status of sponge iron units in orissa
TRANSCRIPT
STATUS OF SPONGE IRON UNITS
IN ORISSA
Prepared by –
Environment Conservation Team (Aruna Murthy, Himansu Sekhar Patra)
September 2005
Vasundhara, E-14, Gajapati Nagar, Bhubaneshwar
STATUS OF SPONGE IRON UNITS IN ORISSA
INTRODUCTION
Steel market in India is in a rising phase as infrastructure development has been rightly given high priority. The secondary sector of steel production has witnessed phenomenal growth in recent years. The steel production through the secondary sectors, which works only 21.39% in 1993-94, has gone up to 35.46% in the year 2001-02. The reasons are:
1. Low investment
2. Ability to produce quality steel economically through this process
3. Availability of Sponge Iron both in quality and quantity, which is a major raw material for secondary steel makers.
In the secondary sector, the steel production is mainly by EAF and induction furnace. Induction furnace route is gaining importance due to low investment cost and ability to produce quality steel at lower cost. A number of induction furnace units have been established with varied production capacity. With the increasing demand of sponge iron as the major raw material for the secondary steel makers, there is mushrooming growth of sponge iron units in the country, particularly in the eastern side. All of them have opted for coal based plants having rotary kilns.
The process of sponge iron making aims to remove oxygen from iron ore. When that occurs, the departing oxygen causes micro pores in the ore body making it porous. The final product, when observed under a microscope, resembles a honey comb structure, looking spongy in texture, hence, the name “Sponge Iron”
RAW MATERIALS REQUIRED
Sponge Iron manufacture is highly sensitive to raw material characteristics. Therefore, it is essential to examine the chemical and physical characteristics of raw materials, both individually and in combination. The basic raw materials for the production of Sponge Iron are iron ore, non-coking coal, and dolomite.
Coal: Important factors determining coal quality are:
1. Chemical properties such as fixed carbon, ash-content, volatile material, etc.
2. Physical properties such as reactivity, and ash-fusion temperature.
Iron Ore: In sponge Iron making, iron ore is reduced in solid state. Unlike in the conventional steel melting process, the gangue content of iron ore cannot be separated as a slag. Therefore, it becomes imperative to select an iron ore with a high iron content and a low gangue content, to optimize yield during steel making. Apart from this, to ensure a better kiln campaign life and output, iron ore is made to undergo a series of other tests such as – Shatter, tumbler and abrasion indices, reducibility, etc.
Dolomite: It acts in the processes as a Desulphuriser removing sulphur from the feed mix during the reduction process. It is mixed in small proportion along with other raw materials before charging into the kiln.
TECHNOLOGY INVOLVED
Production of Steel through the conventional blast furnace requires coking coal of which India has limited reserves. Therefore, evolution of a technology for the reduction of Iron Ore using abundantly available non-coking coal was contemplated, giving birth to direct reduction Iron Technology (DRI).
PROCESS
Iron ore (Hematite) and non-coking coal are the prime raw materials for the production of sponge Iron. These are charged into a rotary kiln in a requisite proportion along with some dolomite. Coal plays a dual role in the process by acting as a reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 950-1050°C. The reduction process occurs in the solid state. The crucial factor in this reduction process is the controlled combustion of coal and its conversion to carbon monoxide to remove oxygen from the iron ore. The overall process requires a duration of approximately 10-12 hrs inside the kiln, during which iron ore is optimally reduced and discharged to rotary cooler for cooling below 120°C, before coming out into the finished product circuit.
