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STATUS OF SPONGE IRON UNITS IN ORISSA

Prepared by –

Environment Conservation Team

(Aruna Murthy, Himansu Sekhar Patra) September 2005

Conservation Team (Aruna Murthy, Himansu Sekhar Patra) September 2005 Vasundhara, E-14, Gajapati Nagar, Bhubaneshwar

Vasundhara, E-14, Gajapati Nagar, Bhubaneshwar

STATUS OF SPONGE IRON UNITS IN ORISSA

INTRODUCTION

Steel market in India is in a rising phase as infrastructure development has been rightly given high priority. The secondary sector of steel production has witnessed phenomenal growth in recent years. The steel production through the secondary sectors, which works only 21.39% in 1993-94, has gone up to 35.46% in the year 2001-02. The reasons are:

1. Low investment

2. Ability to produce quality steel economically through this process

3. Availability of Sponge Iron both in quality and quantity, which is a major raw material for secondary steel makers.

In the secondary sector, the steel production is mainly by EAF and induction furnace. Induction furnace route is gaining importance due to low investment cost and ability to produce quality steel at lower cost. A number of induction furnace units have been established with varied production capacity. With the increasing demand of sponge iron as the major raw material for the secondary steel makers, there is mushrooming growth of sponge iron units in the country, particularly in the eastern side. All of them have opted for coal based plants having rotary kilns.

The process of sponge iron making aims to remove oxygen from iron ore. When that occurs, the departing oxygen causes micro pores in the ore body making it porous. The final product, when observed under a microscope, resembles a honey comb structure, looking spongy in texture, hence, the name “Sponge Iron”

RAW MATERIALS REQUIRED

Sponge Iron manufacture is highly sensitive to raw material characteristics. Therefore, it is essential to examine the chemical and physical characteristics of raw materials, both individually and in combination. The basic raw materials for the production of Sponge Iron are iron ore, non-coking coal, and dolomite.

Coal: Important factors determining coal quality are:

1. Chemical properties such as fixed carbon, ash-content, volatile material, etc.

2. Physical properties such as reactivity, and ash-fusion temperature.

Iron Ore: In sponge Iron making, iron ore is reduced in solid state. Unlike in the conventional steel melting process, the gangue content of iron ore cannot be separated as a slag. Therefore, it becomes imperative to select an iron ore with a high iron content and a low gangue content, to optimize yield during steel making. Apart from this, to ensure a better kiln campaign life and output, iron ore is made to undergo a series of other tests such as – Shatter, tumbler and abrasion indices, reducibility, etc.

Dolomite: It acts in the processes as a Desulphuriser removing sulphur from the feed mix during the reduction process. It is mixed in small proportion along with other raw materials before charging into the kiln.

TECHNOLOGY INVOLVED

Production of Steel through the conventional blast furnace requires coking coal of which India has limited reserves. Therefore, evolution of a technology for the reduction of Iron Ore using abundantly available non-coking coal was contemplated, giving birth to direct reduction Iron Technology (DRI).

PROCESS

abundantly available non-coking coal was contem plated, giving birth to direct reduction Iron Technology (DRI). PROCESS
Iron ore (Hematite) and non-coking co al are the prime raw materials for the production

Iron ore (Hematite) and non-coking coal are the prime raw materials for the production of sponge Iron. These are charged into a rotary kiln in a requisite proportion along with some dolomite. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 950-1050°C. The reduction process occurs in the solid state. The crucial factor in this reduction process is the controlled combustion of coal and its conversion to carbon monoxide to remove oxygen from the iron ore. The overall process requires a duration of approximately 10-12 hrs inside the kiln, during which iron ore is optimally reduced and discharged to rotary cooler for cooling below 120°C, before coming out into the finished product circuit.

