challenges in iron n steel by cpcb

7/23/2019 Challenges in Iron n Steel by CPCB

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Current Challanges in PollutionControl from Iron & Steel,

Aluminium, Cement and Thermal

Power Plants

Dr. B.Dr. B. SenguptaSengupta

Director Director Central Pollution Control BoardCentral Pollution Control Board

Ministry of Environment & ForestsMinistry of Environment & Forests

Govt. of India, DelhiGovt. of India, Delhi

Email: [email protected],

Website: http://cpcb.delhi.nic.in

Presented at workshop held at Raipur on 8th November, 2008



POWER SECTOR (COAL): A PROFILE

Seventy oneSeventy one per cent of electricity production is based on coaland gas in the country.

8383 coal based thermal power plants with total generationcapacity of 62630.9 MW.62630.9 MW.

27 gas/naphtha27 gas/naphtha based power plants with total generationcapacity of 11299.6 MW.

More than 240 million240 million tonnestonnes of coal with ash content 35-45%

was consumed by the Thermal Power Plants

Power plants contribute nearly 82 & 89 % particulate matter &Power plants contribute nearly 82 & 89 % particulate matter &SOSO22 emission load respectively in the countryemission load respectively in the country

Nearly 112 mill ionNearly 112 million tonnestonnes per per annumannum coal ash is generated.

More than 25,000 hectares25,000 hectares of land has been occupied forconventional disposal of ash.

More than 630 million M630 million M33 water is required for disposal of coalash as in slurry formslurry form per annumannum



ENVIRONMENTAL PROBLEMSUse of high ash content coal in power generation leads to

the followingenvironmental problems:

Air Pollution Air Pollution•• Emission of particulate matter (dust)Emission of particulate matter (dust)

•• Emission ofEmission of sulphur sulphur dioxide and Oxides of Nitrogendioxide and Oxides of Nitrogen•• Green House Gas EmissionsGreen House Gas Emissions•• Emission of Mercury (both gaseous and in ash)Emission of Mercury (both gaseous and in ash)•• Fugitive emission of suspended particulate matter fromFugitive emission of suspended particulate matter from

CHP, Wagon Tripler and ash pondCHP, Wagon Tripler and ash pond

Water PollutionWater Pollution

•• Cooling water dischargeCooling water discharge•• Ash pond effluent Ash pond effluent

Solid WasteSolid Waste

•• Large volume of coal ash generation (Fly ash & BottomLarge volume of coal ash generation (Fly ash & Bottomash)ash)

•• Large land requirement for ash disposalLarge land requirement for ash disposal



ENVIRONMENTAL STANDARDS OF COAL BASED THERMAL POWER PLANTS

Emission Standards

Particulate Matter India USA Australia UK Germany

150 mg/Nm3 62 mg/Nm3 80 mg/ Nm3 50 mg/ Nm3 50 mg/m3

Sulphurdioxide * 740 mg/ m3 * 400 mg/ m3 400 mg/ m3

Oxide of Nitrogen * 615 mg/ m3 800 mg/ m3 650 mg/ m3 200 mg/ m3

• : Dispersion of SO2 away from urban areas through use of tall stacks;

Stack Height Requirement

Less than 200/210 MW H= 14 Q 0.3 where Q is emission rate of SO2 in kg/hr andH is

stack height in metre

>200/210 MW or less than 220 m

500 MW

500 MW and above 275 m

Effluent Standards

Cooling Water Temp. 100 C

Ash Pond pH 6.5 - 8.5

SS 100 mg/l



REASON FOR NON-COMPLIANCE OF ENVIRONMENTAL

STANDARDS IN COAL BASED THERMAL POWER PLANTS

High ash content in coal used in power plants

Poor ash chemistry: high silica,high alumina, low sulphur & low sodium

High resistivity of coal

Inconsistent supply of coal

Low calorific value

Delay in supply/installation of ESPs

Low design efficiency of ESP( low SCA)

Poor operation & maintenance of ESPs i.e. timely replacement of

faulty parts such as hanging electrodes

Non installation of state of Art EPIC controllersIn sufficient water pressure below the ESP hoppers

Rapping time not optimum

Inefficient management of ash pondsPaucity of funds



INITIATIVES TAKEN FOR MITIGATION OF

ENVIRONMENTAL PROBLEMS

To minimize the impact of emission of

particulate matter and other Green House

Gases following measures have been taken:

– Use of beneficiated coal

– Promoting utilisation of flyash

– Adoption of clean coal combustion

technologies



1.1. New / expansion power projects to beNew / expansion power projects to beaccorded environmental clearanceaccorded environmental clearanceshall meet the limit ofshall meet the limit of100 mg/Nm100 mg/Nm33 for particulate matterfor particulate matteremission.emission.

2.2. Installation of opacity meters /Installation of opacity meters /

continuous monitoring systems in all thecontinuous monitoring systems in all theunits with proper calibration system.units with proper calibration system.

3.3. Development of guidelines / standardsDevelopment of guidelines / standards

forfor mercury and other toxic heavy metalsmercury and other toxic heavy metalsemissions.emissions.

4.4. Review of stack height requirementReview of stack height requirementandand guidelines for power plants based on microguidelines for power plants based on micro

meteorological data.meteorological data.

ACTION POINTS



5.5. Implementation of use of beneficiated coal as per GOIImplementation of use of beneficiated coal as per GOI

Notification:Notification:

Power plants will sign fuel supply agreement (FSA) toPower plants will sign fuel supply agreement (FSA) to

meet the requirement as per the matrix prepared by CEAmeet the requirement as per the matrix prepared by CEA

for compliance of the notification as short term measurefor compliance of the notification as short term measure

Options/mechanism for setting up of coalOptions/mechanism for setting up of coal washerieswasheries as aas a

long term measurelong term measure

Coal India will set up its ownCoal India will set up its own washerywashery

State Electricity Board to set up its ownState Electricity Board to set up its own washerywashery

Coal India to ask private entrepreneurs to set upCoal India to ask private entrepreneurs to set upwasherieswasheries for CIL and taking washing chargesfor CIL and taking washing charges

SEBsSEBs to select a private entrepreneur to set up ato select a private entrepreneur to set up a

washerywashery near pitnear pit--head installation of coal beneficiationhead installation of coal beneficiationplantplant



6.6. Power plants will indicate their requirement of ofPower plants will indicate their requirement of of

abandoned coal mines for ash disposal & Coal India /abandoned coal mines for ash disposal & Coal India /

MOC shall provide the list of abandoned mines.MOC shall provide the list of abandoned mines.