EXISTING SPONGE IRON UNITS IN ORISSA
List of Sponge Iron Units in the state of Orissa as on 28.02.2005 Sl. No Name and Location
SUNDERGARH DISTRICT
1 Agrasen Sponge (P) Ltd, Mandiakudar, Sundergarh 2 Bajrang Ispat Pvt. Ltd, Kuarmunda, Sundergarh 3 Govindam Project, Kalosihira, Kuarmunda, Sundergarh 4 Jagannath Sponge Pvt. Ltd, Kuarmunda, Sundergarh 5 Jai Balaji Jyoti Steels Ltd., Tainser, Lathikata, Sundergarh 6 Jay Iron and Steels Ltd, Balanda, Sundergarh 7 Kalinga Sponge Iron Ltd., Kalunga I.E. Sundergarg 8 Khaderia Ispat Ltd., Kuarmunda, Sundergarg 9 Maa Tarini Industries Pvt Ltd, Balanda, Sundergarh 10 Mangalam Ispat Pvt Ltd, Usra Road, Kuarmunda, Sundergarh 11 Meta Sponge Pvt Ltd., Kalinga I.E.Sundergarh 12 Neepaz Mattaliks Pvt Ltd. Hariharpur, Kuarmunda Sundergarh 13 OCL India Ltd.(Sponge Iron Division) Rajgangpur, Sundergarh 14 Pawan Jay Sponge Iron Ltd., Bijabahal, kunjaharia, SUndargarh 15 Pooja Sponge Iron Ltd., kalunga I.E. Sundergarh 16 Prabhu Sponge Iron Pvt Ltd., Jhagarpur, Rajgangpur, Sundergarh 17 Reliable Sponge Pvt Ltd. Jhaliaberina, Bonan Sundergarh 18 Rexon Strips Ltd, Kumakala, Sundergarh 19 Scan Sponge Iron Ltd., Ramabahal, Rajgangpur, Sundergarh 20 Scan Steels Ltd.(Sponge Iron Division), Ramabahal, Rajgangpur, Sundergarh 21 Seeta Sponge Iron Ltd, Kalunga I.E.Sundergarh 22 Sri Balaji Metallics Pvt Ltd., Kharibandh, Sundergarh 23 Sri Ganesh Metallics Ltd., Kuarmunda, Sumdergarh 24 Srishti Ispat Ltd.(Sponge Iron Division), Bringatoli, Sundergarh 25 Sponge Udyog Pvt.Ltd, Kalunga, Sundergarh 26 Sri Mahavir Ferroalloys Pvt.Ltd., Kalunga I.E. Sundergarh 27 Suraj Products Ltd., Barapali, Kesarmal, Rajgangpur, Sundergarh 28 Swastik Ispat Pvt Ltd, Kuarmunda, Sundergarh 29 T.R.Chemicals Pvt Ltd., Barapali, Kesarmal, Rajgangpur, Sundergarh 30 Utkal Metalliks Ltd, Kalunga I.E., Sundergarh 31 Veda Vyas Ispat Pvt.Ltd., Kuarmunda, Sundergarh
KEONJHAR
32 Aditya Sponge and Power Pvt Ltd., Telkoi, Dubulpal, Keonjhar 33 Beekay Steels and Power Ltd, Uliburu, Nalda, Keonjhar 34 Crackers India Alloys Ltd. (Sponge) Govardhanpur, Deojhar, Keonjhar
35 Deepak Steel and Power Ltd., Topadihi, Keonjhar 36 Grewal Associates, Matkambeda, Barbil, Keonjhar 37 Hima Ispat Pvt Ltd., Barpada, Guali, Keonjhar 38 Kusum Power Met Ltd., Kutugaon, Chipinda, Keonjhar 39 MSP Sponge Iron Pvt Ltd., Haladiaguna, Gohardhanpur, Keonjhar 40 N.K.Bhojani Pvt Ltd, Rugdihi, Barbil, Keonjhar 41 OMDC Sponge Iron Plant, Thakurani, Keonjhar 42 Orion Ispat Ltd, Ramachandrapur, Keonjhar 43 Orissa Sponge iron Ltd.palasapanga, Keonjhar 44 Rungta Mines (Sponge Iron Division), Karakola, Barbil, Keonjhar 45 Sri Ganesh Sponge Iron Ltd., Kutugaon, Keonjhar 46 Sri Metallics Ltd., Loidapada, Keonjhar 47 Sumrit Metallics Pvt Ltd., Soyabali, Barbil, Keonjhar 48 Tata Sponge Iron Ltd., Bilaipada, Joda, Keonjhar
DHENKANAL
49 Scaw Industries Pvt Ltd., I.E., Gundichapada, Dhenkanal,
ANGUL
50 Shree Metallics Ltd., Amalapada, Anugul
JAJPUR
51 Surya Sponge Iron Ltd., Kalkala, Budakendua, Jajpur
MAYURBHANJ
52 Shiv Shakti Sponge Iron Ltd., Pandersil, Mayurbhanj
SAMBALPUR
53 Maa Samaleswari Sponge Iron Ltd., Kattarbhaga, Rengali, Sambalpur 54 T.R. Chemicals Ltd., Belpada, Bamara, Sambalpur
JHARSUGUDA
55 Bahgavati Steels Pvt.Ltd., Badmal Jharsuguda 56 L.N.Metallics Ltd., Siripura, Jharsuguda 57 Pawan Sut Sponge Iron Pvt Ltd., badmal, Jharsuguda 58 Sri Madhav Ispat Ltd., Siriapali, Parmanpur, Jharsuguda 59 SMC Power generation Pvt Ltd, Hirma, Jharsuguda 60 SPS Sponge Iron Ltd, Badmal, Jharsuguda
CUTTACK
61 Shiva Metallics, Suniamuhan, Mancheswar, Cuttack
LIST OF SPONGE IRON PLANTS GRANTED CONSENT TO ESTABLISH (NOC) As on 14.12.2005
Sl. No Name of Industry Location Block District Kiln No
(Capacity in TDP)