EXISTING SPONGE IRON UNITS IN ORISSA

List of Sponge Iron Units in the state of Orissa as on 28.02.2005

Sl. No

Name and Location

 

SUNDERGARH DISTRICT

1

Agrasen Sponge (P) Ltd, Mandiakudar, Sundergarh

2

Bajrang Ispat Pvt. Ltd, Kuarmunda, Sundergarh

3

Govindam Project, Kalosihira, Kuarmunda, Sundergarh

4

Jagannath Sponge Pvt. Ltd, Kuarmunda, Sundergarh

5

Jai Balaji Jyoti Steels Ltd., Tainser, Lathikata, Sundergarh

6

Jay Iron and Steels Ltd, Balanda, Sundergarh

7

Kalinga Sponge Iron Ltd., Kalunga I.E. Sundergarg

8

Khaderia Ispat Ltd., Kuarmunda, Sundergarg

9

Maa Tarini Industries Pvt Ltd, Balanda, Sundergarh

10

Mangalam Ispat Pvt Ltd, Usra Road, Kuarmunda, Sundergarh

11

Meta Sponge Pvt Ltd., Kalinga I.E.Sundergarh

12

Neepaz Mattaliks Pvt Ltd. Hariharpur, Kuarmunda Sundergarh

13

OCL India Ltd.(Sponge Iron Division) Rajgangpur, Sundergarh

14

Pawan Jay Sponge Iron Ltd., Bijabahal, kunjaharia, SUndargarh

15

Pooja Sponge Iron Ltd., kalunga I.E. Sundergarh

16

Prabhu Sponge Iron Pvt Ltd., Jhagarpur, Rajgangpur, Sundergarh

17

Reliable Sponge Pvt Ltd. Jhaliaberina, Bonan Sundergarh

18

Rexon Strips Ltd, Kumakala, Sundergarh

19

Scan Sponge Iron Ltd., Ramabahal, Rajgangpur, Sundergarh

20

Scan Steels Ltd.(Sponge Iron Division), Ramabahal, Rajgangpur, Sundergarh

21

Seeta Sponge Iron Ltd, Kalunga I.E.Sundergarh

22

Sri Balaji Metallics Pvt Ltd., Kharibandh, Sundergarh

23

Sri Ganesh Metallics Ltd., Kuarmunda, Sumdergarh

24

Srishti Ispat Ltd.(Sponge Iron Division), Bringatoli, Sundergarh

25

Sponge Udyog Pvt.Ltd, Kalunga, Sundergarh

26

Sri Mahavir Ferroalloys Pvt.Ltd., Kalunga I.E. Sundergarh

27

Suraj Products Ltd., Barapali, Kesarmal, Rajgangpur, Sundergarh

28

Swastik Ispat Pvt Ltd, Kuarmunda, Sundergarh

29

T.R.Chemicals Pvt Ltd., Barapali, Kesarmal, Rajgangpur, Sundergarh

30

Utkal Metalliks Ltd, Kalunga I.E., Sundergarh

31

Veda Vyas Ispat Pvt.Ltd., Kuarmunda, Sundergarh

 

KEONJHAR

32

Aditya Sponge and Power Pvt Ltd., Telkoi, Dubulpal, Keonjhar

33

Beekay Steels and Power Ltd, Uliburu, Nalda, Keonjhar

34

Crackers India Alloys Ltd. (Sponge) Govardhanpur, Deojhar, Keonjhar

35

Deepak Steel and Power Ltd., Topadihi, Keonjhar

36

Grewal Associates, Matkambeda, Barbil, Keonjhar

37

Hima Ispat Pvt Ltd., Barpada, Guali, Keonjhar

38

Kusum Power Met Ltd., Kutugaon, Chipinda, Keonjhar

39

MSP Sponge Iron Pvt Ltd., Haladiaguna, Gohardhanpur, Keonjhar

40

N.K.Bhojani Pvt Ltd, Rugdihi, Barbil, Keonjhar

41

OMDC Sponge Iron Plant, Thakurani, Keonjhar

42

Orion Ispat Ltd, Ramachandrapur, Keonjhar

43

Orissa Sponge iron Ltd.palasapanga, Keonjhar

44

Rungta Mines (Sponge Iron Division), Karakola, Barbil, Keonjhar

45

Sri Ganesh Sponge Iron Ltd., Kutugaon, Keonjhar

46

Sri Metallics Ltd., Loidapada, Keonjhar

47

Sumrit Metallics Pvt Ltd., Soyabali, Barbil, Keonjhar

48

Tata Sponge Iron Ltd., Bilaipada, Joda, Keonjhar

 

DHENKANAL

49

Scaw Industries Pvt Ltd., I.E., Gundichapada, Dhenkanal,

 

ANGUL

50

Shree Metallics Ltd., Amalapada, Anugul

 

