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Pollution Control Mechanism in Iron & Steel Plant
Pollution Control Mechanism in Iron & Steel Plant
BEHERA
SENIOR ENVIRONMENTAL SCIENTIST
Parameter Standards
New Existing
Batteries Batteries
Sulphur in Coke Oven gas used for heating (mg/Nm3) 800 800
Contd..
3. Blast Furnace
Hazardous Waste
Charge of tar sludge / ETP sludge to Coke Oven
(Tar sludge, acid sludge, waste lubricating oil and used type
fuel falls in the category of Hazardous Waste.)
Contd..
5. Water conservation / Water Pollution
Contd..
Recommendation
1. Emission standard as notified under EP Act 1986 for
sintering plant, blast furnace (BF), steel melting
shop(SMS), coke oven etc to be strictly enforced
• Char
• Dedusting dust from pollution control
equipment of Product handling area
• Kiln accretion waste
• Dedusting dust from pollution control
equipment of Cooler discharge area
• Scrubber sludge (scrubber is installed as
pollution control equipment of Kiln)
• Process dust from pollution control
equipment of Kiln
ENVIRONMENTAL STANDARDS
– Process
z Installing of control equipments – ESP, GCT,
Characterisation of Waste
Methodology
Literature Survey
Study on Manufacturing Process & Operational
Features
Field Visits & Interaction with Industrial
Authorities
Collection of Waste Samples Analysis in State
Pollution Control Board Laboratory (Based on
source) Heavy Metal, TCL
PRODUCTION OF PIG IRON AND FINISHED
(CARBON) STEEL IN INDIA
1. Hydrochloric Acid 20
2. Caustic Soda 30
3. Calcium Carbide 50
4. Sodium Silicate 70
5. Common Salt 100
6. Phenol Sulphuric Acid 20
7. Soda Ash 60
8. Sodium Dichromate 13
WASTE GENERATION IN ROURKELA STEEL PLANT
COKE
OVEN Used in Sintering
1 Coke Fines Coke Quenching Pit 36,000
Plant
Waste
31 Furnaces 9 Dumped
Refractories
Effluent
35 Bag Filter Dust PC Equipment 120 treatment in
CRM
NAME OF THE SOLID QUANTITY PRESENT
UNIT WASTE SOURCE IN METHOD OF
T/YEAR DISPOSAL
STEEL 36 LD Slag LD Converter 364750 Dumped
MELTING 37 LD Dust LD, GCP (SMS-I) 1825 Dumped
SHOP (SMS I 38 Sludge GCP Thickner 93775 Dumped
& II)
Gas
39 Conditioning LD Furnaces 54 Dumped
Tower Sludge
40 Desulphurisati Desulphurisation 200 Recycled
on Slag Plant
Continuous Dumped after
41 Casting Slag Continuous Casting 30800 removal of
metallic portion
Continuous Used in
42 Casting Sludge Continuous Casting 5930 Sintering plant
(Mill Scale)
Mixing Un it
Unit
43 Deducting Bag PC measures 20 Reused
Filter Dust
Slag from Ladle and Hot
44 Mixer and Metal Reactor 22000 Dumped
Reacting area
45 Rejected LD Converter Ladle 24625 Sold/Dumped
Refractories
46 Cooling Tower Coding Tank 55 Dumped
Sludge
NAME OF THE SOLID QUANTITY PRESENT