1 M/s Shisti Ispat Ltd (Sponge Iron Div.)
Budhakata, Bringatoli Sundergarh 2 X 100
2 M/s Sri Mahavir Ferro Alloys Pvt. Ltd.
Kalunga Industrial Estate Sundergarh 2 X 100
3 M/s Suraj Products Ltd. Barapali, Kesarmal, Rajgangpur Sundergarh 3 X 50
4 M/s Mangalam Ispat (P) Ltd. Usra Road, Kuarmunda Sundergarh 1 X 100
5 M/s Neepaz Metalliks Pvt. Ltd Chadrihariharpur, Kuarmunda Sundergarh 5 X 100
6 M/s OCL India Ltd., (Sponge Iron Division) Lomloi Rajgangpur Sundergarh 4 X 100
7 M/s Maa Tarini India (P) Ltd. Balanda, Kalunga Sundergarh 2 X 50
8 M/s T.R.Chemicals (P) Ltd. Barpalli Rajgangpur Sundergarh 3 X 50
9 M/s Prabhu Sponge (P) Ltd. Jhagarpur Rajgangpur Sundergarh 3 X 50
10 M/s Sree Metalliks Ltd. Mukundapur, Amalapada Angul 2 X 100
11 M/s Shiva Metalliks (P) Ltd. Sanuimuhan, Mancheswar Cuttack 1 X 50
12 M/s Shree Jagannath Metalliks Industries
Khaprakhai, Palaspanga Keonjhar 1 X 100
13 M/s Orion Ispat Ltd. Ramchandrapur Keonjhar 2 X 100
14 M/s N.K.Bhojani (P) Ltd. Rugudihi, Guali, Barbil Keonjhar 3 X 40
15 M/s Surya Sponge Iron Ltd. Budhakendua, Kalkala Jajpur 2 X 40
1X 100
16 M/s Pawanjay Sponge Iron Ltd. Bijabahal, Kunjharia Sundergarh 3 X 50
17 M/s Orissa Sponge Ltd. Palaspanga Keonjhar 1 X 350
18 M/s Utkal Metalliks Ltd. Kalunga Industrial Estate Sundergarh 1 X 50
1X 40
19 M/s Shiva Shaki Sponge Iron Ltd Pandersil, Sukruli Mayurbhanj 2 X 100
20 M/s Ganesh Sponge Metalliks Ltd. Chandrahariharpur Sundergarh 3 X 100
21 M/s Hima Ispat Pvt. Ltd. Barpada, Guali Keonjhar 1 X 300
22 M/s Grewal Associates (P) Ltd. Matkambeda Barbil Keonjhar 2 X 100 1X 100
23 M/s Pawansut Sponge (P) Ltd. Badmale, Kukurjanga Sambalpur
24 M/s L.N. Metalliks (P) Ltd Siripura Jharsuguda 1 X 100
25 M/s Golden Trexim (P) Ltd.(Beekay Steels and Power Ltd.)
Ulliboni, Nalda Keonjhar 1 X 300
26 M/s Khedaria Ispat Ltd Kuarmunda Sundergarh 1 X 50
27 M/s Cracker India Alloys (P) Ltd. Gobardhanpur, Deojhar Keonjhar 1 X 100
28 M/s Sponge Udyog (P) Ltd. Jaibahal, Kalunga Sundergarh 1 X 100
29 M/s Sumrit Metalliks (P) Ltd Soyabali, Barbil Keonjhar 1 X 50
30 M/s Aarati Steels (P) Ltd Ghantikal, Athagarh Cuttack 2 X 500
31 M/s Rungta Mines Ltd., (Sponge Iron Division) Karakolha Barbil Keonjhar 4 X 500
32 M/s Agrasen Sponge (P) ltd Mandiakudar Sundergarh 2 X 50
33 M/s Bajranga Ispat (P) Ltd. Naikinbahal, Kuarmunda Sundergarh 2 X 40
1 X 100
34 M/s Vedvyas Ispat (P) Ltd Gobira, Kuarmunda Sundergarh 1 X 100
35 M/s Sri Ganesh Sponge Iron (P) Ltd. Kutugaon, Chipinda Keonjhar 1 X 100
36 M/s Tata Sponge Iron Ltd. (Expansion) Bileipada, Joda Keonjhar 2 X 375
37 M/s Kusum Power Met (P) Ltd Kutugaon, Chipinda Keonjhar 2 X 50 1 X 100