JAJPUR

51

Surya Sponge Iron Ltd., Kalkala, Budakendua, Jajpur

 

MAYURBHANJ

52

Shiv Shakti Sponge Iron Ltd., Pandersil, Mayurbhanj

 

SAMBALPUR

53

Maa Samaleswari Sponge Iron Ltd., Kattarbhaga, Rengali, Sambalpur

54

T.R. Chemicals Ltd., Belpada, Bamara, Sambalpur

 

JHARSUGUDA

55

Bahgavati Steels Pvt.Ltd., Badmal Jharsuguda

56

L.N.Metallics Ltd., Siripura, Jharsuguda

57

Pawan Sut Sponge Iron Pvt Ltd., badmal, Jharsuguda

58

Sri Madhav Ispat Ltd., Siriapali, Parmanpur, Jharsuguda

59

SMC Power generation Pvt Ltd, Hirma, Jharsuguda

60

SPS Sponge Iron Ltd, Badmal, Jharsuguda

 

CUTTACK

61

Shiva Metallics, Suniamuhan, Mancheswar, Cuttack

LIST OF SPONGE IRON PLANTS GRANTED CONSENT TO ESTABLISH (NOC) As on 14.12.2005

         

Kiln No

Sl. No

Name of Industry

Location

Block

District

(Capacity

in TDP)

1

M/s Shisti Ispat Ltd (Sponge Iron Div.)

Budhakata,

 

Sundergarh

2

X 100

Bringatoli

2

M/s Sri Mahavir Ferro Alloys Pvt. Ltd.

Kalunga Industrial Estate

 

Sundergarh

2

X 100

3

M/s Suraj Products Ltd.

Barapali, Kesarmal, Rajgangpur

 

Sundergarh

3

X 50

4

M/s Mangalam Ispat (P) Ltd.

Usra Road,

 

Sundergarh

1

X 100

Kuarmunda

5

M/s Neepaz Metalliks Pvt. Ltd

Chadrihariharpur,

 

Sundergarh

5

X 100

Kuarmunda

6

M/s OCL India Ltd., (Sponge Iron Division)

Lomloi

Rajgangpur

Sundergarh

4

X 100

7

M/s Maa Tarini India (P) Ltd.

Balanda, Kalunga

 

Sundergarh

2

X 50

8

M/s T.R.Chemicals (P) Ltd.

Barpalli

Rajgangpur

Sundergarh

3

X 50

9

M/s Prabhu Sponge (P) Ltd.

Jhagarpur

Rajgangpur

Sundergarh

3

X 50

10

M/s Sree Metalliks Ltd.

Mukundapur,

 

Angul

2

X 100

Amalapada

11

M/s Shiva Metalliks (P) Ltd.

Sanuimuhan,

 

Cuttack

1

X 50

Mancheswar

12

M/s Shree Jagannath Metalliks Industries

Khaprakhai,

 

Keonjhar

1

X 100

Palaspanga

13

M/s Orion Ispat Ltd.

Ramchandrapur

 

Keonjhar

2

X 100

14

M/s N.K.Bhojani (P) Ltd.

Rugudihi, Guali,

 

Keonjhar

3

X 40

Barbil

15

M/s Surya Sponge Iron Ltd.

Budhakendua,

 

Jajpur

2

X 40

Kalkala

1X 100

16

M/s Pawanjay Sponge Iron Ltd.

Bijabahal,

 

Sundergarh

3 X 50

Kunjharia

17

M/s Orissa Sponge Ltd.

Palaspanga

 

Keonjhar

1 X 350

   

Kalunga Industrial Estate

   

1 X 50

18

M/s Utkal Metalliks Ltd.

Sundergarh

1X 40

19

M/s Shiva Shaki Sponge Iron Ltd

Pandersil, Sukruli

 

Mayurbhanj

2 X 100

20

M/s Ganesh Sponge Metalliks Ltd.

Chandrahariharpur

 

Sundergarh

3 X 100

21

M/s Hima Ispat Pvt. Ltd.

Barpada, Guali

 

Keonjhar

1

X 300

         

2

X 100

22

M/s Grewal Associates (P) Ltd.

Matkambeda

Barbil

Keonjhar

1X 100

23

M/s Pawansut Sponge (P) Ltd.