7.7. Power Plants will provide dryPower Plants will provide dry flyashflyash to the users outsideto the users outside

the premises or uninterrupted access to the users.the premises or uninterrupted access to the users.

8.8. Power Plants should provide dryPower Plants should provide dry flyashflyash free of cost to thefree of cost to the

usersusers

9.9. State P.W.Ds/construction & development agencies shallState P.W.Ds/construction & development agencies shall

also adhere to the specifications /Schedules of CPWDalso adhere to the specifications /Schedules of CPWDfor ash / ash based productsfor ash / ash based products utilisationutilisation..



10.New plants to be accorded environmental10.New plants to be accorded environmental

clearance shall adopt either dryclearance shall adopt either dry flyashflyash extraction orextraction ordry disposal system or medium (35dry disposal system or medium (35--40 %) ash40 %) ash

concentration slurry disposal system or Lean phaseconcentration slurry disposal system or Lean phase

with hundred percent ash water recirculationwith hundred percent ash water recirculation

system depending upon site specific environmentalsystem depending upon site specific environmental

situation.situation.11.11. New plants shall promoteNew plants shall promote adoption of cleanadoption of clean

coal and clean power generation technologiescoal and clean power generation technologies..



India Ranks World's 2nd largest cement producing country

No. of Large Cement Plants in the country - 123

Total Annual Installed Capacity- 135.55 Million Tonnes

(As on December, 2001)

Annual Cement Production - 98.35 Million Tonnes(As on December, 2001)

India World Average

97 kg/Annum 256 kg/Annum

BACKGROUND OF CEMENT SECTOR

Per Capita Consumption of Cement (1999)



S. No. Section Pollution Control Equipment

1. Crusher Bag Filter

2. Raw Mill Bag Filter/ESP

3. Kiln Bag Filter/ESP with GCT

4. Clinker Cooler ESP/Bag Filter with heat

exchanger

5. Coal Mill Bag Filter/ESP

6. Cement Mill Bag Filter/ESP

7. Packing Plant Bag Filter

AIR POLLUTION CONTROL EQUIPMENT

FOR DIFFERENT SECTIONS IN CEMENT INDUSTRY



Particulate matter Emission nor to exceed mg/Nm3Plant capacity

in tonnesperday

Protected Area Other Area

<200 250 400

>200 150 250CPCB/SPCB may fix stringent standards, if required as per Air Act, 1981/

Environment (Protection ) Act, 1986

Country Particulate Matter Emission Limit (mg/Nm3)

Australia 50

Germany 50South Africa 120

Switzerland 50

Japan 100

USA 100/ 50

Portugal 100/50

EMISSION STANDARDS IN OTHER COUNTRIES

EMISSION STANDARDS IN INDIA



Waste material Generation

(MT/Annum)

Utilization

(MT/Annum)

Flyash 100 6.25

Blast FurnaceSlag

10 5.5

Steel Slag 4.0 0.5

Phospho-gypsum 6.0 2.5

Lime sludge 4.5 0.5

GENERATION OF MAJOR INDUSTRIAL WASTES

& ITS UTILIZATION IN CEMENT MANUFACTURE

IN INDIA (2000-01)

(MT : Million Tonne)



Non Compliance of Emission Standards in few units

Requirement of Load based Standards

Control of fugitive emission from following units ofCement Plants

Raw Material Storage

Loading/Unloading Operation Material Transfer Point

Continuous dust monitoring system & itscalibration

Environmental implication of use of petroleum coke

as fuel in kiln – (emission of SO2, V, Ni, PM10)

ENVIRONMENTAL ISSUES IN CEMENT SECTOR



Frequent tripping of Kiln ESP Poor industrial solid waste utilisation in cement

manufacturing Flyash

Blast Furancae Slag

Lime Sludge

Phospho Gypsum

Posssibility of use of Hazardous Waste in Cement Kiln

Reduction of Green House Gases• Reduction in power consumption

• Reduction in coal consumption

• Promotion of Energy Efficient Technology

Waste heat recovery from kiln & clinker cooler exit gases

ACTION POINTS



ACTION POINTS

1. Cement Plants located in critically polluted or urbanareas (including 5 km distance outside urban

boundary) will meet 100 mg/Nm3 limit of particulate

matter and continue working to reduce the emission of

particulate matter to 50 mg/Nm3.

2. The new cement kilns to be accorded

NOC/environmental clearance, will meet timplehe limitof 50 mg/Nm3 for particulate matter emission.

3. Load based standards evolved by CPCB to be

implemented.

4. The cement industries will control fugitive emissions

from all the raw material and products storage and

transfer points as per CPCB Guildelines(www.cpcb.nic.in)



5. Use of high calorific value hazardouswastes as partial fuel in cement kiln shall

be promoted as per CPCB guidelines.

LIST OF INDUSTRIES WITH LOCATION



Source : Questionnaire survey by CPCB (1999-2000)

LIST OF INDUSTRIES WITH LOCATION

LocationS.

No

Name of

Industry Alumina Plant Smelter Power Plant Mines

1. NALCO Damanjodi, Distt

:Koraput, Orissa

Angul, Distt.:

Angul, Orissa

Angul, Distt.:

Angul , Orissa

Panchpatmali Distt.:

Koraput, Orissa

2. BALCO

(Sterlite)

Korba,

Chhattisgarh

Korba,

Chhattisgarh

Korba,

Chhattisgarh

Mainpat, Distt.

