MANAGEMENT OF WASTESDr.Kishore ChennaAsst. Gen.ManagerEnvironment Mgt. Dept.

Environmentsurroundings in which an organisation operates, including air, water, land, natural resources, flora, fauna, humans, and their interrelationsurroundings in this context extend from within an organisation to the global system

Environment

DEVELOPMENT WHICH MEETS THE NEEDS OF THE PRESENT WITHOUT COMPROMISING THE ABILITY OF FUTURE GENERATIONS TO MEET THEIR OWN NEEDS

Global Environmental IssuesHealth Environment ManagementEconomicsSocial responsibility

INTRODUCTIONSteel production and environment

INTRODUCTIONSteel production and environmentIt means that a ton of steel:Requires energy equivalent to 938 litres of petrol (11,000 km of travel by medium sized car) Requires water equivalent to daily consumption of 200 people Emits CO2 that 210 mature trees will sequester in a year About 25-30% of input is converted into wasteAlso . Iron and steel industry consumes 15% of the total energy used by industries Is responsible for fugitive emissions from handling and storage of huge amounts of raw materials Is responsible for emissions of pollutants like, poly aromatic hydrocarbons, SO2, NOx, VOCs, carcinogens etc Water pollutants contain organic, inorganic and toxic wastes

What does it mean ?

Waste is a useful Material in a wrong form or in a wrong place Forms of wasteDefective productAir EmissionsWaste Water DischargesSolid WastesHazardous WastesProduction LossExcess EnergyExcess Water consumptionInefficient use of labourInefficient use of raw materialsUnusable/Discarded Chemical ResiduesWHAT IS WASTE ?

What is waste minimization ?It is a new and creative way of thinking about products and the processes which make them.

It is achieved by continuous application of strategies to minimize the generation of wastes and emissions.

NEED FOR WASTE MINIMISATIONTo reduce the consumption of process inputs like raw material, water, chemicals, energy, etc. Which are increasingly becoming costlier day by day.To increase competitivenessTo consistently meet the prescribed environment standards.Easier / simpler treatment of wastesTo reduce waste treatment costsTo reduce capital costs of pollution control systemsTo reduce environmental liability costsTo reduce litigation with NGOs and public and improve relations with them.

REDUCTION IN Raw material use Energy Use Waste Quantity Capital Costs of new Pollution Control Systems Waste Treatment Cost Clean-up costs RejectsIMPROVEMENTS IN Working Conditions Safety Aspects Environmental Performance`BENEFITS OF WASTE MINIMISATION

Technical causes Poor housekeeping Leaking taps / valves/ Flanges Spillages Overflowing tanks Worn out material transfer belts Operational and maintenance negligenceUnchecked water / air consumptionUnnecessary running of equipmentSub optimal loadingLack of preventive maintenanceSub optimal maintenance of process conditionRitualistic operationPoor raw material qualityUse of substandard cheap raw material Lack of quality specification Shortages of supply Improper purchase management system & storageTYPICAL CAUSES OF WASTE

Technical causes contd.

Poor Process / equipment designMismatched capacity of equipmentWrong material selectionMaintenance prone designAdoption of avoidable process stepsPoor planningUnplanned / adhoc expansionPoor space utilization planBad material movement planBad TechnologyContinuation of same technology despite product / raw material changeHigh cost of better technologyLack of availability of trained manpowerSmall plant sizeLack of information

Inadequately trained personnelIncreased dependence on casual/contract labourLack of formalised training system/facilitiesJob insecurityFear of losing trade secretsLack of availability of personnelUnderstaffing hence work overpressureEmployee De-motivationLack of recognitionAbsence of reward / Punishment systemEmphasis only on production, not on peopleLack of commitment and attention by top management

