Date post: | 21-Nov-2014 |
Category: |
Documents |
Upload: | sandeep-sharma |
View: | 150 times |
Download: | 3 times |
1
Environment Management
2
II
25-A
pr-01
CCP I
14-A
ug-99
CO I
19-Nov-04
0.6 Mt
CO II
30-Mar-06
2 x 0.6 Mt
Pellet Plant
28-Nov-00
3.0 Mt
4.2 Mt-04
Sinter Plant
26-July-06
2.3 Mt
Corex I
08-Aug-99
0.64 Mt
BF I
19-Aug-04
0.9 Mt
BOF I
14-Aug-99
120 t
II
15-Oct-
99
2 x 120 t
BF II
10-Aug-06
1.3 Mt
III
3 x 130 t
27-Apr-0
6
III
13-N
ov-06
1999 – ISP of 0.64 Mtpa was born2001 – Capacity enhanced to 1.6 Mtpa2004 – Capacity enhanced to 2.5 Mtpa2006 – Capacity enhanced to 3.8 Mtpa
HSM
23-A
ug-97
1.25 Mt RHF 1
2.0 Mt RHF 2-04
2 x 130 t
0.8 Mt - 00
Corex II
15-Apr-01
0.8 + 0.8 Mt
2.5 Mt
1.2 Mt 2.5 Mt3.8 Mt3.8 Mt
1.6 Mt
2.3 Mt5.0 Mt 3.8 Mt
JSW Steel - GROWTH SINCE INCEPTION
3
4
ORE STEELMAKING
STEELPDTS
PRODUCTUSAGE
BF-BOFDRI-EAFBF-EAF
FLATLONG
CONSTRUCTIONAUTOMOBILESWHITE GOODS
STEEL - LIFE CYCLE
5
Steel Products – Environment Friendly
• Very good mechanical properties• Long product Life cycle• Low environmental impacts• Magnetic, 100% recyclable
Steel manufacture is not !
6
STEELMAKING
RAW MATERIALS(3)
WATER(5)
Air(9)
STEEL PRODUCTSt(1.0)
WASTEWATER : 2.0SOLID WASTES : 1.0
AIR POLLUTANTS(13)SO2, NOx, DUST
CO2
Steel Making has major environmental impact• Globally , Non Renewable raw materials & Energy(CO2)• Locally, due to air, water, land pollution
7
GLOBAL
• RENEWABLE RAW MATERIALS– INCREASED RECYCLE OF SCRAP– HIGHER EFFICIENCY OF PRODUCTION– SELECTION OF TECHNOLOGY
• ENERGY– REDUCTION OF PROCESSES– ENERGY EFFICIENCY– WASTE HEAT RECOVERY
8
LOCAL
• AIR POLLUTION CONTROL– CLEAN TECHNOLOGY– POLLUTION ABATEMENT
• WASTEWATER– INCREASED RECYCLE– TREATMENT
• SOLID WASTES– RECYCLE– RE USE
9
Harsh climatic conditionsScanty rainfallPoor infrastructureNon – availability of skilled man power
JSW STEEL - THEN
10
Corex -Before
11
N
WNW (MAR – NOV)
WSW ( MAR – NOV)
ESE ( DEC – FEB)
