Current Challanges in Pollution

Control from Iron & Steel,

Aluminium, Cement and Thermal
Power Plants
Dr. B. Sengupta
Director
Central Pollution Control Board
Ministry of Environment & Forests
Govt. of India, Delhi
Email: bsg1951@yahoo.com,
Website: http://cpcb.delhi.nic.in
Presented at workshop held at Raipur on 8th November, 2008

POWER SECTOR (COAL): A PROFILE

Seventy one per cent of electricity production is based on coal

and gas in the country.

83 coal based thermal power plants with total generation

capacity of 62630.9 MW.

27 gas/naphtha based power plants with total generation

capacity of 11299.6 MW.

More than 240 million tonnes of coal with ash content 35-45%
was consumed by the Thermal Power Plants

Power plants contribute nearly 82 & 89 % particulate matter &

SO2 emission load respectively in the country

Nearly 112 million tonnes per annum coal ash is generated.

More than 25,000 hectares of land has been occupied for

conventional disposal of ash.

More than 630 million M3 water is required for disposal of coal

ash as in slurry form per annum

ENVIRONMENTAL PROBLEMS
Use of high ash content coal in power generation leads to
the followingenvironmental problems:
Air Pollution
Emission of particulate matter (dust)
Emission of sulphur dioxide and Oxides of Nitrogen
Green House Gas Emissions
Emission of Mercury (both gaseous and in ash)
Fugitive emission of suspended particulate matter from
CHP, Wagon Tripler and ash pond
Water Pollution
Cooling water discharge
Ash pond effluent
Solid Waste
Large volume of coal ash generation (Fly ash & Bottom
ash)
Large land requirement for ash disposal

ENVIRONMENTAL STANDARDS OF COAL BASED THERMAL POWER PLANTS

Emission Standards
Particulate Matter

India

USA

Australia

UK

Germany

150 mg/Nm3 62 mg/Nm3 80 mg/ Nm3 50 mg/ Nm3 50 mg/m3

Sulphurdioxide
*
740 mg/ m3 *
400 mg/ m3 400 mg/ m3
Oxide of Nitrogen
*
615 mg/ m3 800 mg/ m3 650 mg/ m3 200 mg/ m3
: Dispersion of SO2 away from urban areas through use of tall stacks;
Stack Height Requirement
Less than 200/210 MW
H is

H= 14 Q 0.3 where Q is emission rate of SO2 in kg/hr and

stack height in metre

>200/210 MW or less than

500 MW
500 MW and above
Effluent Standards
Cooling Water
Ash Pond

220 m
275 m

Temp.
pH
SS

100 C
6.5 - 8.5
100 mg/l

REASON FOR NON-COMPLIANCE OF ENVIRONMENTAL

STANDARDS IN COAL BASED THERMAL POWER PLANTS
High ash content in coal used in power plants
Poor ash chemistry: high silica,high alumina, low sulphur & low sodium
High resistivity of coal
Inconsistent supply of coal
Low calorific value
Delay in supply/installation of ESPs
Low design efficiency of ESP( low SCA)
Poor operation & maintenance of ESPs i.e. timely
faulty parts such as hanging electrodes
Non installation of state of Art EPIC controllers
In sufficient water pressure below the ESP hoppers
Rapping time not optimum
Inefficient management of ash ponds
Paucity of funds

replacement of

INITIATIVES TAKEN FOR MITIGATION OF

ENVIRONMENTAL PROBLEMS
To

minimize

the

impact

of

emission

of

particulate matter and other Green House

Gases following measures have been taken:
Use of beneficiated coal
Promoting utilisation of flyash
Adoption

of

technologies

clean

coal

combustion

ACTION POINTS
1.

New / expansion power projects to be

accorded
environmental
clearance
shall
meet
the
limit
of
for
particulate
matter
100
mg/Nm3
emission.

2.

Installation
of opacity meters /
continuous monitoring systems in all the
units with proper calibration system.

3.
for

Development of guidelines / standards

mercury and other toxic heavy metals
emissions.

4.
Review of stack height requirement
and guidelines for power plants based on micro
meteorological data.

5. Implementation of use of beneficiated coal as per GOI

Notification:
Power plants will sign fuel supply agreement (FSA) to
meet the requirement as per the matrix prepared by CEA
for compliance of the notification as short term measure
Options/mechanism for setting up of coal washeries as a
long term measure

Coal India will set up its own washery

State Electricity Board to set up its own washery

Coal India to ask private entrepreneurs to set up

washeries for CIL and taking washing charges

SEBs to select a private entrepreneur to set up a

washery near pit-head installation of coal beneficiation
plant

6.

Power plants will indicate their requirement of of

abandoned coal mines for ash disposal & Coal India /
MOC shall provide the list of abandoned mines.

7.

Power Plants will provide dry flyash to the users outside

the premises or uninterrupted access to the users.

8.

Power Plants should provide dry flyash free of cost to the

users

9.

State P.W.Ds/construction & development agencies shall

also adhere to the specifications /Schedules of CPWD
for ash / ash based products utilisation.

10.New plants to be accorded environmental

clearance shall adopt either dry flyash extraction or
dry disposal system or medium (35-40 %) ash
concentration slurry disposal system or Lean phase
with hundred percent ash water recirculation
system depending upon site specific environmental
situation.
11. New plants shall promote adoption of clean
coal and clean power generation technologies.

