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STEEL LIMITED BRINGING ALIVE A BILLION DREAMS
FLOW OF PRESENTATION
12
JSW Steel Overview
Steel Making- Process Route23
Steel Making- Process Route
Environment Management at JSW
4 Best Practices Case Studies
Steel making capacity of 14.3 MTPA 6 manufacturing facilities in India
VASIND / TARAPUR
JSW STEEL - COMPANY AT A GLANCE
HR Coils
HRPO Hot Rolled
HSM Plates
DOLVI
VIJAYANAGAR
KALMESHWAR
SALEM
Integrated Steel Plant Downstream Plant
Slabs
HRPO Coils
Coated Products
Cold Rolled CA,GL
Long Products
Hot Rolled Plates
HISTORICAL BACKGROUND
The foundation stone for “Vijayanagar Steel Plant”
under Public Sector, was laid by then India’s PM,
in 1971
More than 20 years later, in spite of Economic
BIRTH OF JSW STEEL
More than 20 years later, in spite of Economic
Liberalization in 1992, no one came forward to
fulfill the dreams of the PM, because none
considered it a viable proposition
The invitation from the Govt. of Karnataka in 1994,
& naturally was accepted as a challenge:
THUS, JINDAL VIJAYANAGAR STEEL LIMITED WAS FORMED IN 1994
Barren Land
Inadequate Water Source
No Electricity
CHALLENGES
THIS WAS VIJAYANAGAR WHEN WE ARRIVED
THIS IS WHAT WE MADE OUT OF IT…
No Electricity
Poor Road And Rail Connectivity
Poor Infrastructure
Non Availability Of Carbon Fuel
People To Build / Operate
Low Quality Iron Ore
MILESTONES
0.8 1.6 2.5 3.8
6.8
10*
1999 2001 2004 2006 2009 2011
*Production capacity for Vijayanagar Works only
FLOW OF PRESENTATION
12
JSW Steel Overview
Steel Making- Process Route23
Steel Making- Process Route
Environment Management at JSW
4 Best Practices Case Studies
Coal CoalIron ore Fluxes
Coke Oven
SinteringPelletization
Beneficiation
Lu
mp
ore
Lu
mp
ore
JSW: Process Flow
HSM CRM
Billet Caster
Converter LHF, RH Slab Caster
HMPT
Corex Blast Furnace
Wire Rod / Re Bar Mill
WIDE RANGE OF PRODUCTS – FLAT AND LONG
Products
HR - CoilsSlabs Plates & Sheets
HRPO, HRSPO, CRFH and CRCA Wire Rods TMT Bars
Low grade Iron Ore Upgradation
UNIQUE PLANT CONFIGURATION
Pellet Plant + Sinter Plant
Heat Recovery + Gas Recovery
Corex + Blast Furnace + DRI
Beneficiation
Coke making
Iron making
Iron ore agglomeration
Convertor + EAF
Cement + Sand
Self reliant in Power
Flat + Long Products
Steel Making
Slag Utilization
Power plant to utilise gases
Mills
Above configuration provides flexibility w.r.t raw material usage and makes JSW Steel
ENVIRONMENT FRIENDLY STEEL PLANT WITH ZERO EFFLUENT DISCHARGE
FLOW OF PRESENTATION
12
JSW Steel Overview
Steel Making- Process Route23
Steel Making- Process Route
Environment Management at JSW
4 Best Practices Case Studies
ENVIRONMENT MANAGEMENT ACTIVITY
Environment Management Department
Projects , Planning and
O&M
O&M
Projects
Environmental Compliance and
Monitoring
Statutory Clearance
and compliance
Monitoring-Manual and Continuous
Department
Environment Management
System
Air
Water
Solid Waste
ECC
Sustainability and
Management Systems
Sustainability & Awards
Management System and
TQM
ExternalInternal
INPUT
AIRWaste gases : 14 tonsWater vapor: 3.0 tons
STEEL MANUFACTURING - MASS BALANCE
JSW Steel
INPUTRaw materials: 3.8 tonsWater : 4.0 tonsAir : 12 tons
WASTESWastewater : 1.0 tonsSolid wastes: 0.8 tons
OUTPUTSteel : 1 ton
Energy Intensive
Environmental Infrastructure
Air Water Solid Waste
ESP 18 RWTP 9 Micro pellet plant 1600 TPD
Bag Filter 223 RO Plants6 Units (17650 m3/day)
MSB Plant 600 TPD223 RO Plantsm3/day)
600 TPD
Scrubbers 32 ETP 9 Units Incinerator 250 kg/hr
Dry fog 112 Guard Ponds 3 Centralized Oil Storage 1 Unit
CEMS 35 ZLD Plant 1 WWP 1000 TPD
Online Flow meters
7
100
120
140
160 150 150
100
mg/Nm3
JSW Steel Dust Norms - getting stricter
0
20
40
60
80
4 Mtpa 7 Mtpa 10 Mtpa 16 Mtpa
50 5050
30
10
Norm Design consideration
mg/Nm
Secondary Fume Extraction(SMS-2) Sinter Plant-3 Process ESP
Air Pollution Control Performance Assurance
• Choice of APC equipment- Preference towards Bag filters
• Periodic audit of APC health through internally developed audit methodology.
