jsw steel - environment management

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Environment Management

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II

25-A

pr-01

CCP I

14-A

ug-99

CO I

19-Nov-04

0.6 Mt

CO II

30-Mar-06

2 x 0.6 Mt

Pellet Plant

28-Nov-00

3.0 Mt

4.2 Mt-04

Sinter Plant

26-July-06

2.3 Mt

Corex I

08-Aug-99

0.64 Mt

BF I

19-Aug-04

0.9 Mt

BOF I

14-Aug-99

120 t

II

15-Oct-

99

2 x 120 t

BF II

10-Aug-06

1.3 Mt

III

3 x 130 t

27-Apr-0

6

III

13-N

ov-06

1999 – ISP of 0.64 Mtpa was born2001 – Capacity enhanced to 1.6 Mtpa2004 – Capacity enhanced to 2.5 Mtpa2006 – Capacity enhanced to 3.8 Mtpa

HSM

23-A

ug-97

1.25 Mt RHF 1

2.0 Mt RHF 2-04

2 x 130 t

0.8 Mt - 00

Corex II

15-Apr-01

0.8 + 0.8 Mt

2.5 Mt

1.2 Mt 2.5 Mt3.8 Mt3.8 Mt

1.6 Mt

2.3 Mt5.0 Mt 3.8 Mt

JSW Steel - GROWTH SINCE INCEPTION

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4

ORE STEELMAKING

STEELPDTS

PRODUCTUSAGE

BF-BOFDRI-EAFBF-EAF

FLATLONG

CONSTRUCTIONAUTOMOBILESWHITE GOODS

STEEL - LIFE CYCLE

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Steel Products – Environment Friendly

• Very good mechanical properties• Long product Life cycle• Low environmental impacts• Magnetic, 100% recyclable

Steel manufacture is not !

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STEELMAKING

RAW MATERIALS(3)

WATER(5)

Air(9)

STEEL PRODUCTSt(1.0)

WASTEWATER : 2.0SOLID WASTES : 1.0

AIR POLLUTANTS(13)SO2, NOx, DUST

CO2

Steel Making has major environmental impact• Globally , Non Renewable raw materials & Energy(CO2)• Locally, due to air, water, land pollution

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GLOBAL

• RENEWABLE RAW MATERIALS– INCREASED RECYCLE OF SCRAP– HIGHER EFFICIENCY OF PRODUCTION– SELECTION OF TECHNOLOGY

• ENERGY– REDUCTION OF PROCESSES– ENERGY EFFICIENCY– WASTE HEAT RECOVERY

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LOCAL

• AIR POLLUTION CONTROL– CLEAN TECHNOLOGY– POLLUTION ABATEMENT

• WASTEWATER– INCREASED RECYCLE– TREATMENT

• SOLID WASTES– RECYCLE– RE USE

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Harsh climatic conditionsScanty rainfallPoor infrastructureNon – availability of skilled man power

JSW STEEL - THEN

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Corex -Before

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N

WNW (MAR – NOV)

WSW ( MAR – NOV)

ESE ( DEC – FEB)

WIND DIRECTIONHills

Hills

Hills

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Wind Speed - scavenger of pollutants

0

5

10

15

20

25

30

35

40

45

Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec

Month

W.S

in k

m/h

r

Wind Speed Max Wind Speed Min Wind Speed Avg

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Solar Radiation - Facilitates convective movement of pollutants

0.00

100.00

200.00

300.00

400.00

500.00

600.00

700.00

800.00

900.00

1000.00

6:00

7:00

8:00

9:00

10:00

11:00

12:00

13:00

14:00

15:00

16:00

17:00

18:00

19:00

20:00

21:00

22:00

23:00 0:0

01:0

02:0

03:0

04:0

05:0

0

Time

Sola

r rad

iatio

n in

W/m

2

Solar Radiation in W/m2

140

200

400

600

800

1000

1200

1400

1600

1 3 5 7 9 11 13 15 17 19 21 23

Mixing heights – Lid for pollution

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Rainfall

0

50

100

150

200

250

300

Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec

Month

Rai

nfal

l in

mm

Rainfall Max Rainfall Min Rainfall Avg

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Evaporation Rate

0

0.5

1

1.5

2

2.5

Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec

Month

Evap

.Rat

e in

cm

Without Evaloc With Evaloc

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Relative Humidity

0

20

40

60

80

100

120

Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec

Month

R.H

in %

Relative Humidity Max Relative Humidity Min Relative Humidity Avg

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Temperature

0

5

10

15

20

25

30

35

40

45

50

Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec

Month

Tem

pera

ture

in D

eg.C

Temperature Max Temperature Min Temperature Avg

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Environment Management – Focus on

