MANAGEMENT OF WASTES

Dr.Kishore Chenna
Asst. Gen.Manager
Environment Mgt. Dept.

Environment
surroundings in which an organisation
operates, including air, water, land, natural
resources, flora, fauna, humans, and their
interrelation
surroundings in this context extend from
within an organisation to the global
system

Environment
SPACE
(aakash)

FIRE
(agni)
AIR
(vayu)

EARTH
(dharti)

WATER
(jala)

DEVELOPMENT WHICH MEETS

THE NEEDS OF THE PRESENT
WITHOUT COMPROMISING
THE ABILITY OF FUTURE
GENERATIONS TO MEET
THEIR OWN NEEDS

Environment Management

Global Environmental Issues

Social responsibility
Health
Economics

INTRODUCTION
INTRODUCTION

Steel production and environment

~ 3-3.5 T CO2
~ 3-4 Kg of SPM
~5 kgs of SO2,NoX etc

3-4 T Raw Materials

4-10 Cu. M Water

~ 1000MJ Energy

1-2 T solid wastes

For every
every ton
ton of
of
For
Steel
Steel
Produced
Produced

1 T of Steel

1-2 Cu M effluent

Affect environment
directly

INTRODUCTION
INTRODUCTION

What does it mean ?

Steel production and environment

It means that a ton of steel:

Requires energy equivalent to 938 litres of petrol
(11,000 km of travel by medium sized car)
Requires

water equivalent to daily consumption of 200 people

Emits CO2 that 210 mature trees will sequester in a year
About 25-30% of input is converted into waste
Also .
Iron and steel industry consumes 15% of the total energy used by
industries
Is responsible for fugitive emissions from handling and storage of huge
amounts of raw materials
Is responsible for emissions of pollutants like, poly aromatic hydrocarbons,
SO2, NOx, VOCs, carcinogens etc
Water pollutants contain organic, inorganic and toxic wastes

WHAT IS WASTE ?
Waste is a useful Material
in a wrong form or in a wrong place
Forms of waste
Defective product
Air Emissions
Waste Water Discharges
Solid Wastes
Hazardous Wastes
Production Loss
Excess Energy
Excess Water consumption
Inefficient use of labour
Inefficient use of raw materials
Unusable/Discarded Chemical Residues

What is waste minimization ?

It is a new and creative way of thinking

about products and the processes which
make them.

It is achieved by continuous application of

strategies to minimize the generation of
wastes and emissions.

NEED FOR WASTE MINIMISATION

To reduce the consumption of process inputs like raw material,

water, chemicals, energy, etc. Which are increasingly becoming
costlier day by day.

To increase competitiveness

To consistently meet the prescribed environment standards.

Easier / simpler treatment of wastes

To reduce waste treatment costs

To reduce capital costs of pollution control systems

To reduce environmental liability costs

To reduce litigation with NGOs and public and improve

relations

with them.

BENEFITS OF WASTE MINIMISATION

REDUCTION IN
Raw material use
Energy Use
Waste Quantity
Capital Costs of new Pollution Control Systems
Waste Treatment Cost
Clean-up costs
Rejects
IMPROVEMENTS IN
Working Conditions
Safety Aspects
Environmental Performance`

TYPICAL CAUSES OF WASTE

Technical causes
* Poor housekeeping
Leaking taps / valves/ Flanges
Spillages
Overflowing tanks
Worn out material transfer belts
* Operational and maintenance negligence
Unchecked water / air consumption
Unnecessary running of equipment
Sub optimal loading
Lack of preventive maintenance
Sub optimal maintenance of process condition
Ritualistic operation
*Poor raw material quality
Use of substandard cheap raw material
Lack of quality specification
Shortages of supply
Improper purchase management system & storage

Technical causes

contd.

