A PROJECT REPORT ON "DISTRIBUTION & TRANSPORTATION" OF JSW LTD SUBMITTED BY AJAY DILIP BHAGAT EXAM SEAT NO:1327257 UNDER THE GUIDENCE OF MS.SHWETA MOKAL & MR .PRITISH HALE CA.CS OFFICE (H.R ), J.S.W.LTD SUBBMITTED TO UNIVERSITY OF MUMBAI UNDER THE PARTIAL FULLMENT BACHELOR OF MANAGEMENT STUDIES FOR THE YEAR 2016 -2017 JANATA SHIKSHAN MANDAL’S SAU.JANKIBAI DHONDU KUNTE COMMEECE ALIBAG RAIGAD -402201I undersigned student of T.Y.B.M. th 5" semester declare that I have done the project on which is personally done by me in the year 2016-17 under guidance of Ms. Shweta Mokal & Mr. Pritish hale (hr Officer), J.S.W. All the data represent sn this project is true and correct to the best of knowledge & belief’ [also declare that project report is my own presentation and not copied from anywhere else (Ajay Dilip Bhagat)eee ee ‘Smit. Indirabai G. Kulkarni Arts College, J. B. Sawant Science College and Sau. Janakibai Dhondo Kunte Commerce College and ¥.S.M College of Arts, Science & Commerce (Junior College) Alibag, Dist. Raigad. Pin : 402 201. (Maharashtra) Principal : Dr. Anil K. Patil (M.Sc., Ph.D.) President : Sanjay Datie Patil Permanently Aflsted io University of Mumbai Inchided under ection 2(9, 12 (8) of he WG Pcp y WAAC wt Ret. No. JSMC/BMS/Certi/16-17/ Oate 98/04/2017 CERTIFICATE This is to certify that Mr. Ajay Dilip Bhagat ‘Third Year BMS. student has prepared Project Report titled “Distribution & Transpotion in J.5.W. Salav” in partial fulfillment of BMS Degree from University of Mumbai for the Academic Year 2011-12. Prof. S. B. Datar Dr. N. N. Shere Co-Ordinator Principal Ms. Sweta Mokal Project Guide External ExaminerLam highly indebted to Ms. Shweta Mokal & Mr. Pritish hale for their guidance and constant supervision as W ell as for providing necessary information regarding the project & also to Mrs. Ashwini Dalvi Mr. Varun Paul & Mrs, Rojarani madam for their support in completing the project. L would like to express my gratitude tow ards my parents Tam also thankful to employees of j.s.w Itd tor their kind co-operation and encouragement which help me in completion of this project. 1 would hike to express my special gratitude and thanks to industry person & to my college for giving me such opportunityINDEX (Chapter | —~—~«&@Parrticular — Page | No: No. : 1 | HisToRY | — 2. | INTODUCTION 7 a 2 "3 MARKET ANALYSIS —_ 5 | 4 | VISSION MISSION ANDVALUE 5 ~ 5 |KEYACHIVMENT = AB 6 |SITEACHIVMENT = _ 19 "7 [BIODIVERSITY — a 20 ~ g [OVERVIEW — : —_ 23 g | AREA REQUIPMENT 24 10. SERVIES,UTILITIES & MANPOWER 26 ll | PROCESS AND PRODUSER ‘31 SSION ANDCOREVALUE 39 13 LOCATION AND HIGHLIGHT a 47 14 POLICIES OF COMPANY - 50 15 BIBLOGRAPHY = - 59HISTORY The erstwhile Welspun Maxsteel Ltd unit at Salav is the latest member of the ISW Group, having been formally acquired on 01 November 2014. The plant takes pride in being the first and the only one of its kind in the world to produce both Hot Briquetted Iron (HBI) and Direct Reduced Iron (DRI) from the same Reactor and today the facility is spread over 80 hectares. The unit was first setup as Vikram Ispat under Aditya Birla Group in 1989 with design capacity of 0.75 million tons of Sponge Iron in the form of HBI. In 1998 an external DRI cooling System was installed to cool the hot metal and produce DRI. This in turn increased the capacity to 0.9 MMTPA.The unit was acquired by Welspun Group in May, 2009 and was renamed as Welspun Maxsteel Ltd. Basic Engineering : Davy Dravo, US (now Kvaerner Metals) Detail Engineering : Davy Powergas India (now Kvaerner Powergas India) Civil Engineering : Bhagwati Design Pvt. Ltd. Jetty and Material Handling Plant Basic and detail engineering : Howe India Pvt. Ltd.INTRODUCTION 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 about 83.2 Mtpa crude steel at present. The per capita steel consumption continues to remain at a level of about 60 kg only, compared to about 250 kg in the developed countries and about 150 kg in some of the developing countries Further with nearly 20% of the world population. India’s consumption is only of the order of 4% of the world steel production. The National Steel Policy 2005 had envisaged steel production to reach 110 million tonnes by 2019-20. However, based on the assessment of the current ongoing projects, both in greenfield and brownfield, the Working Group on Steel for the 12th Plan has projected that the crude steel capacity in the country is likely to be 140 Mt by 2016-17. India is world's fourth largest crude steel producer in 2014 with 83.2 million tonnes (Mt) and is expected to become the second largest producer of crude steel in the world by 2015. IJSW Steel Limited operates a 10.0 Mtpa Steel plant at Vijayanagar, Karnataka based on COREX & BF-BOF-CC-HSM process route which is being further expanded to 16.0 Mtpa.also has cold rolling, galvanizing and colour coating plants at Tarapur and Vasind in Maharashtra The JSW group owns and operates JSW Salem Works, which is the only integrated stee! plant in Tamil Nadu, The plant has a capacity of 1.0 Mtpa and there are plans to further expand the plant to 2.0 Mtpa. The JSW group owns and operates a 3.3 Mtpa Steel plant at Dolvi, Maharashtra based on BF-DR-CONARC-CSP process route. It also has cold rolling, galvanizing, colour coating plant at Kalmeshwar, Nagpur in the state of Maharashtra. The next phases of expansion will take the capacity of this plant to 5.0 Mtpa by the year 2015 and 10.0 Mtpa by 2017. JSW Group has completed the acquisition of Welspun Maxsteel Ltd. which operates a 0.75 million tons of Sponge Iron in the form of HBI (Hot Briquetted Iron) at Salav, Raigad district in the state of Maharashtra. The plant has already received Environmental Clearance for expanding the sponge iron plant from 0.75 MTPA to 1.75 MTPA, with Pellet Plant (4 MTPA), Integrated Steel Plant (1.5 MTPA) & Captive Power Plant (330 MW) at Village Salav, P.O. Revdanda, District Raigad, Maharashtra vide MOEF letter No. F.No.J-11011/183/2008-1A.1 (1) dated 27th January 2011. This unit is renamed as JSW Steel (Salav) Ltd. The process of acquisition & non-availability of Natural gas have delayed the proposed expansion. It is therefore now proposed to expand the existing plant & set up additional units to r 4Nature of Pollution: ties such The steel plant would comprise various production fac as Raw Material Yard, Pellet Plant, DRI Plant, Corex Plant, Electric Arc Furnace, Ladle Furnace, RH-TOP, Thin Slab Caster. CSP, Beam Blank/Bloom Caster, Heavy Section Mill, Medium Section Mill Oxygen Plant, Lime & Dolo Calcination Plant, Captive Power Plant, Cement Plant. The inputs to the above facilities will comprise raw materials/in-process materials along with water, fuel and power These would therefore lead to release of emissions to the air, generation of wastewater and solid wastes. The sources