UNIT WASTE SOURCE IN T/YEAR METHOD OF
DISPOSAL
HOT Slabbing Mill Pit &
ROLLING 47 Mill Scales AP –I Oil Separator 7500 Used in SP
MILL
48 Soaking Pit Muck BSM Soaking Pit 20 Dumped
49 Oily Sludge from Oil HSM Oil Storage 500 Dumped
Storage Tank Tank
House Keeping
50 Waste Hot Rolling 200 Dumped
Contaminated with Lubrication water
oil
51 Rejected sand from Filtration for 100 Dumped
filtration unit recycling
Rolling Mill, Pump
52 Mill Scale House, Sett ling
Settling 26090 Recycled
tanks. Soak Pits
Pickling Line
COLD 53 Pickling Tank Sulphuric
Pickling bath
Acid 60 Dumped
Sludge
ROLLING
54 Damaged Pickling Line & Acid 35 Dumped
MILL Refractory Linings Handling
55 Oily Sludge Oil coating area 10 Dumped
ACETYLENE
PLANT 91 Acetylene Sludge Sludge Pits 2,400 Sold / Dumped
Oil quenching
96 Heat treatment 30 Dumped
sheds
PLATE MILL
Grinding & surface
98 Mill scale 600 Used
treatment
LOCO SHED
Oil catch pits &
99 Oily sludge 60 Dumped
maintenance
HEAVY FIELD
House keeping,
MACHINARY 100 Oily Waste 10 Dumped
maintenance
PRESENT
NAME OF THE SOLID QUANTITY
UNIT SOURCE METHOD OF
WASTE IN T/YEAR
DISPOSAL
ELECTRICAL
SHOP 101 Dedusting dust 7.5 Dumped
MISCELLENEOUS
Engine oil,
Transformer oil,
103 Used Oil Hydrolytic oil 559 Recycled
used Lubricant
etc. (All units)
Rejected
105 Containers of All Units 120 Dumped/Sold
Chemical
UNITWISE WASTE GENERATION, ROURKELA STEEL PLANT
SL. UNIT QUANTITY OF WASTE
GENERATION T/ANNUM
1. Coke Oven 36293
2. Coal Chemical Department 959
3. Sinter Plant 9820
4. Blast Furnace 663139
5. Lime Dolomite and Brick Plant (LDBP) 1337
6. Calcining Plant II 12286
7. Steel Melting Shop (SMS - I & II) 544034
8. Hot Rolling Mill 34410
9. Cold Rolling Mill 4669.8
10. SW Pipe Plant 2
11. ERW Pipe Plant 233
12. Silicon Steel Mill 565
13. Foundry 3972
14 Acetylene Plant 2400
15. Oil Reclamation Unit 63
16. Special Plate Mill 1685
17. Plate Mill 600
18. Loco Shed 60
19. Heavy Field Machinery 10
20. Electrical Shop 10
21. Miscellaneous 729
Total 1317276.8
WASTE ANALYSIS RESULT OF SINTERING PLANT, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co
ratio)
Process and
01 Space 8.5 10.0 72.0 8.0 8.0 0.8 27.5
Dedusting
Scrubber
02 10.2 8.2 25.0 4.0 2.0 -- --
Sludge
House Keeping
03 Waste for 8.2 11.4 86.0 12.0 6.0 1.2 6.8
Disposal
WASTE ANALYSIS RESULT OF COKE OVEN, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH
Cu Zn Pb Ni Cd Co
(1:20 ratio)
01 Coke Fines 7.6 7.4 96.0 3.0 13.2 ND 6.7
Coke Oven Door
02 6.2 10.3 112.0 4.0 14.2 ND 2.5
Cleaning Waste
Coke Handling
03 7.2 6.9 90.0 3.0 12.8 ND 6.7
Screen Dust
Drain Cleaning
04 7.5 12.0 210.0 6.0 10.8 ND 4.5
Sludge
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co CN
ratio)
Decanter Tar
