rashtriya ispat nigam ltd. - visakhapatnam steel plant
TRANSCRIPT
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Rashtriya Ispat Nigam Limited - Visakhapatnam Steel Plant
(RINL-VSP), a Navratna PSE, is the country’s first shore based in-
tegrated steel plant. The company is 100% owned by GoI. The
plant is a 3 Million ton based Integrated Steel Plant being ex-
panded to 6.3 Million tons.
Visakhapatnam Steel Plant
ENVI RONMENTAL STATEMENT (Form V) 2013 -14
Rashtriya Ispat Nigam Ltd.
Address for correspondence:
Environment Management Department
Visakhapatnam Steel Plant
Rashtriya Ispat Nigam Ltd.-530032
Contacts:
Phone: 0891-2518002
Fax: 0891-2518631
E-mail:
Prepared as per requirement under Environment Protection Rules,1986 and publishing as per directives of
Ministry of Environment and Forests
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PART – A (i) Name and address of the owner/ : Sri D N Rao
occupier of the industry operation/ Executive Director (Works)I/c,
process. VISAKHAPATNAM STEEL PLANT,
VISAKHAPATNAM – 530 031
(ii) Industry category Primary-(STC code): -
Secondary (SIC code)
(iii) Production during 2013-14 in tonnes
a) Saleable steel : 3016068 t
b) Pig iron : 327002 t
c) Coal chemicals(Ammonium sulphate : 129127 t
benzol & tar products) ````````
d) Captive power generation : 218.8 MW
(iv) Year of establishment : 18th FEBRUARY, 1982 (incorporated)
(v) Date of last environmental : 29 SEPTEMBER 2013
statement submitted
PART – B Water and raw material consumption
1. Water consumption in KLD
a. In the plant for process (Excluding TPP) : 29002
b. In TPP for power generation : 40586
c. Total in process : 69608
d. In plant for fire fighting & drinking : 18920
----------
Grand total (c+d) : 88528
Name of
product
Process water consumption per unit of product output
During the current financial
year, 2012-13
During the current financial
year, 2013-14
Saleable steel 10.13 cum/tonne of sal. Steel 10.71 cum/tonne of sal. Steel
FORM – V
3
2. Raw material consumption (Unit : ton /ton of Saleable Steel)
Name of
raw material
Name
of
prod-
ucts
Consumption of raw-material Per unit of
output
During the current fi-
nancial year
2012-13
During the current
financial year
2013-14
Coking coal Salea-
ble
steel
1.163 1.080
Iron ore
(lumps &
fines)
1.877 1.641
Sand 0.003 .0037
Lime stone 0.359 0.298
Dolomite 0.191 0.178
Mn.Ore 0.0049 0.0045
Alloys at SMS 0.020 0.0195
Raw Material Handling at VSP
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Pollutants Qty. of pollu-
tants dis-
charged
(mass/day)
Concentration of
pollutants in dis-
charges
(mass/volume)
Percentage of
variation from
prescribed
standards with
reasons#
WATER ( ETP outlet )
TSS 287.6 kg/day 95.4 mg/lt -4.6%
O&G 22.3 kg/day 7.4 mg/lt -26.0%
PHENOL 1.5 kg/day 0.5 mg/lt -50.o%
COD 732.3 kg/day 242.9 mg/lt -2.8%
BOD 76.3 kg/day 25.3 mg/lt -15.6%
AMM.N2 124.8 kg/day 41.4 mg/lt -17.2%
# Reduced concentrations due to stabilization in performance of Me-
chanical Biological and Chemical treatment plant of Coke Ovens
Air emissions from process
Pollutants Qty. of pollu-
tants dis-
charged
(mass/day)
Concentration of
pollutants in dis-
charges
(mass/volume)
Percentage of
variation from
prescribed
standards with
reasons
PM 4968 kg/day
against the
Consent value
of 7165 kg/day
-
-30.66
PART –C
