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Rashtriya Ispat Nigam Limited - Visakhapatnam Steel Plant

(RINL-VSP), a Navratna PSE, is the country’s first shore based in-

tegrated steel plant. The company is 100% owned by GoI. The

plant is a 3 Million ton based Integrated Steel Plant being ex-

panded to 6.3 Million tons.

Visakhapatnam Steel Plant

ENVI RONMENTAL STATEMENT (Form V) 2013 -14

Rashtriya Ispat Nigam Ltd.

Address for correspondence:

Environment Management Department

Visakhapatnam Steel Plant

Rashtriya Ispat Nigam Ltd.-530032

Contacts:

Phone: 0891-2518002

Fax: 0891-2518631

E-mail:

Prepared as per requirement under Environment Protection Rules,1986 and publishing as per directives of

Ministry of Environment and Forests

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PART – A (i) Name and address of the owner/ : Sri D N Rao

occupier of the industry operation/ Executive Director (Works)I/c,

process. VISAKHAPATNAM STEEL PLANT,

VISAKHAPATNAM – 530 031

(ii) Industry category Primary-(STC code): -

Secondary (SIC code)

(iii) Production during 2013-14 in tonnes

a) Saleable steel : 3016068 t

b) Pig iron : 327002 t

c) Coal chemicals(Ammonium sulphate : 129127 t

benzol & tar products) ````````

d) Captive power generation : 218.8 MW

(iv) Year of establishment : 18th FEBRUARY, 1982 (incorporated)

(v) Date of last environmental : 29 SEPTEMBER 2013

statement submitted

PART – B Water and raw material consumption

1. Water consumption in KLD

a. In the plant for process (Excluding TPP) : 29002

b. In TPP for power generation : 40586

c. Total in process : 69608

d. In plant for fire fighting & drinking : 18920

----------

Grand total (c+d) : 88528

Name of

product

Process water consumption per unit of product output

During the current financial

year, 2012-13

During the current financial

year, 2013-14

Saleable steel 10.13 cum/tonne of sal. Steel 10.71 cum/tonne of sal. Steel

FORM – V

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2. Raw material consumption (Unit : ton /ton of Saleable Steel)

Name of

raw material

Name

of

prod-

ucts

Consumption of raw-material Per unit of

output

During the current fi-

nancial year

2012-13

During the current

financial year

2013-14

Coking coal Salea-

ble

steel

1.163 1.080

Iron ore

(lumps &

fines)

1.877 1.641

Sand 0.003 .0037

Lime stone 0.359 0.298

Dolomite 0.191 0.178

Mn.Ore 0.0049 0.0045

Alloys at SMS 0.020 0.0195

Raw Material Handling at VSP

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Pollutants Qty. of pollu-

tants dis-

charged

(mass/day)

Concentration of

pollutants in dis-

charges

(mass/volume)

Percentage of

variation from

prescribed

standards with

reasons#

WATER ( ETP outlet )

TSS 287.6 kg/day 95.4 mg/lt -4.6%

O&G 22.3 kg/day 7.4 mg/lt -26.0%

PHENOL 1.5 kg/day 0.5 mg/lt -50.o%

COD 732.3 kg/day 242.9 mg/lt -2.8%

BOD 76.3 kg/day 25.3 mg/lt -15.6%

AMM.N2 124.8 kg/day 41.4 mg/lt -17.2%

# Reduced concentrations due to stabilization in performance of Me-

chanical Biological and Chemical treatment plant of Coke Ovens

Air emissions from process

Pollutants Qty. of pollu-

tants dis-

charged

(mass/day)

Concentration of

pollutants in dis-

charges

(mass/volume)

Percentage of

variation from

prescribed

standards with

reasons

PM 4968 kg/day

against the

Consent value

of 7165 kg/day

-

-30.66

PART –C

Waste Water Treatment

System of SMS

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PART – D Hazardous wastes (As specified under Hazardous Wastes (M&H) Rules,

Hazardous wastes

Total quantity (Generation)