• Centralized Procurement of filter bags to ensure Quality Control
• In house Bag Filter Testing laboratory
Fugitive Dust Emission Control (PM 10)Infrastructures
• Dust Suppression System
• Wind curtains
• Paved areas
• Vacuum Cleaning
• Tyre washing • Tyre washing
• Surveillance through high resolution CCTV Cameras.
• Internally developed audit methodology for junction house and transfer tower
healthiness
• Dedicated water spraying tankers to suppress dust
Administrative Measures
Fugitive Emission Control
Foam Dust Suppression System Dust Suppression SystemFoam Dust Suppression System Dust Suppression System
Vacuum sweeping in shops Vacuum sweeping on roads
Fugitive Emission Control
Spraying in RMHSSpraying in stock yards with latex Spraying in RMHS
Water Spraying in coal yard Wind Curtain in Energy yard
Spraying in stock yards with latex
Water usage – Company “Policy”
1. Efficient use of water
• Reduction of evaporation rate
• Maximize use of alternate sources rain water & seepage.
• Reduction of fresh water in closed circuits by higher COC.
• Reverse osmosis plant for recovering good quality water.
2. Zero Discharge
• Cascading usage of water
• Use of blow down water in other processes
• Treated sewage for makeup
Guard Pond-1Guard Pond-2
Towards ZERO water discharge (ZLD)
Slag & Coke quenchingOre washing
Environmental Performance - Water
Continual
improvement
measures to
reduce Specific
Water
Consumption in
spite of
continuously 2.86
2.91
3.02
3.09
3.15
2.8
23
54
63 64
54
20
30
40
50
60
70
2.8
2.9
3
3.1
3.2
Spe
cifi
c W
ate
r C
on
sum
pti
on
, m3/T
CS
% o
f K
rish
na
Wat
er
Use
d
CREP Guidelines : 5.0 m3/tcs - Long ProductCREP Guidelines : 8.0 m3/tcs - Flat Product
continuously
increasing TDS
(due to increase
in usage of
Krishna water
with 45% higher
TDS)
2.8
00
10
20
2.6
2.7
2.8
2010-11 2011-12 2012-13 2013-14 2014-15 2015-16
Specific Water Cons, m3/TCS % of Krishna River Water Used
Spe
cifi
c W
ate
r C
on
sum
pti
on
, m
% o
f K
rish
na
Wat
er
TDS Value of Krishna River Water:350 mg/LTDS of Tunga Bhadra River Water:200 mg/L
Variation in Inlet Water TDS and Specific Water Consumption
1.50
2.00
2.50
3.00
3.50
4.00
200
250
300
350
400
450
TDS,
mg/
L
Sp. W
ate
r C
on
sum
pti
on
, m3
/TC
S
0.00
0.50
1.00
1.50
0
50
100
150
200
TDS (TB Dam) TDS (Almatti Water) Sp. Water Consumption
TDS,
mg/
L
Sp. W
ate
r C
on
sum
pti
on
, m
Month
Zero Liquid Discharge Plant
FLOW OF PRESENTATION
12
JSW Steel Overview
Steel Making- Process Route23
Steel Making- Process Route
Environment Management at JSW
4 Best Practices Case Studies
The organic chemical laden effluent from coke oven byproduct is treated through MBR+ RO system
4000 m3/day of treated clear water of high quality is generated
• MBR technology incorporated for Shankar Hill Town(SHT) Sewage Treatment Plant( STP)
• The high quality treated water of 3000 m3/day is used as replacement of make-up water in CRM-2 water systems
MBR ZLD at Coke oven
• Objective: Produce Slag Sand for
Concrete
• Project Cost: Rs. 2 Cr.