MANAGERIAL CAUSES

WASTE MINIMISATION TECHNIQUESSOURCE REDUCTIONRECYCLING (ONSITE & OFFSITE) PRODUCT CHANGES- PRODUCT SUBSTITUTION PRODUCT CONSERVATION CHANGE IN PRODUCT COMPOSITION SOURCE CONTROL USE AND REUSE- RETURN TO ORIGINAL PROCESS RAW MATERIAL SUBSTITUTE FOR ANOTHER PROCESS RECLAMATION

- PROCESSED FOR RESOURCE RECOVERY PROCESSED AS A BY PRODUCT INPUT MATERIAL CHANGES- MATERIAL PURIFICATION MATERIAL SUBSTITUTION TECHNOLOGY CHANGES- PROCESS CHANGES EQUIPMENT, PIPING OR LAYOUT CHANGES ADDITIONAL AUTOMATION CHANGES IN OPERATIONAL SETTINGSGOOD OPERATING PRACTICES- PROCEDURAL MEASURES LOSS PREVENTION WASTE STREAM SEGREGATION MANAGEMENT PRACTICES MATERIAL HANDLING IMPROVEMENTS PRODUCTION SCHEDULING

Film on Consumerism and Waste

SOLID WASTES (Resources) AT VSPAIR POLLUTION CONTROL -Wastes.WASTE WATER TREATMENT PLANT - WastesPROCESS WASTES - SOLID CO- PRODUCTS - SLAGS -SCRAPS - OTHERSHAZARDOUS WASTES E WASTE

AIR POLLUTION CONTROLWet scrubber in SPESP of GCP in SP Bag house in RMHPTotal qty. of raw materials handled: 12 Mt/yr.Total length of Belt-Conveyors: 138 kmHuge qty. of dust generation at all transfer points

Air Pollution Control (DE) Systems in VSPNote: Data excludes ventilation systems in VSP

Deptt.Cyclone (dry)Scrubber (wet)ESP (dry)Bag filterTotalNo. of chimeys (height)C&CCD---*32---1*333(120m)RMHP25------1843TPP---050505153flues (180.5m)SMS------*02 (CVS)1-ISBH, 1-IRUT, 1-LF51 (80m)BF02---*02 (BHS)*02(CHES)04102(80m)2(100m)CRMP---------19194(52m)ES&F---10---0717---SP---33*02(ACP)*02(GCP)01382(120m)WRM---------------1(45m)LMMM---------------1(87m), 1(40m)MMSM---------------1(80m)G. Total2780155818021

Dust from DE Systems

WATER TREATMENT80% water uncontaminated recycled20% treated in treatment plants before recycling

Sl.No.LocationType of solid waste recovered1WTP-1:BF-ISludge2WTP-2:BF-II-do-3WTP-3:SMS/GCP-do-4WTP-4:SMS/CCDMill scales5WTP-7: Mills-do-6WTP-8: Mills-do-7Met. Sludge shifted from Mini pondBF, SMS & Mills8WTP:CCCDCoke sludge

Sludges from Water Treatment Plants

PROCESS WASTES

Process Solid Co-Products

Process Slags

Process Scraps

Process Wastes

ECONOMICS OF

SOLID WASTE MANAGEMENT ( 2008-09)Total value of wastes recycled / sold :Rs1153 CrTotal expenditure on operation / maint.: Rs.110 Cr of P.C. equipment Net gain:Rs. 1043.6 CrTurn over : Rs. 10,000Cr% of turn over :~10.4 %

PROBLEM AREAS

FLY ASHT P P = 247.5 MWCoal = 40% ashFly ash generation= 1500 t/day (0.52 Mt/yr.) = 14% of total wastes (3.21Mt/yr)Dry fly ash storage / delivery project cost= Rs 2.94cr.Capacity = 3.42 t/hr (silo: 100t)

Status of LD utilisation in VSPFigures in tons# process means utilisation in SP,BF,SMS & Traffic and excluding construction

YearGenera-tionUtilisationUtilisationSPSMSBFTrafficCEDConstQty%% ut process #08-0932866546095064736697916000021049064.0523.9807-0832713177305126022687755514353022519368.8436.2606-07343936786252490204154986016013010027891479.8453.3505-06396303727201870393365027108509621.4710004-05391238997305132331140365555011776430.1100