Badmale,

 

Sambalpur

 

Kukurjanga

24

M/s L.N. Metalliks (P) Ltd

Siripura

 

Jharsuguda

1

X 100

 

M/s Golden Trexim (P)

       

25

Ltd.(Beekay Steels and Power Ltd.)

Ulliboni, Nalda

Keonjhar

1

X 300

26

M/s Khedaria Ispat Ltd

Kuarmunda

 

Sundergarh

1

X 50

27

M/s Cracker India Alloys (P) Ltd.

Gobardhanpur,

 

Keonjhar

1

X 100

Deojhar

28

M/s Sponge Udyog (P) Ltd.

Jaibahal, Kalunga

 

Sundergarh

1

X 100

29

M/s Sumrit Metalliks (P) Ltd

Soyabali, Barbil

 

Keonjhar

1

X 50

30

M/s Aarati Steels (P) Ltd

Ghantikal,

 

Cuttack

2

X 500

Athagarh

31

M/s Rungta Mines Ltd., (Sponge Iron Division)

Karakolha

Barbil

Keonjhar

4

X 500

32

M/s Agrasen Sponge (P) ltd

Mandiakudar

 

Sundergarh

2

X 50

33

M/s Bajranga Ispat (P) Ltd.

Naikinbahal,

 

Sundergarh

2

X 40

Kuarmunda

1

X 100

34

M/s Vedvyas Ispat (P) Ltd

Gobira, Kuarmunda

 

Sundergarh

1

X 100

35

M/s Sri Ganesh Sponge Iron (P) Ltd.

Kutugaon, Chipinda

 

Keonjhar

1

X 100

36

M/s Tata Sponge Iron Ltd. (Expansion)

Bileipada, Joda

 

Keonjhar

2

X 375

37

M/s Kusum Power Met (P) Ltd

Kutugaon, Chipinda

 

Keonjhar

2

X 50

1

X 100

38

M/s Meta Sponge (P) Ltd.

Kalunga Industrial Estate

 

Sundergarh

1

X 40

39

M/s Gobindam Project (P) Ltd

Kalosihira,

   

1

X 100

Kuarmunda

40

M/s OMDC Ltd

Dalki, Thakurani

 

Keonjhar

1

X 100

41

M/s Puja Sponge (P) Ltd

Kalunga Industrial Estate

 

Sundergarh

1

X 100

42

M/s SMC Power Generation Ltd.

Hirma

 

Jharsuguda

1

X 300

43

M/s Kalinga Sponge Iron Ltd.

Kalunga Industrial Estate

 

Sundergarh

1

X 100

44

M/s Rungta Mines Ltd.

Kamando

 

Sundergarh

 

45

M/s Scaw Industries (P) Ltd

Gundichapada

Dhenkanal

1

X 300

Industrial Estate

46

M/s Bindal Sponge Ltd.

Sunakhani, Talcher

Angul

1

X 300

47

M/s Jagannath Sponge (P) Ltd.

Kuarmunda

Sundergarh

1

X 50

48

M/s Maa Samaleswari Sponge Iron ltd.

Katarbagha,

Sambalpur

1

X 100

Rengali

49

M/s SMS Sponge Iron Ltd.

Badmal

Jharsuguda

6

X 100

50

M/s Sree Madhab Ispat (P) Ltd

Siriapali

Jharsuguda

2

X 100

51

M/s Swastik Ispat Pvt. Ltd.

Naikinbahal,

Sundergarh

1

X 50

Kuarmunda

52

M/s Jyoti Iron & Steel Ltd.

Tainsar, Lathikata

Sundergarh

2

X 100

53

M/s Nixon Steel & Power Ltd

Kalunga Industrial Estate

Sundergarh

1

X 350

54

M/s Seeta Sponge Ltd

Kalunga Industrial Estate

Sundergarh

1

X 50

55

M/s Bhushan Steel

Telkoi, Rengali

Sambalpur

2

X 500

   

Balisuan,

   

56

M/s MSP Sponge Iron (P) Ltd

Haladiaguna,

Gobardhanpur

Keonjhar

2

2

X 40

X 50

57

M/s Scan Sponge Iron Ltd

Ramabahal,

Sundergarh

1

X 50

Rajgangpur

58

M/s Atcom Metalliks Ltd.

