Environment Management

1
 JSW Steel - GROWTH SINCE INCEPTION
1999 – ISP of 0.64 Mtpa was born
2001 – Capacity enhanced to 1.6 Mtpa
2004 – Capacity enhanced to 2.5 Mtpa
2006 – Capacity enhanced to 3.8 Mtpa
1.2 Mt 5.0 Mt 2.3 Mt 3.8 Mt 3.8 Mt 3.8 Mt 2.5 Mt

2 x 0.6 Mt 2.3 Mt 2.5 Mt 1.3 Mt 3 x 130 t

0.6 Mt 4.2 Mt-04 1.6 Mt 0.9 Mt 2 x 130 t 2.0 Mt

RHF 2-04
3.0 Mt 0.8Mt
0.8 + 0.8
- 00Mt 2 x 120 t

0.64 Mt 120 t 1.25 Mt

RHF 1

CO I CO II Pellet Plant Sinter Plant Corex I Corex II BF I BF II BOF I II III CCP I II III HSM

-04 06 -00 -06 -99 -01 -0

4 -0
6 -99 t-9
9 6 9

1
- -0 -9

7
v y g r

6
r l g g

r-0
v o u p g

-9
a u c r g

-0
o -N J A -A u u u p
-M 26- 08- -O u

ug
-N 28 -A -A -A

v
15 -A

Ap
19 30 14 15 A

No
19 10 7 -

-A
2 4

-
1

23
-
25

13
2
3
 STEEL - LIFE CYCLE

ORE STEEL STEEL PRODUCT

MAKING PDTS USAGE

BF-BOF FLAT CONSTRUCTION

DRI-EAF LONG AUTOMOBILES
BF-EAF WHITE GOODS

4
 Steel Products – Environment Friendly

• Very good mechanical properties

• Long product Life cycle
• Low environmental impacts
• Magnetic, 100% recyclable

Steel manufacture is not !

5
 AIR POLLUTANTS(13)
SO2, NOx, DUST
CO2

RAW MATERIALS(3)
WATER(5) STEEL STEEL PRODUCTSt(1.0)
MAKING
Air(9)

WASTEWATER : 2.0
SOLID WASTES : 1.0

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

7
 LOCAL

• AIR POLLUTION CONTROL

– CLEAN TECHNOLOGY
– POLLUTION ABATEMENT
• WASTEWATER
– INCREASED RECYCLE
– TREATMENT
• SOLID WASTES
– RECYCLE
– RE USE

8
JSW STEEL - THEN
Harsh climatic conditions
Scanty rainfall
Poor infrastructure
Non – availability of skilled man power

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Corex -Before

10
 N

Hills WIND DIRECTION

WNW (MAR – NOV)

ESE ( DEC – FEB)

Hills

WSW ( MAR – NOV)

Hills

11
 Wind Speed - scavenger of pollutants
45

40

35

30
W.S in km/hr

25

20

15

10

0
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month

Wind Speed Max Wind Speed Min Wind Speed Avg

12
 Solar Radiation - Facilitates convective
1000.00 movement of pollutants
900.00

800.00
Solar radiation in W/m2

700.00

600.00

500.00

400.00

300.00

200.00

100.00

0.00
00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00 :00
6: 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 0 1 2 3 4 5

Tim e

Solar Radiation in W/m2

13
 Mixing heights – Lid for pollution

1600
1400
1200
1000
800
600
400
200
0
14
 Rainfall

300

250

200
Rainfall in mm

150

100

50

0
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month

Rainfall Max Rainfall Min Rainfall Avg

15
 Evaporation Rate

2.5

2
Evap.Rate in cm

1.5

0.5

0
Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec
Month

Without Evaloc With Evaloc

16
 Relative Humidity

120

100

80
R.H in %

60

40

20

0
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month

Relative Humidity Max Relative Humidity Min Relative Humidity Avg

17
 Temperature

50

45
40
Temperature in Deg.C

35
30
25
20
15
10
5
0
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month

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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 SCHEMATIC DIAGRAM OF CONVENTIONAL BYPRODUCT PLANT

Coke to Clean COG

Blast Wash oil to Consumer
Furnaces Sulphuric acid Departments

Crude
Coke
COG Gas Ammonia Benzol
Oven ETP Exhausters
Cooling Removal Removal
Battery

Ammonium
Ammonia
Coal Tar Excess Sulfate for
Liquor Hydro-Refining
Decanters Liquor sale
Distillation Unit

Biological
Oxidation Benzene Still
plant Toluene Bottoms
Solvent
Treated
Naphtha
Tar Water Xylene
Distillation Used for Quenching