of pollution from the proposed project and the types of environmental pollution likely to occur are summarizedMARKET ANALYSIS General: JSW Steel (Salav) Ltd., propose to expand the existing plant & achieve a 3.0 Mtpa steel making capacity at Salav. In order to arrive at a reasonable product-mix for the plant, a quick desk study based on the secondary data has been carried out and derived in the following paragraphs. Global Steel Scenario: World steel industry experienced growth during the previous years followed by a period of downturn. The fall in demand ts attributed to the global downturn. Some major steel-producing countries and regions showed marginal growth and some showed slight fall in 2014. The, Asia Middle East & North America had marginal growth rates while Europe, South America, Africa & Australia recorded negative growth in 2014. World crude steel production during 2014 was reported as 1,661.5 se on the annual 2013 total of Million tonnes (MU), 1.2% ine! 1,642.2 Million tonnes. Annual production for Asia was 1,132.3 Mt of crude steel in 2014, an increase of 1.4% compared to 2013 World trade in finished steel, expressed as a percentage of world steel consumption is generally about 40 percent. Accordingly,may be expected that total trade in finished steel will be of the order of 450 Million tonnes annually, of which flat products may constitute upto 60 percent i.e. about 270 Million tonnes and long Indian Steel Scenario: India is the fourth largest crude steel produced with a global share of 5.0%. China has a share of 49.5% and India, Japan, USA, Russia have shares of 4 to 6% each. Steel is crucial to development of any economy and the steel consumption is treated as an important index of the level of socioeconomic development. India’s per capita consumption was about 60 kg in 2013, according to WSA and is expected to rise substantially. This is expected to rise to 175 kg in 2025-26 and since the population is projected to grow to 1.43 billion that year, the steel consumption is likely to be around 250 million tonnes. The table below shows the product wise percentage share of steel demand forecast — Rapid rise in production has resulted in India becoming the 4th largest producer of crude steel and the largest producer of sponge iron or DRI in the world. As per the report of the Working Group on Steel for the 12th Five Year Plan, there exist many factors which carry the potential to raise the per capita steel consumption in the country. These include among others, an estimated infrastructure investment of nearly a trillion dollars, a projected growth of manufacturing from Current 8% to 11-12%, increase in urban population to 600 million by 2030 from the current level of 400 million, emergence of the rural market for steel currently consuming around 10 kg per 6annum buoyed by projects like Bharat Nirman, Pradhan Manin Gram Sadak Yojana, Rajiv Gandhi Awaas Yojana among others Import-Export Outlook: Import and Export scenario of flat steel products are going through an unstable phase this fiscal as compared to the last fiscal. Total amount of Flat Steel imported in the country in FY 13 was 4.8 MnT which had witnessed a growth of 11% in comparison to FY 12, which was around 4.35 MnT. However, in FY 14, Flat Steel import has seen a sharp decline owing to the fall in rupee value, slow infrastructure growth and poor demand from automobile industry. On the other hand, Flat Steel exported out of the country in FY 13 was 3.97 MnT compared to 3.39 MnT of FY 12 witnessing a growth of 17%. This increment shows that the country is now producing export quality material meeting international demands. Demand for steel in the country is expected to improve in Q4 FY s projects may 14, owing to increase in construction activities expedite completion before closure of the financial year.Site Location : The proposed units of 3.0 Mtpa Steel Plant is proposed to be set up within the existing plant area. The plant is situated in Salav village of Raigad district in the state of Maharashtra. The site is at a distance of 150 km from Mumbai, and about 45 km from Roha by Road. The location map and the regional map of the proposed site have been shown in the drawing no. JSW/SALAV/PR/001 and drawing no. JSW/SALAV/PR/002 respectively The indicative coordinates of the proposed site are given below: "N Latitudes : 18°31°1” - 18°32 Longitudes : 72°56°39” - 72°57°54” EThe area requirement for the proposed plant has been estimated based on the following factors: + Area requirements of individual technological and service Yr facilities > Smooth and uninterrupted flow of incoming and outgoing materials with minimum counterflow for different technological r facilities. > Logistics in location of technological units as well as services > facilities. > Safety requirements and statutory provisions. + Adequate green belt all around the plant. > Optimum lead for service lines. > Maximum utilization of the land. Logistic approach in location of technological units as well as services with assumption that area is flatTransaction processing: is information processing in computer science that is divided into individual, indivisible operations called transactions. Each transaction must succeed or fail as a it can never be only partially complete. complete unit; For example, when you purchase a book from an online bookstore, you exchange money (in the form of credit) for a book. If your credit is good, a series of related operations ensures that you get the book and the bookstore gets your money However, ifa single operation in the series fails during the exchange, the entire exchange fails. You do not get the book and the bookstore does not get your money The technology responsible for making the exchange balanced and predictable is called transaction processing. Transactions ensure that data-oriented resources are not permanently updated unless all operations within the transactional unit complete successfully. By combining a set of related operations into a unit that either completely succeeds or completely fails, one can simplify error recovery and make one's application more reliable. Transaction processing systems consist of computer hardware and software hosting a transaction-oriented application that performs the routine transactions necessary to conduct business. Examples include systems that manage sales order entry, airline reservations, payroll, employee records, manufacturing, and shipping. Since most, though not necessarily all, transaction processing today is interactive the term is often treated as synonymous with online transaction proc ssing 10Description : Transaction processing 1s designed to maintain a system's Integrity (typically a in a known, consistent state, by ensuring that database or some modern {i interdependent operations on the system