Visakhapatnam Steel Plant...Visakhapatnam Steel Plant Rashtriya Ispat Nigam Ltd. Half yearly...

Visakhapatnam Steel Plant Rashtriya Ispat Nigam Ltd. Half yearly Environment Compliance Report in respect of stipulated conditions while issuing Environmental Clearance For submission to Ministry of Environment and Forests (MoEF) Central Pollution Control Board (CPCB) Andhra Pradesh Pollution Control Board (APPCB) Rashtriya Ispat Nigam Limited - Visakhapatnam Steel Plant(RINL-VSP) is the country’s first shore based integrated steel plant. The company is 100% owned by GoI. The plant is a 6.3 Million ton Integrated Steel Plant and is a market leader in long products.

• First Integrated Steel Plant to be certified for Quality, Health & Safety, Environment & Energy– ISO 9001, OHSAS 18001, ISO 14001 & ISO 50001

• First Steel plant in India to be certified for CMMI Level 3 for Information Technology

Period: Apr’17

To Sept’17

of 24

PART-A

Brief Overview of Visakhapatnam Steel Plant:

2. Technological facilities of Expansion units Product New Major Unit Facilities

Hot Metal Blast Furnace - 3 1 X 3800 Cu.M furnace with water cooled hearth bottom to produce

2.5Mtpa of Hot metal with a state- of- art technology with profilometer, copper staves, pulverized coal injection, top gas recovery turbine etc. Sinter Plant - 3 1X400 Sq.M sinter machine with circular cooler, multi slit burners etc. to produce 3.61 Mtpa of sinter. Raw Material Handling System Material preparation and handling system through extensive conveyor system (Total 45km length) Liquid Steel

Steel Melt Shop(SMS) Converter Shop 3 x 150 Cu.MConverters to produce 2.8Mtpa with facilities like combined blowing, for better yield and quality, Secondary fume extraction system for cleaner environment etc. SMS – continuous casting Machine 3 x 6 strand square billet casters with auto mould technology, electromagnetic stirring for cleaner steel. SMS – LH & RH Secondary metallurgy facilities like 2 nos. of Ladle Furnace, one RH unit for producing Special steel grades. Finished Steel Wire Rod Mill - 2 6 lakh tonne per annum capacity high speed mill (105-110 m/s). Special Bar Mill 7.5 lakh tonne per annum capacity mill for customized sizes with low tolerance Structural Mill 7 lakh tonne per annum capacity with high speed roughing stands to produce 75-175 mm structurals.

1. Main facilities of the plant (Not Exhaustive) S. No Department Facilities & technological features Capacity 1 Coke oven 4 coke oven batteries of 67 ovens each, of height 7m, with 100% dry quenching 2.261 Mt of blast furnace coke (3 battery capacity) 2 Sinter plant 2 sinter machines with 312 Sq.m grate area 5.256 Mt of gross sinter 3 Blast Furnace 2 nos. 3200 Cu.m blast furnaces with bell less top equipment and cast house slag granulation 3.4 Mt of hot metal 4 Steel Melting Shop 3 nos. 133 Cu.m LD converter with 6 nos. of 4 strand bloom casters 3.0 Mt Liquid Steel 2.82Mt Cast bloom/yr 5 Light and Medium Merchant Mill 7 stand continuous Billet Mill and 2 strand continuous Bar Mill with “Tempcore” technology for Rebar rolling 1.857 Mt billets 0.710 Mt Bar products 6 Wire Rod Mill 4 strand continuous mill with “Stelmor” cooling 0.850 Mt Wire rods 7 Medium Merchant & Structural Mill 20 stand continuous mill 0.850 Mt Medium structural products

of 24

Principal products & services The principal products of VSP include steel products comprises of re-bars, wire rods, rounds, structurals, blooms and billets, and pig iron. Also, the company markets by-products such as Ammonium Sulphate, Benzol products, slag etc.

3. Environmental friendly technology installed Aspect Benefit

Waste heat Utilization at Coke Dry Cooling plant Generation of Power (2X7.5MW) through BPTS Waste gas utilization (CO, BF & LD gas) Used as fuel Utilization of pressure Energy of BF gas Generation of power (2X12MW) through GETS Dry fog dust suppression at RMHP, SP , BF Reduced dust Evaporative cooling systems at LMMM & MMSM Generation of process steam Waste heat utilization in COB-IV 14MW power generation Waste heat recovery at Sinter Plant 20.6 MW power generation TRT at BF-3 14 MW power generation Waste gas based Captive Power Plant-2 2 X 60 MW power generation from waste gases Waste water recovery system 3 Plants with capacity to recover 1000 m3/hr of

waste water Rain water harvesting system 2 systems with potential to recover 54 lakh cum

of rain water annually.

of 24

PART-B

COMPLIANCE REPORT ON IMPLEMENTATION OF CONDITIONS LAID DOWN BY THEDEPARTMENT OF ENVIRONMENT WHILE ACCORDING CLEARANCE TO VSP AS PER DEPARTMENT OF ENVIRONMENT LETTER NO. 11011/1/87-IA DATED 4.1.1988. Condition: I. a) ENVIRONMENT MANAGEMENT PLAN (EMP) MUST BE PREPARED WHICH AMONG OTHERS, SHOULD CONTAIN RESULTS OF AIR AND WATER QUALITY MONITORING TO BE DONE IN THE PROJECT AREA. Status: Environment management plan which contains results of air and water quality monitoring along with the other details is prepared and submitted. Besides, air & water quality is being monitored regularly & results submitted vide half yearly reports to

1. The Addl. Chief Conservator of Forests Ministry of Environment, Forests and Climate Change Regional Office South zone, 4th floor E&F wings Kendriyasadan, 17th Main Road Koramangala, Bangaluru

2. Scientist ‘D’, GOI, MoEF& CC Regional office South zone 1st& 2nd floor HEPC Bldg no. 34 Cathedral garden road Chennai-600034