BACKGROUND OF CEMENT SECTOR

India Ranks World's 2nd largest cement producing country

No. of Large Cement Plants in the country -

Total Annual Installed Capacity- 135.55 Million Tonnes

(As on December, 2001)
Annual Cement Production
- 98.35 Million Tonnes
(As on December, 2001)

123

Per Capita Consumption of Cement (1999)

India

World Average

97 kg/Annum

256 kg/Annum

AIR POLLUTION CONTROL EQUIPMENT

FOR DIFFERENT SECTIONS IN CEMENT INDUSTRY
S. No. Section

Pollution Control Equipment

1.

Crusher

Bag Filter

2.

Raw Mill

Bag Filter/ESP

3.

Kiln

Bag Filter/ESP with GCT

4.

Clinker Cooler

5.

Coal Mill

ESP/Bag Filter with heat

exchanger
Bag Filter/ESP

6.

Cement Mill

Bag Filter/ESP

7.

Packing Plant

Bag Filter

EMISSION STANDARDS IN INDIA

Plant capacity
in tonnes per
day

Particulate matter Emission nor to exceed mg/Nm3

Protected Area

Other Area

<200

250

400

>200
150
250
CPCB/SPCB may fix stringent standards, if required as per Air Act, 1981/

Environment (Protection ) Act, 1986

EMISSION STANDARDS IN OTHER COUNTRIES

Country

Particulate Matter Emission Limit (mg/Nm3)

Australia

50

Germany

50

South Africa

120

Switzerland

50

Japan

100

USA

100/ 50

Portugal

100/50

GENERATION OF MAJOR INDUSTRIAL WASTES

& ITS UTILIZATION IN CEMENT MANUFACTURE
IN INDIA (2000-01)

Waste material
Flyash
Blast Furnace
Slag
Steel Slag
Phospho-gypsum
Lime sludge
(MT : Million Tonne)

Generation
(MT/Annum)

Utilization
(MT/Annum)

100
10

6.25
5.5

4.0
6.0
4.5

0.5
2.5
0.5

ENVIRONMENTAL ISSUES IN CEMENT SECTOR

Non Compliance of Emission Standards in few units

Requirement of Load based Standards
Control of fugitive emission from following units of
Cement Plants

Raw Material Storage

Loading/Unloading Operation

Material Transfer Point

Continuous dust monitoring system & its

calibration
Environmental implication of use of petroleum coke
as fuel in kiln (emission of SO2, V, Ni, PM10)

Frequent tripping of Kiln ESP

Poor industrial solid waste
manufacturing
Flyash
Blast Furancae Slag
Lime Sludge
Phospho Gypsum

Posssibility of use of Hazardous Waste in Cement Kiln

Reduction of Green House Gases

utilisation

in

cement

Reduction in power consumption

Reduction in coal consumption
Promotion of Energy Efficient Technology

Waste heat recovery from kiln & clinker cooler exit gases

ACTION POINTS
1. Cement Plants located in critically polluted or urban
areas (including 5 km distance outside urban
boundary) will meet 100 mg/Nm3 limit of particulate
matter and continue working to reduce the emission of
particulate matter to 50 mg/Nm3.
2. The
new
cement
kilns
to
be
accorded
NOC/environmental clearance, will meet timplehe limit
of 50 mg/Nm3 for particulate matter emission.
3. Load based standards evolved by CPCB to be
implemented.
4. The cement industries will control fugitive emissions
from all the raw material and products storage and
transfer
points
as
per
CPCB
Guildelines
(www.cpcb.nic.in)

5.

Use of high calorific value hazardous

wastes as partial fuel in cement kiln shall
be promoted as per CPCB guidelines.

LIST OF INDUSTRIES WITH LOCATION

S.
No

Name of
Industry

1.
2.

Location
Alumina Plant

Smelter

Power Plant

NALCO

Damanjodi, Distt
:Koraput, Orissa

Angul, Distt.:
Angul, Orissa

Angul, Distt.:
Angul, Orissa

Panchpatmali Distt.:
Koraput, Orissa

BALCO
(Sterlite)

Korba,
Chhattisgarh

Korba,
Chhattisgarh

Korba,
Chhattisgarh

Mainpat, Distt.
Sarguja, Chhatisgarh

i)

(i) Alupuram,
Kalamasssery,
Kerala
(ii) Belgaum (not
in operation
since 1993)
(iii) Hirakud,
Orissa

i)

Renukoot,
Distt.:
Sonbhadra, UP

Renukoot,
Distt.: Sonbhadra,
UP

Renusagar,
Distt.:
Sonbhadra,
UP

i) Lohardaga,
Jharkhand
ii) Amarkantak, MP

Metturdam,
Tamilnadu

Metturdam,
Tamilnadu

Metturdam,
Tamil nadu

i)Yercaud, Distt.: Salem

ii)Kolli; Distt: Namakkal
iii)Poondi; Distt.
Dindigul

3.

INDALCO

4.

HINDALCO

5.

MALCO

Belgaum,
Karnataka
ii) Muri,
Jharkhand

Mines

Dugmanwadi,
Maharashtra State
ii) Lohardaga,
Jharkhand

Hirakud, Orissa

Source : Questionnaire survey by CPCB (1999-2000)

INSTALLED CAPACITY & PROPOSED FUTURE EXPANSION

S.
No
.

Name of Smelter

1.

Installed capacity (TPA)

Future Expansion Proposed (TPA)

Alumina

Aluminiu
m Metal

Aluminium
Products

Alumina

Aluminium
Metal

Aluminium
Products

NALCO, Angul,
Orissa

8,00,000
(at
Damanjod
i)

2,18,000

2,43,000

15,75,000

3,45,000

2.

BALCO Korba,
Chhattisgarh

2,00,000

1,00,000

3.