Poor Process / equipment design

*
Mismatched capacity of equipment
*
Wrong material selection
*
Maintenance prone design
*
Adoption of avoidable process steps
Poor planning
# Unplanned / adhoc expansion
# Poor space utilization plan
# Bad material movement plan
Bad Technology
> Continuation of same technology despite product / raw
material change
> High cost of better technology
> Lack of availability of trained manpower
> Small plant size
> Lack of information

MANAGERIAL CAUSES
Inadequately trained personnel
Increased dependence on casual/contract labour
Lack of formalised training system/facilities
Job insecurity
Fear of losing trade secrets
Lack of availability of personnel
Understaffing hence work overpressure
Employee De-motivation
Lack of recognition
Absence of reward / Punishment system
Emphasis only on production, not on people
Lack of commitment and attention by top
management

WASTE MINIMISATION TECHNIQUES

RECYCLING
(ONSITE & OFFSITE)

SOURCE
REDUCTION

PRODUCT
CHANGES
- PRODUCT
SUBSTITUTION
- PRODUCT
CONSERVATION
- CHANGE IN
PRODUCT
COMPOSITION
INPUT MATERIAL
CHANGES
- MATERIAL
PURIFICATION
- MATERIAL
SUBSTITUTION

SOURCE CONTROL

USE AND
REUSE
- RETURN TO
ORIGINAL
PROCESS
- RAW MATERIAL
SUBSTITUTE FOR
ANOTHER PROCESS

TECHNOLOGY
CHANGES
- PROCESS CHANGES
- EQUIPMENT, PIPING OR
LAYOUT CHANGES
- ADDITIONAL AUTOMATION
- CHANGES IN
OPERATIONAL SETTINGS

RECLAMATION
- PROCESSED
FOR
- RESOURCE
RECOVERY
- PROCESSED
AS A BY
PRODUCT
GOOD OPERATING
PRACTICES
- PROCEDURAL MEASURES
- LOSS PREVENTION
- WASTE STREAM
SEGREGATION
- MANAGEMENT PRACTICES
- MATERIAL HANDLING
IMPROVEMENTS
- PRODUCTION

Film on Consumerism and Waste

SOLID WASTES (Resources) AT VSP

AIR POLLUTION CONTROL -Wastes.
WASTE WATER TREATMENT PLANT - Wastes
PROCESS WASTES
- SOLID CO- PRODUCTS
- SLAGS
-SCRAPS
- OTHERS
HAZARDOUS WASTES
E WASTE

AIR POLLUTION CONTROL

Total qty. of raw materials handled
: 12 Mt/yr.
Total length of Belt-Conveyors
: 138 km
Huge qty. of dust generation at all transfer points

Bag house in RMHP

Wet scrubber in SP

ESP of GCP in SP

Air Pollution Control (DE) Systems in VSP

Deptt.

Cyclone Scrubber
ESP (dry)
(dry)
(wet)

Bag filter

Total

No. of chimeys
(height)

C&CCD
RMHP
TPP

--25
---

*32
--05

----05

1
18
05

*33
43
15

3flues (180.5m)

SMS

---

---

*02 (CVS)

1-ISBH,
1-IRUT, 1-LF

1 (80m)

BF

02

---

*02 (BHS)
*02(CHES)

04

10

2(80m)
2(100m)

CRMP
ES&F

-----

--10

-----

19
07

19
17

4(52m)
---

SP

---

33

*02(ACP)
*02(GCP)

01

38

2(120m)

WRM
LMMM
MMSM
G. Total

------27

------80

------15

------58

------180

1(45m)
1(87m), 1(40m)
1(80m)
21

Note: Data excludes ventilation systems in VSP

3(120m)

Dust from DE Systems

WATER TREATMENT
80% water uncontaminated recycled
20% treated in treatment plants before recycling

Sl.
No.
1
2
3
4
5
6
7
8

Location
WTP-1:BF-I
WTP-2:BF-II
WTP-3:SMS/GCP
WTP-4:SMS/CCD
WTP-7: Mills
WTP-8: Mills
Met. Sludge shifted
from Mini pond
WTP:CCCD

Type of
solid waste
recovered
Sludge
-do-doMill scales
-do-doBF, SMS
& Mills
Coke sludge

Sludges from Water Treatment Plants

PROCESS WASTES

Process Solid Co-Products

Process Slags

Process Scraps

Process Wastes

ECONOMICS OF
SOLID WASTE MANAGEMENT ( 2008-09)
Total value of wastes recycled / sold :
Total expenditure on operation / maint.:
of P.C. equipment

