Free Essays for Competitive Exams-Energy and Environment Management

Energy and Environment Management

Environment management and energy efficiency constitute an important benchmark for assessing any sector or company both globally and domestically. The Ministry of Steel through various schemes and regulations of the Government is facilitating reduction in energy consumption and emission of environmental pollution in steel plants. Some of the steps/initiatives taken by the Ministry of Steel through various forums and mechanism during the year are:

Charter on Corporate Responsibility for Environment Protection (CREP)

This is an initiative of the Ministry of Environment and Forests (MoEF)/Central Pollution Control Board (CPCB) in association with the Ministry of Steel and the main/major steel plants to set mutually agreed targets with the purpose to go beyond the compliance of regulatory norms for prevention and control of pollution.

A National Task Force in CPCB reviews the compliance of CREP action points and targets. The areas where environmental performance are particularly monitored are:- fugitive emissions from coke ovens; secondary emission control in steel melting shops; use of BOF slag for treatment of acidic soils; Effective operation of coke oven by product effluent treatment plants; and monitoring of ambient air quality.

Further, measures for reduction of energy consumption in respect of the following areas (i) injection of coal/tar in blast furnaces; and (ii) water consumption (in respect of which the primary target was achieved by most integrated plants) are also reviewed.

Clean Development Mechanism (CDM) under Kyoto Protocol

Under this scheme, the Ministry of Steel is facilitating, through the National CDM Authority in the MoEF, adoption of energy efficient clean technologies in iron and steel plants. A large number of iron and steel plants have obtained approvals for availing carbon credit by adopting energy efficient clean technologies.

UNDP-Global Environment Facility (GEF) Steel Project

Under this project, a scheme has been developed with contribution from the United Nations Development Programme (UNDP) and the Ministry of Steel to facilitate diffusion of energy efficient low carbon technologies in steel re-rolling mills in the country to bring down energy consumption, improve productivity and cost competitiveness together with a reduction in Green House Gas (GHG) emission and related pollution levels. Towards this objective, 67 model units have been identified and so far, technology packages have been commissioned in 30 units.

NEDO Model Projects

Ministry of Steel has been advocating for setting up of energy efficient, environment friendly projects known as Model Projects in different steel plants with financial assistance from Japan. These projects are implemented by New Energy and Industrial Technology Development Organisation (NEDO), Japan.

So far, two projects have been commissioned at TATA Steel and one more project is at advanced stage of commissioning there. One model project for sinter cooler waste heat recovery at Visakhapatnam Steel Plant of RINL is under progress.

National Mission for Enhanced Energy Efficiency (NMEEE)

NMEEE has dealt with measures for improving Energy Efficiency of the industrial sectors, including steel.

By virtue of the Energy Conservation Act, 1961, steel producing units consuming 30000 MTOE (Million Tonnes Oil Equivalent) or more will be designated consumers, for whom a benchmark will be applicable.

Steel manufacturing units operating at a level better than the benchmark will be eligible to obtain an Energy Saving Certificate (ESC) that can be traded in the market. Bureau of Energy Efficiency (BEE) has worked closely with Ministry of Steel for benchmark in energy consumption in various technological routes of steel making using a wide variety of raw materials, which have already been notified. Under the NMEEE, a market based mechanism namely ‘Perform, Achieve and Trade (PAT)’ has been launched with an aim to improve energy efficiency in 08 energy intensive sectors including iron and steel. The unit-wise targets have since been notified for the steel sector. Units/industry which overachieve the targets will get incentives in the form of energy saving certificates, which can be traded and can be bought by other unit/ industry unable to achieve the targets.

Steel Authority of India Ltd. (SAIL)

Consistent efforts by SAIL has resulted in achievement of best ever results in the following key Environmental Performance indicators, as shown below:

Indicators	2010-11	2011-12	2012-13 (Apr’12 to Dec’2012)
Particulate Matter (PM) Emission (Kg/tcs)	1.11	1.01	0.89
Specific Water Consumption (m3/tcs)	4.06	3.86	3.77
Specific Effluent Discharge (m3/tfs)	2.49	2.26	2.22
Solid Waste Utilization (%)	84	86	88 (Apr-Nov’12)

Note: Figures are 2012-13 are average for 4 ISPs i.e. BSP, DSP, RSP and BSL.

Figures are total Solid Waste Utilization include all 5 ISPs of SAIL.

Emission and Consumption Levels

• PM emission load has reduced from 2.2 kg/tcs (tonnes crude steel) in 2007-08 to 1.01 kg/tcs in 2011-12, a reduction of 54% during the last 5 years.