01 7.1 ND 111.2 63.3 ND 0.4 3.0 293.0
Sludge
02 Catch Pit Sludge 7.04 35.5 180.2 72.1 41.4 5.4 54.2 302.0
Drain Cleaning
03 7.0 24.5 121.7 93.6 8.0 3.0 10.0 258.0
Sludge
04 Acid Tar 1.2 42.0 158.4 98.4 42.5 8.0 12.0 1028.0
Pipe Line --
05 6.8 ND 49.2 29.0 1.7 16.0 52.0
Cleaning Waste 20.1
06 Sulphur Muck 6.69 90.9 159.5 141.5 56.1 1.2 36.3 --
07 Spent Catalyst
08 ETP Sludge 6.21 28.0 265.4 36.7 16.5 3.2 9.5 --
Refractory
08 3.7 13.5 197.4 1.4 13.5 0.3 7.8 --
Debries
Reactor
10 2.81 8.0 48.8 10.9 22.8 1.3 17.8 --
Cleanings/Resin
WASTE ANALYSIS RESULT OF COLD ROLLING MILL, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH (1:20
Cu Zn Pb Ni Cd Co Oil
ratio)
Pickling Line
Pickling Tank
01 2.1 2512.6 60.4 42.8 215.0 3.0 67.4 --
Sludge
Damaged
02 3.78 63.8 4419.1 181.2 29.3 1.9 25.4
Refractory Linings
03 Oily Sludge 7.52 45.6 23.4 84.7 27.5 3.4 28.2 112.0
Acid Tank Cleaning
04 3.52 18.6 112.5 81.5 22.6 8.5 18.6
Sludge
Reversing Mill
05 Oily Sludge 6.0 26.7 44.6 128.6 21.7 7.2 25.4
Tandem Mill
Magnetic Filter
06 7.22 1651.0 215.5 119.6 316.8 4.6 37.6 1250.6
Waste
Cellulose Filter
07 6.94 563.7 1691.8 90.7 113.8 0.9 13.5 313.7
Waste
08 Oily Sludge 6.1 462.0 38.4 75.6 64.6 0.8 12.8 2512.0
09 ETP Sludge 5.6 762.4 212.5 96.6 215.0 12.5 8.2 43.0
Galvanising
10 Zinc Dross 7.94 7.94 57.5 788856.8 897.9 8.2 1.0 9.4
3512.0 18855.6
11 Dichromate Sludge -- -- -- -- -- --
(Cr+6) (Cr+3)
WASTE ANALYSIS RESULT OF COLD ROLLING MILL, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH
Cu Zn Pb Ni Cd Co Oil
(1:20 ratio)
Tin Plating
12 Bath Sludge 2.98 1604.7 63.1 67.1 427.9 2.0 53.9
13 Tin Ash -- -- -- -- -- -- -- --
14 Chrome Sludge 1974 (Crvl) 13923.8 (CrIIl)
Acid Regeneration Unit
Effluent
15 Neutralisation 4.0 1526.2 612.0 68.2 316.6 4.0 48.2
Sludge
16 Deep Sump
Cleaning Sludge 2.3 68.4 97.2 112.8 136.7 8.0 12.6
Damaged
17 Refractory 1.8 57.5 786.5 106.6 47.5 4.0 8.7
Linings
18 House
Waste
Keeping 3.2 67.6 318.6 72.6 88.4 4.3 7.2
Annealing
Annealing 432.
19 Burner Pipe 7.53 400.4 23.2 13.1 41520.3 1.6 3
Cleaning
20 Annealing
Decreasing 8.85 8.85 344.2 281.8 67.1 82.5 2.6 42.4
21 House Keeping 1 -- -- -- -- -- -- --
WASTE ANALYSIS RESULT OF BLAST FURNACE, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co CN
ratio)
Granulated
01 8.57 304.3 92.0 84.2 84.3 0.8 14.3
Slag
Air Cooled
02 8.65 118.4 226.4 92.1 21.1 4.8 21.0
Slag
03 Flue Dust 8.8 8.7 310.8 118.6 10.8 2.5 15.1 50.8
Thickener
04 8.37 8.0 4446.5 2145.1 13.6 7.9 19.3
Sludge
Cooling
05 Tower 7.22 0.7 3.2 1.2 14.0 0.1 3.1
Sludge
WASTE ANALYSIS RESULT OF HOT ROLLING MILLS, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co
ratio)
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co
ratio)