38 M/s Meta Sponge (P) Ltd. Kalunga Industrial Estate Sundergarh 1 X 40
39 M/s Gobindam Project (P) Ltd Kalosihira, Kuarmunda 1 X 100
40 M/s OMDC Ltd Dalki, Thakurani Keonjhar 1 X 100
41 M/s Puja Sponge (P) Ltd Kalunga Industrial Estate Sundergarh 1 X 100
42 M/s SMC Power Generation Ltd. Hirma Jharsuguda 1 X 300
43 M/s Kalinga Sponge Iron Ltd. Kalunga Industrial Estate Sundergarh 1 X 100
44 M/s Rungta Mines Ltd. Kamando Sundergarh
45 M/s Scaw Industries (P) Ltd Gundichapada Industrial Estate Dhenkanal 1 X 300
46 M/s Bindal Sponge Ltd. Sunakhani, Talcher Angul 1 X 300
47 M/s Jagannath Sponge (P) Ltd. Kuarmunda Sundergarh 1 X 50
48 M/s Maa Samaleswari Sponge Iron ltd.
Katarbagha, Rengali Sambalpur 1 X 100
49 M/s SMS Sponge Iron Ltd. Badmal Jharsuguda 6 X 100
50 M/s Sree Madhab Ispat (P) Ltd Siriapali Jharsuguda 2 X 100
51 M/s Swastik Ispat Pvt. Ltd. Naikinbahal, Kuarmunda Sundergarh 1 X 50
52 M/s Jyoti Iron & Steel Ltd. Tainsar, Lathikata Sundergarh 2 X 100
53 M/s Nixon Steel & Power Ltd Kalunga Industrial Estate Sundergarh 1 X 350
54 M/s Seeta Sponge Ltd Kalunga Industrial Estate Sundergarh 1 X 50
55 M/s Bhushan Steel Telkoi, Rengali Sambalpur 2 X 500
56 M/s MSP Sponge Iron (P) Ltd Balisuan, Haladiaguna, Gobardhanpur
Keonjhar 2 X 40 2 X 50
57 M/s Scan Sponge Iron Ltd Ramabahal, Rajgangpur Sundergarh 1 X 50
58 M/s Atcom Metalliks Ltd. Gundichapada Industrial Estate Dhenkanal
59 M/s Agarwal Minerals Rugudi Keonjhar
60 M/s Aditya Sponge & Power Ltd. Telkoi, Dubulapal Keonjhar 2 X 100
61 M/s Deepak Steel & Power Ltd. Tapadihi Keonjhar 2 X 50 2 X 100
62 M/s Sumasankar Sponge Iron (P) Ltd Khuntaketa Keonjhar
63 M/s Ganesh Sponge (P) Ltd. Krushnachandrapur, Parang Angul 1 X 100
64 M/s Bhushan Steel & Strips Ltd. Meramundali Dhenkanal
65 M/s Dinabandhu Steel and Power Ltd.
Kalinga Nagar, Industrial Growth Centre
Jajpur
66 M/s Samaleswari Ferro Metals (P) Ltd Bisalkhinda, Sasan Sambalpur 1 X 100
67 M/s Maa Shakumbari Sponge Naikinbahal, Kuarmunda Sundergarh 1 X 100
68 M/s Reliable Sponge Pvt Ltd. Jhaliaberena, Bonai Sundergarh 1 X 100
69 M/s B.R.Sponge & Power Ltd. Bad-Tumkela, Rajamunda Sundergarh 2 X 100
70 M/s Rana Sponge Ltd. Kulei Dhenkanal
71 M/s Maheswari Ispat Ltd. Rampei, Khuntuni Cuttack 2 X 100
72 M/s Jay Iron & Steel Ltd. Balanda, Kalunga Sundergarh
73 M/s Ores ispat Pvt. Ltd. Gurundipalli Sundergarh
74 M/s Balajee Metalliks (P) Ltd. Khairabanda Sundergarh 1 X 50
75 M/s Bhagabati Steel (P) Ltd Kukurjanga, Badmal Jharsuguda 1 X 50
76 M/s T.R.Chemicals (P) Ltd. Belpara, Basra, Bonai Sambalpur 1 X 100
77 M/s Rexon Strips Ltd. Kumkela Sundergarh 2 X 100