Slag Sand Preparation Unit
Environmental Control Measures 2014-15
• Vertical Shaft Impact Crushed (VSI)
• Plant capacity: 40 tonnes/day
• The unit produces sand meeting the
IS-383 gradation requirements
• Environmental Friendly alternative to
river sand
Environmental Control Measures 2015-16
Ceramembrane
1. Material of construction: Aluminium oxide, silicon carbide, titanium oxide, or zirconium oxide
2. Range: Microfiltration to Ultrafiltration
3. Benefits:
• Suitable for continuous operation across full pH range of 0 to14.
• Suitable for elevated temperature operation
• Increased membrane permeability, chemically-durable, high abrasion resistance, removes oil and grease
Solid Waste Management
• To recover the iron and carbon content from process waste generated from steel making . Around 1000 TPD are available for recycling.
• Plant Capacity: 600 TPD of iron concentrate with 65-68% Fe(utilized in Pellet Plant)
Waste to wealth plant(WWP)
Fe(utilized in Pellet Plant)
Precious Slag Ball Plant
Process: Air quenching of slag which generated from steel making process by means of Slag Atomizing Technology
Characteristics: Superior to sand or Copper Slag on compressive strength, hardness for
Plant Capacity: 0.2 MTPA
• JSW has planned to develop greenery for an area of 517 Acres out of which 287 Acres are
Greenery Development beyond Steel Plant
completed in FY 2015-16.
• 8 km pipeline was laid and 2 intermediate pump houses are erected to cater the water
requirement for the development on the hillocks.
• Treated blow-down water from process (4500 m3/day) will be utilized for the development of
greenery on surrounding hillocks.
Environment Product Declaration
A single, comprehensive disclosure of a product’s impact on the environment throughout its A single, comprehensive disclosure of a product’s impact on the environment throughout its
lifecycle.
JSW Steel Ltd is the first Indian Steel Industry to declare its footprint through EPD
Third Party verification of the EPD report under progress.
Customers will have access to environmental foot print data of the product and can chose for
sustainable product.
The technology is aimed at reducing the LOI of the fly ash from CPP boilers
Air classifier will separate coarse and fine fractions (Cut off fraction is 45µ).
Fine fraction will be sold as product and coarse fly ash with high carbon as aby-product
Capacity of classifier : 40 TPH
Fly Ash Beneficiation
Initiatives Started in FY 16
CO2 injection Objective`:Treatment of BOF recirculation water for the removal of
hardness.
The replacement of Na2CO3 in BOF recirculation water by CO2
0.3 to 0.6 Tons/TLS is required .
Cost of treatment @ 1.0 kg/TCS= Rs. 3.0/TCS
Advantages: Drastic reduction in TDS, water conservation, Wasteminimization
Municipal Waste Treatment • Objective: Minimize the cost of hazardous waste
disposal.
• Hydrological Studies Cost: Rs. 20 Lakh
• Currently sent to landfill of Ramky atDabaspet, Bangalore Disposal cost : Rs.20 Cr. perannum (300 days)
Transportation cost : Rs. 8 Cr. per annum (300 days)
• Objective: Convert municipal solid wastein to segregated dried waste for use asfuel.
• Cost: Rs. 3 Crore (20 Tons/day)• Technology:
Drying, Segregation, sorting, shreddingand conversion to RDF
TSDF Landfill
Initiatives Started in FY 16
Transportation cost : Rs. 8 Cr. per annum (300 days)
MAKING STEEL IS OUR
PROFESSION…
…GENERATING SMILES IS OUR
PASSION