Sarguja, Chhatisgarh

3.

INDALCO

i) Belgaum,

Karnataka

ii) Muri,

Jharkhand

(i) Alupuram,

Kalamasssery,

Kerala

(ii) Belgaum (not

in operationsince 1993)

(iii) Hirakud,

Orissa

-

-

Hirakud, Orissa

i) Dugmanwadi,

Maharashtra State

ii) Lohardaga,

Jharkhand

4. HINDALCO Renukoot,

Distt.:Sonbhadra, UP

Renukoot,

Distt.: Sonbhadra,UP

Renusagar,

Distt.:Sonbhadra,

UP

i) Lohardaga,

Jharkhandii) Amarkantak, MP

5. MALCO Metturdam,

Tamilnadu

Metturdam,

Tamilnadu

Metturdam,

Tamil nadu

i)Yercaud, Distt.: Salem

ii)Kolli; Distt: Namakkal

iii)Poondi; Distt.Dindigul

INSTALLED CAPACITY & PROPOSED FUTURE EXPANSION



INSTALLED CAPACITY & PROPOSED FUTURE EXPANSION

Installed capacity (TPA) Future Expansion Proposed (TPA)S.

No

.

Name of Smelter

Alumina Aluminiu

m Metal

Aluminium

Products

Alumina Aluminium

Metal

Aluminium

Products

1. NALCO, Angul,

Orissa

8,00,000

(at

Damanjod

i)

2,18,000 2,43,000 15,75,000#

3,45,000 -

2. BALCO Korba,Chhattisgarh

2,00,000 1,00,000 - - - -

3. INDALCO

Alupuram,

Kerala

- 13,500 8,000 - - -

4. INDALCO

Belgaum,

Karnataka

2,70,000 (pots

being to

shifted to

Hirakud)

- - - -

5. INDALCO

Hirakud, Orissa

72,000

(at Muri)

30,000 30,000 - 57,200 57,200

6. HINDALCO

Renukoot, UP

4,50,000 2,42,000 1,33,700 6,60,000 3,56,200 -

7. MALCO

Metturedam, TN

60,000 30,000 69,500 - - -

Total Capacity 18,52,000 7,06,500 5,16,800 - - -

-

Action Points



Action Points

S.S.

No.No.

IssuesIssues Action Points Action Points TargetsTargets

Allowing new

Potlines only

with Pre-bakedTechnology

Environmental clearance for

new pot lines to be given by

MoEF, only with pre-bakedtechnology.

1. Technology

Prescribing

maximum size of

the plant

Maximum size of the plant

shall be decided based on the

assimilative capacity of eachplant location.

2. Fluoride

Emissions

Revision of

fluoride

emission

standards

For Soderberg Technology-

2.8 kg/t[1.0 kg/t (VSS) & 1.30 kg/t

(HSS) by Dec 2010]*

For Pre-baked Technology-

0.8 kg/t

*National Task Force will submit the proposal within three months



S. No Issues Action Points Targets

Phasing out Wet

Scrubbing Systemfor fluoride

With Immediate effect.

Monitoring of

fugitive emissionsfrom pot rooms

Monitoring of secondary

fluoride emission shall bedone as per CPCB guidelines.

3. Fluoride

Consump-

t ion

Fluorideconsumption per

tonne of aluminiumproduced (as F-)

[ForSoderberg Te c hno lo g y -

15 kg/t

For Pre-baked Tec hno lo g y -

10 kg/t

4. Ambient

Fluoride

Forage fluoride

standards

• Twelve consecutive months

average- 40 ppm

• Two consecutive months

average – 60 ppm

• One month – 80 ppm



S.

No.

Issues Action Points Targets

Setting up a centralized

SPL treatment & disposal

facility with aluminium

fluoride recovery andutilisation of SPL in

steel/cement industries

With immediate effect

Limit for pot life (for new

pots installed after

December 31, 2003

[2500 days (average)]

5. Spent Pot

Lining (SPL)

SPL (Carbon &

Refractory) to be

disposed in Secured

Landfill

With immediate effect.

However, the carbon

portion of SPL may be used

in Cement Plant as partialfuel.



S.No.

Issues Action Points Targets

Phasing out Wet disposal With immediate effect.6. Red Mud

Red Mud Utilisation

7. Anode

Baking Oven

Achieving particulate

matter limit of 50 mg/Nm3

With immediate effect.

INTEGRATED IRON AND STEEL PLANTS IN INDIA



Installed Capacity – Million Tonne per Annum

Based on BF Technology

Steel Authority of India Limited (SAIL)

Bhi lai Steel Plant (BSP) 4.0 MTPA

Bokaro Steel Plant (BSL) 4.0 MTPA

Rourkela Steel Plant (RSP) 2.5 MTPA

Indian Iron & Steel Company (IISCO) 1.0 MTPA

Durgapur Steel Plant (DSP) 1.6 MTPA

Rastriya Ispat Nigam Ltd. (RINL)

Visakapatnam Steel Plant 3.0 MTPA

Tata Iron & Steel Co. Ltd. (TISCO)

Tata Steel 3.5 MTPA

Based on COREX Technology

Jindal Vijaynagar Steel Ltd. (JVSL) 3.0 MTPA

Based on DRI

ESSAR Steel 2.0 MTPA

EMISSION STANDARDS :



StandardsParameter

NewBatteries

ExistingBatteries

Fugitive Visible Emissions

(a) Leakage from door 5 (PLD)* 10 (PLD)*

(b) Leakage from charging lids 1 (PLL)* 1 (PLL)*

(c) Leakage from AP Covers 4 (PLO)* 4 (PLO)*

(d) Charging emission (second/charge) 16

(withHPLA)*

50

(withHPLA)*

Stack Emission of Coke Oven

(a) SO2(mg/Nm3) 800 800

(b) NOx, (mg/Nm3) 500 500

(c) SPM, (mg/Nm3) 50 50

(a) SPM emission during charging (stack emission) mg/Nm3 25 25

(b) SPM emission during coke pushing (stack emission)gm/ton of coke

5 5

COKE OVEN PLANTS (BY PRODUCT RECOVERY TYPE)MoEF Notif ication G.S.R. 631(E), dated 31st October, 1997