78 M/s Scan Steels Ltd.(Sponge Iron Div) Rambahal Rajgangpur Sundergarh 1 X 50
79 M/s Sree Metalliks Ltd. Loidapada Keonjhar 2 X 50 4 X 100
80 M/s Maa Vaishnavdevi Sponge Ltd.
Kalunga Industrial Estate Sundergarh 2 X 50
81 M/s Vasundhara Metalliks (P) Ltd Podajalanga, Bilaimunda, Himgir Sundergarh 1 X 50
82 M/s Singhal Enterprises Hirma Jharsuguda 1 X 100
83 M/s B.R.G.Steel (P) Ltd. Kurunti, Puspanga Dhenkanal
84 M/s Mahakali Ispat (P) Ltd. Gurundipali, Bonai Sundergarh
85 M/s Sree Sai Sradha Steels (P) Ltd.
Bijabahal, Kunjharia Sundergarh 1 X 25
86 M/s Bhaskar Steel & Ferro Alloys Ltd.
Bad-Tumkela, Rajamunda Sundergarh 1 X 300
87 M/s Surendra Mining Ind (P) Ltd. Bakhamusa, Bonai Sundergarh
88 M/s Shyam DRI Power Ltd. Pandloy, Rengali Sambalpur
89 M/s Deepak Steel & Power Ltd. Kuliguna, Nalda Keonjhar
90 M/s K.J.Ispat Ltd. Jakhapura, Kalinganagar Industrial Complex
Jajpur
91 M/s Sri Hari Sponge (P) Ltd. Kendrikela, Bonai Sundergarh
92 M/s Shiv Metalliks (P) Ltd. Gurundipalli, Bonai Sundergarh 1 X 100
93 M/s Ocean Ispat (P) Ltd. Basantapur, Joda Keonjhar
94 M/s Deo Mines& Minerals Thiberna, Bonai Sundergarh
95 M/s Maa Samaleswari Industries (P) Ltd Lapanga Sambalpur 2 X 100
96 M/s Jai Hanuman Udyog Ltd. Raghunathpalli, Kolihira Jharsuguda 1 X 100
97 M/s Maithan (Mal) Industries Ltd. Kalinga Nagar, Ind. Complex, Duburi Jajpur
98 M/s Aryan Ispat & Power (P) Ltd Rengali Sambalpur
99 M/s Monica Holdings (P) Ltd Bad-Tumkela, Bonai Sundergarh
100 M/s Vishal Metalliks (P) Ltd Barhamusa Sundergarh
101 M/s Vikram (P) Ltd. Tumkela Sundergarh
102 M/s Action Ispat & Power (P) Ltd Pondaripathor & Marakutta Jharsuguda
103 M/s B.R.G. Iron & Steel Co. Ltd. Kurunti, Kuspanga Dhenkanal
104 Kaushal Ferro Metals (P) Ltd. Badbahal, Kundukela Sundergarh
105 R.B.Sponge Iron (P) Ltd. Kenghati, Jayantpur Sambalpur
ENVIRONMENTAL IMPACT OF SPONGE IRON UNITS Right from the raw material yard to disposal of the final product (Sponge Iron), at every step of its handling there is pollution. Sponge Iron Plants have the following pollution hazards:
1. Dust emission during raw material preparation and product discharge and handling: A definite size of iron ore and coal is required for the production of sponge iron. The suppliers are not adequately equipped to cater to the needs of the sponge iron industries. Therefore, the industries crush and size the raw materials at their plant premises. During such crushing and sizing operations, generation of fugitive dust and discarded ore fines and coal fines in inevitable. Major dust emitting areas include areas such as product discharge from cooler to conveying system, magnetic separator, and raw material preparation unit.