3. Scientist (B) Central Pollution Control Board Parivesh Bhavan East Arjun Nagar New Delhi-110032

4. The Environmental Engineer A P Pollution Control Board Plot No.14, Flat No.103 & 104 Journalist Colony Marripalem, VUDA Colony Opp. to Spencers Visakhapatnam -530 009

of 24

Condition: b) CONTINUOUS MONITORING OF AIR ANDWATER QUALITY MUST BE INITIATEDIMMEDIATELY. WATER TO BE MONITOREDMUST INCLUDE BOTH MARINE AND INLANDWATERS. Status: 8 ambient air quality monitoring stations are established and monitoring being done since 1992. 4 stations within the plant premises, 2 in residential areas (Townshop & Gantyada) and one at Zoo park and other one at Kondkarla lake area. Later 3 nos. of continuous ambient air quality monitoring stations within the plant premises have been installed in 2006 and 4th station at Pedagantyada residential area (down wind direction of the plant) have been installed in 2008 and working. Hourly data is being posted to APPCB website since 2011. All major stacks (~20) are monitored regularly using stack kits since 1993. Hourly data is being posted to APPCB website since 2011. Now 34 stacks (after 6.3 MTPA) are provided with on-line stack monitors and minute to minute data being posted to CPCB site. Water quality at all outfalls including marine water is being done regularly. On line pH and flow meters are installed at the designated outfalls (ETP outlet & DM plant outlet) and minute to minute data being posted to CPCB VSP initiated procurement action to install continuous effluent monitoring systems with COD, BOD, TSS, Phenol, CN etc.,) by Dec’17. Monitoring of air & water quality including marine water is being done regularly. Results of Ambient air, effluents, stack emissions, fugitive emissions from coke oven batteries, etc are enclosed at Annexure I to IV respectively. Condition: c) MINIMUM THREE AMBIENT AIR MONITORING STATIONS MUST BE INSTALLED. Status: Complied. For details pl. refer explanation of above of condition (b).

Condition: d) AN AIR MONITORING STATION IN THE ZOOLOGICAL PARK IN THE NORTH EAST MUST BE INSTALLED. Status: An ambient air monitoring station (Repairable dust sampler) is installed in the zoo park and monitoring being done regularly.

of 24

View of Kondakarla Lake

Condition: e. TWO MONITORING STATIONS - ONE FOR AIR AND OTHER FOR WATER MUST BE SET UP AT KONDAKARLA LAKE TOWARDS THE SOUTH OF VISAKHAPATNAM. Status:Monitoring of Air quality and Water Quality at Kondakarla Lake towards South of VSP is being carried out regularly.

Condition: II. THE PROJECT AUTHORITIES (VSP) MUST CONSIDER USING LOW SULPHUR GAS/OIL. IF SUCH USE IS NOT POSSIBLE, APPROPRIATE FLUE GAS DESULPHURISATION DEVICES MUST BE INSTALLED AT THE RELEVANT UNIT Status: VSP is using low sulphur fuels and composition of these fuels has been submitted earlier. The power plant of VSP is using Talcher coal which has sulphur content of 0.17%. The Calcining& Refractory Material Plant of VSP is using coal tar fuel (A by-product of Coke oven & Coal Chemical Dept.) with sulphur content of less than 0.5%. Condition: III. VSP AUTHORITIES MUST RECYCLEEFFLUENTS TO THE EXTENT POSSIBLE.IN ANY CASE, THE TREATED EFFLUENTSMUST BE USED FOR IRRIGATION OF AFFORESTED AREA. Status: Made a provision for part quantity of treated effluent is being used for dust suppression at RMHP as and when required. Township sewage water is being used as makeup water in Rolling mills & SMS after treatment in Ultra-filtration plant since Dec’2005. In addition to the above 3 Waste water recycling scheme are implemented at VSP. The quantities of waste water recovered &treated for reuse is given below:

of 24

In addition to the above treated effluent from MBC (Mechanical, Biological & Chemical treatment plant), that treats contaminated water generated during Coke making and also is being used for spraying on Boiler coal stock piles to prevent fugitive dust emissions &self ignition of coal in RMHP (Raw Material Handling Plant). Condition: IV. VSP AUTHORITIES MUST DIVERT THE STORM WATER TOWARDS THE SOUTH SIDE AWAY FROM THE CREEK (WHICH IS ON THE NORTHEN SIDE). Status: This condition was dropped by MoEF vide letter no. J-11014/75/90-1A .II(i) Dated 20.07.2000 Condition: V. VSP AUTHORITIES MUST RELOCATE SLUDGE/DEBRIS DUMP, THE ASH POND, THE LABOR AND STAFF COLONY SHOWN IN THE SOUTH WEST CORNER AWAY FROM THE SEA SHORE. REVISED PLAN IN THIS REGARD MUST BE SUBMITTED TO THIS MINISTRY FOR APPROVAL. Status:New slag dump yard area has already been constructed away from sea-shore as per the advice of Prof. Dave and Department of Environment. Revised plan wassubmitted vide letter no. 869/DE dt.30.7.88. Condition: VI. PRESENT AND FUTURE LINKAGE FOR COAL MUST BE ESTABLISHED AND REPORTED TO THE

MINISTRY. Status: The coal linkage for VSP is as follows. 1. Steam coal is from collieries of Talcher&Ib Valley of M/s Mahanadi Coal Fields 2. Coking coal is imported from Australia, New Zealand and USA etc., through Gangavaram Port

limited. 3. Medium coking coal is from washeries -Rajarappa, Swang and Kathara of M/s Central Coal

fields. Condition: VII. a) VSP AUTHORITIES MUST PROVIDE A GREEN BELT OF 3600 HECTARES.

