Orissa State Pollutin Control Board

Industry Statistics

Major Industrial Areas/ Zones in

Major Industrial Areas/ Zones in Orissa

Sl.	Area	Type of Industries
1.	Rourkela–Rajgangpur	Iron and Steel, Sponge Iron, Cement, Secondary Steel Melting and Rolling Mill, Refractories, Chemicals and Engineering
2.	Ib Valley and Jharsuguda area	Thermal Power, Sponge Iron, Refractories and Coal Mines (Aluminium, Coal Washeries)
3.	Hirakud	Aluminium, Rolling Mill
4.	Talcher – Angul	Thermal Power, Aluminium, Coal Washeries, Ferro Alloys, Coal Mines
5.	Choudwar	Ferro Alloys, Thermal Power, Pulp and Paper, Coke Oven
6.	Balasore	Pulp and Paper, Ferro Alloys, Rubber Industries
7.	Chandikhol	Stone Crusher, Coke Oven
8.	Duburi	Integrated Steel, Ferro Alloys, Mineral Processing
9.	Paradeep	Fertilizer, Sea Food Processing, Petroleum Coke
10.	Khurda – Tapang	Stone Crusher
11.	Joda – Barbil	Pig Iron, Sponge Iron, Ferro Alloys, Iron Ore Crusher, Mineral Processing
12.	Rayagada	Pulp and Paper, Ferro Alloys

Currently 2754 industries in large, medium and small scale are operating in the state and a sectoral analysis of industries is presented in Table 2.2.

TABLE: 2.2

Sector-Wise Industries Operating In Orissa

Sl. No.	Sector		No. of Industries
Sl. No.	Sector		Large	Medium	Small	Total
1.	Iron and Steel
	a.	Integrated Iron and Steel	01	--	--	01
	b.	Pig Iron	03	--	--	03
	c.	Sponge Iron *	82	11	--	93
	d.	Ferro Alloy Plant	07	03	01	11
	e.	Secondary Steel Melting Like Induction Furnace etc. (Stand alone)	06	35	03	44

*Out of 93 Sponge iron plant 13 plants also have steel making facilities through DRI-IF/EAF route.

Sl. No.	Sector		No. of Industries
Sl. No.	Sector		Large	Medium	Small	Total
	f.	Rerolling Mills and Others and Reheating Furnace	--	20	21	41
2.	Aluminium		02	--	--	02
3.	Pulp and Paper		04	02	--	06
4.	Sugar		04	01	--	05
5.	Fertilizer		02	01	--	03
6.	Thermal Power		10	--	--	10
7.	Cement		07	02	01	10
8.	Fermentation Industries
	a.	Distilleries	02	--	01	03
	b.	Breweries	02	--	--	02
	c.	IMFL Bottling Plant	--	07	--	07
9.	Chemical Industries
	a.	Chloro Alkali	01	--	--	01
	b.	Bulk Drugs	--	--	01	01
	c.	Dye and Dye Intermediate	--	01	--	01
	d.	Pesticides	--	01	02	03
10.	Mineral Processing and Crushers
	a.	Stone Crushers	01	05	918	924
	b.	Chrome Ore Benefication	02	02	25	29
	c.	Graphite Benefication	--	01	25	26
	d.	Coal Washeries	01	03	--	04
	e.	Iron Ore Crushers	04	97	75	176
	f.	Mineral Sand Processing	01	--	--	01
	g.	Alumina Refinery	01	--	--	01
	h.	Coke Ovens	01	07	--	08
	i.	Iron Ore Benefication	04	01	--	05
11.	Food Processing and Allied Industries
	a.	Rice Mills	--	32	218	250
	b.	Sea Food Processing	--	12	08	20
	c.	Beverages	01	08	01	10
	d.	Flour Mills	--	17	19	36
	e.	Dairy/Milk Chilling Centre	--	05	10	15
	f.	Bakery	--	06	11	17
	g.	Vegetable Oil /Edible Oil	--	13	07	20
12.	Refractory/Bricks/Tiles
	a.	Brick Kiln	--	--	231	231
	b.	Refractory and Ceramics	02	22	08	32
	c.	Fly Ash Bricks	--	--	15	15
13.	Other Industries
	a.	LPG Bottling and POL Depot	07	21	01	29
	b.	Explosives	02	08	--	10
	c.	Poly Propylene Products	--	31	12	43
	d.	Poultry and Cattle Feed	--	10	06	16
	e.	Industrial Gases (Oxygen and Acetylene)	--	12	03	15
	f.	Engineering Industries	03	11	--	14