Waste Water Treatment
System of SMS
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PART – D Hazardous wastes (As specified under Hazardous Wastes (M&H) Rules,
Hazardous wastes
Total quantity (Generation)
During the current
year 2012-13
During the current
year 2013-14
(a) From process
Waste oil sludge 275.82t 234.52 t
Tarry acids/muck(sludge) 2821.1t 2643.17t
Benzol muck 413t 489.84t
Discarded oil drums 9.5t 2.0 t
(b) From pollution control facilities
Activated sludge
(MBC/ETP)
214.4t 729.66t
Exclusive facilities for handling
and treatment of hazardous waste
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PART – E Solid Wastes
Solid Waste
Total genera-tion
(t/year) (a)
Recycled or Reused (t/year)
(b)
Sold (t/year)
(c)
Utilized in construc-tion activi-
ties
%Utilization For 2012-13=
{(b+c)/a}*100
a) From Pollution Control Systems
Dust from ESP's,DE Systems
249085 196611 56629 0 101.67#
Sludge from Water Treatment Plants
240532 335060 0 0 139.30*
b) From Process
BF Slag 1397080 0 1495596 19295 108.43$
LD Slag 410673 150971 0 0 36.76
Total 2297370 682642 1552225 19295 98.12
#- Additional 4155 of dust recycled from previous stock * Additional 94528 tons of sludge recycled from previous stock $ Additional 117811 tons of BF slag utilised/sold from previous stock
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PART – F Please specify the characterization (in terms of composition and quan-tum) of hazardous as well as solid wastes and indicate disposal practice
adapted for both these categories of wastes.
Characteristics and practice of disposal
Type of
Waste
(Non-
hazardous)
Yr: 13-14
FeO
(%)
CaO
(%)
MgO
(%)
SiO2
(%)
Al2O3
(%)
MnO
(%)
Basic-
ity
Method of
disposal
BF SLAG 0.37 36.59 8.14 34.7 17.77 0.11 1.05 Sold to
external
parties
LD SLAG 15.76 51.65 10.47 16.99 1.12 1.20 3.09 Partly re-
cycled ,
partly
stacked for
future use.
Others T.Fe CaO MgO SiO2 Al2O3 MnO LOI Method of
disposal
Met.
Wastes
42.29 2.42 0.21 3.93 0.85 - 31.0 100% recy-
cled in SP
Type of Waste ( Non-Hazardous)
Press Filter at Blast Furnace –3
for recovery of Sludge from
Waste Water of Gas Cleaning
Plant
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PART – F Please specify the characterization (in terms of composition and quan-tum) of hazardous as well as solid wastes and indicate disposal practice
adapted for both these categories of wastes.
Characteristics and practice of disposal
Type of Waste (Hazardous)
S
L
Parame-
ter Unit Conc. Limit
as per
HW(MWTM)
Rules 2008
MBC
Sludge
ETP
Sludge
Tank
bot-
tom
Sludge
Tar
Sludge
ASP
Sludge
Benzol
Sludge
1 Cadmi-
um mg/kg 50 9.54
15.52 4.16 5.8 1.48 4.16
2 Total Cr. mg/kg 5000 106.8 75.8 16.3 3.63 30.8 5.454
3 Copper mg/kg Not App. 32.2 8.05 6.75 2.85 7.7 2.08
4 Iron % 5000 8347 7400 3317 236.1 3800 430
5 Nickel mg/kg 5000 93 10 3.6 2.3 39 BDL
6 Lead mg/kg 20000 72 434.8 216.3 57.2 46.6 6.4
7 Zinc mg/kg Not applica-
ble 320.9 1061 372.8 153.7 317.9 24.8
8 Cyanide mg/kg 50 1088 904 48 424 32 107
9 Carbon % Not applica-
ble 26.67 19.17 57.11
- 15.6
-
Facilities at Coke Ovens for charging
Hazardous waste into batteries
Disposal :All the above wastes are recycled in the Coke Oven Batteries
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PART – G Impact of pollution abatement meausres taken on conservation of natural resources.
Sl.N
o.