Gundichapada

Dhenkanal

 

Industrial Estate

59

M/s Agarwal Minerals

Rugudi

Keonjhar

 

60

M/s Aditya Sponge & Power Ltd.

Telkoi, Dubulapal

Keonjhar

2

X 100

61

M/s Deepak Steel & Power Ltd.

Tapadihi

Keonjhar

2

X 50

2

X 100

62

M/s Sumasankar Sponge Iron (P) Ltd

Khuntaketa

Keonjhar

 

63

M/s Ganesh Sponge (P) Ltd.

Krushnachandrapur,

Angul

1

X 100

Parang

64

M/s Bhushan Steel & Strips Ltd.

Meramundali

Dhenkanal

 

65

M/s Dinabandhu Steel and Power Ltd.

Kalinga Nagar, Industrial Growth Centre

Jajpur

 

66

M/s Samaleswari Ferro Metals (P) Ltd

Bisalkhinda, Sasan

Sambalpur

1

X 100

67

M/s Maa Shakumbari Sponge

Naikinbahal,

Sundergarh

1

X 100

Kuarmunda

68

M/s Reliable Sponge Pvt Ltd.

Jhaliaberena, Bonai

 

Sundergarh

1

X 100

69

M/s B.R.Sponge & Power Ltd.

Bad-Tumkela,

 

Sundergarh

2

X 100

Rajamunda

70

M/s Rana Sponge Ltd.

Kulei

 

Dhenkanal

 

71

M/s Maheswari Ispat Ltd.

Rampei, Khuntuni

 

Cuttack

2

X 100

72

M/s Jay Iron & Steel Ltd.

Balanda, Kalunga

 

Sundergarh

 

73

M/s Ores ispat Pvt. Ltd.

Gurundipalli

 

Sundergarh

 

74

M/s Balajee Metalliks (P) Ltd.

Khairabanda

 

Sundergarh

1

X 50

75

M/s Bhagabati Steel (P) Ltd

Kukurjanga,

 

Jharsuguda

1

X 50

Badmal

76

M/s T.R.Chemicals (P) Ltd.

Belpara, Basra,

 

Sambalpur

1

X 100

Bonai

77

M/s Rexon Strips Ltd.

Kumkela

 

Sundergarh

2

X 100

78

M/s Scan Steels Ltd.(Sponge Iron

Rambahal

Rajgangpur

Sundergarh

1

X 50

Div)

79

M/s Sree Metalliks Ltd.

Loidapada

 

Keonjhar

2

X 50

4

X 100

80

M/s Maa Vaishnavdevi Sponge Ltd.

Kalunga Industrial Estate

 

Sundergarh

2

X 50

81

M/s Vasundhara Metalliks (P) Ltd

Podajalanga, Bilaimunda, Himgir

 

Sundergarh

1

X 50

82

M/s Singhal Enterprises

Hirma

 

Jharsuguda

1

X 100

83

M/s B.R.G.Steel (P) Ltd.

Kurunti, Puspanga

 

Dhenkanal

 

84

M/s Mahakali Ispat (P) Ltd.

Gurundipali, Bonai

 

Sundergarh

 

85

M/s Sree Sai Sradha Steels (P) Ltd.

Bijabahal,

 

Sundergarh

1

X 25

Kunjharia

86

M/s Bhaskar Steel & Ferro Alloys Ltd.

Bad-Tumkela,

 

Sundergarh

1

X 300

Rajamunda

87

M/s Surendra Mining Ind (P) Ltd.

Bakhamusa, Bonai

 

Sundergarh

 

88

M/s Shyam DRI Power Ltd.

Pandloy, Rengali

 

Sambalpur

 

89

M/s Deepak Steel & Power Ltd.

Kuliguna, Nalda

 

Keonjhar

 

90

M/s K.J.Ispat Ltd.

Jakhapura, Kalinganagar Industrial Complex

 

Jajpur

 

91

M/s Sri Hari Sponge (P) Ltd.

Kendrikela, Bonai

 

Sundergarh

 

92

M/s Shiv Metalliks (P) Ltd.

Gurundipalli, Bonai

Sundergarh

1 X 100

93

M/s Ocean Ispat (P) Ltd.