Sl. No.	Sector		No. of Industries
Sl. No.	Sector		Large	Medium	Small	Total
	g.	Automobile Service Stations	--	05	25	30
	h.	Auto Tyre Manufacture	01	--	--	01
	i.	Hotels	04	08	131	143
	j.	Others like Conductors, Cold Storage, Masala Grinding Unit, Cotton Yarn, Aluminium Utensils, Concrete Sleepers, Glass Works, Plaster of Paris, Detergent, Granite Polishing, Mineral Water, Cotton Ginning, Vermicelli, Ice Cream	--	50	337	387
		TOTAL	167	471	2116	2754
(Large > 5 Crores, Medium 60 Lakhs to 5 Crores, Small < 60 Lakhs)

On the basis of pollution potential the Ministry of Environment of Forests, Government of India, have categorized as Red, Orange and Green. The industries in the state are accordingly categorized and presented in Table 2.3.

TABLE: 2.3

Industry Categorisation

Sl. No.	Category	No. of Industries
Sl. No.	Category	Large	Medium	Small	Total
1.	Red	159	311	1309	1779
2.	Orange	08	104	449	561
3.	Green	0	56	358	414
TOTAL		167	471	2116	2754

It may be seen that most of the industries (65%) in the state being engaged in primary manufacturing activities fall within the red category. Categorywise industries are graphically presented in Figure 2.1.

Figure 2.1

Categorisation of Industries

Central Pollution Control Board has identified 17 categories of industries as highly polluting type because of their high pollution potential. The break up of these highly polluting units are compiled in Table 2.4. Out of 17 categories of industries identified by Central Pollution Control Board, Orissa has 12 categories of industries. Most of these industries are in large and medium sector.

TABLE: 2.4

17 Categories of Polluting Industries in Orissa

Sl. No.	Sector	No. of Industries			Total
Sl. No.	Sector	Large	Medium	Small	Total
1.	Thermal Power	10	--	--	10
2.	Integrated Iron and Steel	01	--	--	01
3.	Sponge Iron, Pig Iron and Steel	85	11	--	96
4.	Aluminium	02	--	--	02
5.	Cement	07	02	01	10
6.	Sugar	04	01	--	05
7.	Distillery	03	--	01	04
8.	Pesticide	--	01	02	03
9.	Chloro – Alkali	01	--	--	01
10.	Dye and Dye Intermediate	--	01	--	01
11.	Pulp and Paper	04	02	--	06
12.	Fertilizer	02	01	--	03
13.	Bulk Drug	--	--	01	01
TOTAL		119	19	05	143

Further classification of industries have been done by Central Pollution Control Board as “Grossly Polluting Industries” based on their water pollution load. If the total BOD load from an industry exceeds 100 Kg/Day or if its effluent contains any hazardous chemicals, then the industry is categorized as Grossly Polluting Industry. Orissa has 18 such industries. Status of these industries operating in the state are compiled in Table 2.5.

