1 Excellence In Water Management By V.S.Subramani DGM (WMD)/VSP VIZAG STEEL - PROFILE First shore-based pl ant of 3.

0 MT liquid steel capacity - operating at 120 % . Certi fi ed for all 3 International standards of ISO 9001,14001 & 18001. Set up with lat est CDM t echnologies like 100% LD gas recovery, dry quenching of coke,100% Cast House Slag Granulation and Torpedo Ladl e for transporting liquid hot metal. The Company is primarily manufacturing Long P roducts like Bars, Wire rods, Rebars, Rounds, Channels, Angl es et c., which are mostly used in Construction Indust ry. Company’s products enjoy premium in the local Market. Major Production cat ers to Domestic Market. Gross turnover during 07-08 is 10,433 Cr & Net profit after tax is 1,943 Cr against previous year fig of 9,151 Cr &1,363 Cr respectively. Growth: Phase Capacity (Mt) Invest ( C r) Cum Invest (Cr) I (09-10) 6.8 9192 9192 II 8.5 2220 11412 III 13.0 8400 19812 IV (BY 2020) 16.0 6000 25812 2 Water in steel industry • Equipment cooling • Absorption / removal of heat • Steam generation • Drinking and sanitary purpose • Fire fighting • Plant process • Gas scrubbing / cleaning TYPICAL WATER CIRCUIT IN VSP YELESHWARAM RESERVIOR KBR RAW WATER RWTP TREATMENT TREATMENT FIRE AND DRINKING WATER FOR INDUSTRY MAKE UP WATER FOR INDUSTRIAL USE DRINKING WATER TREATMENT FOR TOWNSHIP 3 BASIS FOR REPORTING OF QUANTITIES ØMA KEU P W AT E R C ON S UM PT I ON F O R TH E PL AN T I S RE COR DE D FROM T HE ON LINE F LOW METER INSTA LL ED IN MAKEUP WATER PUMP HOUSE Ø CO N S UMPT I O N I N IN DI V I DU AL R E CI R CU LAT I O N PUMP HO U S E S I S ME A S U R E D B Y O N L I N E F LOW ME T E R AN D MEASURING TIME TO TIME WITH ULTRASONIC FLOW METER Ø INTAKE WATER INTO RESERVOIR IS MEASURED FROM THE PARSHALL FLUME READINGS RECORDED JOINTLY BY STATE GOVT. & VSP Employees/Community Involvement in Water Conservation èMass Awareness through Individual Responsibility ØScroll in Cable TV & Pamphlet Distribution

7 470 34 Installation of 2 nos of pumps in diversion channel to recove r rain water 5 Introduction of Jan. Exploring additional sources.ØAppeal through Recorded Voice in telephones (dial tone) wide publicity of Tel nos of contact persons for water leakages etc. 06 1752000 105 500 45 . Identification of waste water sources for immediate implementation.55. • Water Recirculation & conservation • Complete chemical Treatment • Converting Waste Water into Makeup water grade • Recovery of metallurgical waste and recycling of water • Technological Discipline • Cost economics at every step • Periodic review of all step CONSTRUCTION --.550 DM WATER 5399 --. èDiscussions in departmental union and samalochana meetings èSpecial suggestions drive through suggestion melas èFormation of separate QCs èPropaganda at schools èMessage by CMD & Directors in various forums èFormation of Special inspection groups in various departments èMeetings with canteen contractors è Monitoring by Higher Management through Presentation by Environment Mgmt Dept on all water wastage points in ED (Works) coordination meetings. è Extensive re-cycling.62700 1380 RM 5140 10680 15820 40 SMS 5415 6160 11575 260 BF 12865 9520 22385 270 SP 900 1926 2826 70 COCCP 10052 980 11032 265 ZONE CLEAR CONTAMINATED TOTAL MAKE -UP WATER RECIRCULATION IN Cu.1000 10 ASP 9920 --.494 3750 DRINKING --.M /Hr WATER MAPPING FOR PLANT WORKS 5 VARIOUS WATER CONSERVATION MEASURES (IN LAST 4 YEARS) July 06 438000 165.432 25 TPP 62700 --.2200 130 CH-2 1000 --.4000 10 CWP-1 5250 --.9920 80 CWP-3 4000 --.5250 10 AS 432 --.5399 400 SOFT WATER 2200 --. 4 Total Water Management • Water Balancing & Water Audit • Treatment & Freezing the end user requirement for various processes • Supply and distribution of water through out the plant at required quality & quantity parameters. Eliminating all wastages.250 TOTAL 1.

5 2.9 Utilizing Cooling tower – 21 blow down in SMS 3 June 05 175200 10.56 2 1 Diversion of exhaust cooling water in BHS 1 to PH -6 9 Ma r 07 876000 131.5 1.4 296 27.mtr/Hr 1 Rs.8 Utilizing Cooling tower – 22 blow down in Mills 2 Jun 04 2190000 131.Ultra Filter plant 4 Aug.03 Recycling of Secondary Sp ra y Cooling water in SMS 250 Cu.40 200 18 Replacement of damaged pipe lines in various   . Ma de Annual Wa ter Year of Sav ings Implementation Title of Wa ter Sav ing proj ect implemented Sl No VARIOUS WATER CONSERVATION MEASURES (IN LAST 4 YEARS) Feb 08 438000 65.40 585 54 Settling tanks for recove ry of metallurgical waste 8 Ma r 07 876000 131.5 2. 10 Dec 07 350400 52.7 2. 05 262800 15. Lakhs Rs. Lakhs m3 Payback Period (Months) Inv est.70 100 18 Renovation of all cooling towers in coke ove n area.

