnace including package boiler will be heated by LPG/Propane a clean

fuel gas. It is estimated that nearly 50t /day propane would be required.

Baking ovens of the paint line will be heated by hot waste gas of incinerator

for VOC emissions of paint line.

02.05 WATER

The process requires de-mineralized water for strip rinsing and quenching

operation. The clarified industrial water supply from the water supply network

of Jamshedpur Utilities & services Company Ltd (JUSCO) is made available to

TBSL. The coating lines would require around 90 m3/h of industrial water for

which a provision of 100m3/h of water supply from JUSCO is arranged.

JUSCO receives water from the existing river water intake pump houses. Of

total requirement of 90 m3/h industrial water, the DM plant of coating lines

would require around 40m3/h for various process operations.

02.06 TECHNOLOGY

TBSL uses technology from BlueScope Steel, Australia. The Coated Steel

business of Tata BlueScope Steel supplies zinc and aluminium alloy metallic

coated and pre-painted steel products under the brand names

ZINCALUME® steel and COLORBOND® steel. Its manufacturing plant at

stitchercleaning and

pretreatment

section

primer

applicators

galvanised

steel coilbaking curing

baking curing

finishing coat

applicatorssliter and shearer

(slit to narrow plate

then cut into sheets)

tension

levelling unit painted sheets

Fig. - 2.3 : Schematic Diagram of the Paint / Colour Coating Line



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Jamshedpur has an annual metallic coating capacity of 250,000 tonne and

pre-painting capacity of 150,000 tons.

The demand for coated steel is increasing due expanding steel market and

shift from GC (Galvanized Corrugated) and other conventional roofing and

walling solutions. The coated steel products ZINCALUME® steel and

COLORBOND® steel finds its usage in various applications like Pre-

Engineered Buildings (PEB), colour coated roofing and walling, Solar

structures, silos, LGFS, Pipe cladding etc.

The Expansion:

Paint Coated Line: since there is a good demand for paint coated product in

the market instead of metal coated strips, TBSL has decided to add another

Colour Coating Line similar to the existing paint coated line having capacity

150,000MT/year. The line is similar to metal coating having process steps as

alkali cleaning, chromate passivation, polyester based primer paint coating,

followed by baking, quenching, drying and final paint coating followed by

baking again, quenched, dried, embossed and sizing of painted coil strips for

dispatch. This will add value to overall production and shall utilize half of the

metal coated strips and rest shall be purchased from the market(~50% of

feed strips shall be purchased).

Addition utility requirement has already been discussed and shall be arranged

from existing sources. Vacant land lying besides CCL shed shall be gain fully

utilized for establishment of this Colour Coated Line (CCL)

The product mix after this expansion shall be as follows:

a) Metal Coated Strips – 100,000 MT/Year

b) Colour Coated Strips – 300,000MT/Year



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02.07 Plant Layout

Attached as separate sheet



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CHAPTER-3: SITE DETAILS

03.01 Site Location



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‘© 2017 Tata Blue Scope Steel Limited. All rights reserved’

03.02 METEOROLOGY OF THE AREA:

The nearest meteorology station is located at Jamshedpur operated by

meteorological department. The height of the station is 129 M above

mean sea level which matches closely with the plant at Giridih. Based on

above the region experiences hot summer and cold winter, Strong wind is

experienced in summer and on the eve of Monsoon and during winter

season calm condition prevails. The characteristics of weather are

Average wind speed : 4.05 Km/Hr.

Predominant wind direction : West- Northwest

Mean maximum temperature : 42.5°C

Mean minimum temperature : 15.4°C

Average rain fall : 1100-1200 mm

03.03 Plant Area and Land Acquisition Details

Existing Project site fall Under Jamshedpur Notified Industrial Area, at Bara,

PO- Agrico, Jamshedpur Dist.- East Singhbhum (Jharkhand). No additional

land is required, as proposed expansion through addition of one more Colour

Coating Line will be within the existing plant premises of 24h.

LAND AREA DETAILS

S. No. Particular for Proposed Expansion Area(h)

1. Shaded Area 9.4h

2. Without Shaded Area including green cover 4.4h

3. Infrastructure Area 3.0h

4 Others (Gardening / Rain Harvesting etc) 7.2h

5 Total Plant Area 24h



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03.04 Logistics

The raw material sources are already connected by road which will require

no further upgradation as the cold rolled coil will be sourced from Tata

cold rolled mill located in nearby of plant.

