PART – A

General Information

Name of the Company Bhushan Steel Limited

1. Name & Address of the owner/occupier of the industry, operation or process

Sri Rahul Sengupta Executive Vice President Bhushan Steel Limited At-Narendrapur PO – Kusupanga Via- Meramandali Dist-Dhenkanal Pin -759121 Odisha

2. Industry Category Primary (STC Code), Secondary(STC Code)

Secondary (AAACB1247MST006)

3. Production capacity-Units 5.6 MTPA Steel

4. Year of establishment 2007

5. Date of last statement 29.09.2014

PART – B

Water & Raw material Consumption

B-1 : Total Water Consumption (m3/d) Total Water Consumption (m3/d)

Category 2013-14 2014-15

Process (m3/d) 5240 5671*

Cooling (m3/d) 41074 43299*

Domestic(m3/d) 2873 3017*

* Increase in water consumption is due to higher production.

B-2 : Water Consumption per unit of the product (m3/MT)

Name of the Products Process Water Consumption per unit

of product m3/MT)

2013-14 2014-15

1. Steel 1.33 0.94

It can be noted here that above data shows only process water consumption per ton of product.

However in Charter on Corporate Responsibility for Environment Protection, limit for total water

consumption (process as well as cooling) has been specified as 8 cum/ton of crude steel produced. We

are regularly monitoring this specific water consumption and found that during 2014-15 our specific

water consumption was 4.7 cum/TCS against the limit of 8 cum/TCS (Ton crude steel). We have

Environment Audit Statement FORM – V

(See rule 14 of The Environment Protection Act, 1986) Environmental Audit Report for the financial year ending the 31st March 2015.

collected data from other steel plants in India and graphical presentation of the same is given below-

It is also to inform that during current year i.e., 2015-16 we have achieved specific water

consumption as about 4.15 cum/TCS which shows continual improvement.

Specific water consumption has been reduced from 7.0 cum/TCS to 4.7 cum/TCS due to the

following measures taken.

• Installation of water flow meters in water incoming pipelines in various water consuming

departments.

• Optimizing water requirement of various departments.

• Supplying only optimized water quantity to various departments.

• Preventing any kind of wastage of water.

• Close monitoring of water flow.

• Recycling of all the waste water after necessary treatment thus minimizing make up water

requirement.

B-3 : Raw Material Consumption

Name of Raw materials Name of Products Raw material consumption per unit of crude steel (MT/MT)

2013-14 2014-15

1. Iron ore 1. Steel 1.61 1.41

2. Iron Pellet 0.17 0.12

3. Lime stone & Dolomite 0.22 0.31

4. Coke (including nut coke and breeze coke)

0.54 0.14

5. Quartz 0.05 0.06

6. Coking coal - 0.79

7. Purchase scrap - 0.02

PART – C

Pollution discharged to environment per unit of output ( Parameters as specified in the consent issued)

C-1 : Water Pollution

Pollutant Parameter Prescribed Standard

Quantity discharge (kg/d)

Concentration discharge (mg/l)

Percentage of variation from prescribed

standards with reasons - - Nil Nil -

It is to be noted that since we are maintaining zero discharge of effluent hence the above discharge load is also zero.

We have achieved zero discharge by installing appropriate ETPs in each department for proper treatment of effluent and recycling back. Sewage from various sources is sent to Sewage Treatment Plants and after treatment it is reused in greenbelt development. Details of few specific ETPs and STPs are given below. Common effluent treatment plant - All Waste water like blow down, floor washing and filter back wash water from various units are being routed through settling tank, water treatment facility and after maximum utilization through recycling pumps, it is being sent to common effluent treatment plant of capacity 350 m3/hr. After treatment it is reused as cooling tower make up, ash handling, dust suppression and green belt development.

Effluent Treatment Plant (ETP) Capacity: 350 m

3/hr

1. Coke oven - The waste water generated from Coke-oven process is taken to specific

effluent plant called Biological Oxidation and Dephenolisation plant. After treatment the

water is reused in coke quenching.

2. Blast furnace - Waste water generated from Gas Cleaning Plant is treated in effluent

treatment plants and the treated water is recycled back to the Gas Cleaning Plant

process.