are either all completed successfully or all canceled successfully. For example, consider a typical banking transaction that involves moving $700 from ings account to a customer's checking account. This transaction a customer’ involves at least two separate operations in computer terms: debiting the savings account by $700, and crediting the checking account by $700. If one operation succeeds but the other does not, the books of the bank will not balance at the end of the day. There must therefore be a way to ensure that either both operations succeed or both fail, so that there is never any inconsistency in the bank's database as a whole. Transaction processing links multiple individual operations in a single, indivisible transaction, and ensures that either all operations in a transaction are completed without error, or none of them are. If some of the operations are completed but errors occur when the others are attempted, the transaction-processing system "rolls back" all of the operations of the transaction (including the successful ones), thereby erasing all traces of the transaction and restoring the system to the consistent, known state that it was in before processing of the transaction began. If all operations of a transaction are completed successfully, the transaction is committed by the system, and all changes to the database are made permanent, the transaction cannot be rolled back once this is done.ing guards against hardware and software errors that might leave Transaction proc a transaction partially completed. If the computer system crashes in the middle of a transaction, the transaction processing system guarantees that all operations in any uncommitted transactions are cancelled. ed concurrently. If they overlap (i.e. need to touch the Generally, transactions are 18s same portion of the database), this can create conflicts. For example, if the customer mentioned in the nsfer $100 to a different person while at the same time moving $100 to the xample above has $150 in his savings account and attempts to tra checking account, onl: processed sequentially is inefficient. Therefore, concurrent implementations of y one of them can succeed. However, forcing transactions to be g is programmed to guarantee that the end result reflects a transaction processin} ecuting the transactions conflict-free outcome, the same as could be reached if exe izability). In our example, this sequentially in any order (a property called seria means that no matter which transaction was issued first, either the transfer to a different person or the move to the checking account succeeds, while the other one fails.Responsible Supply Chain : An effective supply chain management ensures uninterrupted business activity and flexibility. ISW Steel key elements of supply chain include, (i) procurement of key raw materials like, coal, iron ore, lime stone, dolomite, coke etc. (ii) transportation of raw materials (iii) procurement of support services. Raw materials are procured from within the country and also from outside. JSW Steel use ship, rail and road transportation. Also, the company has been able to achieve, reduction in logistical footprint by making conscious efforts to increasingly shift to transportation of raw materials and products within India by rail. In FY 2014-15, about 83% of all goods were transported via rail, as compared to 76% in FY 2013-14. IJSW Steel's code of conduct and our policies related to work conditions. human rights, environment, and safety, are applicable to our suppliers. These form a part of our contract with our suppliers and suppliers from time to time are made aware and assisted in complying with these requirements. Our supply chain audits will have to be further complimented with stress on EHS. Labor, Human Rights and Societal Impact aspects. Supplier engagement, in the form of interactions and supplier meet, is carried out at JSW Steel. JSW Steel is sensitive to possible impacts of our supply chain on environment society and economy, and take preventive actionsIJSW Steel identifies service providers that potentially could engage in unfair labor practices and monitoring, evaluation of such suppliers, regarding issues related to labor practices including human rights, is made rigorous. During the reporting period, there were no penal actions or notices by relevant regulators, for violation of labor practices in the supply chain. JSW Steel ensures that its suppliers deliver goods and services as per contract and are paid, as in contract, on time. in turn, e value for local economy and to create positive economic impact, ISW To generat Steel engages with local suppliers. ‘JSW Steel is in the process of setting up a mechanism to define capture and track the extent and type of local suppliers. Presently, JSW Steel identifies and builds capacity of local suppliers, before and during the engagement with them.ion, Mission and Values SW") believes in creating sustainable growth while balancing ISW Steel Limited (. utilization of natural resources and social development in its business decisions It also believes in pursuing its business objectives ethically, transparently and with accountability to its stakeholders across the value chain. JSW is committed to promote integrated responsible behaviour and value for social and environmental well-being. JSW’s commitment to do business responsibly is built into the core values of the Company to conduct every aspect of business responsibly and sustainably + A dynamic leadership + Adherences to core values + A well-articulated Enterprise Risk Management framework. * Practices that seek to sustain and enhance the long term competitive advantage of JSW with care for the society and environment.Corporate Citizenship at JSW : Regular engagement with different stakeholder groups forms an integral part of s al part of our pusiness strategy. With best of our efforts, we strive towards transforming our s trans Du stakeholder engagement into an active two-way dialogue. We strive to be a responsible corporate citizen and conduct our business with this aim in mind. Our policies are based on the ideology of maintaining transparency and in the Management and Board dealings. Our executives contribute to the openne: ideologies and work towards embedding robust corporate governance principles in their practices. Cutting edge technology combined with our application and customer service skills help us to create value for all our stakeholders. With growing scarcity of primary and non-renewable sources of energy, we are striving to minimize our energy consumption through process optimization and energy conservation initiatives while deploying new technologies. Since inception, we have consistently aggregated competencies from diverse cultures, educational backgrounds and domain experience with