• Clean technologies

• Choice of Pollution control equipment

• Raw material quality

• Good Operational practices &

• Continuous improvements through EMS

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Clean Technology - Corex

Corex 1&2: 0.8 mtpa

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Gas based power plant

JSWEL, CPP-1 & 2: 490 MW

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Clean technology- NR Coke ovens

4 batteries of 156 ovens : 1.2 mtpa

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Coke Oven

Battery

Gas Cooling ETP Exhausters Ammonia

RemovalBenzol

Removal

Clean COG to Consumer Departments

Crude COG

Coke to Blast

Furnaces

Tar Decanters

AmmoniaLiquor

Distillation

BiologicalOxidation

plant

Used for Quenching

SCHEMATIC DIAGRAM OF CONVENTIONAL BYPRODUCT PLANT

ETP – Electrostatic Tar Precipitation

COG – Coke Oven Gas

Treated Water

Ammonium Sulfate for

sale

Tar Distillation

Light Oil

Wash Oil

HP Naphthalene

Anthracene oil

Phenol Pitch CT Fuel

Hydro-Refining Unit

BenzeneToluene

Solvent Naphtha

Xylene

Still Bottoms

Excess Liquor

Coal

Sulphuric acidWash oil

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Coke Oven

Battery

Gas Cooling ETP Exhausters Ammonia

Removal

Clean Desulphurised

COG to Consumers

Crude COG

Coke to Blast

Furnaces

SCHEMATIC DIAGRAM OF BYPRODUCT PLANT AT JSW STEEL

ETP – Electrostatic Tar Precipitation

COG – Coke Oven Gas

Tar for sale

Ammonia Cracking

H2SRemoval

Sulfur Removal

Sulfur for sale

Tar Decanters

Tar Storage

AmmoniaLiquor

Distillation

BiologicalOxidation

To Coke quenching

Treated Water

Excess Liquor

Coal

Cracked N2 & H2

to BF gas main

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HSMWire Rod Mill

Re Bar MillCold Rolling Mill

Coke OvensSintering

Blast FurnacesBOF

Slabs/Billets

Steel Making Steel Finishing

SurplusBFG,LDG,COG

& Corex

BFG,LDG,COG & Corex300-350 MCal/t~ 35 Kg LPG/t

Surplus to PP

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ESP5%

Bag filters72%

DSS5%Cyclones

8%

Scrubbers10%

I. JSW Preference for BF over ESP.

II. Design 100 mg/Nm3 50 mg/Nm3 at 7 mtpa30 mg/Nm3 at 10 mtpa

III. Pleated design of filter bags

IV. Use of gaseous fuels for power generation

Bag filters- 110 nosESP - 8 nosScrubber - 16 nosCyclones - 9 nosDSS - 8 nos

Pollution Control Equipment - Air

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ICW Circuit21%

DCW Circuit58%

Soft / DM Circuits

21%I. > 98% recycle (COC 6 to 10)

II. Cascading use of water

III. Fin – Fan heat exchanger

DCW Circuits - 19 nos

ICW Circuits - 7 nos

Soft / DM water – 7 nos

Pollution Control Equipment-Water

One of the BEST in India

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Energy Energy Conservation

Coal dust injection & oxygen enrichment in BF Replacement of Light Diesel Oil by Corex gas in HSM Elimination of boosters in Lime & Pellet plant by using

Corex gas at higher pressure. Highest LD gas recovery rate of 110 m3/t of steel. Coal drying facility for Corex units. Waste heat recovery from waste gases-490 MW