01 Pickling Bath
2.1 12.0 312.0 1.2 18.8 1.6 8.4
Sludge
02 Rejected
1.8 8.2 80.7 2.4 18.7 2.3 6.1
Refractories
03 Acid Treatment 13.
9.0 392.0 ND 16.1 0.8
Plant Sludge 7
04 Waste Oil from ATP 2.3 16.0 185.6 ND 18.5 1.2 7.2
05 Annual Cleaning
Sludge of
Equalisation Scrap, 4.2 7.4 38.4 ND 22.4 0.8 8.2
Oil Recirculation
Tank
WASTE ANALYSIS RESULT OF FOUNDRY, ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co
ratio)
Concentration in mg/kg
Sl. Waste pH
(1:20 Cu Zn Pb Ni Cd Co
ratio)
01 LD Slag 12.67 10.7 20.6 41.4 29.7 5.9 38.3
GCP Thickner
02 12.59 36 171.7 3.9 24.2 2.7 13.1
Sludge
Continuous
03 7.5 19.2 216.8 8.6 27.5 ND 11.2
Casting Slag
Desulphurisation
04 10.78 41.3 435.6 36.1 7.7 43.3
Slag
Mixing Unit
05 Dedusting Bag 8.55 49.0 759.3 ND 32.7 8.6
Filter Dust
Rejected
06 -- -- -- -- -- -- --
Refractories
WASTE ANALYSIS RESULT OF PIPE PLANT
(SPIRAL & ERW PIPE, ROURKELA STEEL PLANT)
pH
(1:20 Cu Zn Pb Ni Cd Co
ratio)
Calcenig
02 12.65 11.4 44.3 46.7 27.1 5.1 33.0
Plant Dust
LEACHATE ANALYSIS RESULT OF SINTERING PLANT,
ROURKELA STEEL PLANT
House
Keeping
03 ND ND ND ND ND ND
Waste for
Disposal
LEACHATE ANALYSIS RESULT OF COKE OVEN, ROURKELA STEEL PLANT
Sl. Waste
Concentration in mg/Ltr.
Cu Zn Pb Ni Cd Co
Granulated
01 ND ND ND ND 0.003 ND
Slag
Thickener
04 ND 0.01 ND ND 0.001 ND
Sludge
Cooling Tower
05 ND 0.01 ND ND ND 0.04
Sludge
LEACHATE ANALYSIS RESULT OF HOT ROLLING MILLS,
ROURKELA STEEL PLANT
Concentration in mg/kg
Sl. Waste
Cu Zn Pb Ni Cd Co
01 Soaking Pit 0.02 0.06 ND 0.001 0.026 ND
02 Oily Sludge -- -- -- -- -- --
04 Oil -- -- -- -- -- --
Contaminated
House Keeping
Waste
LEACHATE ANALYSIS RESULT OF SILICON STEEL MILL,
ROURKELA STEEL PLANT
Concentration in mg/Ltr.
Sl. Waste
Cu Zn Pb Ni Cd Co
01 LD Slag 0.007 ND 0.1 ND ND 0.05
GCP Thickner
02 0.02 ND ND ND 0.006 0.03
Sludge
Continuous
03 0.006 ND ND ND 0.004 0.04
Casting Slag
Desulphurisatio
04 0.015 ND ND ND ND 0.02
n Slag
Mixing Unit
05 Dedusting Bag 0.015 0.006 0.16 ND 0.017 0.03
Filter Dust
Rejected
06 -- -- -- -- --
Refractories
LEACHATE ANALYSIS RESULT OF PIPE PLANT
(SPIRAL & ERW PIPE), ROURKELA STEEL PLANT
Concentration in mg/Ltr.
Sl. Waste
Cu Zn Pb Ni Cd Co
Cok e O v en
Foundry
Loc oshed
Mis cellaneous
HAZARDOUS WASTE CATEGORISATION
BASED ON DISPOSAL / TREATMENT OPTIONS
Incinerable
19%
Land Disposable
51%
Recyclable
30%