Pollution Abatement Measures Impact on conserva-
tion of natural re-
sources (13-14)
Impact on cost
of produc-
tion(13-14)
1 Recycling of waste water using- i)
Balacheruvu waste water system ii)
Appikonda waste water treatment
systems and iii) Ultra filtration plant
for treatment of township waste wa-
ter
Saving of 478.87 MG
of water
Savings of Rs
6.99 crores
2 a. Recycling of wastes collected
from i) Dust Extraction Systems ii)
Waste Water Treatment plants
b. Utilisation of Blast Furnace and
LD slag
Saving of natural re-
sources to the tune
of 2.31 million tons
Savings of Rs
254.18 crores
3 Utilisation and waste heat and pres-
sure recovery systems for generation
of power and steam
Saving of coal of
about
6.09 lakh tons
Savings of Rs
148.09 Crores
4 Utilsation of by product gases in
place of coal
Saving of coal of
about 13.17 lakh
tons
Savings of Rs
320.40 Crores
The following are the details of impact on conservation of natural resources and
cost of production due to various pollution abatement and environmental protection
measures taken at VSP in the year 2013-14
Balacheruvu Waste Water
Pumping Station
Appikonda Waste Water Treatment
Plant Showing RO skids as inset
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PART – H
Additional measures / investment proposal for environmental protection
including abatement of pollution, prevention of pollution.
1. Revamping & up-gradation of ESPs of SP-1
and BF 2 are taken up at a cost of Rs 144.6 Cr.
to reduce the stack emissions from
115mg/Nm3 to 50mg/Nm3.
ESP of Blast Furnace-1 ESP : Under
Up gradation
2. Rain water harvesting schemes,
to conserve 3.3MGD of water, are
taken up at a cost of Rs 13.84 Cr.
and are at an advanced stage of
implementation. On completion
they shall result in total wa-
ter saving of : 3.3 MGD
Dog House—SMS2
Additional Environment protection measures taken in in 13-14
3. Dog house commissioned and
put in operation in Steel Melt
Shop-2 , thereby preventing roof
top emissions from convertor shop
Rain water Harvesting : Under
implementation
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PART – H
Additional measures / investment proposal for environmental protec-
5. All Halon based fire fighting sys-
tems at VSP were replaced a with
Inergen based fire fighting systems,
incurring an expenditure of Rs 6.14
crores. In the process 3885 kgs of
Halon was phased out systematically.
Additional Ammonia Columns provid-
ed for stabilising input load to MBC
Additional Environment protection measures taken in in 13-14
Enhanced flocculent dosing system at
4. Mechanical, Biological and Chemical
(MBC) treatment plant of Coke Ovens ,
which was upgraded incurring an ex-
penditure of Rs 46 Cr was stabilised.
This was done by further addition of
facilities such as
a) 2 sets of new Ammonia columns in
parallel for stabilizing the input load
b) Replacing the problematic roots blow-
ers with centrifugal blowers and modi-
fying the air distribution system for
adequate air supply for sustaining
oxidation process
c) Enhancing the flocculent system for
proper dosing of flocculants and co-
agulants
This has resulted in:
Bringing down the ammonical nitro-
gen below the norm of 50 mg/l.
Bringing down the COD (Chemical Ox-
ygen Demand) below the norm of
250mg/l.
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Improvement of Communication :
1.A software dedicated to Environmental Activities ‘ ENVISION ‘ has been developed
in-house, for facilitating in capture of real
time emission data from on-line stack mon-
itors installed at all twenty (20) major chim-
neys and four (4) continuous Ambient Air
Quality Monitoring stations and publishing
to all stakeholders . ENVISION also facili-
tates in scheduling of environmental moni-
toring, report preparation and collation of
environmental data from various depart-
ments. It also interfaces with other software
systems to provide information on process
parameters, status of ESPs in the plant, con-
sumption trends of utility gases - thereby enabling problem diagnosis and correc-
tive action.
2. Real time weather data being broadcasted through intranet of VSP.
Afforestation :
1..VSP is participating in the ambitious “Green Visakha- Plantation Program” , where it
is targeted to plant 40 lakh trees in Visakhapatnam in 5 years, @ 8 lakh trees per
year. The program is initiated by the Parliamentary Standing Committee on Science &
Technology and Environment, Forests. VSP has already planted 25000 avenue planta-
tion and 75000 block plantation under Green Visakha Programme. Also in-principle ap-
proval of Board of Directors is taken up for plantation of 5 lakh trees in 5 years, under
this program, at an estimated cost of Rs 5.5 Crores .