a singular objective: e reinforced this focus through an institutionalize nufacturing to holistic personality followed by to accelerate growth. W d multi- hierarchical training extending from steel ma development which commences from day one of employment, specialized trainings at regular intervals. andards for the safety and wellbeing of our We strive to maintain the highest st during day-to-day operation: s. Our employees which minimize injuries and casualties ning programmes to instil the concept of safety team conducts regular trai 16y safe operations g ees, educate them maintain fe operations among our employees and to educat in rate them on the safety norms and procedures to be followed in case of any incident ‘The JSW group believes in the policy of ‘People First’ and the object : a jective of our activities 1S 10 make a tangible difference in the lives of the people in th ; : 1e areas surrounding our operations. As a responsible organization, we are committed 1 woe e “ete investing a minimum of 2 percent of our PAT towards community development Employees are encouraged to contribute upto 40 hours towards community development activities per employee per year. Promoting on a wider platform The JSW Earth Care Awards is aimed at highlighting action of direct relevance to tackle challenges posed by climate change. The award extending over SAARC region is for excellence in climate change mitigation and adaptation. JSW is fundamentally committed to sustainable business and the 9 principles of National Voluntary Guidelines on Social, Environmental and Economic Responsibilities of Business Limited reporting on GRI framework ass\ 2005) on International Standards for Assurance Enga f these principles are Board approved a d 3 Executive Directors is oversee (NVGs) it has been pursuing in spirit while at JSW Steel ured by third party independently (since FY ements (ISAE) 3000. The policies in the context 0! nd a Committee of Board comprising 3 Independent an ing the same. quarterly, CSO structure implements the sustainability oversight reporting. All of us at the JSW Group are committed to live by these tenetsKey achievements: Prime Minister's Trophy JSW Steel is the only integrated steel plant in the country to produce ten million tonnes from a single location. In addition, it has been producing over 1,700 MW of power and close to 0.5 million tonnes of cement.ite Achievements ; anagar Plant won the prestigious P: rime Minister's Trophy for excellence in performance of Integrated Steel Plants for the year 2012-13 CIFEXIM Bank Business Excellence Award - 2014, awarded by th awa y the Confederation of Indian Industry (CH) Commendation Cenificate Significant Achievement received on November20, 2014 for CILITC Sustainability Award 2014: Awarded Commendation Certificate for Significant Achievement received on December 19, 2014 IMC Ramakrishna Bajaj National Quality Award 2014: Won the IMC Ramakrishna Bajaj National Quality Award in the Manufacturing Category award received on March 20, 2015 Salem Plant has won Second prize in IIM Sustainability Award under the Alloy Steel category. Salem Plant has won Gold Trophy from ASSOCHAM for the Best ITI Skill Development through PPP Scheme in India.Bio Diversity : Manufacturing operations of JSW Steel do not cause any significant negative impact on biological diversity. JSW Steel expects its suppliers involved in mining and similar operations, with potential impact on biodiversity, to be compliant with applicable laws and take due care of biodiversity. In addition, JSW Steel undertakes activities in and around our manufacturing sites to conserve, preserve and enhance the biological diversity We are signatories to the India Business & Biodiversity Initiative. 20qhe Vijayanagar Works has implemented a plethora of initiatives to enhance the biological diversity in its Reighhourhood me of these include setting up a biodiversity park containing medicinal plants on he WON red-hst [Le , endangered species}, treating the sewage from the township the using root zone treatment with the help of select plants, undertaking watershed ement programme in the neighbouring villages resulting in multiple crops and gnagen y the Works area aproving agricultural yields, extending the green belt in and around the Works a and township, and many moreTeam Achievements International Convention on Quality Circle Chapter (ICQCC): Gold A: Innovator Quality Circle Team” from SMS-II received on October oma, Sri Lanka. , “ National Convention on Quality Circle (NCQC): Three teams (Innovators - SMS-2, Janani-BF3, and Abhimanyu-BF4) were conferred with Par Excellence award, which is the highest honour in the category and one team (Sarthak-Coke Oven) was adjudged excellent award, the second highest honour and was received on December 22, 2014 at Pune. Chapter Convention on Quality Circle (CCQC) All the teams (Innovators — SMS-2, Janani-BF3, and Abhimanyu-BF4, Sarthak ~ Coke Oven)were conferred with Gold award on September 7, 2014 at Bengaluru. ISW Steel Ltd., Salem Par Excellence Award from National Convention on Quality Concepts for Six Sigma projectOverview 7th Earth Care Awards 2016 Awards for Excellence in climate ch ange Mitigation Adaptation Earth Care ¢ Dr Raghunath 22, 2016, the Earth Care Awards Jury chaired by Dr Rag wn eid 4 applicants (out of the 273 this year) worthy of the awards. Mashe} pplicant from Bangladesh has been confirmed for a ‘commendation’. One a| is proud that its effort has found national and international acceptance as many Be industry and civil society peers are filing their applications senior stry ory in i y ‘Leadership in Urban Climate v categ ‘oduced this year. namely “Lea : Wad eran popular among urban municipal bodies with many corporations Action’ ha: competing this year.Area Requirement: ‘the area for the proposed plant has been estimated as 3809 acres. Apart from technological and Service units, raw wat er storage, green belt as per statutory requirement, etc. have been included in area estimation. The area requirement for the proposed plant has been minimized since the infrastructure and auxiliary facilities are already existing Special attention has been made to provide connectivity to the existing facilities viz. utilities, raw material corridors, etc The general layout of the proposed site has been shown in the drawing no. JSW/SALAV/PR/005. Logistics: The raw material is proposed to be transported to site by waterways which will require to be further upgraded. It is proposed to expand the existing Jetty to suitable length and connect it with covered conveyors to the plant.Road: ‘The Nationa phwa The National Highway NH-17 (Mumsba-Coay 9 jae about 50 km from the plant. St ay also Passes on the east Ay also passes on the west side of the plant. Mumbai City is located at about 150 ki Z m ate