INDALCO
Alupuram,
Kerala

13,500

8,000

4.

INDALCO
Belgaum,
Karnataka

2,70,000

(pots
being to
shifted to
Hirakud)

5.

INDALCO
Hirakud, Orissa

72,000
(at Muri)

30,000

30,000

57,200

57,200

6.

HINDALCO
Renukoot, UP

4,50,000

2,42,000

1,33,700

6,60,000

3,56,200

7.

MALCO
Metturedam, TN

60,000

30,000

69,500

18,52,000

7,06,500

5,16,800

Total Capacity

Source : Questionnaire survey by CPCB (1999-2000) # Expansion completed

Action Points
S.
No.

Issues

1.

Technology

Action Points

Targets

Allowing
new
Potlines
only
with Pre-baked
Technology

Environmental clearance for

new pot lines to be given by
MoEF, only with pre-baked
technology.

Prescribing
Maximum size of the plant
maximum size of shall be decided based on the
the plant
assimilative capacity of each
plant location.
2.

Fluoride
Emissions

Revision of
fluoride
emission
standards

For Soderberg Technology2.8 kg/t

[1.0 kg/t (VSS) & 1.30 kg/t
(HSS) by Dec 2010]*
For Pre-baked Technology0.8 kg/t

*National Task Force will submit the proposal within three months

S. No

Issues

Action Points

Targets

Phasing out Wet

With Immediate effect.
Scrubbing System
for fluoride
Monitoring of
Monitoring
of
secondary
fugitive emissions fluoride emission shall be
from pot rooms
done as per CPCB guidelines.
3.

Fluoride
Fluoride
Consump- consumption per
tonne of
tion
aluminium
produced (as F-)

[For Soderberg Technology 15 kg/t

For Pre-baked Technology10 kg/t

4.

Ambient
Fluoride

Twelve consecutive months

average- 40 ppm
Two consecutive months
average 60 ppm
One month 80 ppm

Forage fluoride
standards

S. Issues
No.
5.

Action Points

Targets

Spent
Pot Setting up a centralized With immediate effect
Lining (SPL) SPL treatment & disposal
facility with
aluminium
fluoride recovery and
utilisation of SPL in
steel/cement industries
Limit for pot life (for new [2500 days (average)]
pots
installed
after
December 31, 2003
SPL
(Carbon
&
Refractory)
to
be
disposed
in
Secured
Landfill

With
immediate
effect.
However,
the
carbon
portion of SPL may be used
in Cement Plant as partial
fuel.

S. Issues
No.
6.

Red Mud

Action Points
Phasing out Wet disposal

Targets
With immediate effect.

Red Mud Utilisation

7.

Anode
Achieving
particulate With immediate effect.
Baking Oven matter limit of 50 mg/Nm3

INTEGRATED IRON AND STEEL PLANTS IN INDIA

Installed Capacity Million Tonne per Annum
Based on BF Technology
Steel Authority of India Limited (SAIL)
Bhilai Steel Plant (BSP)

4.0 MTPA

Bokaro Steel Plant (BSL)

4.0 MTPA

Rourkela Steel Plant (RSP)

2.5 MTPA

Indian Iron & Steel Company (IISCO)

1.0 MTPA

Durgapur Steel Plant (DSP)

1.6 MTPA

Rastriya Ispat Nigam Ltd. (RINL)

Visakapatnam Steel Plant

3.0 MTPA

Tata Iron & Steel Co. Ltd. (TISCO)

Tata Steel

3.5 MTPA

Based on COREX Technology

Jindal Vijaynagar Steel Ltd. (JVSL)

3.0 MTPA

Based on DRI
ESSAR Steel

2.0 MTPA

EMISSION STANDARDS :
COKE OVEN PLANTS (BY PRODUCT RECOVERY TYPE)
MoEF Notification G.S.R. 631(E), dated 31st October, 1997

Parameter

Standards
New
Batteries

Existing
Batteries

Fugitive Visible Emissions

(a) Leakage from door

5 (PLD)*

10 (PLD)*

(b) Leakage from charging lids

1 (PLL)*

1 (PLL)*

(c) Leakage from AP Covers

4 (PLO)*

4 (PLO)*

(d) Charging emission (second/charge)

16
(with
HPLA)*

50
(with
HPLA)*

(a) SO2(mg/Nm3)

800

800

(b) NOx, (mg/Nm3)

500

500

(c) SPM, (mg/Nm3)

50

50

(a) SPM emission during charging (stack emission) mg/Nm3

25

25

Stack Emission of Coke Oven

(b) SPM emission during coke pushing (stack emission) 5

gm/ton of coke

5
Contd

Parameter

Standards
New
Batteries

Existing
Batteries

Sulphur in Coke Oven gas used for heating (mg/Nm3)

800

800

Emission for quenching operation

Particulate matter gm/MT of coke produced

50

50

Benzo-Pyerine (BOP) concentration in work zone air (ug/m3)

Battery area (top of the battery)

Other units in coke oven plant

Ambient standards (ng/m3)

10

10

ENVIRONMENTAL STANDARDS FOR COKE OVEN PLANTS USEPA

Clean Air Act Amendments (CAAA) 1990
Existing Batteries - MACT Option
- Extension Track Option
(MACT-Max. Achievable Control Tech.)
New Batteries - MACT Option
MACT Option
MACT Standards* by 31st December, 1995
MACT standards : PLD 8, PLL1, PLO 5, 16/ S/C
(Review after every 7 years) and works practice standards and
Ample margin of Safety residual risk based standard**