Contd…



StandardsParameter

NewBatteries

ExistingBatteries

Sulphurin Coke Oven gas used for heating (mg/Nm3) 800 800

Emission for quenching operation

Particulate matter gm/MT of coke produced 50 50Benzo-Pyerine (BOP) concentration in work zone air (ug/m3)

Battery area (top of the battery) 5 5

Other units in coke oven plant 2 2

Ambient standards (ng/m3) 10 10

ENVIRONMENTAL STANDARDS FOR COKE OVEN PLANTS – USEPA



Clean Air Act Amendments (CAAA) 1990

Existing Batteries - MACT Option

- Extension Track Option

(MACT-Max. Achievable Control Tech.)

New Batteries - MACT Option’

MACT Option

MACT Standards* by 31st

December, 1995•MACT standards : PLD 8, PLL1, PLO 5, 16/ S/C

(Review after every 7 years) and works practice standards and

Ample margin of Safety’ residual risk based standard**

** Achieve emission reduction that will reduce cancer risk to 1x10-4

(i.e. one in 10000 chance)

EXTENSION TRACK OPTION



Extension in complying residual risk based standardsupto 1.1.2020subject to:

To qualify for the extension the existing batteries have to meet

•By 15.11.93

8 PLD, 1PLL, 5PLO and 16 S/C

•By 1.1.98 (LAER)

3 PLD (5PLD for tall), 1 PLL, 4 PLO, 16 S/C

(with an exclusion for just charged door)

(LAER II) by 1.1.2010 yet to be fixed

USEPA to evaluate for the installation of New Batteries- JEWELL Thompson Design non recovery oven

- Other non recovery tech.

- Other Appropriate emission control

ACTION POINTS



1. Coke Oven Plants

To meet the parameters PLD (% leaking doors), PLL(%leaking lids), PLO (% leaking off take), of the notified

standards.

Industry will submit time bound action plan and PERT Chartalong with the Bank Guarantee for the implementation of the

same.

- To rebuild at least 40% of the coke oven batteries* in next 10years (December 2012).

2. Steel Melt ing Shop

Fugitive emissions -To reduce 100% by March 2008 (including

installation of secondary de-dusting facilit ies)

* As per rebuilding schedule submitted to CPCB / MoEF.Contd..

3 Bl t F



3. Blast Furnace

Direct inject of reducing agents

4. Solid Waste / Hazardous Waste Management

Utilization of Steel Melting Shop (SMS) / Blast Furnace (BF)Slag

Hazardous WasteCharge of tar sludge / ETP sludge to Coke Oven

Inventorization of the Hazardous Waste as per Hazardous

Waste (M&H) Rules, 1989 as amended from time to time andimplementation of the Rules

(Tar sludge, acid sludge, waste lubricating oil and used type

fuel falls in the category of Hazardous Waste.)

Contd..

5. Water conservation / Water Pollution



• To reduce specific water consumption to 5 m3/t for long

products and 8 m3/t for flat products.• To operate the CO-BP effluent treatment plant efficiently to

achieve the notified effluent discharge standards.

6. Installation of Continuous stack monitoring system & its

calibration in major stacks, on line ambient air quality

monitoring stations.

7. To operate the existing pollution control equipments efficiently

and to have proper record keeping of pollution control

equipment run hours, failure time and efficiency with

immediate effect. Compliance report to be submitted to CPCB /SPCB every three months

8. Implementation of recommendations of Life Cycle Assessment(LCA) study sponsored by MoEF.Contd..



9. The industry will initiate the steps to adopt the following clean

technology/measures to improve the performance of the

industry towards production, energy and environment.

– Energy recovery of top Blast Furnace (BF) gas.

– The use of Tar-free runner linings. – Cast House de-dusting (tap holes, runners, skimmers, ladle

charging points)

– Suppression of fugitive emissions using nitrogen gas or anyother inert gas.

– To study the possibility of slag and fly ash transportation back to

the abandoned mines to fill up the cavities through emptyrailway wagons when they return and its implementation.

– Yearly progress report on these issues will be submitted by the

industry to CPCB and MoEF.Contd..



– Processing of the waste containing flux & ferrous wastes

through Waste recycling plant.

– To implement rain water harvesting.

– Reduction of Green House Gases by:

. Reduction in power consumption

. Use of By-production gases for power generation

· Promotion of Energy Optimisation Technology,

including energy audit

–

To set targets for Resource Conservation such as Rawmaterial, energy and water consumption to match

International Standards

Contd..



- Up-gradation in the monitoring analysis facilities forair and water pollutants. Also to impart elaboratetraining to the manpower in the environmental

monitoring laboratories, so as realistic data can beobtained.

- To improve house keeping.



SPONGE IRON PLANTSSPONGE IRON PLANTS – –

POLLUTION CONTROL STANDARDPOLLUTION CONTROL STANDARD

Process in Brief – Sponge Iron Plant



• Inside the rotary kiln, the DRI gases flow counter-current to the

kiln feed. The temperature at the product discharge end in a

rotary kiln is about 950-1050oC compared to 750-900oC towards

the feed end. The counter-current flow of hot DRI gases enable it

to remove the moisture content from feed. The hot DRI gases

contains huge amount of fine dust comprising oxides and

unburnt carbon and toxic carbon monoxide. It needs treatment

before discharging into the atmosphere

• The raw material feed side of rotary DRI Kiln has a naturalstructure below the After Burner Chamber (ABC) that acts as

Dust Settling Chamber (DSC). About 15-20% coarse dust settles

in DSC by means of gravity. In ABC, the CO content of gases is

converted to CO2. This conversion process is exothermic and thetemperature of gases rises to 1000-1050oC

• Some plants (very few) have Gas Conditioning Tower (GCT)

followed by pollution control equipment and cleaned gas isemitted through stacks

Air pollution mitigation measuresAir pollution mitigation measures



• In case no pollution control are installed

by the unit the particulate matter emission

was observed around 25 gm/Nm3.