• Specific Water Consumption has reduced from 4.00m3/tcs in 2007-08 to 3.86m3/tcsin 2011-12: a reduction of 3.5% during the last 5 years.

• Specific effluent discharge from SAIL plants has reduced from 2.62m3/tfs (tonnes finished steel) in 2007-08 to 2.26 m3/tfs; a reduction of around 18% over the last 5 years.

Environmental Plantation

During 2011-12, a total no. of 2.81lakh saplings were planted in and around SAIL plants and mines. Plantation done during the period April-December 2012, in SAIL units was 2.24lakhs saplings.

Implementation of Environment Management System (EMS) Linked to ISO 14001

• Visvesvaraya Iron and Steel Plant under close association with EMD received the ISO 14001:2004 certificate from M/s TUV-NORD India Pvt. Ltd. Bengaluru.

• During the year 2012-13, EMD has selected new areas viz. the Hyderabad Warehouse under Central Marketing Organisation and the BTSO, Vizag under Transport and Shipping Organisation, for implementation of EMS-ISO 14001:2004.

Clean Development Mechanism

• The verification process for carbon credits (VERs) accrued through the following two VER projects of VCS standards has been successfully completed by the verifier, M/s RINA:

- Introduction of BF gas firing in Boiler #6 at P&BS of BSP.

- Introduction of BF gas firing in Boiler Unit B of ISP.

Subsequently, M/s RINA, Italy have issued the verification statement along with detailed verification report for the accrued carbon credits for the period 2006-2010.

Environmental Awareness Programmes

• Various awareness programmes like celebration of World Environment Day, Earth Day, Ozone Day, Environment Month, Mines and Mineral Conservation week were organized for spreading environmental awareness.

Energy Consumption of SAIL Plants is as under:

Consumption of Energy per tonne of crude steel (Gcal/tcs)

Plant	2010-11	2011-12	2012-13 (Apr - Dec)
BSP	6.67	6.85	6.64
DSP	6.74	6.75	6.48
RSP	6.87	6.86	6.76
BSL	6.78	6.78	6.70
ISP	8.17	8.34	8.02
SAIL	6.79	6.86	6.68

Rashtriya Ispat Nigam Ltd. (RINL)

Energy Management

Energy Consumption (Gcal / tCS )& CO2 Emissions(Tons/tCS):

Year	Specific Energy Consumption (Gcal/tcs)	CO2 Emissions (tonnes/tcs)
2011-12	6.06	2.61
2012-13 (till Dec)	6.33	2.66

Measures taken/being taken for reduction in Energy Consumption (2012-13)

• Commissioning of 14MW Coke oven battery-IV Turbine and generation of a power of 20MW from waste heat.

• Reduction of BF gas bleeding from 3.84 % to 3.36 % by taking up proactive measures and optimizing distribution through Supervisory Control and Data Acquisition system (SCADA).

• Replacement of Tubular air heater in Boiler-4 in thermal power plant.

• Replacement of Air Recuperartors in F/C-1& F/C-2 of LMMM.

• Replacement of Gas Recuperator at the reheating furnace of WRM.

• Commissioning of Waste Heat Recovery system in stoves of BF-3.

Adoption of Energy Management System

• RINL Upgraded from BS EN 16001 Energy Management Systems to ISO-50001 Energy Management System. RINL is the first and only integrated steel plant to implement the standard.

Clean Development Mechanism

The progress of CDM projects is as given below:

• As a part of validation of two CDM projects (Waste Heat Recovery from Stoves of Blast Furnace-3 and Power Generation using Top Pressure Recovery Turbine of BF-3) webhosted for global stake holder comments and site visit completed by Designated Operational Entity.

• Eight CDM projects have been accorded HCA by National CDM Authority. Out of eight, four projects are under validation.

• Submitted Project Design Documents (PDD) for nine numbers of projects to National CDM Authority for Host Country Approval (HCA).

• The PDD for Generation of 120 MW of Electricity by using Waste Blast Furnace Gas has been submitted to NCDMA for HCA.