ETP – Electrostatic Tar

Light Wash HP Anthracene Phenol Pitch CT Precipitation
Oil Oil Naphthalene oil Fuel
COG – Coke Oven Gas 23
 SCHEMATIC DIAGRAM OF BYPRODUCT PLANT AT JSW STEEL

Coke to
Blast
Furnaces

Crude Clean
Coke
COG Gas H2S Ammonia Desulphurised
Oven ETP Exhausters
Cooling Removal Removal COG to
Battery
Consumers

Ammonia
Coal Tar Excess Ammonia
Liquor
Decanters Liquor Cracking
Distillation Sulfur
Removal Cracked
Tar Biological N2 & H2
Storage Oxidation to BF gas main
Treated
Water
Tar for sale To Coke quenching Sulfur for sale

ETP – Electrostatic Tar

Precipitation
COG – Coke Oven Gas 24
 Steel Making Steel Finishing

Coke Ovens HSM

Sintering Wire Rod Mill
Slabs/Billets
Blast Furnaces Re Bar Mill
BOF Cold Rolling Mill

Surplus BFG,LDG,COG & Corex

BFG,LDG,COG 300-350 MCal/t
& Corex ~ 35 Kg LPG/t

Surplus to PP
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 Pollution Control Equipment - Air

I. JSW Preference for BF over

ESP.

DSS II. Design 100 mg/Nm3

Cyclone s5% 50 mg/Nm3 at 7 mtpa
8%
30 mg/Nm3 at 10 mtpa
S crubbe rs
10%
III. Pleated design of filter bags
IV. Use of gaseous fuels for
ES P
power generation
5%

Bag filters- 110 nos

ESP - 8 nos
Bag filt e rs
72%
Scrubber - 16 nos
Cyclones - 9 nos
DSS - 8 nos
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 Pollution Control Equipment-Water

S oft / D M One of the BEST in

Circu its
21% India
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
CW Circu it
21% Soft / DM water – 7 nos

D CW Circu it
58%

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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 earned
New projects underway - 20 nos

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 Raw Materials

• 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

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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

Consum
Blow Down
ptive DCW
use

Blow Down

DM/Sof ICW Blow Down

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 Good Practices- Water Management

• > 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

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 Water Cascading – Corex Plant

Corex –DM
Water Circuit

Corex –ICW Corex –Slurry

Water Circuit to PP

Corex –GCP GCP Water

Water Circuit Clarifier

Blow down to
Ore
Beneficiation SLIME POND

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 Dust & Sludge recycle

Pellet Plant
Raw material

Corex I&II
Slurry
Tank

Mixer S
I
L
BF I&II
O

Disc
Pelletier

Sludge from ETPs of BF, Corex, Dust from Bag Filters

BOF BOF,HSM,PP used in Mixer Collected in Closed Tankers

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

HSM
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 Good Practices- Solid Waste Mgmt

• 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

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 N

Hills AAQ STATIONS

(SPM, SOX, NOX VALUES)
KARADIDHAMA

GADIGANUR
(194,14,16 ) (192,13,16 )
KUREKUPPA
(353,43,18 )
SG COLONY
KUDITINI
(221,15,16 )
BASAPURA TORANAGALLU

(303,15,18 ) VADDU

(238,14,16 ) TALUR
VID.TOWNSHIP
Hills
(345,17,19 )

SULTAPURA
(316,15,18 )

Hills

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Environmental Quality monitoring

LEGEND
A6

SW3
AAQ Stations
SW2
(A1-A7)

N5 Meteorological
N7 N4 Station (M1)
A3
A4
SW4 S2
S1 GW2
SW1
S3 GW4
Surface Water Sampling
N6
S4 A1 Locations
N2 M1 (SW1-SW4)
GW1 N1
A2

Ground Water Sampling

N3 Locations
A5
GW3 (GW1-GW4)

Soil Sampling
Locations
(S1-S4)

Noise Monitoring
Locations (N1-N7)

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

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 Environmental Quality – Monthly Monitoring

1 Stacks 55
2 Work area 80
3 Water & wastewater 98
3 Noise 75
4 AAQ monitoring 205
5 EMS Visits 4

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Good Practices –Vacuum sweeping

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Good Practices – Wind curtains

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Good Practices – Water Sprays

45
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 slag

2. Desulphurisation of Coke oven gas to reduce H2S in the gas from 3.2
g/nm3 to ,0.5 g/nm3
3. Coke dry quenching
4. Top gas recovery turbine (TRT) for power generation from BF waste
gases
5. New type of gas recovery plant for coke ovens
6. 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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57