Highw: on the North-West side of the plant, The Road linkage of the proposed site is shown in Drg. No JsW/SALAV. Railways: ‘The nearest railway station Roha is about 50 km from the plant site and is located in the east on the Konkan Railway Mumbai - Mangalore main line. Rail linkage from plant site has to be established. Air Connectivity: Nearest airport is 150 km away at Mumbai and is connected through major roads. The proposed Navi Mumbai International airport is 90 km away from plant site. Water: The make-up water for the proposed plant is about 16 MGD.SERVICES, UTILITIES & MANPOWER REQUIREMENT General: pesides raw materials, other major requirements of the Proposed «tee! plant are water, power and fuel. Corex gas & Natural gas will be used to meet the demand of fuel of different consuming units The power demand of the plant will be met from the proposed power plant. Power System: The total power requirement of the proposed steel plant is about 330 MW which shall be met from the proposed power plant of capacity 330 MW. From the main receiving and step down station of the plant, power will be stepped down to 33 kV to feed to the various plant load centers. These load centers will have provision to step down further to 11 kV/6.6 kV and 415 V for distribution of power at required voltages. Necessary power compensation equipment and harmonic filters will be provided to take care of the fluctuating load of EAF shop and casters. For all 220 kV, 33 kV, 1 kV and 6.6 kV supplies, centralized Supervision, monitoring and emergency control system will be adopted.water System: he total water requirement for the steel plant and captive power plant with township will be about 16 MGD. Raw water treatment plant will be installed for pretreatment of raw water and the clarified water will be pumped through MS pipeline to the proposed units. ‘The different categories of water to be used in the recirculating system are: a) Demineralised (DM) water for closed recirculating cooling systems. b) Soft water for closed recirculating cooling systems. c) Indirect cooling water (ICW) for secondary cooling of the water-to-water heat exchangers of the closed cooling circuits. 4) Direct cooling water (DCW) for gas cleaning circuits, slag granulation, open machinery cooling and scale flushing. e) Make-up water & service water for captive power plant. For conserving water, independent recirculating systems have been proposed along with cooling towers, pump houses and treatment units. Make-up water for different process units will be made available from main plant make-up water ring main and will be conveyed to Fespective cold wells of various recirculating systems and storage Teservoirs, 'n order to combat industrial pollution and to comply with Suidelines laid down by the statutory authorities, suitable ‘reatment units and neutralization pits will be provided to controlater pollution m different water system ut le by making — of bleed water from cooling tower and other effluent water for gust suppression. Waste water gencrated from different areas of plant will be treated 10 the desired extent and recycled in the recirculating eystem aS far as possible, facilitating adequate reuse of water plackwash water gencrated from different pressure filters will be treated 17 8 treatment plant having sludge disposal facilities. The treated water will be reused in the direct cooling cireuitwee" owen re ng. secondary refining units of steel melting shop, cutting ating: § 99.5% purity will be required for EAF blowing and in the casters and other general purpose use in v; io ation | arious of ats ofthe ste! plant ons nitrogen , Nitrogen will be mainly required for gas cleaning, gas line purging nd general PUTPOSe applications. a Argon: {ygon willbe required for bottom blowing in the EAP, processgas- refining in secondary steel making units of SMS, and shrouding in the tundish for continuous casting plant and for hottom purging in LF. Argon will also be needed for laboratories Compressed air system: Requirement of compressed air will be provided by Central Compressed air station with piped compressed air to the different consumption points.chilled Water System: chilled water is required for air conditioning of contro} rooms, a various areas of the steel plant, Two vapour compre ete, it . SiON type chilled water plants will be provided, Water inlet and pe . outlet temperatures of chiller plant will be maintained at 16 oC and Joc respectively. Gas Systems: The by-product gases will be wilized for heating and burning applications in different sections of the steel Plant. Available gases, after meeting the above applications may be utilized for steam and power generation. Plant Automation: Ithas been envisaged that Level-1 and Level-2 automation systems will come along with the various equipment/facilities to provide process and equipment level control including supervisory automation functions. In addition, higher-level computer system will be provided to cater to the needs for Production Planning & Control (PPC) as well as Management Information System (MIS) for the whole plant. The Centralized Production Planning & Control system will be Provided for overall and area/shop wise production planning. This System will be interfaced to the automation systems of various Plant units through suitable gateways to enable downloading of Production t fi largets and uploading of production and consumption ures. The Management Information System will provide Recessary information about the plant and other administrativeP . ROCESS AND PROCEDURE Jant is desig) i i rhe HYL II] plant is designed with two independent sections: ¢ : Ss: One generatin ig the ;_q gas and the other for reduc : reducing 2 luction of iron oxides. Th ” fe reducing gas jon s n consists , generation section consists of natural gas - steam reformer and related and related equipment Reforming reaction takes place at high temperature in high-alloy tub -alloy tubes packed with nl the reactor. I temperature flow upwards as countercurrent to the descending moving bed of g iron ckel-based catalyst. In reduction section, Iron Oxide is reduced to I 0 Iron in in the Reactor, which operates at pressure, the reducing gas at high ; ig oxide resulting in reduction of iron oxide. The reactor exhaust gases are cooled quenched, mixed with makeup reformed gas, de-carbonated and sent back to Reactor after heating. The hot direct reduced iron from Reactor is continuously fed in either to the briquetting machines or to the cooler. In the briquetting machine briquettes are formed at high t hot briquetted iron. In the c lemperature and pressure. This results in highly dense and compact ooler, circulating gas till it attains near ambient temperature for safe storage cools direct reduced iron. JSW Steel (Salav) Limited is the only plant in