International Conference on Environmental Compliance and
Enforcement - the Emerging Global Trend
Environmental Challenges:
A steel industry perspective
Environment Management Division
Kolkata
March 19-20, 2013
Ancient Philosophy –
Respect for Environment
In ‘Rig Veda’, it is stated:
Sky is like a father
Earth is like a mother
Space is as their children
It reflects that environment is to be valued like parents
and loved like children
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Environmental Challenges
• India’s economic development propelled by rapid
industrial growth and urbanization is causing severe
environmental problems that have local, regional and
global significance.
• Deforestation, soil erosion, water pollution and land
degradation continue to be areas of major concern.
• Rapid industrialization and urbanization in India’s
metropolises are straining the limits of municipal
services and causing serious environmental problems.
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Environmental Challenges
• Assuming continued economic liberalization and increased
urbanization, the damage to environment and health
could be enormous if precautionary measures are not
taken.
• The challenge, therefore, is to maintain the quality of air,
water and land and protect the environment by
reconciling
environmental,
social
and
economic
imperatives.
• To address these environmental challenges in
coordination with the state governments, the central
government has identified and targeted 17 highly
polluting industries.
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Environmental Challenges
• The chemical and engineering industries are at the top of
the government’s list, since they are the major
contributors to air, water, and waste pollution.
• These industries include integrated iron and steel plants,
non ferrous metallurgical units, pharmaceutical and
petrochemical complexes, fertilizers and pesticide plants,
thermal power plants, textiles, pulp and paper, tanneries
and chloralkali units.
• Government of India has established an environmental
legal and institutional system to meet these challenges
within the overall framework of India’s development
agenda and international principles and norms.
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Environmental Legislations
Stockholm Conference on Human
Environment in 1972
Ever since the ‘Stockholm Conference’ in June,1972,
there has been a great proliferation of legislations and
regulations in India for protection and improvement of
environment in response to the challenge of
SUSTAINABLE DEVELOPMENT.
In India, protection of Environment and Sustainable use
of natural resources received due attention after
Stockholm Conference in 1972.
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Environmental Legislations
The Rio Earth Summit, 1992
• From 3-14 June 1992, Rio de Janeiro hosted the United
Nations Conference on Environment and Development
(UNCED).
• The focus of this conference was the state of the
global environment and the relationship between
economics, science and the environment in a political
context.
• The conference concluded with the Earth Summit, at
which leaders of 105 nations gathered to demonstrate
their commitment to sustainable development.
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Environmental Legislations
Why Environmental Legislations ?
• Threat to sustainable economic development due
to stretching use of natural resources beyond their
replenishing capacity
• Environmental law play a very crucial preventive as
well as remedial role
• Organisation demonstrate sound environmental
performance on account of growing stringent
compulsion
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Initiatives from Government
• Environmental Rules and Regulations, notified from time to
time
- recently harmonized the notification for iron and steel industries
• Charter on Corporate Responsibility for Environmental
Protection (CREP), 2003
- to go beyond the compliance with the environmental standards
• National Environmental Policy (NEP), 2006
- promotes sustainable development
• National Action Plan for Climate Change (NAPCC), 2008
identified 8 National Missions,
- to achieve sustainable development
• Sustainable Development / MOU Guidelines issued by
Department of Public Enterprise
- including Sustainable Development as a compulsory element for
Central Public Sector Enterprises
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Environmental Legislations
Various Legislations and Regulations in India, dealing
with protection of environment
•
•
•
•
•
Water (Prevention & Control of Pollution) Act, 1974
Water (Prevention & Control of Pollution) Cess Act,1977
Forest Conservation Act, 1980
Air (Prevention & Control of Pollution) Act, 1981
Environmental (Protection) Act, 1986
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Hazardous Wastes (Management, Handling & Transboundary
Movement) Rules 2008
Manufacture, Storage & Import of Hazardous Chemical Rules,2000
Battery (Management & Handling) Rules, 1998
Bio-medical Wastes, Municipal Wastes, 1998
Noise (Regulation & Control) Rules, 2000
Ozone Depleting Substance Rules, 2000
Notification on Fly-ash, 2009
E-waste (Management & Handling) Rules, 2011
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Coastal Regulation Zone Notification, 2011
National Environment Policy-2006
•
National Environment Policy is a response to our commitment
to ‘Clean Environment’ , mandate in constitution of India in
Article 48A and 51A (g), under Article 21.