4. Steel Melting Shop (SMS) - Waste water generated from process is treated in effluent treatment plants and the treated water is recycled back to the Steel Melting Shop process.

5. Cold Rolled Mill - Waste water generated from process is treated in effluent treatment

plants and the treated water is recycled back to the process.

6. Hot Strip Mill - Process waste water is skimmed for oil and scale and then recycled

back to the HSM cooling process.

7. Sewage treatment plants (STP) – We have total five nos. of sewage treatment plant

in entire Bhushan steel complex. Sewage generated from Colony/office is treated in

Sewage treatment plants and the treated water is 100% reused for horticulture and

green cover.

C-2 : Air Pollution

Pollutant Parameter Prescribed Standard (mg/Nm3)

Quantity discharge (kg/d)

Concentration discharge (mg/Nm3)

Percentage of variation from prescribed

standards with reasons

Particulate matter Please Refer the Annexure – 1

No Deviation. Values are within the prescribed standard because the ESP & Bag filters are maintained properly.

Appropriate air pollution control technology has been adopted for minimizing air

pollution at source itself. About 26 nos. of Electrostatic precipitator, 50 nos. of bag filter

and 04 nos. of scrubbers, 43 nos. of DFS with 252 nos. of nozzles, 69 nos. of gun

sprinklers have been installed in various departments which are keeping stack emission

well within norms. The details are attached as annexure-2.

PART – D

Hazardous Wastes (As specified under The Hazardous Waste Management, Handling & Transboundary

Movement Rules, 2008) D-1 : Generation from Process

Name Total Quantity (MT/KL)

2013-14 2014-15

1. Used Oil 43.1 KL 160.94 KL

2. Waste residue containing oil 1.95 T 4.75 T

3. Spent Resin 0.7 KL Nil

4. Rejected Chemical Container 708 nos. 3530 nos.

5. Insulation Material - 154 T

6.Acid Residue - 134.5 T

7. Alkali Residue - 27 T

8. Flue gas cleaning residue - 2000 T

9.Oily Sludge - Nil

PART – E

Solid Wastes E-1 : Generation from Process

Name Total Quantity (MT)

2013-14 2014-15

1. Char 237080 39703 2. Bottom Ash 95742 71287

3. BF Slag 395184 970572

4. SMS Slag 277957 378430

E-2 : Generation from Pollution Control Facilities

Name Total Quantity (MT)

2013-14 2014-15 1. Fly Ash 352374 358698

E-3 : Quantity Recycled/Reutilized within the Unit Name Total Quantity (MT)

2013-14 2014-15

1. BF Slag Nil 32627

2. SMS Slag 277957 378430*

3. Fly Ash 352374 358698 * Increase in generation is due to commissioning of new SMS-3

E-4 : Quantity Sold Name Total Quantity (MT)

2013-14 2014-15

1. BF Slag 395184 937945*

* Increase in generation is due to commissioning of new Blast furnace-2

E-5 : Quantity Disposed Name Total Quantity (MT)

2013-14 2014-15

1. Char 237080 39703* (Stored for future use)

* Decrease in generation is due to the fact that plant is now under shut down.

D-2 : Generation from Pollution Control Facilities

Name Total Quantity (MT/KL)

2013-14 2014-15

1. BOD plant Sludge 8.5 54.95

2. Decanter Tar Sludge 53.4 196.4

3. ETP Sludge from CRM - 862.67

PART – F

Please specify the characterizations (in terms of composition in quantum) of hazardous as well as solid wastes and indicate disposal practice adopted for both this categories of

wastes

F-1 : Hazardous Wastes

Description Constituent parameter

Concentration Disposal practice

1. Used Oil Analysis report attached as Annexure - 3

Sold to Authorized Recycler

2. Waste residue containing oil _ _ Storage in MS drum under covered shed then treatment by incinerator

3. Spent Resin - -

Storage in barrel under cover shed with concrete floor. This will be disposed at Common Hazardous Waste Treatment Storage Disposal Facility (CHW TSDF) site when we will have sufficient quantity.