** Achieve emission reduction that will reduce cancer risk to 1x10-4

(i.e. one in 10000 chance)

EXTENSION TRACK OPTION

Extension in complying residual risk based standards upto 1.1.2020
subject to:

To qualify for the extension the existing batteries have to meet

By 15.11.93
8 PLD, 1PLL, 5PLO and 16 S/C
By 1.1.98 (LAER)
3 PLD (5PLD for tall), 1 PLL, 4 PLO, 16 S/C
(with an exclusion for just charged door)
(LAER II) by 1.1.2010 yet to be fixed
USEPA to evaluate for the installation of New Batteries
- JEWELL Thompson Design non recovery oven
- Other non recovery tech.
- Other Appropriate emission control

ACTION POINTS
1. Coke Oven Plants
To meet the parameters PLD (% leaking doors), PLL
(%leaking lids), PLO (% leaking off take), of the notified
standards.
Industry will submit time bound action plan and PERT Chart
along with the Bank Guarantee for the implementation of
the
same.
- To rebuild at least 40% of the coke oven batteries* in next 10
years (December 2012).
2.

Steel Melting Shop

Fugitive emissions -To reduce 100% by March 2008 (including
installation of secondary de-dusting facilities)
* As per rebuilding schedule submitted to CPCB / MoEF.

Contd..

3.

Blast Furnace
Direct inject of reducing agents

4.

Solid Waste / Hazardous Waste Management

Utilization of Steel Melting Shop (SMS) / Blast Furnace (BF)
Slag
Hazardous Waste
Charge of tar sludge / ETP sludge to Coke Oven
Inventorization of the Hazardous Waste as per Hazardous
Waste (M&H) Rules, 1989 as amended from time to time and
implementation of the Rules
(Tar sludge, acid sludge, waste lubricating oil and used type
fuel falls in the category of Hazardous Waste.)

Contd..

5. Water conservation / Water Pollution

To reduce specific water consumption to 5 m3/t for long

products and 8 m3/t for flat products.
To operate the CO-BP effluent treatment plant efficiently to
achieve the notified effluent discharge standards.

6. Installation of Continuous stack monitoring system & its

calibration in major stacks, on line ambient
air quality
monitoring stations.
7. To operate the existing pollution control equipments efficiently
and to have proper record keeping of pollution control
equipment run hours, failure time and efficiency with
immediate effect. Compliance report to be submitted to CPCB /
SPCB every three months
8. Implementation of recommendations of Life Cycle Assessment
(LCA) study sponsored by MoEF.

Contd..

9. The industry will initiate the steps to adopt the following clean
technology/measures to improve the performance of the
industry towards production, energy and environment.

Energy recovery of top Blast Furnace (BF) gas.

The use of Tar-free runner linings.

Cast House de-dusting (tap holes, runners, skimmers, ladle

charging points)

Suppression of fugitive emissions using nitrogen gas or any

other inert gas.

To study the possibility of slag and fly ash transportation back to

the abandoned mines to fill up the cavities through empty
railway wagons when they return and its implementation.

Yearly progress report on these issues will be submitted by the

industry to CPCB and MoEF.

Contd..

Processing of the waste containing flux & ferrous wastes

through Waste recycling plant.

To implement rain water harvesting.

Reduction of Green House Gases by:

.

Reduction in power consumption

Use of By-production gases for power generation

Promotion of Energy Optimisation Technology,

including
energy audit

To set targets for Resource Conservation such as Raw

material, energy and water consumption to match
International Standards

Contd..

Up-gradation in the monitoring analysis facilities for

air and water pollutants. Also to impart elaborate
training to the manpower in the environmental
monitoring laboratories, so as realistic data can be
obtained.
- To improve house keeping.

SPONGE IRON PLANTS

POLLUTION CONTROL STANDARD

Process in Brief Sponge Iron Plant

Inside the rotary kiln, the DRI gases flow counter-current to the
kiln feed. The temperature at the product discharge end in a
rotary kiln is about 950-1050oC compared to 750-900oC towards
the feed end. The counter-current flow of hot DRI gases enable it
to remove the moisture content from feed. The hot DRI gases
contains huge amount of fine dust comprising oxides and
unburnt carbon and toxic carbon monoxide. It needs treatment
before discharging into the atmosphere

The raw material feed side of rotary DRI Kiln has a natural
structure below the After Burner Chamber (ABC) that acts as
Dust Settling Chamber (DSC). About 15-20% coarse dust settles
in DSC by means of gravity. In ABC, the CO content of gases is
converted to CO2. This conversion process is exothermic and the
temperature of gases rises to 1000-1050oC

Some plants (very few) have Gas Conditioning Tower (GCT)

followed by pollution control equipment and cleaned gas is
emitted through stacks

Air pollution mitigation measures

In case no pollution control are installed
by the unit the particulate matter emission
was observed around 25 gm/Nm3.
This indicated that installation of pollution
control devices is must to protect the
environment.
The
pollution
control
devices like ESPs, Bag filters, and wet
scrubbers installed by the industries.

Fugitive dust generation

The sources of fugitive dust generation are:
Raw Material Handling Yard (unloading,
stacking, reclaiming operations)
Product
discharge
system
(cooler
discharge conveyors, transfer points,
junction
house,
screens,
magnetic
separators, storage silos, truck loading
and packing operations).