TABLE: 2.5

Grossly Polluting Industries in Orissa

Sl.	Name of the Industry	Public Sector/ Private Sector	Category	Effluent Recipient Place	Concerned River
1.	NALCO, CPP, Angul (Industrial effluent other than ash pond overflow, Ash Pond water is completely reused)	Public Sector	Thermal Power	Nandira Jhor	Brahmani
2.	NTPC, Kanhia (Industrial Effluent)	Public Sector	Thermal Power	Tikira River	Brahmani
2A.	NTPC, Kahnia (Ash pond overflow effluent)	Public Sector	Thermal Power	Tikira River	Brahmani
3.	TTPS (NTPC), Talcher (Industrial Effluent)	Public Sector	Thermal Power	Nandira Jhor	Brahmani
3A.	TTPS (NTPC), Talcher (Ash pond overflow effluent)	Public Sector	Thermal Power	Nandira Jhor	Brahmani
4.	Central Orissa Straw Board	Private Sector	Pulp and Paper	Mahanadi	Mahanadi
5.	Steel Township Rourkela	Public Sector	Urban Body	Koel River	Brahmani
6.	Fertilizer Plant, SAIL, Rourkela	Public Sector	Nitrogenous Fertilizer	Guradih Nallah	Brahmani
7.	ICCL (CPP), Choudwar, Cuttack	Private Sector	Thermal Power	Birupa	Birupa
8.	IDL Chemicals, Sonaparbat, Rourkela	Private Sector	Explosive	Balijodi Nallah	Brahmani
9.	Rourkela Steel Plant, Rourkela (Coke oven byproduct effluent)	Public Sector	Iron and Steel	Guradih Nallah	Brahmani
10.	Fertilizer Township Rourkela	Public Sector	Urban Body	--	Brahmani
11.	INDAL Smelter Hirakud (Domestic Effluent)	Private Sector	Aluminium Smelter	Mahanadi	Mahanadi
12.	Paradeep Phosphate Ltd.	Public Sector	Phosphatic Fertilizer	Atharbanki Creek	Bay of Bengal
13.	Ballarpur Industries (Sewa) Jeypore	Private Sector	Pulp and Paper	Nallah	Kolab
14.	Jayashree Chemicals Ltd., Ganjam	Private Sector	Chloro Alkali	Rushikulya	Rushikulya
15.	Emami Paper Mill Balgopalpur	Private Sector	Pulp and Paper	Swapna Nallah	Sona
16.	IFFCO Fertilizer Plant	Public Sector	Phosphatic Fertilizer	Creek	Mahanadi

The industries in the state thus vary widely in their size, activity and pollution potential. Table 2.6 provides a view of sectoral annual production status in the state.

TABLE: 2.6

Sectoral Distribution of Industries in Orissa

Sl. No.	Major Industrial Sector		Unit/Year	Annual Capacity
Sl. No.	Major Industrial Sector		Unit/Year	Annual Capacity
1.	Iron and Steel
	a.	Integrated Iron and Steel	Ton x 10⁶	2.7
	b.	Pig Iron	Ton x 10⁶	1.3
	c.	Sponge Iron	Ton x 10⁶	6.0
	d.	Ferro Alloys Plant	Ton x 10⁶	0.63
	e.	Secondary Steel Melting Like Induction Furnace etc.	Ton x 10⁶	0.5
	f.	Rerolling Mills and Others and Reheating Furnace	Ton x 10⁶	0.36
2.	Aluminium		Ton	410000
3.	Pulp and Paper		Ton	248500
4.	Sugar		Ton
5.	Fertilizer		Ton	3099600
6.	Thermal Power		MW	5336
7.	Cement		Ton	3954000
8.	Fermentation Industries
	a.	Distilleries	KL	15720
	b.	Breweries	KL	29000
	c.	IMFL Bottling Plant	CASES	720000
9.	Chemical Industries
	a.	Chloro Alkali	Ton	24500
	b.	Bulk Drugs	Ton	96
	c.	Dye and Dye Intermediate	Ton	480
	d.	Pesticides	Ton	600
10.	Mineral Processing and Crushers
	a.	Stone Crushers	Ton x 10⁶	11.425
	b.	Chrome Ore Benefication
	c.	Graphite Benefication
	d.	Coal Washeries	Ton	387500
	e.	Iron Ore Crushers	Ton x 10⁶	21.12
	f.	Others like Mineral Sand Processing	Ton
	g.	Alumina Refinery	Ton	1575000
	h.	Coke Ovens	Ton	240000
	i.	Iron Ore Benefication	Ton
11.	Food Processing and Allied Industries
	a.	Rice Mills	Ton	1875000
	b.	Sea Food Processing	Ton	18600
	c.	Beverages	Cases
	d.	Flour Mills	Ton	36000 x 12
	e.	Dairy/Milk Chilling Centre	KL	140000

Sector wise Industrial Scenario

The industrial topology varies widely, but most of them are mineral based and engaged in primary manufacturing activities. The state industrial scenario is dominated by iron and steel, power, cement, ferro alloy, sponge iron, pulp and paper and fertilizer industries. In small scale sector rice mills, stone crushers and brick kilns have a significant presence in the state. The following section presents a sectoral discussion.