4. BOD plant Sludge _ _ Reused in Coke oven plant

5. Decanter Tar Sludge _ _ Reused in Coke oven plant

6. Rejected Chemical Container _ _

Sold to authorize recycler.

7. Insulation Material _ _

Disposed to CHWTSDF

8.Acid Residue

_ _

Stored in a Secured manner in storage tanks having acid proof bricks and rubber lined then in house process in ETP. Will be disposed to CHWTSDF site.

9. Alkali Residue

_ _

Collected in leak proof PVC barrels stored in under shed. Disposed to CHWTSDF site.

10. Flue gas cleaning residue _ _

Storage in designated area then internally reused.

11. ETP Sludge from CRM _ _ Disposed to CHWTSDF site.

F-2 : Solid Wastes

Description Constituent parameter

Concentration Disposal practice

1. Char Analysis report attached as Annexure - 4

Stored inside the plant premises for future use

2. Bottom Ash Analysis report attached as Annexure - 5

Utilized for reclamation of low lying area

3. Fly Ash Analysis report attached as Annexure - 5

Utilized for reclamation of low lying area filling and road construction

4. SMS Slag Analysis report attached as Annexure - 6

Used in road construction and floor making

5. BF Slag Analysis report attached as Annexure - 7

Granulated slag sold to Cement plant (ACC & OCL) and bolder slag used for low lying filling and road construction.

We have made proper arrangements for storage of hazardous waste. Covered shed with concrete floor, all round garland drain and catch pit has been organized for safe storage before disposal to authorize recyclers.

We have stored char inside our plant premises. We have reclaimed the char dump area with green coverage except the present active portion.

We have permission for ash disposal into mine void as well as abandoned stone queries in Karanda. We have started disposing fly ash into mine void and bottom ash into abandoned stone queries. At mine void, we have made one of the best arrangements for fly ash disposing into mine void which ensures absolute pollution free ash disposal into mine. Ash is passed through ash conditioning system where water is mixed with ash to make it slurry before disposing into mine. This prevents any ash emission into atmosphere thus ensure pollution free ash disposal into mine. This has been appreciated by MoEF&CC, CPCB and SPCB officials during their visits. The detail report on fly ash disposal at mine void is enclosed as annexure – 8.

Ash disposal at Jagannath quarry no 4 of MCL

Char dump before reclamation Char dump after reclamation

Ash disposal at abandoned stone quarry near Karanda

Slag from SMS is processed through slag granulation unit to make precious slag ball for road making after removing of magnetic percentage. The magnetic portion is being sent to sinter plant for making sinter which is being further used as a raw material for our blast furnace1 & 2. We have two slag granulation units (One unit in blast furnace-1 and another in blast furnace-2). The granulated blast furnace slag is being sent to cement manufacturing unit like OCL & ACC through rail.

Soil filling and plantation at ash disposal area at abandoned stone quarry near Karanda

PART – G

Impact of pollution control measure on conservation of natural resources and cost of production

G-1 : Cost estimation of Pollution Control

Description Expenditure in Crore during 2014 - 15

Capital cost Recurring cost

1. Water Pollution 0.125 5.35 0.11 0.32 3.97

6.63 45.00 57.94 7.73 2.27

2. Air Pollution

3. Solid & Hazardous Waste Management

4. Green belt development

5. Others (Housekeeping)

Total 9.875 119.57

PART – H

Additional measures/investment proposal (future plan) for environmental protection including abatement of pollution, prevention of pollution

H-1 : Water Pollution

Description Purpose Estimated Cost in Crores

Year of installation

Details is enclosed as Annexure-9

H-2 : Air Pollution

Description Purpose Estimated Cost in Crores

Year of installation

Details is enclosed as Annexure-9

H-3 : Solid & Hazardous waste management

Description Purpose Estimated Cost in Crores

Year of installation

Details is enclosed as Annexure-9

H-4 : Greenbelt development

Description Purpose Estimated Cost in Crores

Year of installation

Details is enclosed as Annexure-9

We have planted about 3.36 lakhs nos. of plant in and around the plant premises covering about 360 acres which is about 22 % of total plant area. More and more trees will be planted during next 2-3 years to achieve greenbelt norm of 33%. Care is taken to plant large number of trees of local origin which are maintained properly to ensure survival rate up to 90%. This year we have also distributed free of cost 30276 nos. of sapling to nearby educational institutions, local villagers/Panchayat. The graphical representation of plantation details is given below.