Water Pollution Mitigation Measures

The water requirement in rotary kiln DRI plant is
mainly for cooling the discharge feed from 950-1050oC
to below 100oC. Water is continuously sprinkled over
the rotary cooler shell and is allowed to fall on a
settling tank located below the rotary cooler/ near the
cooler. In ABC water is sprayed through the nozzles in
the form of spray to control the temperature of the
gases.
Make-up water is added in the tank to cool the hot
water and compensate evaporation loss. The water
from settling tank is re-circulated for sprinkling over
the rotary cooler
The water requirement varies from 4-6 m3/ t of DRI.

Solid Waste Generation

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
equipment of Kiln

pollution

control

ENVIRONMENTAL STANDARDS

The standards will be applicable with effect from the

date of notification to all new, green field units set up
after the date of this notification and all expansion/
modernisation of existing units taken up after the
date of the notification. However, the existing units
shall install effective pollution control system within
six months and shall conform to the standards, after
six months of the date of notification.

ENVIRONMENTAL STANDARDS
1.0 Emission Standards
1.1 Stack Emission

100 mg/nm3 (Coal based)*

Standards for Kiln

50 mg/Nm3 (Gas based)

*12% CO2 correction

Combustion Efficiency (CE) :

of After Burner Chamber (ABC)

shall be atleast 99.9% and be

computed as below:

CE= % CO2//[%CO2 + %CO]*100

1.2 Stack Emission Standards for de-dusting units

Particulate matter (PM)

Stack Height ** (minimum)

100 mg/Nm3
Coal/gas

30.0 m
Q0.3

** Stack height shall be calculated as H=14.0

emission of Sulphur Dioxide (SO2) in kg/hr.ie.

where Q is

SO2 (kg/hr) Height (metre)

upto 12.68 30
12.69 33.08
40
33.09 69.06
50
69.07 127.80
60
127.81 213.63
70

1.3 Fugitive Emission Standards

(Rotary Kiln/
De-dusting unit)

Particulate
matter unit

Existing
Unit

New

Note:
(i) the existing industry shall comply with the standard of 2000
g/m3 after one year from the date of notification.
(ii) Fugitive Emission shall be monitored at a distance 10.0 metre
from the source of fugitive emission.

Fugitive Emission Monitoring Location

S.N

Area

Monitoring Location

1.

Raw material
handling area

Wagon
tippler,
Screen
area,
Transfer Points, Stock Bin area

2.

Crusher area

Crushing plant, vibrating screen,

transfer points

3.

Raw material feed

area

Feeder area, Mixing area, transfer

points

4.

Cooler discharge
area

Over size discharge area, Transfer

Points

5.

Product
processing area

Intermediate
stock
bin
area.
Screening
plant,
Magnetic
Separation unit, Transfer Points,
Over size discharge area, Product
separation area, Bagging area

6.

Other areas

Areas as specified
Pollution Control Board

by

State

2.0 Effluent Discharge Standards

(i)

All efforts should be made to reuse and re-circulate the

water and to maintain zero effluent discharge.

(ii)

Storm water / garland drain should be provided in the

plant.

(iii) In case of maintenance/ cleaning of the system the

settling tanks effluent of wet scrubbing system or
re-circulation system if require to be discharged,
should be treated suitably to conform to the following
standards:
pH
Total Suspended Solids (TSS)
Chemical Oxygen Demand (COD)
Oil and Grease (O&G)

:
:
:
:

Between 5.5 to 9.0

100 mg/l
250 mg/l
10 mg/l

GUIDELINES
1.0

Air Pollution

1.1

Stack Emission from Kiln

(i) Adequately designed ESP or any other adequate air

pollution control system/combination of system should
be installed to achieve the prescribed stack emission
standards.
As installation and operation of Pollution Control
Equipment for plants with less than 100 TPD capacity is
not economically viable, therefore, it is recommended
that plants with less than 100 TPD shall not be permitted
in future.
Program for phasing out old plants having capacity less
than 100 TPD shall be worked out by the State Pollution
Control Board.

GUIDELINES (contd..)
(ii) All Pollution control equipment should be provided
with separate electricity meter and totaliser for
continuous recording of power consumption. The
amperage of the ID fan should also be recorded
continuously. Non-functioning of Pollution control
equipment should be recorded in the same
logbook along with reasons for not running the
Pollution Control Equipment.
(iii) The safety cap/emergency stack of rotary kiln type
plant, which is generally installed above the After
Burner Chamber (ABC) of feed end column should
not be used for discharging untreated emission,
bypassing the air pollution control device.

GUIDELINES (contd..)
(iv) In order to prevent bypassing of emissions through safety
cap and non-operation of ESP or any other pollution
control device, software controlled interlocking facility
should be provided on the basis of real time data from the
plant control system, to ensure stoppage of feed
conveyor, so that, feed to the kiln would stop
automatically, if safety cap of the rotary kiln is opened or
ESP is not in operation. The system should be able to
take care of multiple operating parameters and their inter
relations to prevent any possibility of defeating the basic
objective of the interlock. The system should be foolproof
to prevent any kind of tempering. The software based
interlocking system, proposed to be installed by industry
should be get approved by the concerned State Pollution
Control Board, for its adequacy, before installation by the
industry.

GUIDELINES (contd..)
(v)

Mechanical operated system for timely collection

and removal of the flue dust generated in ESP or
any other pollution control device shall be
installed.

1.2

Stack Emission from de-dusting units

All de-dusting units should be connected to a
stack having a minimum stack height of 30 m.
Sampling porthole and platform etc. shall be
provided as per CPCB emission regulation to
facilitate stack monitoring. De-dusting units can
also be connected to ABC Chamber and finally
emitted through common stack with kiln off-gas
emissions.