Iron and Steel Industries

Iron and steel sector are undergoing rapid change in the state. Till 1995 there were only two Iron and Steel Plant in the state. Between 1995-2000 there was a marginal growth and period from 2000 onwards witnessed a rapid growth in iron and steel sector. The steel making route also witnessed a deviation from BF-BOF route to DRI-EAF/DRI-IF route. There are 14 steel plants in Orissa. Besides, four plants are now producing pig iron at Kalinga Nagar and at Barbil. The details of production capacity of these industries are compiled in Table 2.7 and Table 2.8.

TABLE: 2.7

Iron and Steel Plants in Orissa

Sl.	Name of Industry	Production Capacity (Million Ton / Annum)
1.	Rourkela Steel Plant	1.800
2.	Adhunik Metaliks	0.260
3.	OCL India Ltd. (Sponge Iron Division)	0.086
4.	Pawanjay Sponge Iron Ltd.	0.027
5.	Rexon Strips Ltd.	0.025
6.	Scan Steels Ltd.	0.002
7.	Shristi Ispat Ltd.	0.067
8.	Bhaskar Steel and Ferro Alloys Ltd.	0.072
9.	MSP Sponge Iron (P) Ltd.	0.018
10.	N. K. Bhojani (P) Ltd.	0.053
11.	Orissa Sponge Iron Ltd.	0.096
12.	Sree Metaliks (P) Ltd (Keonjhar)	0.130
13.	Sree Metaliks (P) Ltd (Angul)	0.051
14.	Bhusan Power and Steel Ltd.	0.108
TOTAL		2.795

TABLE: 2.8

Pig Iron Plants in Orissa

Sl.	Name of the Industry	Production Capacity (Million Ton / Annum)
Sl.	Name of the Industry	Production Capacity (Million Ton / Annum)
1.	Nilachal Ispat Nigam Ltd.	0.6
2.	MESCO Steel Ltd.	0.4
3.	VISA Steel Ltd.	0.175
4.	Kalinga Iron Works	0.15
TOTAL		1.325

Out of 14 plants engaged in steel making only Rourkela Steel Plant is an integrated Steel Plant. Remaining 13 plants are making steel through DRI-IF/EAF route. These plants in addition to producing steel also produce sponge iron. These sponge iron plants are in different stage of expansion and their steel making capacity is likely to increase in near future. Besides, other sponge iron plants and pig iron units are also in different stages of expansion and modernization and likely to graduate to steel plants in future.

Sponge Iron

(a) Recent years have seen a technological shift in steel making. The current trend is to produce steel through DRI-EAF route. Because of availability of sponge grade iron ore and booming market, sponge iron has grown exponentially during last few years. There are 93 sponge iron plants already operating and some more are in the pipeline. Details of districtwise operating sponge iron industries with production capacity and raw materials consumption are given in Table 2.9.

The total installed capacity in sponge iron sector is about 20000 TPD. This sector alone consumes about 10 million ton of iron ore and about 9 million tons of coal annually. Though they are not water intensive Industries, they consume about 20 MLD of water.

TABLE: 2.9

Sponge Iron Industries Operating in Orissa

Sl.	District	Nos.	Capcity (TPD)	Iron Ore Cons. (TPD)	Coal Cons. (TPD)	Water (KLD)
1.	Sundargarh	46	6625	10600	9275	6625
2.	Keonjhar	19	5450	8720	7630	5450
3.	Jharsuguda	08	1750	2800	2450	1750
4.	Angul	03	600	960	840	600
5.	Jajpur	03	600	960	840	600
6.	Mayurbhanj	01	200	320	280	200
7.	Sambalpur	08	2300	3680	3220	2300
8.	Dhenkanal	02	800	1280	1120	800
9.	Cuttack	03	1250	2000	1750	1250
	TOTAL	93	19575	31320	27405	19575

Out of 93 sponge iron plants 13 plants have graduated to integrate steel plant by adding steel making facilities in the plants.