03.04.01 Road

The proposed plant site is well connected by the state highway between

Ranchi and Jamshedpur.

03.04.02 Railways

Tata Nagar is the nearest railway station from the existing plant site.

03.04.03 Air Connectivity

The nearest airport is Sonari at Jamshedpur.



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CHAPTER-4: SERVICES, UTILITIES & MANPOWER REQUIREMENT

04.01 General

Besides raw materials, other major requirements of the plant are water,

power, fuel and manpower.

04.02 Water

The process requires de-mineralized water for strip rinsing and quenching

operation. The clarified industrial water supply from the water supply

network of Jamshedpur Utilities & services Company Ltd (JUSCO) is made

available to TBSL. The coating lines would require around 90 m3/h of

industrial water for which a provision of 100m3/h of water supply from

JUSCO is arranged. JUSCO receives water from the existing river water

intake pump houses. Of total requirement of 90 m3/h industrial water, the

DM plant of coating lines would require around 40m3/h for various

process operations.

WATER REQUIREMENT DETAILS

S.No. Particulars Water required (KLD)

1. Existing 2160

2. Proposed 300



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Project is based on Zero effluent discharge hence no process water will be

discharge outside of the plant premises. Waste water from process and

domestic use will go to Treatment Plant and recycled for various secondary

usages including in horticulture.

04.03 Power

The average power demand would be 8 MW therefore a provision of 12 MW

power demand from the existing 33kV switch board of Tata Timken located

at Gol mury Substation 3 km away from the existing plant site is taken. Total

power requirement after proposed expansion will marginally increase. The

additional requirement will be 3 MVA over and above the existing

requirement which will be sourced from existing JUSCO network having

distribution network.

04.04 Other Utility

The other utility and services for the existing coil coating lines are low

pressure steam of 5-6 tph steam at 10 kscg pressure produced in packaged

steam boiler. 100 Nm3/h hydrogen is produced through electrolysis of water.

At present nitrogen 750 nm3/his purchased from third party supplier.

04.05 Manpower

The production process is a continuous one and of programmed operations,

hence there would be requirement of operation and maintenance staff. The



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total staff strength is around 355 only. This includes production,

maintenance, services and administrative personnel of different categories.

At present the factory employees 355 Persons proposed project will require

another 100 persons. There was large pool of Skilled & Unskilled person

mainly surrounding area from where this requirement will be easily met. This

project will employed good nos. of workmen is direct & indirect job employed

from local area



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CHAPTER-5: ENVIRONMENTAL MANAGEMENT PALN

05.01 While preparing the feasibility report of the plant, Environmental

consideration have been given due importance. The plant has

incorporated elaborate Pollution Prevention & Control System and ensures

a clean environment all the time.

05.02 AREAS OF CONCERN:

i. AIR POLLUTION:

The sources are furnace fume from MCL and CCL line, boiler operation and

incineration of hazardous waste. Waste gases generated in the furnace,

which may contain fumes, Carbon Dioxide, Sulphur Dioxide and Nitrogen

Oxides after due treatment exhausted to atmosphere.

ii. WATER POLLUTION:

Discharge from process and toilets etc. will cause water pollution in the

discharge body. However, a modern treatment facilities is existing which

treat all waste water and reuse is in horticulture and other areas takes

place

iii. SOLID/HAZARDOUS WASTES:

The major solid/Hazardous wastes generated during operation of metal

coating and paint coating process. As such the plant will be equipped with

appropriate and effective waste handling devices to ensure pollution free

ambience.

iv. NOISE POLLUTION

From the equipment’s, such as metal coating line



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05.03 ENVIRONMENTAL MANAGEMENT PLAN (EMP):

TBSL is an ISO 14001 EMS accredited company and EMP incorporates an

action plan on some of the vital areas which have bearing on the

environment quality in and around the plant. The following steps are

taken as part of environment management in order to mitigate

environment impacts.

Entire plant activity is confined to TBSL plant area only and limits to

keep the surrounding areas in undisturbed state.

In a running plant, the fume generating activities will take place and

depending upon the requirement fume extraction measures is adopted

to maintain proper air quality inside the campus, which includes water

scrubber inline.