Basantapur, Joda

Keonjhar

 

94

M/s Deo Mines& Minerals

Thiberna, Bonai

Sundergarh

 

95

M/s Maa Samaleswari Industries (P) Ltd

Lapanga

Sambalpur

2 X 100

96

M/s Jai Hanuman Udyog Ltd.

Raghunathpalli,

Jharsuguda

1 X 100

Kolihira

97

M/s Maithan (Mal) Industries Ltd.

Kalinga Nagar, Ind. Complex, Duburi

Jajpur

 

98

M/s Aryan Ispat & Power (P) Ltd

Rengali

Sambalpur

 

99

M/s Monica Holdings (P) Ltd

Bad-Tumkela,

Sundergarh

 

Bonai

100

M/s Vishal Metalliks (P) Ltd

Barhamusa

Sundergarh

 

101

M/s Vikram (P) Ltd.

Tumkela

Sundergarh

 

102

M/s Action Ispat & Power (P) Ltd

Pondaripathor &

Jharsuguda

 

Marakutta

103

M/s B.R.G. Iron & Steel Co. Ltd.

Kurunti, Kuspanga

Dhenkanal

 

104

Kaushal Ferro Metals (P) Ltd.

Badbahal,

Sundergarh

 

Kundukela

105

R.B.Sponge Iron (P) Ltd.

Kenghati, Jayantpur

Sambalpur

 

ENVIRONMENTAL IMPACT OF SPONGE IRON UNITS

Right from the raw material yard to disposal of the final product (Sponge Iron), at every step of its handling there is pollution. Sponge Iron Plants have the following pollution hazards:

1. Dust emission during raw material preparation and product discharge and handling:

A definite size of iron ore and coal is required for the production of sponge iron. The

suppliers are not adequately equipped to cater to the needs of the sponge iron industries. Therefore, the industries crush and size the raw materials at their plant premises. During such crushing and sizing operations, generation of fugitive dust and discarded ore fines and

coal fines in inevitable. Major dust emitting areas include areas such as product discharge from cooler to conveying system, magnetic separator, and raw material preparation unit.

2. Reduction: The gaseous products of reduction contain mainly raw material dust, and gases like CO 2 , CO, H 2 , NO X , O 2 , unreacted hydrocarbons, and SO X

3. Waste water discharge: The dusts from the gaseous emissions are separated through ESP

or Gas quenching system. In either case, the disposal is done by converting the dust to a

slurry form to avoid flying of the same in ambient air. In order to recycle the water, the slurry is allowed to settle in a clari-flocculator, from where the settled solid particles are pumped out. The polluted slurry water is then allowed to settle in settling ponds, or lagoons from where the clear water is pumped back for reuse. Such water is polluted with dissolved solids.

4. Gaseous emissions: The exhaust gas emerges out of DRI kilns at a temperature of about

900°C having some quantities of combustibles. This gas is used to produce steam in waste heat boilers, which in turn is used to produce power. The dust coming from exhaust gas is either quenched to make slurry for easy disposal or is collected in dry condition or in wet condition from the ESP. So far, no utilization of this dust have been found out which causes

air pollution (due to dust) in the near by areas.

5. Char: The partially burnt coal called char is discharged from the reactor along with sponge iron. After the magnetic separation, the char is separated as waste.

PROBLEMS DUE TO SPONGE IRON UNITS IN ORISSA

In many of the sponge Iron Units in Orissa, ESP has not been installed and where it is installed, these units switch off their ESPs during the nights for a few hours. Thus, the area becomes a huge smoke bowl. In some sponge iron units in Sundergarh, it was found that the precipitators were not running in several of the units. Smoke and soot from the plants carried by the wind cause wheezing problem in kids, and cows and cattle to become restless. The smoke is sometimes so thick that vision even at a distance as close as 1 meter becomes difficult. The clothes worn by people immediately become smeared with coal dust. Even cooking utensils are covered with soot. In Kormunda (Sundergarh) where Neepaz Metallics (a 1.4 lakh tonnes sponge iron plant) is set up, the drinking water becomes covered with black soot. The emissions also cause irritation and watering of eyes in human beings.

LEGISLATION, RULES AND REGULATIONS STIPULATED FOR SPONGE IRON UNITS IN ORISSA

Government of Orissa, Forest and Environment Dept has stipulated the following regulations for the establishment of sponge iron plants in the state of Orissa.