GUIDELINES (contd..)
1.3

Fugitive Emission
The measurement may be done, preferably on
8-hour basis with high volume sampler. However,
depending upon the prevalent conditions at the
site, the period of measurement can be reduced.

2.0

Effluent Discharge

(i)

All efforts should be made to reuse and re-circulate

the water and to maintain zero effluent discharge.
Storm water / garland drain should be provided in
the plant.

(ii)
3.0

Noise Control
The industry should take measures to control the
Noise Pollution so that the noise level standards
already notified for Industrial area are complied.

GUIDELINES (contd..)
4.0

Solid Waste Management

Char
Char should be mixed with coal or coal washery rejects and used as
fuel in Fluidized Bed Combustion Boilers (FBC) for generation of
power. The plants having capacity 200 TPD and above should install
Fluidized Bed Combustion Boilers (FBC) for generation of power.
Also the smaller capacity individual Sponge Iron Plants (Capacity
upto 100 TPD) and operating in cluster can collectively install
common Fluidized Bed Combustion Boilers (FBC) for power
generation. The Sponge Iron Plant are free to explore other options /
possibilities to use char for generation of power. Char can be sold to
local entrepreneurs for making coal briquettes. It can also be mixed
with coal fines, converted to briquettes and used in brick kilns.
Under no circumstances char should be disposed off in agricultural
fields/other areas. Logbook for daily record, of Char production and
usage must be maintained by the industry and the record shall be
made available to officials of CPCB/SPCB/PCC during inspection.

GUIDELINES (contd..)
Kiln Accretions
The kiln accretions are heavy solid lumps and can be
used as sub- base material for road construction or
landfill, after ascertaining the composition for its
suitability and ensuring that it should not have any
adverse environmental impact.

Gas Cleaning Plant (GCP)/Scrubber Sludge

The sludge should be compacted and suitably disposed
off after ascertaining the composition for its suitability
and ensuring that it should not have any adverse
environmental impact.

GUIDELINES (contd..)
Flue Dust / Fly ash
Flue dust is generated from air pollution control
system i.e. ESP or any other air pollution control
system installed with kiln. Secondary flue dust is also
generated from Bag Filters or any other air pollution
control equipment installed with Raw Material
Handling, Coal Crusher, Cooler Discharge and Product
house unit. The reuse/ recycling of the flue dust
generated / collected may be explored and suitably
implemented.
Fly ash brick manufacturing plant should be install for
fly ash utilization. Fly ash can be utilized in cement
making by Cement industry also.

GUIDELINES (contd..)
Bottom Ash
Bottom ash may have objectionable metallic compounds, therefore
should be stored in properly designed landfills as per CPCB
guidelines to prevent leaching to the sub-soil and underground
aquifer.

General
(a) Solid waste management program should be prepared with thrust
on reuse and recycling. Solid waste disposal site should be
earmarked within the plant premises. The storage site of solid
waste should be scientifically designed keeping in view that the
storage of solid waste should not have any adverse impact on the
air quality or water regime, in any way.
(b) The various types of solid wastes generated should be stored
separately as per CPCB guidelines so that it should not
adversely affect the air quality, becoming air borne by wind or
water regime during rainy season by flowing along with the
storm water.

GUIDELINES (contd..)
5.0

Raw Material handling and Preparation

(a) Unloading of coal by trucks or wagons should be carried

out with proper care avoiding dropping of the materials
from height. It is advisable to moist the material by
sprinkling water while unloading.
(b) Crushing and screening operation should be carried out in
enclosed area. Centralized de- dusting facility (collection
hood and suction arrangements followed by de-dusting
unit like bag filter or ESP or equally effective method or
wet scrubber and finally discharge of emission through a
stack) should be provided to control Fugitive Particulate
Matter Emissions. The stack should confirm to the
emission standards notified for de-dusting units. Water
sprinkling arrangement should be provided at raw material
heaps and on land around the crushing and screening
units.

GUIDELINES (contd..)
(c) Work area including the roads surrounding the plant shall be
asphalted or concreted.
(d) Enclosure should be provided for belt conveyors and transfer
points of belt conveyors.
The above enclosures shall be rigid and permanent (and not
of flexible/ cloth type enclosures) and fitted with self- closing
doors and close fitting entrances and exits, where conveyors
pass through the enclosures. Flexible covers shall be
installed at entry and exit of the conveyor to the enclosures,
minimizing the gaps around the conveyors.
In the wet system, water sprays/ sprinklers shall be provided
at the following strategic locations for dust suppression
during raw material transfer:
- Belt conveyor discharge/ transfer point
- Crusher/screen discharge locations

GUIDELINES (contd..)
6.0 Waste Heat Recovery Boiler (WHRB)
Sponge Iron Plants of capacity more than 100 TPD
kilns shall use Waste Heat Recovery Boiler (WHRB)
for generation of power.
7.0 Cooler Discharge and Product Separation Unit
Permanent and rigid enclosures shall be provided
for belt conveyors and transfer points of belt
conveyors. Dust extraction cum control system
preferably bag filters or ESP to arrest product loss
in cooler discharge and product separation area
shall be installed.

GUIDELINES (contd..)
8.0 Char based Power Plant
For plant having capacity of 200 TPD of cumulative kiln capacity, the
power production through FBC boiler using char as a part of fuel, is
a viable option. Power generation through FBC boiler using char as a
part of fuel be implemented in a phased manner within 4 years of
commissioning and targeting for 100% utilization of char.
Individual Sponge Iron Plants of capacity upto 100 TPD and
located in cluster can install a common char based power
plant collectively.