the World where ¢ Both HBI and DRI are produced from the same Reactor. e Zero Power from Grid for total complexCommunication System: Fjephone system will be provided for communication inid eas well as outside the plant. Telephone system shall comprise on; one ironies Private Automation Branch Exchange (EPABX) of Ele ciated cable network along with required line capacity and press-to-talk system, CCTV. VHF wireless system as required. Maintenance Facilities: and maintenance facilities will be centralized to Repair And The plant repair take care of routine repair and periodical maintenance work. Major repairin, sembly of heavy and critical jobs of specialized nature are works involving machining, fabrication and a envisaged to be contracted to outside agencies. Warehouse: ‘A central warehouse has been provided to keep spares of. equipment, hard-wares and consumables. For storing various ferro-alloys and refractories, separate buildings have been envisaged. Ferro-alloys will be received by road trucks in bags/boxes. Refractories will be received in pallets and in bags. Ancillary Facilities: Necessary ancillary facilitie: e building, ch as administrativ canteen, car park, first-aid station etc. shall be additionally provided based on the manpower requirement for the plant.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. 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. The natural drainage nallahs have been left undisturbed. Roads: Adequate plant road system has been provided considering the types of vehicles and traffic volume. The road system has been be designed to minimize cross movement of vehicles. Adequate vehicle parking facilities and road weighbridges will be provided and new roads constructed wherever necessary.fanpower™ Requirement: M tee! plant will not only require management The * and executive manpower but also, skilled, semi-skilled, unskilled and clerical npower- However, a number of jobs like major repair and mal naimtensaTnces cleaning, transportation and loading/unloading of bulk materials, etc. will be done by engaging out side agencies The requirement of total manpower is about 1,800 persons for 3.0 Mpa capacity The above number covers the top management, middle and junior jevel executives and other supporting staff. The above manpower excludes the manpower required for outsourcing of repair and maintenance jobs of the entire plant and also does not cover the personnel for township, medical facilities, etc. The category wise break-up of manpower is indicated in table Category wise break-up of manpower |. Managerial 40 2. Executive 150 3. Skilled 550 4. Semi-skilled 620 5. Unskilled 400 6. Clerical 40 Total 1,800ENVIRONMENTAL MANAGEME a proposed units of steel plant would result in air, water and - pollution of varying nature and degree. This chapter briefly stlines the nature and sources of pollution and also suggests wo d environmental protection measures to be adopted for jimiting pollution within permissible levels. imitingPollution Prevention and Control Me: ‘asures : siderati above states consideration of the above stat -d pollution potential of th e In ee : suitable mitigation schemes are envisaged inte; rated steel plant, in order to cont rol environmental pollution within the permissible norms and keep the environment fairly clean : Design Targets: pollution control measures would be designed on lowing criteria: ironmental monitoring of k zone air quality, noise level and waste water ind surface water stream will have to be carried .d data would be recorded and nece: sary plemented to ensure that design targets y non-compliance of Statutory ‘& environment protection rules laid plant facilities The proposed the basis of the foll stack emission, ambient air Routine env’ quality, wor receiving pond al out. The monitore corrective measures im] are maintained and avoid an Regulations. The guidelines down by MoEF shall be adhered to for thwoise Level Management: f The following measures will be undertaken to reduce e Noise and i ts. impact s equipment will be placed on rubber bushes to reduce Nois: e level at 1m distance to 85 dB(A). «Sound proof enclosures will be provided to operators in high poise ZONE- Workers will be provided with ear muffs/ earplugs and the duration of exposure of the personnel will be ulated as per applicable norms. regl Jar check-up of workers for not «Regu! and if dete ise related health problem cted alternative duty will be provided Plant safety: Plant safety mes asures would form an integral part of the an of the proposed plant. W of concern so as to avoid any dent. In-build safety ade adequate In he life and environment protection pl orkers* safety would be of highest degree form of personal injury oF untoward acci machinery would be m: features of the plant and causing damage to th order to avoid hazardous events Property.Greenbelt and landscaping: Adequate space would be cre: ‘ated for garden ardening and tree tations to dovetail with the existi plan xisting greenbelts. Tt 's. This would he fugitive dust emissions. Unpaved areas, if an} s Unpavi a Yy, within the plant boundary would be provided with grass cover. This would no! plant aesthetics. t only act as ‘lung space” but would also improve th e General: Implementation of the Steel Plant is a challenging task and calls inning, scheduling and monitoring to realize the for meticulous pla ime frame. A highly experienced team project goals in budgeted t is available with JSW to implement the project. Schedule: The implementation schedule for installation of the proposed Steel in the drawing no. Plant is indicated in the form of bar chart i ws that from the JSW/SALAV/PR/006. The overall schedule sho ct (Zero date), the complete p The schedule as presented i ntation logics for Steel PI Jant will be date of start of the proje is based commissioned in 24 months. ant, upon conventional project impleme le and in-house experience. preliminary vendor information availabl as been conceived. considering the The schedule of 24 months h ery schedule of simt 38 existing practices and deliv lar plants.VISION, MISSION AND CORE Vata 2 VALUES , anvisages @ self-reliant In sW envisag liant India. In our aim to becom lob: '¢ global lead: lers in every S rand to make core sect India a technological and infrastructural ictural force 1 0 reckor with, we are committed to our vision and values. vi 1SION: Global recognition for Quality and Efficiency while nurturing Nature and S and Society MISSION: Supporting India's growth in core economic sectors with speed and innovation CORE VALUES: e Transparency e Strive for Excellence e Dynamism e Passion for learningei) cS eet) Quality & Quantit Information Cost & Delivery & Speed Innovations & ec. Intellectual Cap: ‘cli balladad Productivity & Prid Market& People rs Bue ual pases Quality ene aca Shareholder’s V™ 40SWOT ANALYSIS OF THE ¢.sTRENGTH It is the first plant in the Hot Briquetted ORGANISATION world to prox Produce Direct Reduced ron (DRI yand Iron (HBI) using single reactor. DB ses Z wer fi i 2, It uses zero power from grid for total complex and prod: and produce its own electricity. 