STEEL LIMITED BRINGING ALIVE A BILLION DREAMS

FLOW OF PRESENTATION

12

JSW Steel Overview

Steel Making- Process Route23

Steel Making- Process Route

Environment Management at JSW

4 Best Practices Case Studies

Steel making capacity of 14.3 MTPA 6 manufacturing facilities in India

VASIND / TARAPUR

JSW STEEL - COMPANY AT A GLANCE

HR Coils

HRPO Hot Rolled

HSM Plates

DOLVI

VIJAYANAGAR

KALMESHWAR

SALEM

Integrated Steel Plant Downstream Plant

Slabs

HRPO Coils

Coated Products

Cold Rolled CA,GL

Long Products

Hot Rolled Plates

HISTORICAL BACKGROUND

The foundation stone for “Vijayanagar Steel Plant”

under Public Sector, was laid by then India’s PM,

in 1971

More than 20 years later, in spite of Economic

BIRTH OF JSW STEEL

More than 20 years later, in spite of Economic

Liberalization in 1992, no one came forward to

fulfill the dreams of the PM, because none

considered it a viable proposition

The invitation from the Govt. of Karnataka in 1994,

& naturally was accepted as a challenge:

THUS, JINDAL VIJAYANAGAR STEEL LIMITED WAS FORMED IN 1994

Barren Land

Inadequate Water Source

No Electricity

CHALLENGES

THIS WAS VIJAYANAGAR WHEN WE ARRIVED

THIS IS WHAT WE MADE OUT OF IT…

No Electricity

Poor Road And Rail Connectivity

Poor Infrastructure

Non Availability Of Carbon Fuel

People To Build / Operate

Low Quality Iron Ore

MILESTONES

0.8 1.6 2.5 3.8

6.8

10*

1999 2001 2004 2006 2009 2011

*Production capacity for Vijayanagar Works only

FLOW OF PRESENTATION

12

JSW Steel Overview

Steel Making- Process Route23

Steel Making- Process Route

Environment Management at JSW

4 Best Practices Case Studies

Coal CoalIron ore Fluxes

Coke Oven

SinteringPelletization

Beneficiation

Lu

mp

ore

Lu

mp

ore

JSW: Process Flow

HSM CRM

Billet Caster

Converter LHF, RH Slab Caster

HMPT

Corex Blast Furnace

Wire Rod / Re Bar Mill

WIDE RANGE OF PRODUCTS – FLAT AND LONG

Products

HR - CoilsSlabs Plates & Sheets

HRPO, HRSPO, CRFH and CRCA Wire Rods TMT Bars

Low grade Iron Ore Upgradation

UNIQUE PLANT CONFIGURATION

Pellet Plant + Sinter Plant

Heat Recovery + Gas Recovery

Corex + Blast Furnace + DRI

Beneficiation

Coke making

Iron making

Iron ore agglomeration

Convertor + EAF

Cement + Sand

Self reliant in Power

Flat + Long Products

Steel Making

Slag Utilization

Power plant to utilise gases

Mills

Above configuration provides flexibility w.r.t raw material usage and makes JSW Steel

ENVIRONMENT FRIENDLY STEEL PLANT WITH ZERO EFFLUENT DISCHARGE

FLOW OF PRESENTATION

12

JSW Steel Overview

Steel Making- Process Route23

Steel Making- Process Route

Environment Management at JSW

4 Best Practices Case Studies

ENVIRONMENT MANAGEMENT ACTIVITY

Environment Management Department

Projects , Planning and

O&M

O&M

Projects

Environmental Compliance and

Monitoring

Statutory Clearance

and compliance

Monitoring-Manual and Continuous

Department

Environment Management

System

Air

Water

Solid Waste

ECC

Sustainability and

Management Systems

Sustainability & Awards

Management System and

TQM

ExternalInternal

INPUT

AIRWaste gases : 14 tonsWater vapor: 3.0 tons

STEEL MANUFACTURING - MASS BALANCE

JSW Steel

INPUTRaw materials: 3.8 tonsWater : 4.0 tonsAir : 12 tons

WASTESWastewater : 1.0 tonsSolid wastes: 0.8 tons

OUTPUTSteel : 1 ton

Energy Intensive

Environmental Infrastructure

Air Water Solid Waste

ESP 18 RWTP 9 Micro pellet plant 1600 TPD

Bag Filter 223 RO Plants6 Units (17650 m3/day)