2. Reduction: The gaseous products of reduction contain mainly raw material dust, and gases
like CO2, CO, H2, NOX, O2, unreacted hydrocarbons, and SOX 3. Waste water discharge: The dusts from the gaseous emissions are separated through ESP
or Gas quenching system. In either case, the disposal is done by converting the dust to a slurry form to avoid flying of the same in ambient air. In order to recycle the water, the slurry is allowed to settle in a clari-flocculator, from where the settled solid particles are pumped out. The polluted slurry water is then allowed to settle in settling ponds, or lagoons from where the clear water is pumped back for reuse. Such water is polluted with dissolved solids.
4. Gaseous emissions: The exhaust gas emerges out of DRI kilns at a temperature of about
900°C having some quantities of combustibles. This gas is used to produce steam in waste heat boilers, which in turn is used to produce power. The dust coming from exhaust gas is either quenched to make slurry for easy disposal or is collected in dry condition or in wet condition from the ESP. So far, no utilization of this dust have been found out which causes air pollution (due to dust) in the near by areas.
5. Char: The partially burnt coal called char is discharged from the reactor along with sponge
iron. After the magnetic separation, the char is separated as waste.
PROBLEMS DUE TO SPONGE IRON UNITS IN ORISSA In many of the sponge Iron Units in Orissa, ESP has not been installed and where it is installed, these units switch off their ESPs during the nights for a few hours. Thus, the area becomes a huge smoke bowl. In some sponge iron units in Sundergarh, it was found that the precipitators were not running in several of the units. Smoke and soot from the plants carried by the wind cause wheezing problem in kids, and cows and cattle to become restless. The smoke is sometimes so thick that vision even at a distance as close as 1 meter becomes difficult. The clothes worn by people immediately become smeared with coal dust. Even cooking utensils are covered with soot. In Kormunda (Sundergarh) where Neepaz Metallics (a 1.4 lakh tonnes sponge iron plant) is set up, the drinking water becomes covered with black soot. The emissions also cause irritation and watering of eyes in human beings.
LEGISLATION, RULES AND REGULATIONS STIPULATED FOR SPONGE IRON UNITS IN ORISSA
Government of Orissa, Forest and Environment Dept has stipulated the following regulations for the establishment of sponge iron plants in the state of Orissa.