9.0 New Sponge Iron Plants

(i)

No New Sponge Iron Plant will be commissioned without installation

of Pollution control systems as stipulated in the Standards. The
concerned State Pollution Control Board will accord consent to
operate only after Physical verification of the adequacy of the
Installed pollution control systems for meeting the standards and
stipulated conditions in the consent to establish.

GUIDELINES (contd..)
(ii)

All new kilns shall have the independent stack with the kiln or
multi-flue stacks in case two or more kilns are joining the same
stack for better dispersion of pollutants.

(iii) Any entrepreneur having more than 2x100 TPD kiln may install
WHRB for power generation, as its a techno-economic viable
option.
For plants having capacity of 200 TPD or more, power generation
using char in FBC Boiler as part of fuel is techno-economic
viable option, therefore, new plants must install FBC boiler for
power generation at the time of installation of the industry.
(iv) Any new sponge iron plant being installed along with the other
downstream facilities of converting the sponge iron into steel
with/without further processing the steel should meet the target
of 100% utilization of sensible heat of DR (Direct Reduction) Gas
and Char for power generation. Wet scrubbing system for kiln
off-gas treatment for such plants should not be opted.

GUIDELINES (contd..)
10.0 General Guidelines
(a)

Extensive plantation/Green belt shall be developed along the

roads and boundary line of the industry. A minimum 15 m
width Green Belt along the boundary shall be maintained.
However, the green belt may be designed scientifically
depending upon the requirement and local and mix species of
plants may be selected for the green belt.

(b)

Monitoring of stack emissions, fugitive emissions, trade

effluent and noise level shall be done as per CPCB
regulations.

(c)

Pollution control systems shall be operated as an integral part

of production to ensure minimum emissions. Pollution Control
System shall start before conveyor operation/operation of
plant. Similarly pollution control system shall be stopped only
after completion of conveyor operation/operation of plant so
that possibility of dust settlement in ducts can be eliminated.
Continuous evacuation of dust (from Dust catchers, ESPs,
Bag filter hopper etc.) shall be organized.

GUIDELINES (contd..)
11.0 Siting Guideline for Sponge Iron Plants
Siting of new sponge iron plants shall be as per respective
State Pollution Control Board guidelines. However the
following aspects shall also be considered:
(a)

Residential habitation (residential localities/ village) and

ecologically and/or otherwise sensitive areas: A minimum
distance of at least 1000 m (1.0 km) to be maintained.

(b)

The location of Sponge Iron Plant should be at least 500 m

away from National Highway and State Highway.

(c)

Radial distance between two Sponge Iron Plants should

be 5 km for plants having capacity 1000 TPD or more.

(d)

Sponge Iron Plants can be established in designated industrial

areas / Estates as notified by State Govt.

(e)

If any plant/clusters of plants are located within 1 km from any

residential area/ village they may be shifted by State Pollution
Control Board/ State Govt. in a phased manner for which a time
bound action plan is to be prepared by SPCBs.

Specific Recommendation for Industrial

Pollution Control in Chhattisgarh
A. Silatara/Raipur, Raigarh area
1. No new sponge iron plant to be permitted in
Siltara Raipur area.
2. Sponge iron plants shall be permitted in other
areas only after adoption of clean technology
(www.cpcb.nic.in) and installation of WHRB and
AFBC/FBC boiler for char utilization for power
generation.
3. Existing sponge iron plants in Siltara area to be
directed to install AFBC/FBC boiler for use of
char in a time bound manner by Chhattisgarh
Pollution Control Authority.

4. Proper ash management programme to be drawn

giving emphasis' to utilise ash in cement making
etc.
5. Fugitive emission from the sponge iron plants to
be controlled as per CPCB guidelines.
6. Carrying capacity study in Siltara industrial area
to be conducted specially to see the impact of
industries in Raipur city.
7. Integrated steel plants in Chhattisgarh to follow
the emission standards notified under EP Act and
CREP guidelines.

8. Toxic emission (PAH, VOC etc) from Coke Oven

plants to be controlled as per CPCB guidelines.
9. Slag generated from steel melting shop (SMS) to
be properly managed.
10. Blast Furnace Slag to be sent to cement plant for
utilization.
11.
install

Non recovery coke oven plants should

WHRB for power generation.

12. Iron ore mining industry should follow strictly the

standard and guidelines of CPCB.

B. Korba Area
1. In Korba area large number of coal based power
station are being setup.
Based upon regional environmental impact study the
requirement of SO2,Nox and Mercury emission control
to be studied.
2. Ash utlisation plan should be drawn with all stake
holders for proper ash management following may
be considered.
Use of benefeciated coal for power generation.
Dry collection of ash for cement making.
Cement grinding unit to be located close to power
plant to utlise ash.
Power plants to be encouraged to setup their own
cement plants for utilization of ash.
Clean coal technology to be promoted.

3. For Aluminium plant the secondary

emission of fluoride to be controlled to
meet the total fluoride emission as 0.8
Kg/ton.
4. Spent pot lining which is hazardous waste
to be disposed as per Hazardous Waste
Management Rules and carbon portion
may be utilise in cement plant as partial
fuel.

C. General Issue
1. Thick Green Belt to be planted between Raipur and Siltara to
prevent the fugitive emission from industrial area to Raipur
city.
2. In Siltara industrial area all the Kaccha road to be cemented.
3. Continuous Air Quality Monitoring Station to be setup at
Siltara, Raipur, Raigarh, Korba and other industrial area
jointly by industries and data to be displayed in SPCBs
website.
4. TSDF facility should be setup immediately in Siltara/Korba
area for disposal of Hazardous wastes.
5. Chhattisgarh Pollution Control Committee may
initiate
Ambient Air Quality Monitoring based upon new draft Ambient
Air Quality Standards.