MSB Plant 600 TPD223 RO Plantsm3/day)

600 TPD

Scrubbers 32 ETP 9 Units Incinerator 250 kg/hr

Dry fog 112 Guard Ponds 3 Centralized Oil Storage 1 Unit

CEMS 35 ZLD Plant 1 WWP 1000 TPD

Online Flow meters

7

100

120

140

160 150 150

100

mg/Nm3

JSW Steel Dust Norms - getting stricter

0

20

40

60

80

4 Mtpa 7 Mtpa 10 Mtpa 16 Mtpa

50 5050

30

10

Norm Design consideration

mg/Nm

Secondary Fume Extraction(SMS-2) Sinter Plant-3 Process ESP

Air Pollution Control Performance Assurance

• Choice of APC equipment- Preference towards Bag filters

• Periodic audit of APC health through internally developed audit methodology.

• Centralized Procurement of filter bags to ensure Quality Control

• In house Bag Filter Testing laboratory

Fugitive Dust Emission Control (PM 10)Infrastructures

• Dust Suppression System

• Wind curtains

• Paved areas

• Vacuum Cleaning

• Tyre washing • Tyre washing

• Surveillance through high resolution CCTV Cameras.

• Internally developed audit methodology for junction house and transfer tower

healthiness

• Dedicated water spraying tankers to suppress dust

Administrative Measures

Fugitive Emission Control

Foam Dust Suppression System Dust Suppression SystemFoam Dust Suppression System Dust Suppression System

Vacuum sweeping in shops Vacuum sweeping on roads

Fugitive Emission Control

Spraying in RMHSSpraying in stock yards with latex Spraying in RMHS

Water Spraying in coal yard Wind Curtain in Energy yard

Spraying in stock yards with latex

Water usage – Company “Policy”

1. Efficient use of water

• Reduction of evaporation rate

• Maximize use of alternate sources rain water & seepage.

• Reduction of fresh water in closed circuits by higher COC.

• Reverse osmosis plant for recovering good quality water.

2. Zero Discharge

• Cascading usage of water

• Use of blow down water in other processes

• Treated sewage for makeup

Guard Pond-1Guard Pond-2

Towards ZERO water discharge (ZLD)

Slag & Coke quenchingOre washing

Environmental Performance - Water

Continual

improvement

measures to

reduce Specific

Water

Consumption in

spite of

continuously 2.86

2.91

3.02

3.09

3.15

2.8

23

54

63 64

54

20

30

40

50

60

70

2.8

2.9

3

3.1

3.2

Spe

cifi

c W

ate

r C

on

sum

pti

on

, m3/T

CS

% o

f K

rish

na

Wat

er

Use

d

CREP Guidelines : 5.0 m3/tcs - Long ProductCREP Guidelines : 8.0 m3/tcs - Flat Product

continuously

increasing TDS

(due to increase

in usage of

Krishna water

with 45% higher

TDS)

2.8

00

10

20

2.6

2.7

2.8

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16

Specific Water Cons, m3/TCS % of Krishna River Water Used

Spe

cifi

c W

ate

r C

on

sum

pti

on

, m

% o

f K

rish

na

Wat

er

TDS Value of Krishna River Water:350 mg/LTDS of Tunga Bhadra River Water:200 mg/L

Variation in Inlet Water TDS and Specific Water Consumption

1.50

2.00

2.50

3.00

3.50

4.00

200

250

300

350

400

450

TDS,

mg/

L

Sp. W

ate

r C

on

sum

pti

on

, m3

/TC

S

0.00

0.50

1.00

1.50

0

50

100

150

200

TDS (TB Dam) TDS (Almatti Water) Sp. Water Consumption

TDS,

mg/

L

Sp. W

ate

r C

on

sum

pti

on

, m

Month

Zero Liquid Discharge Plant

FLOW OF PRESENTATION

12

JSW Steel Overview

Steel Making- Process Route23

Steel Making- Process Route

Environment Management at JSW

4 Best Practices Case Studies

The organic chemical laden effluent from coke oven byproduct is treated through MBR+ RO system

4000 m3/day of treated clear water of high quality is generated

• MBR technology incorporated for Shankar Hill Town(SHT) Sewage Treatment Plant( STP)

• The high quality treated water of 3000 m3/day is used as replacement of make-up water in CRM-2 water systems

MBR ZLD at Coke oven

• Objective: Produce Slag Sand for

Concrete

• Project Cost: Rs. 2 Cr.