 Environment Management System

VSP is the first Indian Steel plant to be certified for ISO 14001 system standard for Environment. A number of clean technologies based on utilisation of waste heat, waste gas, pressure energy, solid wastes and sludge have been adopted in VSP for the first time in India. RINL-VSP is complying with all statutory requirements, details of Stack Emissions and Solid Wastes are as given below:

I. Stack Emissions:

Stack Emissions(Unit : milligram/Ncum)
Location	Parameter	APPCB Norm	2010-11	2011-12	2012-13 (Upto Dec’12)
Coke Oven Battery 1 to 3	SPM	50	43.5	42.3	44.19
Blast Furnace (BHS-1- &2,CHES-1&2)	SPM	115	79.3	82	73.25
Steel Melt Shop(CVS)	SPM	115	48.4	55.6	51.1
LMMM	SPM	115	39.4	43.8	39.7
Wire Rod Mill	SPM	115	53.8	41	35.6
MMSM	SPM	115	42.7	41	39.7
Sinter Plant(ACP-1&2)	SPM	115	79.2	80.6	86.5
Thermal Power Plant ( Boilers 1-5)	SPM	115	94.8	93.5	91.8

II. Solid Wastes:

Generation & Utilization of BF & SMS Slag
Year	BF Slag % Utilization	SMS Slag % Utilization	Total Slag % Utilization
2010-11	98.91	80.09	94.93
2011-12	81.16	106.83	86.28
2012-13(UptoDec'12)	107.71	31.06	90.40

New Initiatives / Innovative Schemes for improving Environmental Performance

New projects taken up during the year are as given below:

Sl. No.	Project Description	Impact
1	Dry fly ash handling, storage and delivery system for boilers-2,3,4 & 5	Effective utilsation of Fly Ash
2	Replacement of ESP of Burden Handling System of Blast Furnace-1 & Cast House exhaust Station-1	Reduction of Emissions from 115 mg/ Nm3 to below 50 mg/Nm3

Highlights of Environment Management

• The Centre for Science and Environment (CSE) recognized environmental performance of company and awarded with “3 Leaves rating” (1st amongst Integrated Steel Plants in India).

• Commissioning of “Appikonda Waste Water treatment” and ‘Balacheruvu Treatment Plant’ towards Zero Water discharge, first time in india (saving of about 1.5-2.0 MGD of water).

• Four environmental projects have been initiated during the year to bring down Stack Emission concentrations from 115 mg/Nm3 to below 50 mg/Nm3 in BF-1 and Sinter Plant -1.

• Implementing the “E-waste Rules 2011” to dispose E-waste. About 25.38 Tons of E- waste was disposed during the year.

NMDC Ltd.

NMDC‘s projects of Bailadila Iron Ore Mine, Kirandul Complex (Deposit 14/11C) andBacheli Complex (Deposit-5), Donimalai Iron Ore Project and Diamond Mining Project,Majhagawan, Panna were certified with ISO 14001:2004 Environmental Management Systems.

Environmental Monitoring and Pollution Control Measures

NMDC is carrying out post project environmental monitoring studies at all projects through laboratories recognized by Ministry of Environment and Forest (MoEF). The studies show that the environmental parameters are well within the norms prescribed by State Pollution Control Boards and Central Pollution Control Board for Industrial & residential areas.

Air Pollution Control:

• Monitor all environmental parameters such as SPM, PM2.5, SO2, NOx, CO, dust fall rate in ambient air on regular basis following the statutory acts and their amendments of theGOl viz.,

• Fugitive dust emission are being controlled by regular water sprinkling of water on all mine haul roads and other feeder roads. Mist water spray nozzles used for dust suppression at Crushing plant.

Water Pollution Control:

• Monitor water quality as per IS standards in respect of oxidation pond, discharge water from auto shops and service centers, tailing dam discharge water etc., on regular basis.

• The slimes generated during the wet screening operations and impounded in Tailingdams are desilted before onset of monsoon, so that clear water is ensured to discharge from tailing dams to downstream nallahs.

Noise Pollution:

• Noise levels are maintained below 85dBA in the work environment. Workers engaged in the operation of HEMM etc., are provided with ear plugs/muffs.

• Rubber coated screens are used in screening plant and at all transfer points to control noise.

Plantation:

• 50,000 saplings are planted every year at Bailadila projects through Chhattisgarh Raj Van Vikas Nigam Ltd.,

• More than 14 lakhs saplings have been planted in NMDC projects till date.

Energy Conservation

Some measures taken / being taken for reduction in energy consumption are:

a) Energy audit was undertaken for all the projects. Audit recommendations are being implemented for energy conservation.

b) LED laminators are being installed in place of conventional luminaries in phased manner.

c) Power factor is being maintained above 0.96 with static capacitors on HT and LT side.

d) Solar street lights are being installed under CSR initiative.

e) Solar lanterns are distributed in rural areas under CSR intitiative.

MOIL Ltd.

Air Pollution Control

a) Dust suppression of the points of dust generation are being ensured by:

• Wet drilling of blast holes.