April’17-Sept’17 Year 16-17 394.19 MG 748.38 MG

of 24

VSP has developed green belt of 1970 Ha and 1630 Ha afforested in other areas 1970 Ha (4866 acres) is being maintained as green belt. It also includes 700 acres at K Kotapadu given in lieu of land given to M/s Gangavaram Port Limited. b) ABOVE GREEN BELT WILL INCLUDE 500 M WIDE GREEN BELT ON THE BOUNDARY OF THE ACQUIRED LAND. Complied c) OUT OF THE TOTAL GREEN BELT, 1970 HECTARES MUST BE DECLARED AS RESERVE FOREST UNDER THE CONTROL OF VSP AND GOVERNED BY THE FOREST (CONSERVATION) ACT 1980, THE BALANCE 1630 HECTARES MUST NOT BE USED FOR ANY OTHER PURPOSE EXCEPTING FOR FURTHER XPANSION OF THE PLANT. Earlier, the proposal to notify the green belt as a "Reserve Forest" under the control of VSP was not agreed to by the Divisional Forest Officer, Visakhapatnam on the ground that such notification would be preceded by handing over the land to State Forest Department by VSP. Subsequently, the Chief Conservator of Forests, Vide his letter No: EP/1201/30/AD/Vol-5 dt.7.11.97 has clarified that such a declaration is feasible. In this regard Principle Chief Conservator of forests wrote a letter to Principle Secretary to the Govt. of AP vide RC No. 52548/97/51 dated. 12.4.2004. VSP requested the Principle Chief Conservator of forests vide letter no. TA/aff-22/2004/539 dated 28.06.04 to expedite the matter. Now Out of 1630 Ha earmarked for afforestation, 880 has been used for expansion of the Plant. Balance 750 Ha is maintained as afforestation area. d) 2809 HECTARES OF SALT LANDS MUST BE AFFORESTED WITH APPROPRIATE FLORAL SPECIES. THIS AREA WILL BE REGARDED AS PERMANENT RESERVE FOREST UNDER THE CONTROL OF VSP AND WILL BE GOVERNED BY THE FOREST (CONSERVATION) ACT, 1980. It was brought to the notice of Secretary (E&F) vide letter No. CMD -3(6)36/78, dated 9th April,1993 that the area of salt land is 160 Ha. For afforestation of 160 hectares of salt lands (saline area) Central Salt and Marine Chemical Research Institute (CSMCRI) Bhavnagar, have already completed plantation of Salvadora plants in 25 Ha as a pilot project. The balance 135 Ha has been handed over to Govt. of Andhra Pradesh for construction of Gangavaram Port. During 2017-18, afforestation status (including Green Visakha) is given below:

Apri’17- Sept’17 2016-17 60,250 Nos 23722 Nos

of 24

Upgraded Mechanical Biological & Chemical Treatment Plant at Coke Ovens

PART-C COMPLIANCE REPORT ON IMPLEMENTATION OF CONDITIONS LAID DOWN BY DEPARTMENT OF ENVIRONMENT (DOEN) WHILE ACCORDING CLEARANCE TO VISAKHAPATANAM STEEL PLANT According to environmental clearance given to Visakhapatnam Steel Plant's revised cost estimate vide letter No: 11011/75/90-IA - II section, dated 3.5.1993 the present status of conditions are as follows: Condition: 1. THE EFFICIENCY/PERFORMANCE OF 2 DEDUSTING SYSTEMS WILL BE AUGMENTED TO COMPLY WITH THE STANDARDS BY DEC'93. Status: The DE Systems are augmented and are working satisfactorily since December, 1993 after effecting necessary modifications.

Condition: 2. LIQUID EFFLUENTS FOR AMMONICAL NITROGEN AND PHENOLS WILL BE TREATED TO MEET THE STANDARDS BY DEC'93. Status MBC which has been upgraded at a cost of Rs. 55 Cr. has been completely stabilised. All parameters such as Amm.N2, phenols, O&G, COD etc of the

effluent are within norms.

Condition: 5. WATER CONSUMPTION SHOULDBEBROUGHT DOWN FROM 39.05 cum/ tonne of liquid steel

(tLS) to 20 cum/tLS. ACTION TAKEN AND THE TIME FRAME REQUIRED TO IMPLEMENT THE ABOVE SHOULD BE INDICATED BY VSP WITHIN A PERIOD OF 3 MONTHS.

of 24

Continuous Effluent Monitoring System at MBC outlet pH & flow

Status: Has been compiled with.

PART-D

FROM 4 TO 6.5 MTPA AS PER MoEF EC No. J-11011/196/2005 – IA II (i) DATED 11.08.2005

A. SPECIFIC CONDITION Condition: I. GASEOUS EMISSIONS SHALL CONFIRM TO THE LOAD/MASS BASED STANDARDS

AND NOT TO EXCEED THE LIMITS PRESCRIBED BY THE STATE BOARD. Status:

1. Load based emission is given only for Coke oven batteries by Andhra Pradesh Pollution Control Board.CO in Batteries is being monitored & is within the norm of 3 Kg/tonne of coke produced.

2. Air Pollution Control equipment are being upgraded to meet the SPM norm of 50 mg/Nm3.

3. Low NOx burners to reduce NOx load are being used. Condition: II. ADOPT CLOSED LOOP RE-CIRCULATING SYSTEMS Status: All the re-circulating water systems existing at VSP are closed loop only.

• RECYCLE DIRECT CONTAMINATING COOLING GRANULATION & DUST SUPPRESSION

Blow down from indirect cooling water circuit is taken to the direct cooling circuit and contaminated circuit and scale flushing. Blow down from this circuits also used in ash handling net work through Ash pond and no water is discharged.