During the current

year 2012-13

During the current

year 2013-14

(a) From process

Waste oil sludge 275.82t 234.52 t

Tarry acids/muck(sludge) 2821.1t 2643.17t

Benzol muck 413t 489.84t

Discarded oil drums 9.5t 2.0 t

(b) From pollution control facilities

Activated sludge

(MBC/ETP)

214.4t 729.66t

Exclusive facilities for handling

and treatment of hazardous waste

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PART – E Solid Wastes

Solid Waste

Total genera-tion

(t/year) (a)

Recycled or Reused (t/year)

(b)

Sold (t/year)

(c)

Utilized in construc-tion activi-

ties

%Utilization For 2012-13=

{(b+c)/a}*100

a) From Pollution Control Systems

Dust from ESP's,DE Systems

249085 196611 56629 0 101.67#

Sludge from Water Treatment Plants

240532 335060 0 0 139.30*

b) From Process

BF Slag 1397080 0 1495596 19295 108.43$

LD Slag 410673 150971 0 0 36.76

Total 2297370 682642 1552225 19295 98.12

#- Additional 4155 of dust recycled from previous stock * Additional 94528 tons of sludge recycled from previous stock $ Additional 117811 tons of BF slag utilised/sold from previous stock

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PART – F Please specify the characterization (in terms of composition and quan-tum) of hazardous as well as solid wastes and indicate disposal practice

adapted for both these categories of wastes.

Characteristics and practice of disposal

Type of

Waste

(Non-

hazardous)

Yr: 13-14

FeO

(%)

CaO

(%)

MgO

(%)

SiO2

(%)

Al2O3

(%)

MnO

(%)

Basic-

ity

Method of

disposal

BF SLAG 0.37 36.59 8.14 34.7 17.77 0.11 1.05 Sold to

external

parties

LD SLAG 15.76 51.65 10.47 16.99 1.12 1.20 3.09 Partly re-

cycled ,

partly

stacked for

future use.

Others T.Fe CaO MgO SiO2 Al2O3 MnO LOI Method of

disposal

Met.

Wastes

42.29 2.42 0.21 3.93 0.85 - 31.0 100% recy-

cled in SP

Type of Waste ( Non-Hazardous)

Press Filter at Blast Furnace –3

for recovery of Sludge from

Waste Water of Gas Cleaning

Plant

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PART – F Please specify the characterization (in terms of composition and quan-tum) of hazardous as well as solid wastes and indicate disposal practice

adapted for both these categories of wastes.

Characteristics and practice of disposal

Type of Waste (Hazardous)

S

L

Parame-

ter Unit Conc. Limit

as per

HW(MWTM)

Rules 2008

MBC

Sludge

ETP

Sludge

Tank

bot-

tom

Sludge

Tar

Sludge

ASP

Sludge

Benzol

Sludge

1 Cadmi-

um mg/kg 50 9.54

15.52 4.16 5.8 1.48 4.16

2 Total Cr. mg/kg 5000 106.8 75.8 16.3 3.63 30.8 5.454

3 Copper mg/kg Not App. 32.2 8.05 6.75 2.85 7.7 2.08

4 Iron % 5000 8347 7400 3317 236.1 3800 430

5 Nickel mg/kg 5000 93 10 3.6 2.3 39 BDL

6 Lead mg/kg 20000 72 434.8 216.3 57.2 46.6 6.4

7 Zinc mg/kg Not applica-

ble 320.9 1061 372.8 153.7 317.9 24.8

8 Cyanide mg/kg 50 1088 904 48 424 32 107

9 Carbon % Not applica-

ble 26.67 19.17 57.11

- 15.6

-

Facilities at Coke Ovens for charging

Hazardous waste into batteries

Disposal :All the above wastes are recycled in the Coke Oven Batteries

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PART – G Impact of pollution abatement meausres taken on conservation of natural resources.

Sl.N

o.