2. 2.69 Lakh of Trees planted in 2013-14 as part of afforestation efforts
Green Visakha Plantation Program inaugurated by District Collector of Visakhapatnam
PART – I Any other particulars for improving the quality of the environment.
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PART – I continued…. Any other particulars for improving the quality of the environment.
EMS
1. VSP was recertified for ISO-14001 by M/s BVCI , after auditing in Aug’13 .Certification
is valid for a period of 3 years
2. 77 nos of EMS objectives taken up to improve resource consumption, benign han-
dling, storage and disposal of hazardous wastes, greening initiatives, use of environ-
ment friendly materials etc.
ODS Phase out
1. 26 nos Halon Cylinders have been deposited to National Halon Bank at Centre for Fire
and Explosive Safety , New Delhi during the year 2013-14
Noise reduction:
1. New silencer installed at 7 Ata bleeder of BPTS to reduce noise from 120 to below 90
db(A)
Measures Taken for reduction in Energy Consumption ( 2013-14)
1. Reduction of BF gas bleeding from 2.95 % to 1.96 % by taking up proactive measures
and optimizing distribution through Supervisory Control and Data Acquisition system
(SCADA)
2. Replacement of Air Recuperartors in F/C-1 of Light and Medium Merchant Mill
3. Commissioning of Waste Heat Recovery system at Sinter plant no 2(Sinter Machine-3)
for pre heating of combustion air to ignition furnace and supplying hot air to Extended
hood of Sinter Machine-3
4. Commissioning of Energy Efficient fur-
nace with energy efficient burners in
Sinter Plant-2(Sinter Machine-3)
5. Commissioning of 20.6 MW waste heat
recovery system on sinter straight-line
cooler of sinter machine 1 &2.
20.6 MW waste heat recovery system
installed
at straight line cooler of sinter machine
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Waste Management :
1. LD Slag consumption in Sinter Plant is increased to 24.0 Kg / ton of charge sinter
against the norm of 16.0 Kg/ ton of charge sinter .More than 1 lakh tons (1.1) of LD
slag consumed in Sinter plant for the year 2013-14.
2. 3628 T of used refractory bricks recovered and reused in Steel Melting shop
Emissions
1. 52 nos of heating walls of Batt-3 repaired to reduce emissions.
CO2 reduction
1. 1004613 tons of CO2 emissions reduced due to use of clean technologies for genera-
tion of steam and power
2. 2077147 tons of CO2 emissions reduced due to use of CO Gas and LD gas in power
plant in the place boiler coal
CSR activities related to Environment
1. St. Josephs home for aged was provided financial assis-
tance of Rs 26.60 lakhs for providing solar lighting to
the entire building
2. 1000 nos of solar street lights provided in rural areas of
Barabanki district
Use of Environment Friendly material
1. Asbestos rope replaced with ceramic rope at 20 loca-
tions between flash plate and brick wall and in 20 door
frames during replacement & realignment
2. Refractory material procured in 1500 paper bags in-
stead of plastic bags thereby preventing generation of
plastic waste
3. 339.5 CuM of Falg bricks made of fly ash used in civil
maintenance activity
Solar based street lights
provided by VSP
PART – I Any other particulars for improving the quality of the environment.
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Important Environmental Events –2013-14
1. Cycle Rally was conducted on 26.05.2013 on the occasion of World Environment Day
celebrations on 5th June 2013. Director (Finance), Shri P Madhusudan flagged off the
event.
2. “ENVISION” was inaugurated by CMD on
5th June.2013 . This software tool inte-
grates all activities of Environment Manage-
ment & facilities in real time reviewing of
emissions of the plant. The software was
developed in house by IT & Environment
department.
3. Green Awards distributed to the employees
who contributed towards the improvement of
Environment on the occasion of World Environ-
ment Day celebrations on 5th June 2013.
4. Water Conservation Cam-
paigns -One of the several
water conservation campaigns
conducted for sensitising
employees on importance of
water conservation
END