•
NEP recognized that maintenance of Environment is not only
the responsibility of State alone, it is the responsibility of
every citizen.
Objective of National Environment Policy
•
Conservation of critical environmental resources
•
Integration of environmental concerns in economic and social
development
•
Efficiency in resource use
•
Enhancement of resources for environmental conservation
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National Action Plan on Climate Change
• NAPCC document released on 30th June, 2008, relates
to sustainable development, co-benefits to society at
large, focus on adaptation, mitigation, and scientific
research.
• Identified 8 National Missions to achieve Sustainable
Development
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−
−
−
−
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National
National
National
National
National
National
National
National
Solar Missions
Mission for Enhanced Energy Efficiency
Mission on Sustainable Habitats
Water Mission
Mission for Sustaining the Himalayan Ecosystem
Mission for a Green India
Mission for Sustainable Agriculture
Mission on Strategic Knowledge on Climate Change
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Charter on CREP
Charter on Corporate Responsibility for Environment
Protection (CREP)
• Government and Industry have united and come to an
understanding through CREP in March, 2003
• Action points formulated under CREP for 17 categories of
polluting industries
• A step beyond compliance with the regulatory norms
• Target is set in the Charter are ahead of existing standards
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Charter on CREP
Charter on Corporate Responsibility for Environment
Protection (CREP)
Target is set for the following:
– Rebuilding of Coke Oven Batteries
– Solid Waste Utilization
– Inventorisation and Management of Hazardous Wastes
– Water Consumption
– Introduction of CDI/CTI facilities
– Installation of Secondary emission control system in SMS
– Adoption of Cleaner Technology
– Implementation of recommendation of LCA
– Keeping records for efficient running of pollution control
equipment and reporting
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Environmental Aspects of Iron &
Steel Industries
• The process of iron and steel
making itself is highly resource
intensive, consequently emitting
and discharging pollutants and
therefore, the cause of
environmental concern across the
world.
• Steel as a product has minimum impact on environment
because of its high recyclability.
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Environmental Norms applicable to
Steel Industries
Currently steel industry is required to be in compliance with
regulations for meeting both generic standards for air, water,
noise, waste management as well as specific standards for
steel industry. Salient among these are :
 Environmental Norms for Coke Ovens, Sinter Plant, Blast
Furnace, Steel Melting Shop, Rolling Mills, Arc Furnace,
Cupola-Foundry, Induction Furnace, Calcination Plant/ Lime
Calcination/Dolomite Plant notified on 31 March, 2012 for
Stack emission, Fugitive emission & Effluent discharge.
 National Ambient Air Quality standards.
Steel plants of SAIL have taken measures to comply with the
laid down stipulated environmental norms and further
improvement in their environmental performance.
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Environment Policy of SAIL
We, the Steel Authority of India Limited (SAIL), manufacture various products of iron and
steel. The company owns and operates five integrated steel plants at Bhilai, Durgapur,
Rourkela, Bokaro and Burnpur and three special steels plants at Salem, Durgapur and
Bhadravati along with captive mines for iron ore, limestone, dolomite and coal and has a
Ferro-alloys Plant at Chandrapur. We also have an extensive marketing network spread across
the length and breadth of the country.
SAIL reaffirms its commitment to contributing towards a clean and sustainable environment
and continually enhancing its environmental performance as an integral part of its business
philosophy and values. Towards this commitment, we shall :
•
•
•
•
•
•
•
•
Integrate sound environmental management practices in all our activities.