The species planted are Cassia seamaea, Peltophorum pterocarpum, Delonix regia, Lagerstroemia speciosa, Plumeria alba, Bahaunia alba, Alistonia scholaris, Jacaranda mimosifolia, Polyalthia longifolia, Spathodea campanulata, Pouteria sapota, Psidium guajava, Mangifera indica, Ficus religiosa, Ashoka longifolia, Prunus avium, Mimusops elengi, Anthocephalus cadamba, Ficus starlight, Plumer, Dypsis lutescens, Ficus blackiana, Dalbergia sissoo, Azadirachta indica, Albizia saman, Pongamia pinnata, etc.

PART – I

Any other particulars undertaken for improving the quality of environment (ongoing)

• Ash slurry disposal to mine void Presently ash is being disposed into mine void via bulkers. But our final planning is to lay pipe from plant to mine void having distance of 32 Km. All necessary permissions have been obtained from various Government organizations. Pipes and pumps have also been procured and installation work has started inside the plant. Hopefully in next 2 year’s time pipelines will be laid and entire ash will go to mine void via pipelines. Excess decanted water from the mine void will be recycled back to plant.

• Mechanized housekeeping practiced in the entire plant areas. Housekeeping is a very important aspect in cleanliness of the industrial plant. All our industrial housekeeping operations like floor cleaning, drains cleaning and roads sweeping are fully mechanized. We have procured many mechanized housekeeping equipments like road sweeping machines, excavator for drain cleaning, bobcats for muck and waste lifting, hyvas for transportation of waste etc. We also plan to procure sewer suction machine cum jet cleaner which will help in cleaning of septic tanks and also jammed culverts etc. All waste CG sheets etc. are lifted and compacted by machine so that it is easy to handle and put in melting furnace. We are also planning to buy a municipal waste compactor so that collection and transportation becomes handy.

• Establishing of ETP # 3

A new ETP of 12000 m3 holding volume is under construction near coke oven 2 to treat the surface run off. After treatment water will be recycled back to process to reduce make up water consumption and achieve zero discharge. However, during rains, treated water will go out.

• Roads construction In plant we have about 40 kms of roads and out of that about 38 Kms are now concreted and work is under progress on rest of the roads. Along the roads drains have also been established to carry surface runoff and in the entire complex all the roads and drains will be completed by March 2016.

• New STP of 100 m3/day capacity is commissioned at BF-1 area. In plant we have total 5 nos. of STPs to treat sewage effluents. The treated water is used for watering of green areas. A new STP has been established in BF1 area. Treated waste water from this STP is completely utilized for watering the green areas.

• Up-gradation of township STP

We have undertaken the work of up-gradation of STP at township from 500 KLD to 1000 KLD to meet the excess waste water generation. The entire treated waste water is being utilized for green area development.

• Sibapur ash dump reclamation. Initially we used to dump ash at a designated place and it became an ash mound. Its reclamation was a challenge to us but we decided to make it one of the best reclaimed ash mound. Accordingly we started its reclamation and followed all C-Farm guidelines for ash dump / mound management. Ash mound was made in different layer with benches at different intervals and proper slope was maintained. Ash was covered with soil and then compacted. Garland drain was provided to channelize runoff water. At slope grassy vegetation was provided so that erosion is minimized in first year itself. Then proper tree plantation has also been done on top and slope so that ash mound becomes totally green with enriched ecological wealth. In time to come we will keep on adding new varieties of botanical plant species to enrich biodiversity and we are sure in future birds will make their home here and it will one of the best examples of ecological reclamation of ash dump sites.

• Bio Medical Waste Management

Obtained authorization from SPCB, Odisha under Bio Medical Waste (Management and Handling) Rules 1998 vide letter no.10306 dated 23.06.2015. Bio medical wastes generated from Health Centre are suitably treated and disposed to comply with Bio Medical Waste (Management and Handling) Rules 1998.