Pollution Abatement Measures Impact on conserva-

tion of natural re-

sources (13-14)

Impact on cost

of produc-

tion(13-14)

1 Recycling of waste water using- i)

Balacheruvu waste water system ii)

Appikonda waste water treatment

systems and iii) Ultra filtration plant

for treatment of township waste wa-

ter

Saving of 478.87 MG

of water

Savings of Rs

6.99 crores

2 a. Recycling of wastes collected

from i) Dust Extraction Systems ii)

Waste Water Treatment plants

b. Utilisation of Blast Furnace and

LD slag

Saving of natural re-

sources to the tune

of 2.31 million tons

Savings of Rs

254.18 crores

3 Utilisation and waste heat and pres-

sure recovery systems for generation

of power and steam

Saving of coal of

about

6.09 lakh tons

Savings of Rs

148.09 Crores

4 Utilsation of by product gases in

place of coal

Saving of coal of

about 13.17 lakh

tons

Savings of Rs

320.40 Crores

The following are the details of impact on conservation of natural resources and

cost of production due to various pollution abatement and environmental protection

measures taken at VSP in the year 2013-14

Balacheruvu Waste Water

Pumping Station

Appikonda Waste Water Treatment

Plant Showing RO skids as inset

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PART – H

Additional measures / investment proposal for environmental protection

including abatement of pollution, prevention of pollution.

1. Revamping & up-gradation of ESPs of SP-1

and BF 2 are taken up at a cost of Rs 144.6 Cr.

to reduce the stack emissions from

115mg/Nm3 to 50mg/Nm3.

ESP of Blast Furnace-1 ESP : Under

Up gradation

2. Rain water harvesting schemes,

to conserve 3.3MGD of water, are

taken up at a cost of Rs 13.84 Cr.

and are at an advanced stage of

implementation. On completion

they shall result in total wa-

ter saving of : 3.3 MGD

Dog House—SMS2

Additional Environment protection measures taken in in 13-14

3. Dog house commissioned and

put in operation in Steel Melt

Shop-2 , thereby preventing roof

top emissions from convertor shop

Rain water Harvesting : Under

implementation

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PART – H

Additional measures / investment proposal for environmental protec-

5. All Halon based fire fighting sys-

tems at VSP were replaced a with

Inergen based fire fighting systems,

incurring an expenditure of Rs 6.14

crores. In the process 3885 kgs of

Halon was phased out systematically.

Additional Ammonia Columns provid-

ed for stabilising input load to MBC

Additional Environment protection measures taken in in 13-14

Enhanced flocculent dosing system at

4. Mechanical, Biological and Chemical

(MBC) treatment plant of Coke Ovens ,

which was upgraded incurring an ex-

penditure of Rs 46 Cr was stabilised.

This was done by further addition of

facilities such as

a) 2 sets of new Ammonia columns in

parallel for stabilizing the input load

b) Replacing the problematic roots blow-

ers with centrifugal blowers and modi-

fying the air distribution system for

adequate air supply for sustaining

oxidation process

c) Enhancing the flocculent system for

proper dosing of flocculants and co-

agulants

This has resulted in:

Bringing down the ammonical nitro-

gen below the norm of 50 mg/l.

Bringing down the COD (Chemical Ox-

ygen Demand) below the norm of

250mg/l.

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Improvement of Communication :

1.A software dedicated to Environmental Activities ‘ ENVISION ‘ has been developed

in-house, for facilitating in capture of real

time emission data from on-line stack mon-

itors installed at all twenty (20) major chim-

neys and four (4) continuous Ambient Air

Quality Monitoring stations and publishing

to all stakeholders . ENVISION also facili-

tates in scheduling of environmental moni-

toring, report preparation and collation of

environmental data from various depart-

ments. It also interfaces with other software

systems to provide information on process

parameters, status of ESPs in the plant, con-

sumption trends of utility gases - thereby enabling problem diagnosis and correc-

tive action.

2. Real time weather data being broadcasted through intranet of VSP.

Afforestation :

1..VSP is participating in the ambitious “Green Visakha- Plantation Program” , where it

is targeted to plant 40 lakh trees in Visakhapatnam in 5 years, @ 8 lakh trees per

year. The program is initiated by the Parliamentary Standing Committee on Science &

Technology and Environment, Forests. VSP has already planted 25000 avenue planta-

tion and 75000 block plantation under Green Visakha Programme. Also in-principle ap-

proval of Board of Directors is taken up for plantation of 5 lakh trees in 5 years, under

this program, at an estimated cost of Rs 5.5 Crores .