3. It has well equipped jetty. 4 W-WEA we steam whi The st hich comes out from power generation turbine is used for other process turbine therefore ensures less wastage of steam. Brand Name. Employees stay in the nearby colony therefore there is no travelling stress Bow oN ESS More time is taken to start the plant to More monitoring and data is req . The company is certified with the following ISO certifications. 1% ISO 9001 2000 ISO 14001 1996 OHSAS 18001 1999 SA 8000 produce the product (around | week) . More time is taken to safe stop the plant. uired to maintain the quality! process, 4orrORUNITY : 1. Integrated steel plant ibe established fi. reduce the product gost and ii, overcome flexibility in steel market. 2, Full utilization of jetty for commercial and various other purpose. 3, Putting up pelletization plant which will help to produce pellets from iro s n ore thus reduce the overall economics. J-THREATS 1. Lack of natural gas availability according to the plant requirement 2. Fluctuation in the global steel market. 3. Heavy rains because of geographical location which is unfavourable for the plant. 4. Dusty atmosphere.Rector Exhaust : Reactor exhaust reducing [ asses thi e reduci gegree € and passes through the reducing gas heat exchanger (wh recovered to preheat reducing gas going to the process aera er energy is ching /scrubl systet are ‘aS heater) and then to quenching /scrubbing system, There, water produced during the te : s is condensed and removed. Also most of the dust carried with th oe z ith the g eaves the reactor at 380 eliminated. as is scrubbed gas stream containing carbon Dioxide (C\ The Sed Gas also having 8% Carbon Dioxide TeTRISReo hee Remugh COZ removal system ie. Absorber having paisa oleae countercurrent flow of G.V solution. The G.V_ solution, mainly ies i Carbonate (K2CO3 removes the Carbon Dioxide from the gas stream by Gemical absorption. The CO2 rich K2CO3 coming out of Absorber is passed to L.P and H.P regenerator towers where CO2 is stripped off and solution is teeireulated. Part of stripped off Carbon Dioxide is used to produce Liquid CO2 eit Dry Ice. The capacity of Liquid CO2 plant is 100 MTPD and of Dry tee is 14 MTPD. Decarbonated reducing gas leaving the absorption column is preheated to 80 degree C in regenerator interchanger by CO? gas and then to 135 degree C in DCG preheater by L.P. steam, mixed with process natural gas (for HBI carbon content control) and the gas mixture enters the reducing gas heat exchanger & then process gas heater, thus closing the reduction circuit. 2, REDUCTION TOWER: The reduction tower includes the Reactor and the Charging and Discharging systems. Iron ore pellets, lump ore or mixture of both, are transported by conveyor systems to the top of the reduction tower. An automated system of bins and pressure locks allows receiving the feedstock at atmospheric pressure in an open bin, pressurization in an intermediate bin and discharge into a feeding bin, which continuously feeds the reactor. Oxygen removal from the iron ore / is accomplished by the reaction of hot reducing gases and also the product 's carburized. a3Rotary valve. located at the bottom of the react, ity flow of the reduced DRI at 700 degree © down eilMe® the continuous ‘As thro the Ce pri from reactor bottom is sent to either the DRIc a ie he Reactor . OF to the Briquetting be Hot DRI is sent to Briquetting system by aes Briquetung avs a ech isting of Pressurized Bins, Atmospheric Bins and a set of solid sr rube Plug Valves. Hot DRI at 700 degree © 4s pressed in and ut off valve Briquetting The compacted Briquettes are quenched in vibrating cooling conve: pes qed to yard through product conveyors pransportes roducing DRI, hot DRI discharged from Reactor bottom is divened For P' soler, Circulating Natural Gas Cools DRI to 40 degree C Cold DRI prio hthehelpof yigcharged.wit 44ated mechanism, t0 Pipe Conveyor from where it 4, transported to DRI ome a shed pri Screening harge Reactor ts in line, a separate charging system feed the tron e cold disc! sto the vides 1 orated at bot incorpor™ arge Reactor, Cooling arrangement of hot DRI has by om part of the Reactor, A Rotary valve, located at the bottom egulates the continuous gravity flow of the reduced cold DRI and of the a een automated discharge system to Pipe Conv discharged OY ot from ported to DRI shed through on - line DRI Screening Station e it is trans where tt first in Reactor operation arrangement is first 1 n This TW the world,LOCATION HIGHLIGHTS situated close to the historical Revdanda Fort and scenic b paigad. the plant is ned by lush green vegetation. aa py Sala village, there iS 4 well furnished township for employees and mike & beaches: Higher secondary school, affiliated to C.B.S.E. board and a eee a ‘ospital pARTICUL DETAILS | | Latitude 180 31° 31.16” North Latitude \ Longitude 720 5717.74" East Longitude | Elevation above MSL | 25 ft above Mean Sea Level | Climatic Conditions Annual Maximum Temperature : (As per IMD) 40° C Annual Minimum Lemnerature ~ 10° C Nearest Highway NH- 17 (45 km in East direction) | Nearest Railway Station Roha Railway Station (35 km inSE | Seismic Zone Zone -IV __H > @ acum wow wou glee 5 [e saecops 3 Magnet Sede SS. ~ Cogn! LE Compre ana Linked pe ARYo Mumbrs Te Domb ral RAIGARH (Maharashtra) aphid BR? | \ ROR AS aae — Demstsorany y Beast aa \ ae arene tharere cone? Y \ a pu i rn f wegmer/ . : CY ¢ o oO em or 4 whic, ireapur | a JivjaeMure¢ Seach) QS kusa “Ss Roar Bg Manggen Ravia ? as NS again @ . te taka ee peal Panchaan® er \ bin, §8 Danette s Bia Swe © [aprssoaet! wate 5 eo enum ~ “ } our x \ \ ce. ames 49POLICIES OF THE COMPANY av) Limited is comm: ited to deliver values to all all its Stakehold& lers by wsteet(Sah : supplying £88 based HBI(Hot Briquetted Irony/DRI (Direct R ect Reduced tron) oducts as per customer's requirement P e Ti requirements. mely compliance to all applicable Legal Statutory and R, ~ and Regulatory Complying t© Social Accountability standard requirements with th s he Involvement of all employees. ing to bring in Continual improvement in all its performances Strivi with focus on technological changes and Innovations. Adopting Group Code of Conduct,upholding ethical business practices and respecting employees. g of Pollution and Conservation of energy and other natural Preventin resources to protect environment Ensuring improvement in Health, Safety and Education of the employees, contractors and neighboring communities. ivated and competent employ: « Building a team of mot ees through continual training.