• This indicated that installation of pollutioncontrol devices is must to protect the

environment. The pollution control

devices like ESPs, Bag filters, and wetscrubbers installed by the industries.

Air pollution mitigation measures Air pollution mitigation measures



The sources of fugitive dust generation are:

• Raw Material Handling Yard (unloading,

stacking, reclaiming operations)

• Product discharge system (cooler

discharge conveyors, transfer points, junction house, screens, magnetic

separators, storage silos, truck loading

and packing operations).

Fugitive dust generation

Water Pollution Mitigation MeasuresWater Pollution Mitigation Measures



The water requirement in rotary kiln DRI plant ismainly for cooling the discharge feed from 950-1050oC

to below 100oC. Water is continuously sprinkled over

the rotary cooler shell and is allowed to fall on asettling tank located below the rotary cooler/ near the

cooler. In ABC water is sprayed through the nozzles in

the form of spray to control the temperature of thegases.

Make-up water is added in the tank to cool the hot

water and compensate evaporation loss. The waterfrom settling tank is re-circulated for sprinkling over

the rotary cooler

The water requirement varies from 4-6 m3/ t of DRI.

gg

Solid Waste GenerationSolid Waste Generation



• Char

• Dedusting dust from pollution control

equipment of Product handling area• Kiln accretion waste

• Dedusting dust from pollution controlequipment of Cooler discharge area

•

Scrubber sludge (scrubber is installed aspollution control equipment of Kiln)

• Process dust from pollution control

equipment of Kiln

ENVIRONMENTAL STANDARDS



The standards will be applicable with effect from the

date of notification to all new, green field units set up

after the date of this notification and all expansion/

modernisation of existing units taken up after thedate of the notification. However, the existing units

shall install effective pollution control system within

six months and shall conform to the standards, after

six months of the date of notification.

ENVIRONMENTAL STANDARDS



1.0 Emission Standards

1.1 Stack Emission : 100 mg/nm3 (Coal based)*

Standards for Kiln 50 mg/Nm3 (Gas based)

*12% CO2 correction

Combustion Efficiency (CE) : shall be atleast 99.9% and be

of After Burner Chamber (ABC) computed as below:

CE= % CO2//[%CO2 + %CO]*100

1.2 Stack Emission Standards for de-dusting units



Particulate matter (PM) : 100 mg/Nm3

Stack Height ** (minimum) Coal/gas 30.0 m** Stack height shall be calculated as H=14.0 Q0.3 where Q isemission of Sulphur Dioxide (SO2) in kg/hr.ie.

SO2 (kg/hr) Height (metre)upto 12.68 3012.69 – 33.08 4033.09 – 69.06 5069.07 – 127.80 60

127.81 – 213.63 70

1.3 Fugitive Emission Standards

(Rotary Kiln/ Particulate Existing NewDe-dusting unit) matter unit Unit

Note:Note:(i) the existing industry shall comply with the standard of 2000

µg/m3

after one year from the date of notification.(ii) Fugitive Emission shall be monitored at a distance 10.0 metrefrom the source of fugitive emission.

Fugitive Emission Monitoring Location



S.N Area Monitoring Location

1. Raw material

handling area

Wagon tippler, Screen area,

Transfer Points, Stock Bin area

2. Crusher area Crushing plant, vibrating screen,

transfer points

3. Raw material feed

area

Feeder area, Mixing area, transfer

points

4. Cooler dischargearea

Over size discharge area, TransferPoints

5. Product

processing area

Intermediate stock bin area.

Screening plant, MagneticSeparation unit, Transfer Points,

Over size discharge area, Product

separation area, Bagging area

6. Other areas Areas as specified by StatePollution Control Board

2.0 Effluent Discharge Standards



(i) All efforts should be made to reuse and re-circulate thewater and to maintain zero effluent discharge.

(ii) Storm water / garland drain should be provided in theplant.

(iii) In case of maintenance/ cleaning of the system the

settling tanks effluent of wet scrubbing system orre-circulation system if require to be discharged,

should be treated suitably to conform to the following

standards:

pH : Between 5.5 to 9.0

Total Suspended Solids (TSS) : 100 mg/l

Chemical Oxygen Demand (COD) : 250 mg/lOil and Grease (O&G) : 10 mg/l

GUIDELINES



1.0

.0

Air Pollution

ir Pollution

1.1

.1

Stack Emission from Kiln

tack Emission from Kiln

(i) Adequately designed ESP or any other adequate air

pollution control system/combination of system shouldbe installed to achieve the prescribed stack emission

standards.

As installation and operation of Pollution ControlEquipment for plants with less than 100 TPD capacity is

not economically viable, therefore, it is recommended

that plants with less than 100 TPD shall not be permittedin future.

Program for phasing out old plants having capacity less

than 100 TPD shall be worked out by the State PollutionControl Board.

GUIDELINES (contd..)



(ii) All Pollution control equipment should be provided

with separate electricity meter and totaliser for

continuous recording of power consumption. The

amperage of the ID fan should also be recordedcontinuously. Non-functioning of Pollution control

equipment should be recorded in the same

logbook along with reasons for not running the

Pollution Control Equipment.

(iii) The safety cap/emergency stack of rotary kiln type

plant, which is generally installed above the AfterBurner Chamber (ABC) of feed end column should

not be used for discharging untreated emission,

bypassing the air pollution control device.