2. 2.69 Lakh of Trees planted in 2013-14 as part of afforestation efforts

Green Visakha Plantation Program inaugurated by District Collector of Visakhapatnam

PART – I Any other particulars for improving the quality of the environment.

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PART – I continued…. Any other particulars for improving the quality of the environment.

EMS

1. VSP was recertified for ISO-14001 by M/s BVCI , after auditing in Aug’13 .Certification

is valid for a period of 3 years

2. 77 nos of EMS objectives taken up to improve resource consumption, benign han-

dling, storage and disposal of hazardous wastes, greening initiatives, use of environ-

ment friendly materials etc.

ODS Phase out

1. 26 nos Halon Cylinders have been deposited to National Halon Bank at Centre for Fire

and Explosive Safety , New Delhi during the year 2013-14

Noise reduction:

1. New silencer installed at 7 Ata bleeder of BPTS to reduce noise from 120 to below 90

db(A)

Measures Taken for reduction in Energy Consumption ( 2013-14)

1. Reduction of BF gas bleeding from 2.95 % to 1.96 % by taking up proactive measures

and optimizing distribution through Supervisory Control and Data Acquisition system

(SCADA)

2. Replacement of Air Recuperartors in F/C-1 of Light and Medium Merchant Mill

3. Commissioning of Waste Heat Recovery system at Sinter plant no 2(Sinter Machine-3)

for pre heating of combustion air to ignition furnace and supplying hot air to Extended

hood of Sinter Machine-3

4. Commissioning of Energy Efficient fur-

nace with energy efficient burners in

Sinter Plant-2(Sinter Machine-3)

5. Commissioning of 20.6 MW waste heat

recovery system on sinter straight-line

cooler of sinter machine 1 &2.

20.6 MW waste heat recovery system

installed

at straight line cooler of sinter machine

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Waste Management :

1. LD Slag consumption in Sinter Plant is increased to 24.0 Kg / ton of charge sinter

against the norm of 16.0 Kg/ ton of charge sinter .More than 1 lakh tons (1.1) of LD

slag consumed in Sinter plant for the year 2013-14.

2. 3628 T of used refractory bricks recovered and reused in Steel Melting shop

Emissions

1. 52 nos of heating walls of Batt-3 repaired to reduce emissions.

CO2 reduction

1. 1004613 tons of CO2 emissions reduced due to use of clean technologies for genera-

tion of steam and power

2. 2077147 tons of CO2 emissions reduced due to use of CO Gas and LD gas in power

plant in the place boiler coal

CSR activities related to Environment

1. St. Josephs home for aged was provided financial assis-

tance of Rs 26.60 lakhs for providing solar lighting to

the entire building

2. 1000 nos of solar street lights provided in rural areas of

Barabanki district

Use of Environment Friendly material

1. Asbestos rope replaced with ceramic rope at 20 loca-

tions between flash plate and brick wall and in 20 door

frames during replacement & realignment

2. Refractory material procured in 1500 paper bags in-

stead of plastic bags thereby preventing generation of

plastic waste

3. 339.5 CuM of Falg bricks made of fly ash used in civil

maintenance activity

Solar based street lights

provided by VSP

PART – I Any other particulars for improving the quality of the environment.

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Important Environmental Events –2013-14

1. Cycle Rally was conducted on 26.05.2013 on the occasion of World Environment Day

celebrations on 5th June 2013. Director (Finance), Shri P Madhusudan flagged off the

event.

2. “ENVISION” was inaugurated by CMD on

5th June.2013 . This software tool inte-

grates all activities of Environment Manage-

ment & facilities in real time reviewing of

emissions of the plant. The software was

developed in house by IT & Environment

department.

3. Green Awards distributed to the employees

who contributed towards the improvement of

Environment on the occasion of World Environ-

ment Day celebrations on 5th June 2013.

4. Water Conservation Cam-

paigns -One of the several

water conservation campaigns

conducted for sensitising

employees on importance of

water conservation

END