Case Study
M/s. Vinayak Steels, Mahaboobnagar District (100 TPD):
This industry was inspected and made the following
observations:

This industry has provided Emission Control Equipments to all the

sources including fugitive emissions by concealing the following
areas
Screen house
Crusher house
Stock house
Intermediate bin
Product house
Central Burner platform
Cooler discharge building
Belt conveyors
Raw material & Finished product handling
Waste products handling.

PROCESS (Coal Based)

Basic raw materials, for the production of Sponge Iron,
are hematite (Fe2O3), coal (C) and dolomite (CaO &
MgO). These three raw materials are crushed and
screened to a size fraction of 5 to 18 mm and -5mm.
These sized material is fed in to the rotary kiln through
feed tubes.
The rotary kiln is a cylindrical structure with 3 meters
diameter and 42 meters length, the entire kiln is divided
into 7 zones and each zone is provided by a shell air
fan.

PROCESS (contd.)
These fans pump the air in to the kiln which is
necessary for the process.
The kiln is Horizontal, and is supported by support
rollers and is rotated by an Electrical Motor of 100 HP.
The raw materials take 8 to 12 hours to travel from the
feed end to the discharge end, during this travel ore gets
heated up in first 3 zones and starts reduction from the
4th zone onwards.
Finally at 7th zone the reduction will be completed and
the hot sponge Iron at 900 to 1000o C falls into the
cooler through transfer chute.

Some fine coal from the discharge end is also injected

to maintain the temperatures of the outlet zones, which
is necessary to keep the reduction, alive.

PROCESS (contd.)
Reactions involved in Process:
3Fe2O3 + CO
Fe3O4 + CO
FeO + CO

2Fe3O4 + CO2
3FeO + CO2

Fe + CO2

The material which enters into the cooler gets cooled

with the help of indirect cooling. After cooling the
material discharges at 100oC from the cooler, this
material is further processed in the product house and
pure magnetic Sponge Iron is taken out.

Constituents of Sponge Iron

Total Iron (Fe T)

85 to 90 %

Metallic Iron (Fe M)

75 to 85 %

Carbon (C)

0.03 %

Sulphur (S)

0.02 %

Phosphorous (P)

0.02 %

FeO is calculated from Fe M & Fe T

Metallisation is derived from Fe M & Fe T

Gangue comprising of SiO2, Al2O3, and etc. is Calculated from

the above given information.

Non Magnetics.

Effects of various constituents of

Sponge Iron in production of steels
Lower Total Iron

Lower Metallic yield

Higher Slag generation
Higher energy consumption
Higher tap to tap time
Higher metallic Iron

Higher metallic yield (steel output)

Lower FeO content
Lesser slag generation
Lower energy consumption per unit of steel
produced.
Higher Productivity

Effects of various constituents of

Sponge Iron in production of steels
Higher carbon

Adequate carbon boil

Deoxidization
Reducing FeO
Higher yield
Sulphur

Sulphur in Iron Ore and coal used for the

production of Sponge Iron is directly
proportional to the Sulphur content in Sponge
Iron.
Sulphur is injurious to steel. Therefore,
Sulphur content in Sponge Iron should be as
low as possible.

Effects of various constituents of

Sponge Iron in production of steels
Phosphorous
Like Sulphur, Phosphorous content in steel should also be low.
Iron Ore and coal with low S & P should be selected for the
production of Sponge Iron.
Higher FeO
Erosion of acid lined refractory
Lesser lining life
Oxidation of bath
Higher consumption of Fe alloys
Higher requirement of carbonaceous material
Loss of Fe in slag
Excess boiling of the bath
Higher cost of production
Restricting usage of other low grade scrap

Effects of various constituents of

Sponge Iron in production of steels

Metallization
Metallization is a derived figure, which is a ratio in percentage of
Metallic Iron divided by Total Iron. Higher the metallization,
higher the metallic iron, which results in higher productivity.

Higher Gangue content

Delays during melting
Higher tap to tap time
Higher energy consumption
Higher lining erosion
Lesser yield
Hazardous working
Lesser productivity

Effects of various constituents of

Sponge Iron in production of steels

Non-Magnetics
Non Magnetic comprises mainly of char
material. Char does not have any positive
contribution. It generates slag and reduces
the yield.

CLEANER PRODUCTION
TECHNOLOGY OPTIONS

Cleaner Production in Sponge Iron

For implementation of Cleaner Production options
the commitment and willingness of top management
is a must without this it may be very difficult to
implement the CP Options. At times people have
commitment but due to lack of knowledge and
manpower the goals in implementing the CP Options
may not be possible.

Energy Audit
Pollution Control
Management of waste products
Pre- Heating of Iron Ore

Energy Audit
Energy Audit to find out areas where fine tuning of the
Voltage (V), Current (C) and Power Factor (PF) are
required to be carried out.
In Sponge Iron industries, induction motors consume
around 90% of the electricity used. Even a small
increment in the efficiency of these motors can result in
substantial savings which can be possible by adopting
1. System Power Factor should be increased by
connecting proper capacitors
2. Variable frequency drives to be installed
3. Shedding of non-essential loads. Ex:- Lighting, Idle
running of the motors (screen, crusher and product
circuits) and pumps (water circuit)

Pollution Control

Main sources of Air Pollution

Process
Installing of control equipments ESP, GCT,
DSC, Bag Filters and Scrubbers.

Raw Material, Finished Product & Waste

Products