• THE WASTE WATER FROM GAS CLEANING PLANTS, MILLS, POWER PLANT & CT BLOW DOWNS SHALL BE TREATED IN WASTE WATER TREATMENT PLANTS

COMPLIANCE REPORT ON IMPLEMENTATION OF CONDITIONS LAID DOWN BY THE MINISTRY OF ENVIRONMENT & FORESTS WHILE ACCORDING CLEARANCE FOR EXPANSION OF RINL / VISAKHAPATNAM STEEL PLANT

of 24

VSP has extensive treatment facilities in Mills, Power Plant and no water is discharged to drain as explained above.

• THE COKE OVEN EFFLUENT SHALL NOT EXCEED 2880 CUM/DAY (120 CUM/HR)

•

• The Coke oven effluent is about 2000 cum/day only and is being monitored using Continuous Effluent monitoring System.

•

• THE SURPLUS WASTE WATER SHALL BE STORED IN THE HOLDING POND FOR USE IN THE

LEAN PERIOD In addition to the above Waste Water Recycling scheme is implemented incurring a cost of Rs 110 cr. The purpose of this scheme is to capture waste water at three outlets, treat and then reuse in the plant. Details of this scheme are given below:

Location of the Waste Water

Recycling System

Cap. of treatment system

(cum/hr)

Type of treatment Reuse plan

Balacheruvu 300-350

Physical treatment such as

settling/clarification, Oil separation etc.

Treated water is used in the expansion area for fire fighting, dust suppression, gardening,

toilet flushing etc.

Appikonda 500 Reverse Osmosis Treated water is used as make up in Power plant TPP System

and in soft water network

Gangavaram/Coke ovens 80 Reverse Osmosis Treated water is used in

COCCP recirculation system

BF-3 80 Reverse Osmosis Treated water is used in soft

of 24

• THE OVER FLOW FROM POND SHALL BE DISCHARGED THROUGH MARINE OUTFALL INTO

SEA Marine pipeline to discharge the surplus effluents is provided as per details given below:

Description Capacity (m3/hr) Facilities Use

Marine discharge pipe line

300-450 Collecting tank & Pumping system

To pump out water from MBC, rejects from RO plant to marine environment only if they are not used for spraying in Raw Material Handling Plant

• THE DISCHARGE POINT SHALL BE DECIDED IN CONSULTATION WITH NIO NIO has already conducted the studies and suggested the route for marine outfall and is implemented as per their recommendations.

• MARINE ECOLOGICAL STUDY SHALL BE CARRIED OUT TO STUDY THE IMPACT OF WASTE WATER ON MARINE ECOLOGY Study titled “Monitoring of chemical & biological parameters in the marine environment off Appikonda and toxicological studies of the treated effluent of Visakhapatnam Steel Plant” is done by National Institute of Oceanography in the year 2010, wherein it was mentioned that there is no impact of waste water on marine ecology.

• THE SEWAGE WATER AFTER TREATMENT SHALL BE USED IN MILLS / SMS FOR COOLINGPURPOSE Already township sewage is being recycled in SMS & Mills after ultra filtration. Sewage from plant shall also be recycled after commissioning of the RO plant at Coke Ovens.

Condition: III. PROVIDE CONTROL MEASURES FOR CHECKING FUGITIVE EMISSIONS. PROVIDE DUST EXTRACTION / SUPPRESSION SYSTEMS IN RAW MATERIAL HANDLING & WATER SPRINKLING SYSTEM AT THE STOCK YARDS Status: Pollution control measures are extensively planned and implemented in existing plant and expansion areas.

• PROVIDE DRY FOGGING SYSTEM IN CRUSHING & SCREENING PLANT, MATERIAL TRANSFER POINTS ETC.

water network

Marine Discharge Facility

of 24

Coke Oven Battery

Dry Fog System

Dry Fog dust suppression systems are provided in all expansion units .These systems are implemented in 40 areas covering 250 locations.

• WORKZONE AIR QUALITY SHALL BEMONITORED & RECORDS ARE MAINTAINED 131 Work zone air quality locations (53 in existing plant and 34 in expansion area and 44 locations at RMHP, Sinter plant and Blast furnace where dry-fog dust suppression systems are installed) are regularly monitored and data is recorded systematically as per EMS records. The same shall be continued.

Condition: IV. COMPLY WITH THE STANDARDS NOTIFIED VIDE GSR.631 (E) DATED 31ST OCT 1997 TO CONTROL FUGITIVE EMISSIONS FROM BATTERIES Status: Fugitive emissions PLD, PLO, PLL, and charging emissions from coke oven batteries are monitored regularly and are below the norms except charging emissions. Reports are enclosed at Annexure-IV. Condition: V. PARTICULATE EMISSIONS SHOULD BE <50 mg/Nm3 Status: All pollution control equipment is designed for particulate matter emissions to less than 50 mg/Nm3. Existing ESP’s will be upgraded to < 50 mg/Nm3 during capital repairs. Up gradation of Burden handling system and ESP of cast house fume extraction system BF-1 is completed. Up gradation of Burden Handling System (BHS) & Cast House of Exhaust System (CHES) of BF2 are under progress. Plan for up gradation of all ESP’s of stage 1 is as given below:

SNo Project Description Target Completion date Present status

1 Revamping of SHDE systems for BF-2 June 2017 Work in progress. 2 Revamping of CHFE systems for BF-2 June 2017 Work in progress. 3 Revamping and Upgradation of

Electrostatic Precipitators of Air cleaning plant and Gas cleaning plant of Sinter Plant

SP-1 :ACP-1 & GCP-1 by Sep’17

SP-2 : ACP-2 & GCP by Sep'17

Revamping of ESPs of ACP & GCP of Sinter machine-1 is commissioned in July’17 to reduce the Stack emission from 115 mg/Nm3 to 50 mg/Nm3.

4

Upgradation of ESPs of TPP

Jun 2017 for One Boiler followed by 2nd boiler

Revamping of ** ESP's of 2 Boilers is taken up. BHEL to execute at a cost of 68 Crores.