• Haulage roads are frequently sprinkled with water for which truck mounted water tankers with sprinkler arrangement have been provided.

• Maintaining the drilling speed as recommended by the manufacturers should control dust produced during deep large blast hole drilling.

b) The dust respirators are provided to all the workers in dusty atmosphere.

Water Pollution

• The water pumped during underground mining operation is fully utilized for plantation and sand stowing operations.

• The rain water collected in open pit is a source of water for dust suppression and plantation activity which is carried out in every year.

• There is no discharge of water from any of the mine in the nearby water sources.

Solid Waste Management

• On an average 7.40 million m3 of solid waste is produced during the period of report. MOIL has adopted a system to segregate these waste in two categories namely (i) ‘white waste and’ (ii) ‘black waste’. Both the wastes are dumped separately and systematically white waste is totally a waste rock and black waste is mostly magniferous rocks or ‘sub-grade mineral’ which can be utilized in future.

• White dumps, once stabilized, are covered with plantation, MOIL in consultation with National Environmental Engineering Research Institute (NEERI) have successfully carried out plantation over these white dumps.

MECON Ltd.

MECON has put forward significant engineering efforts to achieve zero discharge from production plants being engineered by MECON.

MECON is presently executing the NEDO model project as detail engineering consultant for the 20.6 MW Sinter Cooler Waste Heat Recovery System for the 2 nos. Straight line sinter cooler at RINL, Vizag.

MECON’s Environmental Engg. Laboratory which is recognized under Environment Protection Act, 1986 also renders its services for sampling, testing & analysis of air, water, noise, sewage and soil quality to various Plants in Steel and other Sectors both in private and public.

MECON has prepared Environmental Norms and Standards for Sponge Iron Plants in the country in association with Central Pollution Control Board (CPCB) and has been asked to prepare environmental standards for Sinter Plants by CPCB ; Project on Development of Comprehensive Industry Document (COINDS) and Environmental Standards for Re-rolling Mills ; Development of Guidelines for Management of Solid & Hazardous Waste generated in Integrated Iron & Steel Industry.

MECON has received an assignment for preparation EIA/EMP report for 4 x 700 MW Haryana Atomic Power Project which is under Nuclear Power Corporation Ltd.

MECON has executed rebuilding job of Coke Oven Battery no. 10 at ISP, Burnpur as Consultant with Biological Oxidation and Dephenolisation (BOD) plant for degradation of Coke Oven effluents and is also executing BOD Plant and sewage treatment plants along with sewage lift pump houses for 2.5 MT expansion of ISP, Burnpur. In addition, MECON is carrying out engineering work of sewage treatment plant, sewerage facilities & other effluent treatment facilities, as applicable, for NLC, Neyveli ; SAIL Projects of Bokaro,Bhilai, Burnpur and NMDC as well as for different private sector companies like Bhushan Group, Jindal Group etc.

KIOCL Ltd.

Environment Management

At Mangalore

Pellet Plant, Port Facilities & Captive Power Plant

a) The storm water drains in the plant area are provided with check bunds and catch pits to arrest the silt. The silt accumulated in the drains are removed and has been recycled in the process.

b) 150 water sprinklers are installed and are in operation for suppression of dust in the plant premises.

c) 10 stacks installed in the pellet plant for discharge of emissions have been provided with Air pollution control equipments such as Wet scrubbers, bag filters and multi clones. The discharge from the wet scrubbers are recycled in the process and the dust collected in the multi clones/bag filters are recycled.

At Blast Furnace Unit

a) Blast Furnace is provided with dust catcher, gas cleaning plant and effluent treatment plant.

b) Treatment plant (Thickeners) – The solid separated in thickeners in the form of slurry is being sent to Pellet Plant in tankers for recirculation to conserve the resources.

c) Rain harvesting/water conservation – The system of collecting the monsoon water and storing in 50the reservoir was developed in 2006. Harvesting of monsoon water is being done successfully from 2007 monsoon onwards.

Compliance of Statutory Requirement (in all locations)

a) The standard norms prescribed by Karnataka State Pollution Control Board (KSPCB in respect of Air and water quality monitoring are being adhered to in all area of work.

b) The compliance status with respect to the conditions stipulated in the consents arebeing reported regularly to the concerned authorities. The compliance to consent conditions is satisfactory.

c) The Company has fully implemented the requirement of Battery Rules 2001, Hazardous Waste (M&H) Rules 2008, Bio Medical Waste Rules, 1998, Water Act, 1974, Air Act, 1981 and EP Act, 1986.