Present water availability will meet all the water requirements including

drinking water, sanitation etc. Existing toilets and disposal facilities of

waste water will take care of the sanitary requirements of plant staff.

The waste shall be discharged in Septic Tank followed by sock pit.

All existing infrastructural services such as water supply, sewage,

drainage facilities and electrification are available inside the campus.

Existing toilets will be maintained to ensure minimum environmental

impact.

In order to ensure safety to the worker, helmets, safety shoes, safety

belts and dust mask wherever necessary will be provided.

Extensive landscaping programme including trees and flowering plants

in & around the plant are in continuous stage the similar practice shall

be continued for vegetation cover.



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05.04 MNAGEMENT FOR MITIGATORY MEASURES OF RUNNING PLANT.

05.04.01 MITIGATION MEASURES

Air Pollution Management

Feed coils will be stored in covered sheds

Stack emission will be maintained below 100 mg/Nm3.

CPCB guidelines for control of fugitive emissions will be followed.

Implementation of routine plant schedule maintenance and good

housekeeping to keep small leaks and spills to a minimum will be done.

All the roads inside the plant will be PCC to reduce fugitive emission.

Green belt will be further strengthen along the periphery of the plant

premises & around various plant units to arrest the fugitive emissions if

any.

Water Management

The process is based on closed circuit system; hence there are only

evaporation losses and cooling tower blowdown water which is treated in ETP

and recycled back.

Treated wastewater is used for secondary use & horticulture development.

Rainwater harvesting structures (injection wells with desilting and filter pit) is

existing in the plant premises and used to charge into the underground

resources.



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Sl.

No.

Description Effluent

Generation

ETP Capacity Remarks

1. TBSL Complex 350-375 m3/day Liquid waste=670m3/day

Chrome waste=24m3/day

Resin waste=12 m3/day

Treated waste

water shall be

used internally

for various

uses

Noise Management

All required noise abatement measures are being provided to keep the noise

levels below permissible limits.

Green belt development helps in minimizing the propagation of noise.

Normally monitoring of noise level will be carried out and corrective measures

will be taken, if required.

Solid Waste Management

Dross are generated in the metal coating line about 15MT/month, this is

being sold to authorize vendors and same practice shall be continue in future

Metal scrap generation from the process is 110 MT/month.



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Sl.

No.

Solid wastes Generation

Proposed disposal

1. Metal Scrap 1100 t/month Sold to vendors

2. ETP sludge

# chrome sludge

#Non-chrome sludge

400-600kg/quarter

425-450kg/day

Suitably disposed of in SLF

Suitably disposed off

3. Dross generation

from MCL

15MT/month Sold to vendors

05.04.02 GREEN BELT DEVELOPMENT PROGRAMME:

Native diversified species are planted all around the plant boundary and both

sides of roads as per the CPCB guidelines.

Plantation is done by raising plants in the nursery and afterwards planting

saplings at the site.

05.05 OCCUPATIONAL SAFETY AND HEALTH PLAN:

The health of the employees is the wealth of organization. A well-

documented plan is already exist for monitoring the health status of the

employee on regular basis. The existing plan takes care of all the aspect

of safety of equipment for employees.



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05.06 MONITORING OF ENVIRONMENTAL PARAMETERS: A detailed

monitoring for different environmental parameters is being carried out as

per regulation of state pollution control board.

05.07 ENVIRONMENT AUDIT:

Environment audit shall be carried out on annual basis as per regulatory

requirements. Records of quality of air emissions in term of PM10 are

maintained. As inventory of waste storage area has been maintained

which includes details of the type of waste and the quantity stored,

address of buyers of wastes. Data on stack emission and effluent

monitoring are maintained to ascertain compliance with stipulated

standards.



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CHAPTER-6: BLOCK CAPITAL COST

06.01 BLOCK CAPITAL COST

The estimated capital cost for proposed expansion through addition of one more

colour coating line of capacity 150,000MT/year in plant units to enhance

production to 300,000 MT/year Colour Coated Coils and 100,000MT/Year Metal

Coated Line at Jamshedpur Notified industrial area, Bara, PO Agrico, Jamshedpur

district East Singhbhum has been worked out to be Rs 300 Cr.



Page 34 of 35


Layout drawing of plant:



Page 35 of 35


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