Mar 2019 for remaining Boilers.

of 24

CHFE system provided at BF1,2, & 3

Sinter machine 3 Furnace provided with low NOx burner& Circular cooler Circular Cooler

**-The work “Revamping of one boiler in TPP” awarded to M/s BHEL on nomination basis at a cost of Rs. 35.2 Cr and is expected to be completed by Jun 2018 and remaining 4 ESPs by Mar 2019.

• PROVIDE CAST HOUSE FUME EXTRACTION SYSTEM WITH ESP/BAG FILTER

The existing two blast furnace cast houses and BF-3 (Expn.) are already provided with Cast House Fume Extraction system having ESPs.

• INSTALL LOW-NOX BURNERS TO CONTROL NOX EMISSIONS

Low Nox burners are provided in expansion areas of SP2, Mills & Power plant and all necessary measures are taken to reduce NOx emissions. These measures are also being adopted for the existing sinter machines 1 & 2 during their revamping project.

Condition: VI. ENHANCE EFFORTS TO RE-USE OF SOLID WASTES AS PER PLAN SUBMITTED TO MINISTRY (BF & LD SLAG, FLYASH, REFRACTORY BRICKS, MILL SCALES ETC.) Status: Being done. Utilisation details are given at Annexure-VII

• ALL HAZARDOUS WASTES SHALL BE CHARGED INTO COKE OVEN BATTERIES All hazardous wastes like tar sludge, Benzol muck, acid tar, MBC sludge etc. are charged in to batteries along with charge coal since 1999. The same shall be continued. • SPENT OIL SHALL BE SOLD TO AUTHORIZED REPROCESSORS

Being sold to authorised reprocessors only. Condition:

of 24

OHS & RC Building

VII. DEVELOP GREEN BELT IN BALANCE 34 HA. SELECTION OF SPECIES SHALL BE AS PER CPCB GUIDE LINES Status: The balance area of 34 Hectares in green belt will be taken up after the land dispute is resolved by the State government. Condition: VIII. UNDERTAKE RAIN WATER HARVESTING MEASURES Status: Complied. 9 masonry check dams, 1 Earthen check dam, 94 Percolation pits and 18 recharging, wells have been constructed so far. Building constructed in expansion arealso provided with rain water harvesting measures. 2 major Rain water harvesting schemes are implemented. These Rain water harvesting projects have a potential to capture 54 lakh m3 water annually. Condition: IX. OCCUPATIONAL HEALTH SURVEILLANCE OF WORKERS SHOULD BE DONE ON REGULAR BASIS AND RECORDS TO BE MAINTAINED Status: A fully fledged OHS&RC is functioning since 1992, doing man maintenance programs, toxicological studies, noise surveys, hygiene surveys etc. Records are maintained as per OHSAS: 18001. Condition: X. CREP RECOMMENDATIONS TO BE IMPLEMENTED Status: All points are being complied with. B. GENERAL CONDITIONS Condition:

i. ADHERE TO STIPULATIONS MADE BY APPCB AND APSG Status:Being followed. Condition:

ii. NO FURTHER EXPANSION OR MODIFICATIONS SHALL BE CARRIED OUT WITHOUT PRIOR APPROVAL

Status:Noted and shall be followed. Condition:

iii. AT LEAST 4 AMBIENT AIR QUALITY MONITORING STATIONS SHALL BE ESTABLISHED IN THE DOWNWARD DIRECTION

Status: 3 CAAQM stations have been established within plant premises and fourth station is installed at pedagantyada village in the downwind direction of plant. All stations are working

Rain Water Harvesting scheme implemented at VSP

of 24

Silencer placed at the Oxygen vent for controlling Noise pollution

and real time data being sent to CPCB and APPCB. • DATA ON AMBIENT AIR, STACK EMISSIONS SHOULD BE SUBMITTED TO APPCB, CPCB, MOEF

ONCE IN EVERY SIX MONTHS Status: Half yearly report being submitted regularly. Last report submitted vide Ref. No. VSP/WK/EnMD/86 dt. 29.06.17 Condition: iv. THE WASTE WATER SHALL BE PROPERLY COLLECTED AND TREATED SO AS TO

CONFORM TO NORMS AND SHOULD BE UTILIZED FOR MAKE UP OR PLANTATION Status:

Separate treatment facilities are provided to collect the waste water and effluents and recycle them as make-up after treatment. Refer point ii of special conditions above. Condition:

v. PROVIDE NOISE CONTROL MEASURES TO LIMIT NOISE LEVELS WITHIN 85 db(A) ON ALL SOURCES

Status: Adequate noise control measures are provided. The areas where measures are required for control of noise pollution, necessary action is being taken.

• THE AMBIENT NOISE LEVELS 75 DBA (DAY TIME) & 70 DBA (NIGHT TIME)

Noise limits are within norms (Annexure-VI). • UNDERTAKE SOCIO-DEVELOPMENT ACTIVITIES IN

THE SURROUNDING VILLAGES Being done Condition:

vi. COMPLY ALL RECOMMENDATIONS MADE IN THE REPORTS OF EIA-1994 & EMP.

Status:Complied. Condition:

vii. PROVIDE REQUISITE FUNDS TO IMPLEMENT CONDITIONS STIPULATED BY MOEF, STATE GOVT.