18 nos. /hr. STREGTHENING COOLING SYSTEM IN COKE OVEN Problem Identification: • High Temperature of recirculation water • Huge Drift loss • In effective Cooling 7 STREGTHENING COOLING SYSTEM IN COKE OVEN Modification: • Total renovation of cooling tower includes • Replacement of existing 2 layer fill system to 3 layer • Replacement of Asbestos Drift eliminators by PVC waves and bushes STREGTHENING COOLING SYSTEM IN COKE OVEN Result : • Water saving incurred out of modification of drift eliminators : 50 cum. • Elimination of water spillage to the surroundings.94 nos. Lakhs Rs.zones 7 Jan 07 438000 165. Ma de Annual Wa ter Sav ings Year of Implementation Title of Wa ter Sav ing proj ect implemented Sl No 6 RAIN HARVESTING PROJECTS Vizag Steel has implemented Rain Harvesting measures in a big way as mentioned below : ‾Masonry Check Dams . ‾Percolation Pits . ‾Recharge Wells . . Lakhs m3 Payback Period (Months) Inv est. ‾Earthen Check Dams . • Increased deltaT by 2 – 3 degrees improved the performance of various heat exchangers of coke ovens.7 470 34 Provision of side stream Filters at TPP PH-04 6 Rs.9 nos.1 no.

76 2.33 Vizag Steel’s specific water consumption (cubic meter / ton of liquid .0 03-04 3.56 2.5 China Steel. PRODUCTION 06-07 3.31 04-05 3.t. Taiwan 2.• Cost benefit analysis: • Investment made against procurement of fills and drift eliminators and execution : Rs.5 Bluescope steel Australia As compared to 3.70 lakh per annum 8 WATER CONSUMPTION w. 100 Lakhs • Hence direct Tangible savings : Rs.5 MGD Addtl cons.2 Thyssen Krupp Germany 3.8 6.0 02-03 3.08 35 00-01 2.88 3.6 POSCO 2.61 24.0 ( Due to Construction Activity – 1.56 26.33 4. 65. UK 4.31 2.4 01-02 3. ) 07-08 3.7 7.96 3.0 70 CONSUMPTION (MGD) PRODUCTION YEAR (MT Liq steel) 10.29 2.60 25. WATER CONSUMPTION IN VSP AS COMPARED TO STEEL MAJORS 4.91 40 DESIGNED 3.33 9 SPEC.34 31.7 Corus.0 26.r.5 05-06 3.51 27.

Ø Gol den Peacock award for Environmental manag ement by world Envir onmental .COCCP leakages. us es like fire fighting. toilet flus hing etc.5 Marine Dischar ge Pipe Line Tre ate d wa ter will be use d in soft water network 80 Rev erse Osmosis 18.450 Collec ting Ta nk 11.steel) Source : collected By Sri Ramesh Prasad AGM / Vizag Steel at interna tional forum “IISI” held at Amsterdum. 20. dus t suppression.5 Sewage from the exis ting plants Tre ate d wa ter will be use d as make up in TPP S ys tem and in soft water ne twork Rev erse Osmosis 43.15 500 (incl uding expansion units) Appikonda Tre ate d wa ter will be use d in the expa nsion area for misc. SCHEMES TOWARDS ZERO DISCHARGE To pump out wa ter fr om MBC. CORUS STEEL. garde ning. Oil separation e tc. Balacher uv u 300-350 Remarks Estima ted Cost in Rs in crores Type of treatment Qty of wa ter to be rec ycled in cum/hr Source Total Expected Water Recovery = 1050 cu m / hour 10 VSP – OTHER AWARDS Ø CII – EXIM Bank awar d 2007 for Significant Achievement .6 Sewage from the expansion units Tre ate d wa ter will be use d in COCCP recircula tion sys tem 80 Rev erse Osmosis 21. rej ects from RO pla nt (S TP-!) 300 .1 Physical trea tment like settli ng/clarri fication.

Foundation – 2006 Ø Nati onal energ y conser vati on award – 2006 (7 times i n row) for Energ y effici enc y (First prize for 3 consecuti ve years and also a special award for achievi ng th is).CII HR Excellence Awar d 2006 for Excellence i n HR processes and practices. Ø Nati onal awar d for excell ence i n Water Management by CII–2006 (three consecuti ve year s)..2006 . Ø Str ong Commitment .CII Exim Bank Awar d for Business Excell ence 2006 for Overall Excellence i n all acti viti es of the company. Ø Organi zational Excell ence Awar d for Effici ent sugges tion scheme operation g i ven by INSSAN – 2006 Ø Best Industri al Producti vi ty Award (Jawaharl al Nehru Sil ver Rolling Trophy) fr om FAPCCI for Outstandi ng pr oducti vity in steel producti on. Ø Commendati on prize for str ong commi tment to Excell ence .

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