A. In six sensitive blocks (Kuarmunda, Lathikata, Rajgangpur and Bonaigarh block of Sundergarh district, Jharsuguda Block of Jharsuguda District and Rengali block of Sambalpur district) including 25 Km from block boundary –
No new sponges iron & integrated steel plant will be allowed. Cases which had been received by the state pollution control board before the Government
decided on a prohibition on establishment of sponge iron plants in the state may be considered individually un merit. These proposals can be considered on case to case basis with the condition that they set up a WHRB with a Power plant within 1 year
Proposals of establishment of integrated steel plant where MOUs have already been signed with the state government may be considered on merit
Expansion proposals received by the SPCB before the decision on prohibition on establishment or expansion of sponge iron units was made by the government may be considered on merit within a condition to install WHRB and/or steel plant.
Expansion of existing plant will be allowed for 25/50 TPD to 100TPD for the purpose of installation of WHRB and power plant.
B. Outside the six sensitive zones Cases which had been received by the state pollution control board before the government
decision on prohibition to establish sponge iron plant in the state may be considered. These proposals can be considered on case to case basis with the condition for installation of WHRB power plant within 1 year.
Cases where MOUs have been signed with the State Government may be considered. Cases other than the above 2 shall not be considered till an environmental impact study of
the existing units as well as proposed units is done and it is examined by the SPCB in consultation with steel and mines and industries department.
Expansion proposals of existing sponge iron units may be considered to facilitate installation of WHRB with CPP or expansion to integrated steel plant.
Proposal for integrated steel plants through DRI route may be considered by sSPCB on the basis of merit.
C. The pending cases (i.e. Proposals received before the Government’s decision on the prohibition on establishment of sponge iron) may be cleared with stipulation of installation of ESP, with separate energy meter, automatic change over to DG set and other pollution control measures as decided earlier or, recommended by the state pollution control board. In addition, explicit stipulation for installation of Waste Heat Recovery Boiler (WHRB) with CPP or upgradation of the unit to steel plant within a period of 1 year from the date of issue of the NOC shall also be made.
D. The existing sponge iron units shall be required to install WHRB with CPP within 1 year and take immediate steps for installing equipments for automatic changeover to DG set in case of power breakdown and for installation of separate energy meter as well as other pollution control measures as per the direction of SPCB.
MITIGATORY MEASURES – VASUNDHARA’S APPROACH
1. Study the utilization of Char as Activated Carbon: It has been found that the reactivity of char is high. So, in some cases, a limited quantity of char can be recycled back to the rotary kiln with good results. Char can be used to manufacture activated carbon and as domestic fuel.
2. Study of utilization of Char Fines in Fuel Briquettes formation: The briquettes manufactured from coal char mixed with coal fines are used as a fuel in brick kilns. The rejects and wastes of bricks have been reduced considerably with the use of these briquettes, besides reduction of cost of fuel.
3. Study of utilization of Exhaust Gas Dust for building bricks: Exhaust Gas Dust can be used for building bricks for construction purposes. 4. Establishment of Waste Heat based power plants: Suggest the establishment of Waste Heat based power plants to encourage utilization of waste gases. Suitable amendment to the state legislation has already been proposed - Proper implementation and execution must be ensured. 5. Research on DRI Plant Waste: The research organizations of the state must rise to the occasion to find methods for utilization of the DRI Plant Waste; because the growth potential of DRI plants in the country is quite high and steel production through DRI and induction furnace route is the cheapest of all the processes in the world today. 6. Ensure control on the pollution from the DRI plant through:
Installation of suitable de-dusting/ dust extracting equipments at dust emitting points. Suitable gas cleaning equipment such as ESP or gas quenching system should be
installed. Ensure suitable methods of storing of raw material waste (raw material fines) and
disposal of the same. Suitable disposal of the sludge of waste water and reuse of wastewater. The most
effective way is to save all waste water for reuse without allowing them to mix with any other waste stream.
Utilization of waste char for water purification, making domestic fuel briquettes, and as activated carbon. The stockyard should be judiciously planned to avoid flying of dust in air.
CONCLUSION
It is a fact that the gainful utilization of the generated wastes plays a vital role in the profitability of any organization. From the foregoing discussions, it is clear that the utilization of DRI plant wastes need to be strengthened in order to abate future threat to the environment, besides generating profits for the organization.