Status:Already VSP has spent over Rs 468 cr for pollution control measures. Also Rs1283 cr. expenditure is earmarked for pollution control measures in the expansion units. In addition to the above VSP is incurring over Rs 337 cr. yearly towards Environment management.

of 24

Since 2004, VSP spent Rs. 355.51 Cr on Up grading Environmental projects, 463.37 Cr on providing energy facilities & presently Rs. 218.33 Cr environmental projects are under implementation. Condition:

viii. A SIX-MONTHLY COMPLIANCE REPORT SHOULD BE SUBMITTED TO MOEF, REGIONAL OFFICE, BANGALORE

Status: Being done. Last report submitted vides Ref. No. VSP/WK/EnMD/86 dt. 29.06.17 Condition:

ix. INFORM THE PUBLIC THAT THE ENVIRONMENTAL CLEARANCE OF THE PROJECT HAS BEEN ACCORDED BY MOEF. ADVERTISE THIS IN TWO NEWS PAPERS WITH IN 7 DAYS FROM THE DATE OF CLEARANCE

Status:Complied Condition: x. INFORM THE DATE OF FINANCIAL CLOSURE, FINAL APPROVAL OF THE PROJECT AND DATE OF COMMENCING THE LAND DEVELOPMENT WORK TO MOEF Status: Not applicable as finances for the expansion are met mostly from internal resources. Final approval of the project by GOI is on 28.10.2005. Work started from Jan’2006. The 6.3 mtpa expansion has been progressively completed by April 2015..

END

of 24

VISAKHAPATNAM STEEL PLANT

ENVIRONMENT MANAGEMENT DEPARTMENT Annexure-I

AMBIENT AIR QUALITY - Unit : Microgram /cum.

LOCATION Parameter NORM April'17 May'17 June'17 July'17 August'17 September'17

PM10 100 6.25 - - 75.22 98.60 94.20PM2.5 60 21.55 60.70 52.28 41.25 65.04 65.13SO2 80 15.76 15.76 46.76 16.80 12.50 15.60NOX 80 - - - 22.60 21.60 22.80

PM10 100 49.76 71.71 67.66 74.91 66.90 78.99PM 2.5 60 41.89 36.37 24.95 12.63 29.15 53.94

SO2 80 33.82 6.88 5.58 8.56 19.74 21.67NOX 80 15.76 16.56 16.89 14.68 17.39 15.49

PM10 100 180.60 112.40 123.30 142.30 133.50 115.60PM 2.5 60 - - 58.20 - 58.70 68.70

SO2 80 23.50 - 14.80 21.00 16.30 12.50NOX 80 34.20 - 21.09 28.50 22.90 28.60CO 2000 3.03 1.02 1.20 0.80 0.91 1.20

PM10 100 65.90 28.70 41.20 23.73 27.63 33.50SO2 80 10.10 10.90 13.80 14.15 7.70 12.06NOX 80 13.20 12.80 10.11 12.18 10.27 27.30

PM10 100 72.60 77.40 23.90 16.60 5.78 25.80SO2 80 10.10 11.80 12.91 10.50 9.26 12.69NOX 80 13.80 14.00 11.00 11.20 10.05 16.46

PM10 100 155.63 117.92 135.88 112.48 106.50 91.25SO2 80 11.79 10.74 10.19 11.07 16.50 17.69NOX 80 14.40 14.33 12.79 10.65 25.36 24.83CO 2000 1.09 1.24 1.09 1.05 0.80 1.15

PM10 100 75.50 72.40 68.70 24.73 14.67 52.00SO2 80 12.10 10.80 13.80 12.42 4.22 11.25NOX 80 14.80 14.60 17.50 15.25 9.03 26.10

Note: 1) Data from Maingate, BC gate , CCCD and Pedagantyada are from - Continous Ambient Air Quality Monitoring Stations. 2) Township , kondakarla and Zoo Park monitored using respirable dust sampler.

7. ZOO PARK

1. BC GATE

2. MAIN GATE

3. CCCD

4. TOWNSHIP

5. KONDAKARLA

6. PEDAGANTYADA

of 24

ENVIRONMENT MANAGEMENT DEPARTMENT Annexure-II

EFFLUENT QUALITY Unit: mg/l

Parameter Norm April'17 May'17 June'17 July'17 August'17 September'17

Outlet-1 TRADE EFFLUENTS FROM TPP

Daily discharge (Kilo litres) 4800 3360.0 3360.0 3360.0 3360.0 3720.0 3240.0

pH 6.0-9.0 7.30 6.30 7.01 7.00 7.03 8.00

TSS 100 56.00 13.00 64.00 42.50 36.00 11.00

OIL & GREASE 10 4.20 4.00 4.00 4.00 4.00 4.00

Phenols 1.0 BDL 0.08 0.09 0.15 BDL BDL

Ammonical Nitrogen 50.0 2.80 4.20 BDL 9.10 2.80 2.80

Free Chlorine 0.5 BDL BDL BDL BDL BDL BDL

IRON 1.0 0.96 0.88 0.81 0.80 0.86 0.98

COPPER 1.0 0.05 0.02 0.07 0.03 0.02 0.03

Outlet-2 EFFLUENTS FROM EFFLUENT TREATMENT PLANTDaily discharge (Kilo litres) <9600 2260.2 2254.6 3425.0 4049.5 5610.2 4401.2

pH 6.0-9.0 5.50 6.50 7.10 6.00 6.40 7.20

TSS 100 70.00 94.40 73.62 97.00 85.38 80.00

OIL & GREASE 10 5.05 5.11 6.51 8.19 7.84 6.93

PHENOL 01 0.36 0.30 0.59 1.47 0.39 0.43

COD 250 201.17 202.59 234.31 240.48 232.69 224.88

BOD 30 5.40 5.40 5.00 4.90 6.80 7.20

Cyanide 0.2 0.16 0.18 0.15 0.18 0.12 0.14

AMMONICAL N2 50 49.67 41.42 49.22 23.35 12.74 45.08

Outlet-3 EFFLUENT FROM TOWNSHIP SEWAGE TREATMENT PLANT Daily discharge (Kilo litres) No Norm 2166.0 3132.9 3739.3 3405.5 3488.5 2753.5

pH No Norm 7.67 7.60 7.50 7.37 7.00 7.46

TSS No Norm 10.50 14.00 15.20 12.50 14.80 10.50

BOD No Norm 10.15 10.50 8.70 12.50 7.66 9.50

BDL - Below detectable limit


of 24

Annexure-IIIVISAKHAPATNAM STEEL PLANTEnvironment Management DepartmentStack emissions (mg/Nm3)

