dust mapping and control plan - dmcp by_deepak kumar sahoo

BALASORE ALLOYS LTD.

Dust Generation

Mapping

Elimination &

Control Plan

Sustain

Dust Mapping& Control Plan.

Prepared By : Deepak Kumar Sahoo

Under the guidance of

Mr. S V Bhavani Varma & Mr. J S Verma

Doc. No : BAL/DS/DMCP/A11 Dec’ 13 | Cover Page

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Doc. No : BAL/DS/DMCP/A11 Dec’ 13 | Page - i

Objective

Achieving

Dust Free Environment

in Plant Premises

through

Dust Mapping &Control Plan

[DMCP] Initiative.

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Doc. No : BAL/DS/DMCP/A11 Dec’ 13 | Page – ii

Table of Contents

S/N Contents Pg. No.

1 Introduction -: 01 :-

2 Dust Generation [Source] -: 03 :-

2.1 1. Material Flow -: 04 :-

2.2 2. Transportation -: 06 :-

2.3 3. Environment -: 08 :-

3 Dust Mapping -: 09 :-

4 Elimination & Control Plan -: 12 :-

4.1 1. Material Flow -: 13 :-

4.2 2. Transportation -: 14 :-

4.3 3. Environment -: 15 :-

5 ROI for DMCP Initiative -: 16 :-

6 Sustain -: 17 :-

Authority Measured as: 24 hr mean Relevance

UK Air Quality Standard 50 μg/m3

Air quality in relation to

public healthSPCB, Orissa 100 μg/m3

Industrial 190.6 - 238.2 μg/m3

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Doc. No : BAL/DS/DMCP/A11 Dec’ 13 | Page - 01

Introduction

Dust : It consists of particles in the atmosphere that

come from various sources such as solid particles from raw

materials, soil dust lifted by weather / Wind flow, Flue

Gases, vehicle movement etc.

Dust Level Standard

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Time Line for DMCP Initiatives

Initial

Assessment

Dust

Mapping

Elimination,

Control Plan

& Implementation

Sustain &

Improvement

2 Month

3 Month

9 Months

Kick off

Completion

of Initial

Assessment

Receiving

the Dust

Measuring

Instrument.

Completion

of Dust

Mapping.

Finalization

of

Elimination

& Control

Plan

Will reach

final stage

of

execution –

Control

Plan

Sustain &

Scope for

improvement

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Source of Dust generation

There are various sources of dust generation; but in BAL

Plant, we identified mainly the dust came from 3 major

Sources.

Material flow

Transportation

Environmental

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Material Flow : Flow Diagram

RM

Storage

UG

Bunker

Day bin

Bunker

Weigh

Hoppers

F/C

Chutes

Material

Charging Smelting Tapping Casting Loading

Breaking

yard

Slag Yard

Sales

Cooling

Loading

truck

MRP

plant Loading

truck

Return

Dust Weigh

mint

Storage

area Recycle

UG

Bunker

Screen

House

Detailed Process Map for Material Flow

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Dust Generation : Material Flow

Gate Entry

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Transportation: Flow Diagram

RM Store Area

/ Br.plant

Weigh

bridge

UG

Bunker

Weigh

bridge

Storage

Area

Casting

Metal/Slag

loading

Slag Yard

MRP plant

Weighing

Break yard Weighing Sales yard

Weighing

Material

loading &

Weighment

Raw material feeding

Product handling movement

Raw Material Entry

Weighment

RM yard at

unloading

point

Weighment Exit

Exit

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Dust Generation : Transportation

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Dust Generation : Environment

Open Raw Material Stock Yard

Chimney ( BAL Plant & Br. Plant )

Under Construction

Open Conveyer System

More Fines Generation

Internal Road Conditions

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Dust Mapping : Why ?

If you can MEASURE it,

you can CONTROL it.

We can reduce 30% of the current dust generation, if we

are able to measure the dust level continuously.

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Dust Mapping : Measuring Device

HAZ-DUST Real-time

Area Dust MonitorP311DT-9881 P611

$ 1763 £ 1.764,00£ 847 £ 2425

SKC Inc.PCE Instruments

UK Ltd.

PCE Instruments

UK Ltd.

PCE Instruments

UK Ltd.

The Avg. Cost of Dust Measuring Device is costing around 2 Lacs

INR and the lead time Maximum 15 days. [Date of Payment to

Equipment received @ BAL Plant.]