Slag Sand Preparation Unit

Environmental Control Measures 2014-15

• Vertical Shaft Impact Crushed (VSI)

• Plant capacity: 40 tonnes/day

• The unit produces sand meeting the

IS-383 gradation requirements

• Environmental Friendly alternative to

river sand

Environmental Control Measures 2015-16

Ceramembrane

1. Material of construction: Aluminium oxide, silicon carbide, titanium oxide, or zirconium oxide

2. Range: Microfiltration to Ultrafiltration

3. Benefits:

• Suitable for continuous operation across full pH range of 0 to14.

• Suitable for elevated temperature operation

• Increased membrane permeability, chemically-durable, high abrasion resistance, removes oil and grease

Solid Waste Management

• To recover the iron and carbon content from process waste generated from steel making . Around 1000 TPD are available for recycling.

• Plant Capacity: 600 TPD of iron concentrate with 65-68% Fe(utilized in Pellet Plant)

Waste to wealth plant(WWP)

Fe(utilized in Pellet Plant)

Precious Slag Ball Plant

Process: Air quenching of slag which generated from steel making process by means of Slag Atomizing Technology

Characteristics: Superior to sand or Copper Slag on compressive strength, hardness for

Plant Capacity: 0.2 MTPA

• JSW has planned to develop greenery for an area of 517 Acres out of which 287 Acres are

Greenery Development beyond Steel Plant

completed in FY 2015-16.

• 8 km pipeline was laid and 2 intermediate pump houses are erected to cater the water

requirement for the development on the hillocks.

• Treated blow-down water from process (4500 m3/day) will be utilized for the development of

greenery on surrounding hillocks.

Environment Product Declaration

A single, comprehensive disclosure of a product’s impact on the environment throughout its A single, comprehensive disclosure of a product’s impact on the environment throughout its

lifecycle.

JSW Steel Ltd is the first Indian Steel Industry to declare its footprint through EPD

Third Party verification of the EPD report under progress.

Customers will have access to environmental foot print data of the product and can chose for

sustainable product.

The technology is aimed at reducing the LOI of the fly ash from CPP boilers

Air classifier will separate coarse and fine fractions (Cut off fraction is 45µ).

Fine fraction will be sold as product and coarse fly ash with high carbon as aby-product

Capacity of classifier : 40 TPH

Fly Ash Beneficiation

Initiatives Started in FY 16

CO2 injection Objective`:Treatment of BOF recirculation water for the removal of

hardness.

The replacement of Na2CO3 in BOF recirculation water by CO2

0.3 to 0.6 Tons/TLS is required .

Cost of treatment @ 1.0 kg/TCS= Rs. 3.0/TCS

Advantages: Drastic reduction in TDS, water conservation, Wasteminimization

Municipal Waste Treatment • Objective: Minimize the cost of hazardous waste

disposal.

• Hydrological Studies Cost: Rs. 20 Lakh

• Currently sent to landfill of Ramky atDabaspet, Bangalore Disposal cost : Rs.20 Cr. perannum (300 days)

Transportation cost : Rs. 8 Cr. per annum (300 days)

• Objective: Convert municipal solid wastein to segregated dried waste for use asfuel.

• Cost: Rs. 3 Crore (20 Tons/day)• Technology:

Drying, Segregation, sorting, shreddingand conversion to RDF

TSDF Landfill

Initiatives Started in FY 16

Transportation cost : Rs. 8 Cr. per annum (300 days)

MAKING STEEL IS OUR

PROFESSION…

…GENERATING SMILES IS OUR

PASSION