Conduct our operations in an environmentally responsible manner to comply with
applicable legal and other requirements related to its environmental aspects and strive to
go beyond.
Progressively adopt cleaner and energy efficient technologies.
Minimise waste generation and promote recovery, recycle and reuse.
Increase greenery in and around our plants and mines.
Strive for continual improvement in our environmental performance by setting challenging
targets, measuring progress, taking corrective action and communicating environmental
information to all concerned.
Enhance environmental awareness amongst employees working for and on behalf of us
and the general populace around the plants and mines.
Encourage our business associates to adopt similar approach for environmental protection.
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Initiatives taken at SAIL
The environment policy of SAIL, adopted in the year 1996,
governs the environment management of all operations at
its facilities. It ensures environmental sustainability at its
plants and mines by setting challenging targets,
committing to judicious use of resources and making its
processes cleaner and energy efficient through :
• Phasing out of old technologies and production process,
contributed significantly to the improvement in the
environment and pollution scenario in SAIL Steel works
like :
− Pollution load could be drastically brought down with the
gradual replacement of the open hearth furnaces by BOFs.
− Adoption of continuous casting in place of continuous
ingot casting contributed to energy saving.
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Initiatives taken at SAIL
• Improvement in the environmental front has also been
brought about through the following:
− Gradual rebuilding of Coke Oven Batteries with state-ofthe art Pollution Control facilities
− Installation of Computerised Combustion Control System
at Coke Oven Batteries
− Installation of multi-slit burners in Sinter Plant
− Installation of Dry Fog Dust Suppression System
− Replacement of Scrubbers by ESPs/Bag Filters
− Injection of Direct reducing agents in BFs
− Installation of Cast House de-dusting system at BFs
− Reverse Osmosis process for the treatment of effluent
− Recycling Water from Sewage Treatment Plant
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Environmental Compliance
• With the implementation of the various pollution control
technologies, the steel plants of SAIL have been able to
meet the stipulated norms laid down by the statutory
bodies.
• All the parameters of effluent discharge quality are
meeting the norms in the outlets at the plant boundaries.
• The ambient air quality parameters and the Particulate
Matter (PM) emission from the stacks of the steel plants
are mostly meeting the laid down norms.
• Actions are being taken where the stack emissions are
not meeting the environmental standards.
• With the concerted efforts put on, there has been gradual
improvement in the major environmental indices.
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Improvement in Environmental Indices
Particulate Matter (PM) Emission
Load has reduced from 2.2 kg/tcs
(tonnes of crude steel) in 07-08 to
1.01 kg/tcs in 2011-12, a reduction
of more than 54% during the last 5
years.
During April– Feb. 2013, average PM
emission load further reduced to
0.89 kg/tcs.
Specific Water Consumption has
reduced from 4.0 m3/tcs (tonnes of
crude steel) in 07-08 to 3.86 m3/tcs
in 2011-12, a reduction of more than
3.5 % during the last 5 years. During
April–Feb. 2013, average Specific
Water Consumption further reduced
to 3.74 m3/tcs.
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Improvement in Environmental Indices
Specific Effluent Discharge from
SAIL Plants has reduced to 2.26 m3/tfs
(tonnes of finished steel) in 2011-12; a
reduction of more than 13% over the
last 5 years.
During April – Feb. 2013, average
Specific Effluent Discharge further
reduced to 2.22 m3/tfs.
Specific Effluent Load was 0.13
Kg/tcs in 2011-12 ; a reduction of
around 28% during the last 4 years.
During April–Feb. 2013, average
Specific Effluent Load further
reduced to 0.10 kg/tcs.
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Improvement in Environmental Indices
With continuing thrust on Solid Waste
Utilization at the integrated steel
plants, an improvement of over 18% for
Blast Furnace (BF) Slag and 18% for
Basic Oxygen Furnace (BOF) Slag has
been achieved in the last 5 years.
During April - Feb. 2013, the BF & BOF
Slag utilisation were 95% and 70%
respectively.