(iv) In order to prevent bypassing of emissions through safety

cap and non-operation of ESP or any other pollution

control device, software controlled interlocking facility

should be provided on the basis of real time data from the

plant control system, to ensure stoppage of feedconveyor, so that, feed to the kiln would stop

automatically, if safety cap of the rotary kiln is opened or

ESP is not in operation. The system should be able to

take care of multiple operating parameters and their interrelations to prevent any possibility of defeating the basic

objective of the interlock. The system should be foolproof

to prevent any kind of tempering. The software basedinterlocking system, proposed to be installed by industry

should be get approved by the concerned State Pollution

Control Board, for its adequacy, before installation by the

industry.




(v) Mechanical operated system for t imely collectionand removal of the flue dust generated in ESP or

any other pollution control device shall be

installed.

1.2 Stack Emission from de dusting units

All de-dusting units should be connected to astack having a minimum stack height of 30 m.

Sampling porthole and platform etc. shall be

provided as per CPCB emission regulation to

facilitate stack monitoring. De-dusting units can

also be connected to ABC Chamber and finally

emitted through common stack with kiln off-gas

emissions.




1.3 Fugitive Emission

The measurement may be done, preferably on

8-hour basis with high volume sampler. However,

depending upon the prevalent conditions at the

site, the period of measurement can be reduced.

2.0 Effluent Discharge

(i) All efforts should be made to reuse and re-circulate

the water and to maintain zero effluent discharge.

(ii) Storm water / garland drain should be provided in

the plant.

3.0 Noise Control

The industry should take measures to control the

Noise Pollution so that the noise level standards

already notified for Industrial area are complied.




4.0 Solid Waste Management

Char

Char should be mixed with coal or coal washery rejects and used as

fuel in Fluidized Bed Combustion Boilers (FBC) for generation of

power. The plants having capacity 200 TPD and above should installFluidized Bed Combustion Boilers (FBC) for generation of power.

Also the smaller capacity individual Sponge Iron Plants (Capacity

upto 100 TPD) and operating in cluster can collectively install

common Fluidized Bed Combustion Boilers (FBC) for powergeneration. The Sponge Iron Plant are free to explore other options /

possibilities to use char for generation of power. Char can be sold to

local entrepreneurs for making coal briquettes. It can also be mixed

with coal fines, converted to briquettes and used in brick kilns.

Under no circumstances char should be disposed off in agricultural

fields/other areas. Logbook for daily record, of Char production and

usage must be maintained by the industry and the record shall bemade available to officials of CPCB/SPCB/PCC during inspection.




Kiln Accretions

The kiln accretions are heavy solid lumps and can be

used as sub- base material for road construction orlandfill, after ascertaining the composition for its

suitability and ensuring that it should not have any

adverse environmental impact.

Gas Cleaning Plant (GCP)/Scrubber Sludge

The sludge should be compacted and suitably disposedoff after ascertaining the composition for its suitability

and ensuring that it should not have any adverse

environmental impact.




Flue Dust / Fly ashFlue dust is generated from air pollution control

system i.e. ESP or any other air pollution control

system installed with kiln. Secondary flue dust is alsogenerated from Bag Filters or any other air pollution

control equipment installed with Raw Material

Handling, Coal Crusher, Cooler Discharge and Producthouse unit. The reuse/ recycling of the flue dust

generated / collected may be explored and suitably

implemented.

Fly ash brick manufacturing plant should be install for

fly ash utilization. Fly ash can be utilized in cement

making by Cement industry also.

Bottom Ash




Bottom Ash

Bottom ash may have objectionable metallic compounds, thereforeshould be stored in properly designed landfills as per CPCB

guidelines to prevent leaching to the sub-soil and underground

aquifer.

General(a) Solid waste management program should be prepared with thrust

on reuse and recycling. Solid waste disposal site should be

earmarked within the plant premises. The storage site of solid

waste should be scientifically designed keeping in view that the

storage of solid waste should not have any adverse impact on the

air quality or water regime, in any way.

(b) The various types of solid wastes generated should be stored

separately as per CPCB guidelines so that it should not

adversely affect the air quality, becoming air borne by wind orwater regime during rainy season by flowing along with the

storm water.




5.0 Raw Material handling and Preparation

(a) Unloading of coal by trucks or wagons should be carried

out with proper care avoiding dropping of the materials

from height. It is advisable to moist the material by

sprinkling water while unloading.

(b) Crushing and screening operation should be carried out in

enclosed area. Centralized de- dusting facili ty (collection

hood and suction arrangements followed by de-dusting

unit like bag filter or ESP or equally effective method or

wet scrubber and finally discharge of emission through a

stack) should be provided to control Fugitive ParticulateMatter Emissions. The stack should confirm to the

emission standards notified for de-dusting units. Water

sprinkling arrangement should be provided at raw material

heaps and on land around the crushing and screeningunits.

( ) W k i l di th d di th l t h ll b




(c) Work area including the roads surrounding the plant shall be

asphalted or concreted.

(d) Enclosure should be provided for belt conveyors and transfer

points of belt conveyors.

The above enclosures shall be rigid and permanent (and not

of flexible/ cloth type enclosures) and fit ted with self- closing

doors and close fitting entrances and exits, where conveyors

pass through the enclosures. Flexible covers shall be

installed at entry and exit of the conveyor to the enclosures,

minimizing the gaps around the conveyors.

In the wet system, water sprays/ sprinklers shall be provided

at the following strategic locations for dust suppression

during raw material transfer:

- Belt conveyor discharge/ transfer point- Crusher/screen discharge locations




6.0 Waste Heat Recovery Boiler (WHRB)

Sponge Iron Plants of capacity more than 100 TPD

kilns shall use Waste Heat Recovery Boiler (WHRB)

for generation of power.

7.0 Cooler Discharge and Product Separation Unit

Permanent and rigid enclosures shall be provided

for belt conveyors and transfer points of belt

conveyors. Dust extraction cum control system

preferably bag filters or ESP to arrest product loss

in cooler discharge and product separation area

shall be installed.