(b) The total pig iron production in the state is about 3.3 MT, of which Rourkela Steel Plant (RSP) produces about 2 MT per annum, which is used by RSP for steel production. Out of about 5.9 million tons of sponge iron produced per annum, about 1 million ton is used by various steel producing units. These sectors (pig iron, sponge iron and steel) use about 14.2 MT of iron ore.

Water consumption in the iron and steel/sponge iron sector is about 112 million liters per day (33.6 million cubic meter per annum).

Ferro Alloys

Ferro alloy is another sector which largely feeds on iron and chrome ore and steady power. Because of availability of iron ore and chromite ore in Orissa, ferro alloys plants have witnessed a sound growth in Orissa. There are 9 ferro alloys plants in the state in operation. The list of industries with production capacity and raw materials are given in Table 2.10.

TABLE: 2.10

Ferro Alloys Plants in Orissa

Sl.	Name of Industry	Products	Production Capacity on HCFC Basis (TPA)
1.	FACOR, Randia, Bhadrak	Charge Chrome/ High Carbon Ferro Chrome	50,000
1.	FACOR, Randia, Bhadrak	Charge Chrome/ High Carbon Ferro Chrome	50,000
2.	Ferro Manganese Plant, TISCO, Joda, Keonjhar	High Carbon Ferro Manganese	30,000
2.	Ferro Manganese Plant, TISCO, Joda, Keonjhar	High Carbon Ferro Manganese	30,000
3.	Ferro Alloys Plant, TISCO, Bamnipal	Charge Chrome/ Ferro Chrome	50,000
4.	ICCL, Choudwar	Charge Chrome/ Ferro Chrome	62,500
4.	ICCL, Choudwar	Charge Chrome/ Ferro Chrome	62,500
5.	IMFA (Plant I) Rayagada	Ferro Silicon/ Charge Chrome/High Carbon Ferro Chrome	100,000
6.	Balasore Alloys	Ferro Manganese, Ferro Silicon, Ferro Chrome and Silico Manganese	95,000
7.	Nav Bharat Ferro Chrome	High Carbon Ferro Chrome	50,000
8.	IDCOL Ferro Chrome and Alloys Ltd.	High Carbon Ferro Chrome	21,606
9.	Jindal Stainless Ltd. Kalinga Nagar *	High Carbon Ferro Chrome	1,80,000
Total			6,39,106

* Jindal Stainless Ltd. will ultimately go for stainless steel manufacturing in near future.

These ferro alloy plants produce different alloys depending upon the market demand and accordingly their raw material consumption and production capacity also changes. In the table 2.10 the production capacity has been specified on the basis of HCFC (High Carbon Ferro Chrome)/ Charge Chrome. However specific raw material consumption per ton of product will provide an idea of raw material consumption in this sector (Table 2.11).

TABLE: 2.11

Raw Material Consumption per Ton of Ferro Alloys Production

Product Raw Material	SiMn	FeMn	FeCr
Manganese	1.65	2.55	--
OreCoke / Char Coal	0.75	0.65	0.75
FeMn Slag	0.70	--	--
Chrome Ore	--	--	2.5
Quartzite	0.25	--	0.15

Aluminium

There are two aluminium smelting industries in Orissa and one alumina plant (NALCO) is located in Damanjodi. The products, production technology adopted are compiled in Table 2.12.

TABLE: 2.12

Aluminium Industries in Orissa

Sl.	Name of Industry	Products	Production Technology	Quantity in T/Annum
Sl.	Name of Industry	Products	Production Technology	Existing	After Expansion
1.	NALCO, Angul	Aluminium	PBCW	345,000	460,000
2.	HINDALCO, Hirakud	Aluminium	HSS	65,000	100,000
TOTAL				410,000	560,000

PBWC-Pre Baked Centre Work HSS-Horizontal Stud Soderberg

This industry depends upon alumina and power. Orissa is a big repository of bauxite and coal, which is responsible for development of this sector. Consumptive pattern of major raw materials is presented in Table 2.13.

TABLE: 2.13

Raw Material Consumptive Pattern of Aluminium Industries in Orissa

Sl.	Industry	Raw Material Consumption at Existing Capacity
Sl.	Industry	Alumina (TPD)	Water (KLD)
1.	NALCO	1600	10,000
2.	INDAL	350	1250
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