Solid Fill
: BF Slag
Gradient Fill
: BOF Slag
Specific CO2 Emission reduced from 2.99
kg/tcs (tonnes of crude steel) in 07-08 to
2.81 T/tcs in 2011-12; a reduction of 6%
over the last 5 years.
During April-Feb. 2013, the Specific CO2
emission further reduced to 2.77 T/tcs.
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Initiatives taken at SAIL
• Environment management is an integral part of the
modernization and expansion projects undertaken at
different SAIL units.
• Various state-of-the-art cleaner technologies are being
installed as a part of the on-going expansion cum
modernisation project:
− Beneficiation to use lean ore and to recover iron ore fines
from slime
− Pelletisation of iron ore fines
− Coke Dry Quenching (CDQ)
− Top Pressure Recovery Turbine system (TRT)
− Stock House Dust Suppression system
− Cast House De-fuming system
− Secondary emission control system at BOF
− Gas based (using by-product gas) Power Plant
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Water Management
•
Efficient local re-circulation systems and plugging of leakages,
resulting in reduction of specific water consumption.
• Treatment & Recycling of Municipal waste Water to replenish
the scarce water resource.
• A 30 Million Lit. /Day, Sewage Treatment Plant has been set up
at BSP.
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Solid Waste Management
Blast Furnace Slag
− About 95% of the slag generated in the steel plants is
being utilised.
− Granulated BF slag is a raw material for Cement making
as a replacement of cement clinker.
− New Cast House Slag Granulation plants are coming
along with all new/modernized Blast Furnaces for
maximizing the utilization of Slag and selling it to cement
industries.
− Two JV Cement Plants have been installed, one each at
BSP and BSL, for utilisation of the granulated slag.
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Solid Waste Management
BOF Slag
− About 70% of the BOF slag generated in the steel plants
is being utilised.
− BOF slag is used internally in the base mix of Sinter Plant
as replacement of limestone.
− In Railway tracks as track ballast and in road making
within the works premises.
− Exploring the possibilities with Railways for the use of
weathered LD slag as Rail Track Ballast.
− Taken up a R&D project of “Dry Granulation of LD slag
with Heat Recovery”
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Dry Granulation of LD slag with Heat Recovery
Solid Waste Management
Advantages of Dry Granulation Process over Wet
Granulation Process
• Saving of water at the rate of 1000-1500 Ltr./ton of slag
• Eliminating unwanted gas (eg. SO2) emission
• Recovery of waste heat to reduce energy consumption
and consequent reduction in CO2 footprint.
Uses of granulated LD slag
• Granulated BOF/LD slag can be used up to 15 % in the
cement industry
• Increased use in base sinter mix and in road making
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To sum up
• Adopting sustainable practices for iron & steel making is
the only option to counteract the associated maladies at
this juncture of growing demand.
• Along with the Industry, concerted efforts are needed from
all the major players e.g. the Govt., Policy makers, Media,
Consumers etc.
• Multidisciplinary research work is essential for exploring
newer application and optimising use of existing
technologies for a sustainable and environmentally sound
management.
• SAIL is committed to Environment through progressive
adoption of energy efficient technologies, resource
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conservation and pollution control.
There’s a bit of SAIL in everybody’s life
17 Categories of Highly Polluting Industries
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
CATEGORY
Fertilizer ( Nitrogen Phosphate )
Sugar
Cement
Fermentation & Distillery
Aluminium
Petro Chemicals
Thermal Power
Oil Refinery
Sulphuric Acid
Tanneries
Copper Smelter
Zinc Smelter
Iron and Steel
Pulp and Paper
Dye and Dye Intermediates
Pesticides Manufacturing and Formulation
Basic Drugs and Pharmaceuticals
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National Mission for Enhanced Energy
Efficiency (NMEEE)
Perform Achieve Trade (PAT) Mechanism:
•
•
•
Is a market based mechanism
•
Working groups have been set up to evolve;
Enhances energy efficiency improvement through “PAT”.