R & D Initiatives on Solid Waste Utilization

R&D Projects

Microbial leaching of phosphorous from LD slag

GCP sludge briquetting

Briquetting of metallurgical waste

Title: Microbial removal of Phosphorous

Research partner: IMMT , Bhubaneswar

Objective: Improve the recycling of LD slag

Stage - 11 ton lab scale experiment was conducted at IMMT, Bhubaneswar

Phosphorus reduction was about 40% in lab scale

Stage - 23 Experiments were conducted on 5 ton industrial scale at VSP

Results were not consistent

Looking for alternative methodsMicrobial removal of Phosphorous

Trial 121%Trial 24%Trial 311 %

Research partner: Internal

Objective: Usage of SMS-GCP sludge as a replacement of sized Iron ore in ConverterBriquettes were made using GCP sludge96 tons of briquettes were produced during industrial trial and used in converterNo adverse effects were observedTitle: GCP sludge briquetting

38 tons briquettes were produced and used in SMS as a replacement of sized iron ore.

No adverse effects were found

It has been decided to use them on regular basisGCP sludge briquetting

Research partner: IMMT , Bhubaneswar

Objective: Industrial trial run to study the suitability of briquette made from Solid Metallurgical wastes

8 types of wastes were used in different proportions for making briquettesTitle: Briquetting of Metallurgical Waste

Title: Briquetting of Metallurgical Waste

Coke sludge10%Coke dust5%Iron ore fines20%BHS dust10%Flue dust5%Mini pond sludge20%GCP sludge10%Mill scale20%

500 kg Briquettes were made on Lab scale

Industrial trial of 500 T briquettes is to be conducted in Blast Furnace after making the metallurgical waste briquettes.

Making of briquettes is under progress

After successful completion of industrial trial the same will be implemented on regular basisTitle: Briquetting of Metallurgical Waste

HAZARDOUS WASTES

Hazardous waste means any waste which by reason of any of its physical, chemical, reactive, toxic, flammable, explosive or corrosive characteristics causes danger or is likely to cause danger to health or environment, whether alone or when in contact with other wastes or substances and shall include wastes included in Schedule 1, 2 & 3 of the said rules.

HAZARDOUS WASTESHazardous Wastes practices at VSP

OTHER WASTES

ITEMS DEALT IN DISPOSAL STORESALUMINIUM SCRAPAUTO SCRAPBEARING SCRAPBRASS SCRAPCI SCRAPCONVEYOR BELT SCRAPCOPPER SCRAPCS SCRAPELECTRICAL SCRAPEMPTY GUNNY/HDPE BAGS SCRAPEMPTY MS/PLASTIC DRUMS AND CANS(Detoxified)GI SCRAPGP/GC SHEET SCRAPMS SCRAP15. PLATIUM SCRAP16. RADIATIOR SCRAP

ITEMS DEALT IN DISPOSAL STORES17. RUBBER SCRAP18. SGCI ROLL SCRAP19. SS SCRAP20. STEEL ROLL SCRAP(BROKEN/UNBROKEN)21. TC SCRAP22. TELECOM SCRAP23. TYRE SCRAP24.USED ALUMINIUM/COPPER CABEL SCRAP25.USED ALUMINIUM/COPPER CABLE SCRAP26.USED BATTERIES27.USED COMPRESSORS28. USED LUB/TRANSFORMER OIL29. USED PALLETS30.USED REFRACTORY BRICKS31.USED X-RAY FILMS32. USED/DISCARDED EQUIPMENT/VEHICLES33.WOODEN SLEEPER SCRAP

ITEMS DEALT BY EnMDPOLYETHENE WASTEBOTTLESELECTRICAL WASTERUBBER RELATED WASTEOIL/GREASE SOAKED COTTONE-WASTEPAPER WASTE

THANK YOU

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