= a FUTURE PLAN FOR GROWTH oF ORGANISAT SANISATION the amount of Natural Gas which is the basic Faw material for the production will be increased or will search for Some alternative Integrated steel plant will be established to reduce the product cost and flexibility in steel market. jetty will be fully utilized for commercial and other Purposes. DRI capacity could be increased from 9,00,000 tonnes to 16,50,000 tonnes. Company is planning to use coal which can then used to produce gas which will help to replace almost 40% of natural gas requirements. . Putting up pelletization plant which will help to produce pellets from iron ore thus reduce the overall economics.1. trainin a . Preparation of . HR arranges/organise training programs . Ifa lecture/training is not taken TRAINING MEASURES performance Appraisal system is main source for th i identifi ; ae identification of the Training need identification form is sent along with th en 1 appraisal fe the beginning of the year to each department. “ene Head of department of each department identifies training needs of eeds 0 personnel to be trained based on the competency requirement and ret return the filled form to HR. Training need identification at any time as a preventive action during root cause analysis is also communicated to HR. g needs and identify the trainer(internal/external) erson(DH & FH) and prepare training HR compiles the trainin} in consultation with concerned p! calendar on yearly basis.(July to June) monthly Training calendar after co ry and distribute the same to all ( nfirming the original dates given by the facult intranet) with hard copies to notice boards by the HR. according to monthly training calendar. The information is circulated to all 2-3 days prior of the scheduled training dates. ducted. Attendance of training is maintained as and when it is con place on a scheduled date, it will be xt/subsequent months of the training formed to all including the rescheduled on that month only or ne calendar year. This rescheduling will be in gh a prescribed form. faculty and concerned HOD throuster feedback form 0. admint ck form are taken trom the Participant ts al the e1 end of the training program 6 months of training. 11. After Ining. post assessment of trai ‘aining is IS prescribed 1 to HR from concerned HODs. > For all new . . a resp OD's in consultation with top m ni | prepare induction training schedule as per requirement — quirementsoC IDENTIFICATION OF TRAINING NEEDS DATE: sUMMARISE HIS STRENGTH AND WEAKNESSES A)e ‘ dL LLHAT Eee a PROGRAMMES CouLp HE BE p)* NATED ? MI NGNEED Contents, \ Duration Name of Training _ ae — \ ONAL TRAINING NEED BASED ON MULTI SKILL I FUN MENT & JOB RELATED assESsMEN Type of Training | Name of | Duration | | Name of Contents | (internal / Faculty | | we | External) 1 |eb joral Training needs and functional needs are as follo ws gehavioural raining Need : Effective communication. Leadership skill. Negotiation skill. personality development. Team Work. Self confidence. Interpersonal relationship. Supervisory development training. 9, Positive Work Attitude. 10. Time management. 11, Work Management. sm OauUeene 2. Technical Training Need _ Productivity Improvement. Electronic & Electrical. . Technical program on welding tech Menard Operation sequence technique. 5. Design of experiment 6. troubleshooting 7. 8 I 3. niques. 5 4. . Administration Training. Computer Proficiency 9. Documentation 10. Quality Circle 11. Up to date knowledge 1 !2. Sales AC & finance 13. Induction Trainin n statutory & legal mattersgapine s GRAD Fxecutiy B C 1. Ma 2 Management Category: ! ; un category: H to HI 8 . Union-Workmen Category’ 4. A ‘1 a completing the GE cutive’ 12 to L grade TEM FOLLOWED - | Pos | Vice President t Aue. Vice P - | General Manay DG Manage Dy _GETraine Management Traine: Asst. Engineer Asst. O Jr, Engineer Jr. OTF | Sr. Technician St Ops Technician Operator Coos ete Jr, Technician J Attendant Security Guard Ce r Operalor Securit rok stoG grade 1 Trainee and GE T gels theG the Manageme”ORGANISATIONAL STRUCTURE 58v = tions of IT Department: yu re th function f ensure SMO! oning of CCTY x, | : CTV Network ensure smooth functioning of IT Ie BOTT equipments Jo ensure smooth functioning of SAP and avoid and avoiding unauth 2 unauthorized To establish and maintain a system for upkeep Of Information S ystems, functions of Fire and Safety Department: |, Provide procedure for conducting mock drills of emergency Prepared Y preparedness factory and ensure its compliance with emergency plans. To establish a system for accident prevention, firefighting and rescue in order to minimize the loss in the event of accidental fire and explosion. To establish a system for dealing with emergency situations to minimize haz: to human health, safety of mankind, property and environment idental and explosion. Function of Material Handling Department: during storing and loading of finished product |. To establish methods of handling of handling the material during raw material feeding 2. To establish methods (reclaiming and day bin feeding). ! cking of raw materials 3. To establish methods of unloading and stacking of raw maletio” of Quality and Environment Control rol De Partment: To establish a system for control, caliby » CaliDration. inspec product conformity to required specificat ion. tion, measuring and test e and maintenance ‘quipment used in the a © process to ensure € a tablish methods to 3, Toe ensure that the product conf forms to the specifi pecified requirements: Function of Production Department: 1, To establish methods of control over the process 2, To establish and maintain a system for production planni ing. 5) To establish a system of ensuring control measures during the pr 2 acess of manufacturing HBI/DRI to specified requirements. 4, To establish methods of control over the process of reforming of natural gas with steam. 5 i 5 To establish a system of ensuring control measures during the process of manufacturing HBI/DRI to specified requirements using twin reactor. suring, control measures durin: 6. To establish a system of enst 1g the process of Tunning the utility sections. ig Department: Funeti , ction of Distribution and Marketin stomer quality © ive handling of cu exact require omplaints. le 7 To establish a system for effect ents of the 2 To establish a system for the review of uirements can be met. Cust tomer and whether these req 60BIBLIOGRAPHy. 1, Books: 1, servies marketing (rishabh shabh publication) - | ~ LM pandey 2. E-commerce and digital marketing (H.P.H)- MN. -MNaarora 3. Seales and distribution (Seth Publication) - 1.N chy - LN.chopde 1 Websites: www.jswitd.com www.google.com www.investopedia.com www.marketingi form jent.org 3, ANNUAL REPORT OF JSW LTD: 2011-12 2012-13 2013-14 2014-15 2015-16 ol