Sl.No. STACK PARAMETER NORM April'17 May'17 June'17 July'17 August'17 September'171 BF : BHS 1 PM 50 21.9 19.9 20.7 26.3 24.9 25.7

Flow (Nm3/hr) 2225000 1702954 1745892 1734753 1728456 1742695 17259982 BF :BHS 2 * PM 50 C/Repair C/Repair C/Repair C/Repair C/Repair C/Repair

Flow (Nm3/hr) 2225000 " " " " " "3 BF : CHES 1 * PM 50 19.5 19.98 16.65 17.15 16.85 16.47

Flow (Nm3/hr) 972000 831256 830214 828642 825248 826164 8234134 BF : CHES 2 * PM 50 C/Repair C/Repair C/Repair C/Repair C/Repair C/Repair

Flow (Nm3/hr) 972000 " " " " " "5 SP : ACP * PM 50 98.9 97.12 48.52 89.38 61.93 155.41

Flow (Nm3/hr) 2622000 2156842 2145684 2138945 2102684 2154132 22015986 SP : GCP * PM 50 22.1 20.79 44.43 19.8 23.26 24.02

Flow (Nm3/hr) 3600000 2151752 2168972 2191234 2159874 2255520 23557427 LMMM : WBF PM 50 18.2 20.94 16.68 15.81 17.8 19.78

Flow (Nm3/hr) 196248 176582 177953 175894 174354 173264 1763248 LMMM : RHF PM 50 12.4 13.2 14.63 13.01 17.44 16.35

Flow (Nm3/hr) 7893 7324.0 7264 7183 7314 7325 7301.29 WRM PM 50 16.7 17.94 17.69 16.18 17.5 17.6

Flow (Nm3/hr) 120709 111262 114562 111486 113428 114562 11235410 MMSM PM 50 17.7 17.77 19.03 18.66 18.12 18.38

Flow (Nm3/hr) 141576 132541 134265 130267 131243 132595 13378211 TPP : BOILER 1 & 2 PM 50 164.3 93.26 108.22 195.65 48.42 121.49

Flow (Nm3/hr) 500000 401256 402347 402684 401951 395647 40535713 TPP : BOILER 3 PM 50 24.4 148.65 152.04 402.98 95.74 88.77

Flow (Nm3/hr) 500000 402564 405267 401267 402315 403152 40635114 TPP : BOILER 4 PM 50 144.2 193.58 215.05 83.43 109.92 94.08

Flow (Nm3/hr) 500000 402189 403594 403684 399651 401385 40026115 TPP : BOILER 5 PM 50 229.1 72 77.22 80.94 59.06 76.73

Flow (Nm3/hr) 500000 403567 404537 402672 400159 401261 40531816 CRMP : FK 1&2 PM 50 151.2 231.93 165.2 83.82 146.61 89.54

Flow (Nm3/hr) 416000 281254 275891 271564 239789 271234 24531517 CRMP : FK 3&4 PM 50 133.4 98.53 115.4 121.4 100.5 71.18

Flow (Nm3/hr) 416000 275483 265874 269127 271386 268315 25034818 CRMP : FK 5 PM 50 25.5 32.74 29.88 37.31 37.39 47.64

Flow (Nm3/hr) 208000 162541 161245 150347 152348 145347 14953819 SMS : CVS PM 50 29.3 29.45 29.88 23.12 25.68 15.1

Flow (Nm3/hr) 590000 335641 334567 331264 330269 333261 335159

of 24

Annexure-IIIVISAKHAPATNAM STEEL PLANTEnvironment Management DepartmentStack emissions (mg/Nm3) ..continued

Sl.No. STACK PARAMETER NORM April'17 May'17 June'17 July'17 August'17 September'1720 BATTERY-1 PM 50 21.9 27.5 27.2 26.3 29.2 24.59

SO2 800 191.2 190.5 191 192 185.2 186.2NOX 500 73.2 72.5 68.5 71 78.2 72

Flow (Nm3/hr) 216090 191256 192347 189654 190254 187532 18962421 BATTERY-2 PM 50 30.4 27.23 29.04 21.51 24.65 25.04

SO2 800 180.2 181.5 182 179.8 176.4 177.2NOX 500 78.5 75.1 74.5 77.1 81.5 81.4


SO2 800 180.2 181.2 186.1 181.4 182 181.5NOX 500 83.2 82.5 79.8 80.25 84.9 79.4


SO2 800 192.5 193.1 192.0 191.2 193.0 191.4NOX 500 80.7 81.5 84.2 83.5 80.2 81.4

Flow (Nm3/hr) 216090 191267 191254 189248 188892 189642 191547

24 SP-3 Waste Gas PM 50 13.4 25.6 17.3 17.7 18.7 10.3Flow (Nm3/hr) 1181530 1115431 1102564 1085684 1120354 1092647 1075467

25 SP-3 de-dusting PM 50 29.4 49.2 47.51 37.51 25.55 17.68Flow (Nm3/hr) 732000 689159.0 690245 687758 675992 681574 685264

26 BF-3 CH de-dusting PM 50 64.0 11.25 11.62 14.37 11.88 9.94Flow (Nm3/hr) 1340000 1092642 1112564 1085647 1072674 1076154 1061598

27 BF-3 SH dedusting PM 50 13.9 34.59 17.15 14.69 16.85 36.95Flow (Nm3/hr) 470000 415614 412564 413159 414624 410186 409357

28 SMS-2 MH dedusting PM 50 27.7 26.73 39.91 12.73 18.29 15.74Flow (Nm3/hr) 207500 186751 189651 185642 187264 185642 185315

29 SMS-2 Se control System PM 50 16.3 18.78 19.04 19.22 18.52 15.93Flow (Nm3/hr) 1630000 1312647 1335647 1331159 1325672 1342143 1319842

30 SMS-2 LFRH-1 PM 50 17.8 22.7 17.25 18.2 13.62 14.51Flow (Nm3/hr) 106900 100254 101267 100594 100321 99654 101357

31 SMS-2 LFRH-2 PM 50 21.5 11.86 15.47 14.77 12.62 16.56Flow (Nm3/hr) 106900 101497.0 100351 102134 101264 100984 102001

35 TPP: Boiler-6 PM 50 51.3 56.18 48.52 58.25 52.68 65.54Flow (Nm3/hr) 587880 501815 511864 510267 508164 510268 501264

* Modernisations is in progress.