WIND DIRECTIONHills
Hills
Hills
12
Wind Speed - scavenger of pollutants
0
5
10
15
20
25
30
35
40
45
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month
W.S
in k
m/h
r
Wind Speed Max Wind Speed Min Wind Speed Avg
13
Solar Radiation - Facilitates convective movement of pollutants
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
800.00
900.00
1000.00
6:00
7:00
8:00
9:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00 0:0
01:0
02:0
03:0
04:0
05:0
0
Time
Sola
r rad
iatio
n in
W/m
2
Solar Radiation in W/m2
140
200
400
600
800
1000
1200
1400
1600
1 3 5 7 9 11 13 15 17 19 21 23
Mixing heights – Lid for pollution
15
Rainfall
0
50
100
150
200
250
300
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month
Rai
nfal
l in
mm
Rainfall Max Rainfall Min Rainfall Avg
16
Evaporation Rate
0
0.5
1
1.5
2
2.5
Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec
Month
Evap
.Rat
e in
cm
Without Evaloc With Evaloc
17
Relative Humidity
0
20
40
60
80
100
120
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month
R.H
in %
Relative Humidity Max Relative Humidity Min Relative Humidity Avg
18
Temperature
0
5
10
15
20
25
30
35
40
45
50
Jan Feb Mar Apr May Jun July Aug Sep Oct Nov Dec
Month
Tem
pera
ture
in D
eg.C
Temperature Max Temperature Min Temperature Avg
19
Environment Management – Focus on
• Clean technologies
• Choice of Pollution control equipment
• Raw material quality
• Good Operational practices &
• Continuous improvements through EMS
20
Clean Technology - Corex
Corex 1&2: 0.8 mtpa
21
Gas based power plant
JSWEL, CPP-1 & 2: 490 MW
22
Clean technology- NR Coke ovens
4 batteries of 156 ovens : 1.2 mtpa
23
Coke Oven
Battery
Gas Cooling ETP Exhausters Ammonia
RemovalBenzol
Removal
Clean COG to Consumer Departments
Crude COG
Coke to Blast
Furnaces
Tar Decanters
AmmoniaLiquor
Distillation
BiologicalOxidation
plant
Used for Quenching
SCHEMATIC DIAGRAM OF CONVENTIONAL BYPRODUCT PLANT
ETP – Electrostatic Tar Precipitation
COG – Coke Oven Gas
Treated Water
Ammonium Sulfate for
sale
Tar Distillation
Light Oil
Wash Oil
HP Naphthalene
Anthracene oil
Phenol Pitch CT Fuel
Hydro-Refining Unit
BenzeneToluene
Solvent Naphtha
Xylene
Still Bottoms
Excess Liquor
Coal
Sulphuric acidWash oil
24
Coke Oven
Battery
Gas Cooling ETP Exhausters Ammonia
Removal
Clean Desulphurised
COG to Consumers
Crude COG
Coke to Blast
Furnaces
SCHEMATIC DIAGRAM OF BYPRODUCT PLANT AT JSW STEEL
ETP – Electrostatic Tar Precipitation
COG – Coke Oven Gas
Tar for sale
Ammonia Cracking
H2SRemoval
Sulfur Removal
Sulfur for sale
Tar Decanters
Tar Storage
AmmoniaLiquor
Distillation
BiologicalOxidation
To Coke quenching
Treated Water
Excess Liquor
Coal
Cracked N2 & H2
to BF gas main
25
HSMWire Rod Mill
Re Bar MillCold Rolling Mill
Coke OvensSintering
Blast FurnacesBOF
Slabs/Billets
Steel Making Steel Finishing
SurplusBFG,LDG,COG
& Corex
BFG,LDG,COG & Corex300-350 MCal/t~ 35 Kg LPG/t
Surplus to PP
26
ESP5%
Bag filters72%
DSS5%Cyclones
8%
Scrubbers10%
I. JSW Preference for BF over ESP.
II. Design 100 mg/Nm3 50 mg/Nm3 at 7 mtpa30 mg/Nm3 at 10 mtpa
III. Pleated design of filter bags
IV. Use of gaseous fuels for power generation
Bag filters- 110 nosESP - 8 nosScrubber - 16 nosCyclones - 9 nosDSS - 8 nos
Pollution Control Equipment - Air
27
ICW Circuit21%
DCW Circuit58%
Soft / DM Circuits
21%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
Soft / DM water – 7 nos
Pollution Control Equipment-Water
One of the BEST in India
28
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 earnedNew projects underway - 20 nos
29
• 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
Raw Materials
30
BAG FILTER FOR COREX CAST HOUSE
31
BAG FILTER FOR BF- I CAST HOUSE
32
BAG FILTER FOR BF II CAST HOUSE
33
BOF SECONDARY DEDUSTING SYSTEM (largest bag filter in India)
34
Good Practices- Water Management
GCP
DM/Soft
ICW
DCW
Blow Down
Blow Down
Blow Down
Consumptive use
35
• > 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
Good Practices- Water Management
36
Corex –DM Water Circuit
Corex –ICW Water Circuit
Corex –Slurry to PP
Corex –GCP Water Circuit
GCP Water Clarifier
Blow down to Ore
Beneficiation SLIME POND
Water Cascading – Corex Plant
37
Corex I&II
BOF
HSM
BF I&II
Mixer
Pellet PlantRaw material
SILO
Dust from Bag FiltersCollected in Closed Tankers
DiscPelletier
Sludge from ETPs of BF, Corex,BOF,HSM,PP used in Mixer
Nearly 20,000 tons per month of sludge and dust is recycled
Slurry Tank
Dust & Sludge recycle
38
• 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
Good Practices- Solid Waste Mgmt
39
VADDU
TALURVID.TOWNSHIP
GADIGANUR
TORANAGALLU
SG COLONY
BASAPURA
KUREKUPPA
KARADIDHAMA
SULTAPURA
KUDITINI
N
AAQ STATIONS(SPM, SOX, NOX VALUES)
(192,13,16 )
(221,15,16 )
(303,15,18 )
Hills
Hills
Hills
(238,14,16 )
(345,17,19 )
(194,14,16 )(353,43,18 )
(316,15,18 )
40
N
LEGEND
AAQ Stations (A1-A7)
MeteorologicalStation (M1)
Surface Water SamplingLocations (SW1-SW4)
Ground Water SamplingLocations (GW1-GW4)
Soil SamplingLocations(S1-S4)
Noise MonitoringLocations (N1-N7)
Environmental Quality monitoringEnvironmental Quality monitoring
A1
A2
A3A4
A5
A6
M1
SW1
SW2 SW3
SW4
GW1
GW2
GW3
GW4S1 S2
S3S4
N1N2
N3
N4
N5
N6
N7
41
CONTINUOUS AAQ STATIONS – 3 nos installed 3 ore planned in 2007-08
42
1 Stacks 552 Work area 803 Water & wastewater 983 Noise 754 AAQ monitoring 2055 EMS Visits 4
Environmental Quality – Monthly MonitoringEnvironmental Quality – Monthly Monitoring
43
Good Practices –Vacuum sweeping
44
Good Practices – Wind curtains
45
Good Practices – Water Sprays
46
Good Practices- Dust transfer tanks
47
Good Practices- Vacuum spillage control
48
Good Practices- Vacuum spillage control
49
Good Practices- Tyre washing
50
INCINERATOR – 250 Kg/hr-
51
Best Practices- Guard pond
52
Good Practices-Green Belt
53
Best Practices-Green belt
54
NEW technologies that are being introduced
1. BSSF for granulation of BOF slag2. Desulphurisation of Coke oven gas to reduce H2S in the gas from 3.2
g/nm3 to ,0.5 g/nm33. Coke dry quenching4. Top gas recovery turbine (TRT) for power generation from BF waste
gases5. New type of gas recovery plant for coke ovens6. Note on why we went for recovery ovens
55
BSSF Process of BOF slag quenching
56
Slag Pouring into BSSF
57