8 0 Char based Power Plant




8.0 Char based Power Plant

For plant having capacity of 200 TPD of cumulative kiln capacity, the

power production through FBC boiler using char as a part of fuel, is

a viable option. Power generation through FBC boiler using char as a

part of fuel be implemented in a phased manner within 4 years of

commissioning and targeting for 100% utilization of char.

Individual Sponge Iron Plants of capacity upto 100 TPD and

located in cluster can install a common char based power

plant collectively.

9.0 New Sponge Iron Plants

(i) No New Sponge Iron Plant will be commissioned without installationof Pollution control systems as stipulated in the Standards. The

concerned State Pollution Control Board will accord consent to

operate only after Physical verification of the adequacy of the

Installed pollution control systems for meeting the standards andstipulated conditions in the consent to establish.

(ii) All kil h ll h th i d d t t k ith th kil




(ii) All new kilns shall have the independent stack with the kiln or

multi-flue stacks in case two or more kilns are joining the samestack for better dispersion of pollutants.

(iii) Any entrepreneur having more than 2x100 TPD kiln may install

WHRB for power generation, as it’s a techno-economic viableoption.

For plants having capacity of 200 TPD or more, power generation

using char in FBC Boiler as part of fuel is techno-economicviable option, therefore, new plants must install FBC boiler for

power generation at the time of installation of the industry.

(iv) Any new sponge iron plant being installed along with the otherdownstream facilities of converting the sponge iron into steel

with/without further processing the steel should meet the target

of 100% utilization of sensible heat of DR (Direct Reduction) Gas

and Char for power generation. Wet scrubbing system for kilnoff-gas treatment for such plants should not be opted.

10 0 General Guidelines




10.0 General Guidelines

(a) Extensive plantation/Green belt shall be developed along theroads and boundary line of the industry. A minimum 15 m

width Green Belt along the boundary shall be maintained.

However, the green belt may be designed scientifically

depending upon the requirement and local and mix species of

plants may be selected for the green belt.

(b) Monitoring of stack emissions, fugitive emissions, trade

effluent and noise level shall be done as per CPCBregulations.

(c) Pollution control systems shall be operated as an integral part

of production to ensure minimum emissions. Pollution ControlSystem shall start before conveyor operation/operation of

plant. Similarly pollution control system shall be stopped only

after completion of conveyor operation/operation of plant so

that possibility of dust settlement in ducts can be eliminated.Continuous evacuation of dust (from Dust catchers, ESPs,

Bag filter hopper etc.) shall be organized.

11.0 Siting Guideline for Sponge Iron Plants




11.0 Siting Guideline for Sponge Iron Plants

Siting of new sponge iron plants shall be as per respective

State Pollution Control Board guidelines. However the

following aspects shall also be considered:

(a) Residential habitation (residential localities/ village) andecologically and/or otherwise sensitive areas: A minimumdistance of at least 1000 m (1.0 km) to be maintained.

(b) The location of Sponge Iron Plant should be at least 500 maway from National Highway and State Highway.

(c) Radial distance between two Sponge Iron Plants shouldbe 5 km for plants having capacity 1000 TPD or more.

(d) Sponge Iron Plants can be established in designated industrialareas / Estates as notified by State Govt.

(e) If any plant/clusters of plants are located within 1 km from any

residential area/ village they may be shifted by State PollutionControl Board/ State Govt. in a phased manner for which a timebound action plan is to be prepared by SPCBs.

Specific Recommendation for Industrial

Pollution Control in Chhattisgarh



Pollution Control in Chhattisgarh

A. Silatara/Raipur, Raigarh area

1. No new sponge iron plant to be permitted in

Siltara – Raipur area.

2. Sponge iron plants shall be permitted in other

areas only after adoption of clean technology(www.cpcb.nic.in) and installation of WHRB and

AFBC/FBC boiler for char utilization for power

generation.

3. Existing sponge iron plants in Siltara area to be

directed to install AFBC/FBC boiler for use of

char in a time bound manner by ChhattisgarhPollution Control Authority.

4. Proper ash management programme to be drawn



giving emphasis' to utilise ash in cement makingetc.

5. Fugitive emission from the sponge iron plants tobe controlled as per CPCB guidelines.

6. Carrying capacity study in Siltara industrial areato be conducted specially to see the impact of

industries in Raipur city.

7. Integrated steel plants in Chhattisgarh to follow

the emission standards notified under EP Act and

CREP guidelines.

8. Toxic emission (PAH, VOC etc) from Coke Oven

l t t b t ll d CPCB id li



plants to be controlled as per CPCB guidelines.

9. Slag generated from steel melting shop (SMS) to

be properly managed.

10. Blast Furnace Slag to be sent to cement plant for

utilization.

11. Non recovery coke oven plants should

install WHRB for power generation.

12. Iron ore mining industry should follow strictly the

standard and guidelines of CPCB.

B. Korba Area1. In Korba area large number of coal based power

station are being setup.



g p

Based upon regional environmental impact study the

requirement of SO2,Nox and Mercury emission control

to be studied.

2. Ash utlisation plan should be drawn with all stake

holders for proper ash management following may

be considered.• Use of benefeciated coal for power generation.

• Dry collection of ash for cement making.

• Cement grinding unit to be located close to powerplant to utlise ash.

• Power plants to be encouraged to setup their own

cement plants for utilization of ash.• Clean coal technology to be promoted.

3. For Aluminium plant the secondary



p y

emission of fluoride to be controlled tomeet the total fluoride emission as 0.8

Kg/ton.

4. Spent pot lining which is hazardous waste

to be disposed as per Hazardous Waste

Management Rules and carbon portionmay be utilise in cement plant as partial

fuel.

C. General Issue

1 Thick Green Belt to be planted between Raipur and Siltara to



1. Thick Green Belt to be planted between Raipur and Siltara to

prevent the fugitive emission from industrial area to Raipur city.