* Upgradation of ESP's is in progress @ Rs.143.8 Cr

of 24

VISAKHAPATNAM STEEL PLANTENVIRONMENT MANAGEMENT DEPARTMENT Annexure-IV

Fugitive emissions from CO Batteries (%)April'17 May'17 Jun'17 July'17 Aug'17 Sep'17

Batt.-1 5.56 3.77 4.65 5.97 4.67 4.92

Batt.-2 1.99 2.43 4.48 2.80 2.43 2.84

Batt.-3 3.73 2.99 4.33 4.35 6.35 5.22

Batt.-4 10.69 11.38 13.14 12.32 10.64 9.85

Batt.-1 2.65 1.79 2.87 2.61 2.61 3.29

Batt.-2 1.99 2.24 1.94 2.05 1.49 2.69

Batt.-3 1.24 2.61 1.34 2.27 3.18 2.39

Batt.-4 1.64 4.66 3.14 4.11 3.92 3.43

Batt.-1 0.80 0.62 0.95 0.58 1.00 0.66

Batt.-2 1.00 0.75 0.60 0.62 0.75 0.89

Batt.-3 0.50 0.75 0.62 0.33 0.87 0.70

Batt.-4 0.33 0.25 0.70 0.75 0.50 0.80

Batt.-1 121 126 121 122 123 123

Batt.-2 128 126 121 121 122 120

Batt.-3 120 124 129 121 125 121

Batt.-4 125 130 126 123 124 121

Note :- # High values due to non-availability of Technology, Such as HPLA & Screw feeders

Percentage Leaking Lids

(PLL) Norm=1 %

Percentage Leaking Doors

(PLD) Norm = 10 %

Percentage Leaking Offtakes (PLO) Norm=4

%

Charging # emmission Norm=75

seconds per charge

KONDAKARLA LAKE WATER ANALYSIS Annexure-VUnit: mg/lParameter 29.04.17 20.5.17 19.06.17 19.08.17 23.09.17pH 7.25 7.62 7.32 6.3 7.5Turbidity (NTU) 2.3 3.8 3.4 2Conductivity 946 1159 1218 1167 562Total dissoloved solids 601 618 778 380 330Total hardness as CaCO3 132 120 268 116 76Ca. hardness as CaCO3 88 56 102 - -Mg. Hardness as CaCO3 44 64 158 - -Total Alkalinity as CaCO3 24 28 32 276 216P-Alkalinity as CaCO3 NIL nil NIL - -M-Alkalinity as CaCO3 24 28 32 - -Chlorides 112 200 212 200 80Sulphates 54 62 90 35.5 9.6Fluoride 1 1.1 1.1 - -

of 24


ENVIRONMENT MANAGEMENT DEPARTMENTAnnexure-VI

AMBIENT SOUND LEVELS

Day Night Day Night Day Night Day Night Day Night Day Night

Norm 75.0 70.0 75.0 70.0 75.0 70.0 75.0 70.0 75.0 70.0 75.0 70.0

MIN. 52.3 35.1 57.9 45.4 48.7 35.4 38.3 35.8 39.4 36.9 40 35.6

MAX. 59.8 36.4 48.7 39.8 57.9 37.8 47.6 38.3 47.9 40.1 48.6 40.3

MIN. 58.4 45.2 64.2 52.1 58.9 49.4 47.1 46 47.4 46.1 50.2 46.6

MAX. 64.8 48.4 58.9 46.9 64.2 45.4 58.2 50.1 57.3 48.3 56.4 48.8

MIN. 58.9 50 70.3 64.3 60.3 58.4 58.5 49 57.9 56 59.3 56.4MAX. 66.5 61.8 60.3 58.8 67.6 61.4 68.1 62.3 68.4 61.1 66.8 60.2

Note: Norm for Day time (06 AM to 10 PM) is 75 dB(A)Norm for Night time (10 PM to 06 AM) is 70 dB(A)

LOCATION

CCCD

2

3

BC GATE

MAIN GATE1

Sep'17Aug'17July'17Jun'17May'17April'17

of 24

Solid waste

Annexure-VII

2017-18 Upto SepSludge from Water Treatment PlantGeneration 128464Recycled 137110Sold 0Stack -8646Percentage Utilization 106.73Dust from ESP's,DE SystemsGeneration 111143Recycled 80547Sold 28329Stack 2267Percentage Utilization 97.96Lime Fines DustGeneration 84709.00Recycled 70534.00Sold 14175.00Stack 0.00Percentage Utilization 100

BF SLAGGeneration 737533Recycled 1550Sold 1247431Stack 511448Percentage Utilization 169.35

LD SLAGGeneration 286556Recycled 42122Sold 8098Stack 236336Percentage Utilization 17.53

TOTAL 0Generation 1348405Recycled 331863Sold 1298033Stack 281491Percentage Utilization 120.88Solid Waste Utilization for the month (%) 120.88

Specific Solid Waste Generation for the month (t/tcs) 0.63

Visakhapatnam Steel Plant...Visakhapatnam Steel Plant Rashtriya Ispat Nigam Ltd. Half yearly...

Documents

Transcript of Visakhapatnam Steel Plant...Visakhapatnam Steel Plant Rashtriya Ispat Nigam Ltd. Half yearly...