Specific Energy Consumption (SEC) reduction targets for the
685 energy intensive units which are designated consumers
under the Energy Conservation Act

Norms for energy consumption

Verification process for energy consumption

Issuance process of energy saving certificate, and

Trading Mechanism
Sustainable Development Policy of SAIL
CDQ Process Flow
Crane
Charger
Primary dust catcher
Power plants
Pre-chamber
Steel works
Cooling chamber
Boiler
Water pre-heater
Bucket
Chemical plants
Ejector
Secondary dust catcher
Belt conveyor
Gas recirculating fan
Installed at ISP and being installed at BSP & RSP
In the CDQ system, the
red-hot coke is cooled
by gas circulating in an
enclosed system,
thereby preventing
the release of airborne
coke dust.
The thermal energy of
the red-hot coke, which
is lost in the
conventional system, is
collected and reused as
steam in the CDQ
system.
This technology uses
less fossil fuel and
results in lower CO2
emissions, thereby
contributing to the
prevention of global
warming.
Top Pressure Recovery Turbine (TRT)
Features & Benefits:
• Generates electric power,
utilizing top gas pressure,
which was getting wasted
otherwise
• Excellent operational
reliability
Disadvantages:
• Suitable for larger furnace
with higher temp. & press.
only
• High initial cost
Being installed with new BFs at BSP, RSP and ISP under on-going
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modernisation cum expansion program of SAIL
Walking Beam Furnace at Rolling
Mills
Features & Benefits:
• Highly energy efficient
• Uniform heating
• Enhanced quality
Disadvantages:
• High initial cost
• Retrofitting in existing
system
Installed at BSP and being installed at BSL under on-going
modernization cum expansion program of SAIL
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Conservation of Raw Materials
•
Beneficiation to use lean ore and to recover iron ore
fines from slime
• Incorporation of appropriate
beneficiation system to
maximise use of ore reserve
and to recover additional iron
value from slime
• The slime loss has been
reduced to ~10 % from
~20% with the recovery of
quality fines concentrate.
Being installed at Bolani, Gua, Barsua-Taldih, Chiria and
Dalli Mechanised Iron Ore mines of SAIL
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Conservation of Raw Materials
•
Pelletisation of iron ore fines
Advantages:
• To transform fines concentrate
generated during the iron ore
beneficiation process into pellets,
suitable to feed Blast Furnace or
Direct Reduction plant or Corex.
• Gainful usage of ultrafines, which
other wise would have gone into
slime.
• Usage of agglomerated ore
improves BF productivity
Pellet Plants of capacity 4.0 MTPA and 1.0 MPTA are under
installation at Gua Ore mines and Dalli Mechanised Mines
respectively.
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Efforts towards Pollution Control
Raw Material Handling
•
•
Dry Fog Dust Suppression (DFDS) systems at Wagon Tipplers
Dust Extraction (DE) systems at transfer points
Sinter Making
•
•
Efficient de-dusting system for improved work-zone environment
at Material Handling Area
Process emission control
and area de-dusting through
installation of ESP
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Secondary De-dusting at BOF
SECONDARY DEDUSTING SYSTEM AT BOF
Converter
Mixing Chamber
Bag Filter
Hot Metal Handling
Slag Skimming
Dust Discharge
System
Hot Metal Desulphurisation
Being installed at RSP and ISP with new
BOFs under modernisation and retrofitted
at existing BOFs of BSP, RSP and BSL.
Sources of secondary off-gases
result from re-ladling and deslagging of hot metal, BOF
charging, tapping of liquid steel
and slag from BOF (converters)
and ladles, secondary metallurgy
and tapping operations handling
of additives, continuous casting
etc.
Until the early 70s, oxygen
steelmaking plants were built
without secondary dust collection
equipment. As a result, most of
today’s secondary and
subordinate primary source dust
collecting installations are
retrofitted.
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