CDM Projects: 5 million ton CERs earnedNew projects underway - 20 nos

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• Use of Iron ore fines (>90%)• Iron ore beneficiation • Low “S” and ash imported coal(100%)• Use of non coking coal in NRC & CDI

• Drying of coal for Corex

• Use of DRI, Pellet in steel making

• Maximization of scrap use

Raw Materials

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BAG FILTER FOR COREX CAST HOUSE

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BAG FILTER FOR BF- I CAST HOUSE

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BAG FILTER FOR BF II CAST HOUSE

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BOF SECONDARY DEDUSTING SYSTEM (largest bag filter in India)

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Good Practices- Water Management

GCP

DM/Soft

ICW

DCW

Blow Down

Blow Down

Blow Down

Consumptive use

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• > 95% recycle of treated water in processes • Use of SSPF in CTs to reduce make up• Use of chemicals for higher COC: 6 - 8• Cascading use of process use water

• Wastewater for greenery & gardening

• Water Conservation efforts

Good Practices- Water Management

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Corex –DM Water Circuit

Corex –ICW Water Circuit

Corex –Slurry to PP

Corex –GCP Water Circuit

GCP Water Clarifier

Blow down to Ore

Beneficiation SLIME POND

Water Cascading – Corex Plant

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Corex I&II

BOF

HSM

BF I&II

Mixer

Pellet PlantRaw material

SILO

Dust from Bag FiltersCollected in Closed Tankers

DiscPelletier

Sludge from ETPs of BF, Corex,BOF,HSM,PP used in Mixer

Nearly 20,000 tons per month of sludge and dust is recycled

Slurry Tank

Dust & Sludge recycle

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• BF & Corex Slag – Used for cement making • Recovery of metallics in BOF slag for use in BOF• Lime fines - briquetted & used as burnt lime• Coal fines - used in Power plant & Pellet Plant

Good Practices- Solid Waste Mgmt

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VADDU

TALURVID.TOWNSHIP

GADIGANUR

TORANAGALLU

SG COLONY

BASAPURA

KUREKUPPA

KARADIDHAMA

SULTAPURA

KUDITINI

N

AAQ STATIONS(SPM, SOX, NOX VALUES)

(192,13,16 )

(221,15,16 )

(303,15,18 )

Hills

Hills

Hills

(238,14,16 )

(345,17,19 )

(194,14,16 )(353,43,18 )

(316,15,18 )

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N

LEGEND

AAQ Stations (A1-A7)

MeteorologicalStation (M1)

Surface Water SamplingLocations (SW1-SW4)

Ground Water SamplingLocations (GW1-GW4)

Soil SamplingLocations(S1-S4)

Noise MonitoringLocations (N1-N7)

Environmental Quality monitoringEnvironmental Quality monitoring

A1

A2

A3A4

A5

A6

M1

SW1

SW2 SW3

SW4

GW1

GW2

GW3

GW4S1 S2

S3S4

N1N2

N3

N4

N5

N6

N7

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CONTINUOUS AAQ STATIONS – 3 nos installed 3 ore planned in 2007-08

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1 Stacks 552 Work area 803 Water & wastewater 983 Noise 754 AAQ monitoring 2055 EMS Visits 4

Environmental Quality – Monthly MonitoringEnvironmental Quality – Monthly Monitoring

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Good Practices –Vacuum sweeping

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Good Practices – Wind curtains

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Good Practices – Water Sprays

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Good Practices- Dust transfer tanks

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Good Practices- Vacuum spillage control

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Good Practices- Vacuum spillage control

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Good Practices- Tyre washing

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INCINERATOR – 250 Kg/hr-

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Best Practices- Guard pond

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Good Practices-Green Belt

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Best Practices-Green belt

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NEW technologies that are being introduced

1. BSSF for granulation of BOF slag2. Desulphurisation of Coke oven gas to reduce H2S in the gas from 3.2

g/nm3 to ,0.5 g/nm33. Coke dry quenching4. Top gas recovery turbine (TRT) for power generation from BF waste

gases5. New type of gas recovery plant for coke ovens6. Note on why we went for recovery ovens

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BSSF Process of BOF slag quenching

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Slag Pouring into BSSF

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