2. In Siltara industrial area all the Kaccha road to be cemented.

3. Continuous Air Quality Monitoring Station to be setup at

Siltara, Raipur, Raigarh, Korba and other industrial area

jointly by industries and data to be displayed in SPCB’swebsite.

4. TSDF facility should be setup immediately in Siltara/Korba

area for disposal of Hazardous wastes.

5. Chhattisgarh Pollution Control Committee may initiate

Ambient Air Quality Monitoring based upon new draft Ambient Air Quality Standards.

M/s.M/s. VinayakVinayak Steels,Steels, Mahaboobnagar Mahaboobnagar District (100 TPD):District (100 TPD):

Case Study



This industry has provided Emission Control Equipments to all the

sources including fugitive emissions by concealing the following

areas Screen house

Crusher house

Stock house

Intermediate bin

Product house

Central Burner platform

Cooler discharge building Belt conveyors

Raw material & Finished product handling

Waste products handling.

yy , gg ( )( )

This industry was inspected and made the followingThis industry was inspected and made the followingobservations:observations:

PROCESS (Coal Based)



• Basic raw materials, for the production of Sponge Iron,

are hematite (Fe2O3), coal (C) and dolomite (CaO &

MgO). These three raw materials are crushed and

screened to a size fraction of 5 to 18 mm and -5mm.

These sized material is fed in to the rotary kiln through

feed tubes.

• The rotary kiln is a cylindrical structure with 3 meters

diameter and 42 meters length, the entire kiln is divided

into 7 zones and each zone is provided by a shell airfan.

PROCESS (contd.)



• These fans pump the air in to the kiln which isnecessary for the process.

• The kiln is Horizontal, and is supported by supportrollers and is rotated by an Electrical Motor of 100 HP.

• The raw materials take 8 to 12 hours to travel from thefeed end to the discharge end, during this travel ore getsheated up in first 3 zones and starts reduction from the

4th zone onwards.

• Finally at 7th zone the reduction will be completed andthe hot sponge Iron at 900 to 1000o C falls into the

cooler through transfer chute.

• Some fine coal from the discharge end is also injectedto maintain the temperatures of the outlet zones, which

is necessary to keep the reduction, alive.

PROCESS (contd.)



• Reactions involved in Process:

– 3Fe2O3 + CO 2Fe3O4 + CO2

– Fe3O4 + CO 3FeO + CO2

– FeO + CO Fe + CO2

• The material which enters into the cooler gets cooledwith the help of indirect cooling. After cooling thematerial discharges at 100oC from the cooler, thismaterial is further processed in the product house and

pure magnetic Sponge Iron is taken out.

Constituents of Sponge Iron



Total Iron (Fe T) – 85 to 90 %

Metallic Iron (Fe M) - 75 to 85 %

Carbon (C) - 0.03 % Sulphur (S) - 0.02 %

Phosphorous (P) - 0.02 %

FeO is calculated from Fe M & Fe T

Metallisation is derived from Fe M & Fe T

Gangue comprising of SiO2, Al2O3, and etc. is Calculated fromthe above given information.

Non – Magnetics.

Effects of various constituents of

Sponge Iron in production of steels



• Lower Total Iron – Lower Metallic yield

– Higher Slag generation

– Higher energy consumption

– Higher tap to tap time

• Higher metallic Iron

– Higher metallic yield (steel output)

– Lower FeO content – Lesser slag generation

– Lower energy consumption per unit of steel

produced. – Higher Productivity





• Higher carbon

– Adequate carbon boil

– Deoxidization

– Reducing FeO

– Higher yield

• Sulphur

– Sulphur in Iron Ore and coal used for theproduction of Sponge Iron is directlyproportional to the Sulphur content in SpongeIron.

– Sulphur is injurious to steel. Therefore,

Sulphur content in Sponge Iron should be aslow as possible.





• Phosphorous

– Like Sulphur, Phosphorous content in steel should also be low.Iron Ore and coal with low ‘S’ & ‘P’ should be selected for theproduction of Sponge Iron.

• Higher FeO

– Erosion of acid lined refractory

– Lesser lining life – Oxidation of bath

– Higher consumption of Fe alloys

– Higher requirement of carbonaceous material

– Loss of Fe in slag – Excess boiling of the bath

– Higher cost of production

– Restricting usage of other low – grade scrap





• Metallization

– Metallization is a derived figure, which is a ratio in percentage ofMetallic Iron divided by Total Iron. Higher the metallization,

higher the metallic iron, which results in higher productivity.

• Higher Gangue content

– Delays during melting

– Higher tap to tap time

– Higher energy consumption

– Higher lining erosion

– Lesser yield – Hazardous working

– Lesser productivity





• Non-Magnetics

– Non – Magnetic comprises mainly of char

material. Char does not have any positive

contribution. It generates slag and reducesthe yield.



CLEANER PRODUCTION

TECHNOLOGY OPTIONS

Cleaner Production in Sponge Iron



• Energy Audit

• Pollution Control

• Management of waste products

• Pre- Heating of Iron Ore

For implementation of Cleaner Production options

the commitment and willingness of top management

is a must without this it may be very difficult to

implement the CP Options. At times people have

commitment but due to lack of knowledge and

manpower the goals in implementing the CP Options

may not be possible.

Energy Audit to find out areas where fine tuning of the

Energy Audit



Voltage (V), Current (C) and Power Factor (PF) arerequired to be carried out.

In Sponge Iron industries, induction motors consume

around 90% of the electricity used. Even a small

increment in the efficiency of these motors can result in

substantial savings which can be possible by adopting

1. System Power Factor should be increased by

connecting proper capacitors

2. Variable frequency drives to be installed

3. Shedding of non-essential loads. Ex:- Lighting, Idle

running of the motors (screen, crusher and product

circuits) and pumps (water circuit)

Pollution Control



• Main sources of Air Pollution

– Process

• Installing of control equipments – ESP, GCT,DSC, Bag Filters and Scrubbers.

– Raw Material, Finished Product & WasteProducts

challenges in iron n steel by cpcb

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