A. In six sensitive blocks (Kuarmunda, Lathikata, Rajgangpur and Bonaigarh block of Sundergarh district, Jharsuguda Block of Jharsuguda District and Rengali block of Sambalpur district) including 25 Km from block boundary –

No new sponges iron & integrated steel plant will be allowed. Cases which had been received by the state pollution control board before the Government decided on a prohibition on establishment of sponge iron plants in the state may be considered individually un merit. These proposals can be considered on case to case basis with the condition that they set up a WHRB with a Power plant within 1 year Proposals of establishment of integrated steel plant where MOUs have already been signed with the state government may be considered on merit Expansion proposals received by the SPCB before the decision on prohibition on establishment or expansion of sponge iron units was made by the government may be considered on merit within a condition to install WHRB and/or steel plant. Expansion of existing plant will be allowed for 25/50 TPD to 100TPD for the purpose of installation of WHRB and power plant.

B. Outside the six sensitive zones

Cases which had been received by the state pollution control board before the government decision on prohibition to establish sponge iron plant in the state may be considered. These proposals can be considered on case to case basis with the condition for installation of WHRB power plant within 1 year. Cases where MOUs have been signed with the State Government may be considered. Cases other than the above 2 shall not be considered till an environmental impact study of the existing units as well as proposed units is done and it is examined by the SPCB in consultation with steel and mines and industries department. Expansion proposals of existing sponge iron units may be considered to facilitate installation of WHRB with CPP or expansion to integrated steel plant. Proposal for integrated steel plants through DRI route may be considered by sSPCB on the basis of merit.

C. The pending cases (i.e. Proposals received before the Government’s decision on the prohibition on establishment of sponge iron) may be cleared with stipulation of installation of ESP, with separate energy meter, automatic change over to DG set and other pollution control measures as decided earlier or, recommended by the state pollution control board. In addition, explicit stipulation for installation of Waste Heat Recovery Boiler (WHRB) with CPP or upgradation of the unit to steel plant within a period of 1 year from the date of issue of the NOC shall also be made.

D. The existing sponge iron units shall be required to install WHRB with CPP within 1 year and take immediate steps for installing equipments for automatic changeover to DG set in case of power breakdown and for installation of separate energy meter as well as other pollution control measures as per the direction of SPCB.

MITIGATORY MEASURES – VASUNDHARA’S APPROACH

1. Study the utilization of Char as Activated Carbon:

It has been found that the reactivity of char is high. So, in some cases, a limited quantity of char can be recycled back to the rotary kiln with good results. Char can be used to manufacture activated carbon and as domestic fuel.

2. Study of utilization of Char Fines in Fuel Briquettes formation:

The briquettes manufactured from coal char mixed with coal fines are used as a fuel in brick kilns. The rejects and wastes of bricks have been reduced considerably with the use of these briquettes, besides reduction of cost of fuel.

3. Study of utilization of Exhaust Gas Dust for building bricks:

Exhaust Gas Dust can be used for building bricks for construction purposes.

4. Establishment of Waste Heat based power plants:

Suggest the establishment of Waste Heat based power plants to encourage utilization of waste gases. Suitable amendment to the state legislation has already been proposed - Proper implementation and execution must be ensured.

5. Research on DRI Plant Waste:

The research organizations of the state must rise to the occasion to find methods for utilization of the DRI Plant Waste; because the growth potential of DRI plants in the country is quite high and steel production through DRI and induction furnace route is the cheapest of all the processes in the world today.

6. Ensure control on the pollution from the DRI plant through:

Installation of suitable de-dusting/ dust extracting equipments at dust emitting points. Suitable gas cleaning equipment such as ESP or gas quenching system should be installed. Ensure suitable methods of storing of raw material waste (raw material fines) and disposal of the same. Suitable disposal of the sludge of waste water and reuse of wastewater. The most effective way is to save all waste water for reuse without allowing them to mix with any other waste stream. Utilization of waste char for water purification, making domestic fuel briquettes, and as activated carbon. The stockyard should be judiciously planned to avoid flying of dust in air.

CONCLUSION

It is a fact that the gainful utilization of the generated wastes plays a vital role in the profitability of any organization. From the foregoing discussions, it is clear that the utilization of DRI plant wastes need to be strengthened in order to abate future threat to the environment, besides generating profits for the organization.