• Water meters to measure water consumption at various processes.

Water conservation is one of our endeavors so that this natural resource can be saved

for future generation. We have installed water flow meters in all water consuming lines

in different departments so that we can monitor their water consumption and check

whether they are using less or more and accordingly control the water feed. This will

avoid wastage and also ensure water optimization for various processes and ultimately

help us in optimizing water consumption, minimizing water wastage and ensure water

conservation to a large extent.

• Large scale plantation program

Greenery is our passion. We are trying to green every inch of our space available in

our complex. Along the boundary we are planting trees to create green belt and in

between units, gardens are being established to enhance the green coverage inside

the complex which also enhances aesthetics. We are also contacting local govt.

authorities to give us areas for tree plantation to demonstrate our commitment towards

environment management and to protect ecological wealth of the area. Accordingly we

are doing tree plantation outside our complex also. We have planted about 3.36 lakh of

plant in and around the plant premises covering about 360 acres which is about 22% of

total plant area.

This year we have also distributed free of cost 30276 nos. of sapling to nearby educational institutions, local villagers/Panchayat.

• Online ambient air quality monitoring system Environmental monitoring is very important aspect of environment management to

know the efficacy of all the pollution control systems deployed. We have installed the

state-of-the-art 7(seven) Continuous Ambient Air Quality Monitoring Stations

(CAAQMs) inside the plant premises. The instruments installed are approved by US

EPA, TUV, CPCB & OSPCB. With the help of Y-Cable GPRS technique, our online

instrument data is transmitting to the OSPCB server in a real-time basis.

• Online stack emission monitoring system

We have installed online stack emission monitoring devices on 42 nos. of major stacks inside our integrated steel plant complex. Six stacks are also connected to SPCB server for online data transfer through GPRS.

• Online effluent quality monitoring system We have installed USEPA approved online effluent quality monitoring system at six locations inside the plant premises. These stations are now connected to SPCB server at Bhubaneswar for real time data transmission on continuous basis.

• World environmental Day celebration World Environment Day was celebrated on 5th June 2015 like previous years. Various activities were organized among children, ladies, workers, employees and local villagers to spread awareness about environmental protection, sustenance and eco-conscious growth. Details of the celebration are enclosed as annexure-10.

• Health, Safety & Environment Sankalp Health, Safety & Environment Sankalp is being organized on 1st of every month near main gate to reaffirm our commitment for safe, healthy and environmentally sound work place. Details are enclosed as annexure-11.

• Earth Day celebration Earth day was celebrated on 22nd April 2015 in the plant area. Various awareness programs were organized in the plant involving employees, workers and their family members to make them aware about environment protection. Details are enclosed as annexure-12.

• National Productivity week

National productivity week was celebrated during 12-18th February 2015 in the plant area. The theme was Make in India: Zero defect, zero effect. A detailed report on productivity week celebration is enclosed as annexure-13.

• Energy Conservation Day

Energy Conservation Day was celebrated on 14th December 2015. A detailed report on Energy Conservation Day celebration is enclosed as annexure-14.

• World Ozone Day celebration World Ozone day was celebrated on 16th September 2015 in the plant area. Various awareness programs were organized in various units of the plant. Details are enclosed as annexure-15.

• Swachh Bhushan Abhiyaan

Swachh Bhushan Abhiyaan was celebrated on 02nd October 2014 in the plant area. A detailed report on Swachh Bhushan Abhiyaan is enclosed as annexure-16.

• Additional gun sprinklers at RMHS yards.

Raw material handling and storage area consist of 10 yards covering iron ore, coal, lime stone, dolomite and quartzite. These yards are fitted with high pressure gun sprinklers to ensure zero fugitive emission during handling of raw materials.

• Installation of Dry Fog System Raw material conveying trough conveyer system is likely to generate fugitive dust especially at transfer point and junction houses. To reduce generation of dust during conveying of raw materials, dry fog systems have been installed at all potential location where dust is likely to generate during transportation.