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Dust Map : Area Wise

After receiving the the Dust Measuring device we will

measure the dust level with each individual area and

monitor the dust level on weekly basis.

1. Initial Access the dust level inside the plant

2. Prepare the Dust MAP in the whole Plant.

3. Weekly Dust Tracking – Area wise.

4. Trend Analysis for Dust level.

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Elimination & Control Plan

Elimination and Control Plan may be outsource or develop

in house.

In House

Develop

Consultant

or Expert

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Control Plan : Material Flow

Dust is generating during material flow due to

1. Leakage.

2. Spillage.

3. Wrong Design.

4. Poor Maintenance.

5. Open conveyor System

Suggestion and possible cause : Material Flow

Doc. No : BAL/DS/DMCP/A11-02 Dec’ 13 | Page - 01

Dust Mapping And Control Plan Control Plan Material Flow.

INDEX

Dust Generation

Mapping

Elimination &

Control Plan

Sustain


Control Plan

Material Flow


Suggestion

During material unloading some

of the materials drops to the

platform; that material went to

UG Bunker

S1 : Platform Can be checker

plate.

S2 : Increase the height of side

wall so no material will fall in the

platform

S N Padhi

15.01.14

Discussion with Engineering team.

KAM

Target Date

Support Required



Suggestion

KAM

Target Date

Support Required



Suggestion

If we can arrange the uniform

water spray near bunker the dust

level can be reduce; also at the

same time we need to take care

the moisture level in the raw

materials.

KAM

Target Date

Support Required



Suggestion

Some of the materials are came

through conveyor.

KAM

Target Date

Support Required



Suggestion

Raw Materials falling one corner

of the conveyor.

KAM

Target Date

Support Required



Suggestion

KAM

Target Date

Support Required



Suggestion

GAP between Conveyor and

bunker can be reduce so that

dust particle will go to the

bunker.

KAM

Target Date

Support Required



Suggestion

GAP can be reduce so that dust

particle will go to the bunker.

KAM

Target Date

Support Required



Suggestion

Conveyor can make close type by

using PVC screen arrangement

just like airport luggage x-ray

machine entrance.

KAM

Target Date

Support Required



Suggestion

Conveyor brush required during

return so that raw material can’t

transform.

KAM

Target Date

Support Required


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Control Plan : Transportation


1. High Vehicles movement (Motion Study

required)

2. Internal Road conditions are not up to the

mark.

3. Leakage in Trucks

4. Speedy Movement.

Suggestion and possible cause : Transportation


Dust Mapping and Control Plan Control Plan Transportation.

Dust Generation

Mapping

Elimination &

Control Plan

Sustain


Control Plan

Transportation


Suggestion

KAM

Target Date

Support Required

Dust Mapping and Control Plan Control Plan Transportation.

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Control Plan : Environment


1. Open Raw Material Stock Yard

2. Chimney ( BAL Plant & Br. Plant )

3. Under Construction

4. Open Conveyer System

5. More Fines Generation during process.

6. Open Land Space – both inside and outside

the plant premises.

Suggestion and possible cause : Transportation


Dust Mapping and Control Plan Control Plan Environment.

Dust Generation

Mapping

Elimination &

Control Plan

Sustain


Control Plan

Environment


Suggestion

KAM

Target Date

Support Required

Dust Mapping and Control Plan Control Plan Environment.

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Control Plan : ROI of DMCP

During the pre-assessment the ROI of DMCP will be

calculated .

1. Direct financial benefits

1. Yield – Raw Materials.

2. Productivity improvement.

2. Furnace process stabilization for less dust

generation.

3. Man-hours involve.

4. Brand impact in socio economy life.

5. Employees health impact.

6. Intangible benefits.

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Sustain

1. Dust Mapping Audit : Area Wise

2. Dust Mapping Score interlink with PMS.

3. Reward & Recognition Scheme for Dust

Mapping and Control Plan.

4. Raw Material (From Brqt. To Furnace )

Yield to be monitored and analyzed

periodically.

5. External Consultant for periodical

assessment.

6. Periodically visit for good manufacturing

practice Ferro alloys plant.

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Doc. No : BAL/DS/DMCP/A11 Dec’ 13 | END

BALASORE ALLOYS LIMITED.

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DEEPAK KUMAR SAHOOEmail : [email protected]

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dust mapping and control plan - dmcp by_deepak kumar sahoo

Business

soil dust

dust generation source

completion of dust mapping

source of dust generationthere

dust measuring instrument

weighmentraw material

slag yard mrp plant

weather wind flow