Rs1153 Cr
Rs.110 Cr

Net gain
Cr

Rs. 1043.6

Turn over

Rs. 10,000Cr

% of turn over

~10.4 %

PROBLEM AREAS

FLY ASH
T P P = 247.5 MW
Coal = 40% ash
Fly ash generation= 1500 t/day (0.52 Mt/yr.)
= 14% of total wastes (3.21Mt/yr)
Dry fly ash storage / delivery project cost= Rs 2.94cr.
Capacity = 3.42 t/hr (silo: 100t)

Status of LD utilisation in VSP

Year

08-09

Generation

Utilisation
SP

SMS

BF

Traffic

Utilisation
CED

Const
Qty

% ut
process
#

328665

46095

647

3669

79

160000

210490

64.05

23.98

327131

77305

1260

2268

775

55

143530

225193

68.84

36.26

06-07

343936

78625

2490

2041

5498

60160

130100

278914

79.84

53.35

05-06

396303

72720

1870

3933

6502

71

85096

21.47

100

04-05

391238

99730

5132

3311

4036

5555

117764

30.1

100

07-08

# process means utilisation in SP,BF,SMS & Traffic and excluding construction

Figures in tons

R & D Initiatives on
Solid Waste Utilization

R&D Projects

Microbial leaching of phosphorous from LD slag

GCP sludge briquetting
Briquetting of metallurgical waste

Title: Microbial removal of Phosphorous

Research partner: IMMT , Bhubaneswar
Objective: Improve the recycling of LD slag
Stage - 1
1 ton lab scale experiment was conducted at IMMT, Bhubaneswar

Phosphorus reduction was about 40% in lab scale

Microbial removal of Phosphorous

Stage - 2
3 Experiments were conducted on 5 ton industrial
scale at VSP

Results were not consistent

Looking for alternative methods

Trial 1

21%

Trial 2

4%

Trial 3

11 %

Title: GCP sludge briquetting

Research partner: Internal
Objective: Usage of SMS-GCP sludge as a
replacement of sized Iron ore in
Converter

Briquettes were made using GCP sludge

96 tons of briquettes were produced during

industrial trial and used in converter

No adverse effects were observed

GCP sludge briquetting

38 tons briquettes were produced and used

in SMS as a replacement of sized iron ore.
No adverse effects were found
It has been decided to use them on regular
basis

Title: Briquetting of Metallurgical Waste

Research partner: IMMT , Bhubaneswar

Objective:
Industrial trial run to study the
suitability of briquette made from Solid
Metallurgical wastes

8 types of wastes were used in different

proportions for making briquettes

Title: Briquetting of Metallurgical Waste

Coke sludge

10%

Coke dust

5%

Iron ore fines

20%

BHS dust

10%

Flue dust

5%

Mini pond sludge

20%

GCP sludge

10%

Mill scale

20%

Title: Briquetting of Metallurgical Waste

500 kg Briquettes were made on Lab scale
Industrial trial of 500 T briquettes is to be conducted in Blast
Furnace after making the metallurgical waste briquettes.

Making of briquettes is under progress

After successful completion of industrial trial the same will be
implemented on regular basis

HAZARDOUS WASTES

Hazardous waste means

any
waste
which
by
reason of any of its
physical,
chemical,
reactive,
toxic,
flammable, explosive or
corrosive characteristics
causes danger or is likely
to cause danger to health
or environment, whether
alone or when in contact
with other wastes or
substances
and
shall
include wastes included
in Schedule 1, 2 & 3 of
the said rules.

HAZARDOUS WASTES
Hazardous Wastes practices at VSP

OTHER WASTES

ITEMS DEALT IN DISPOSAL STORES

1. ALUMINIUM SCRAP
2. AUTO SCRAP
3. BEARING SCRAP
4. BRASS SCRAP
5. CI SCRAP
6. CONVEYOR BELT SCRAP
7. COPPER SCRAP
8. CS SCRAP
9. ELECTRICAL SCRAP
10. EMPTY GUNNY/HDPE BAGS SCRAP
11. EMPTY MS/PLASTIC DRUMS AND CANS(Detoxified)
12. GI SCRAP
13. GP/GC SHEET SCRAP
14. MS SCRAP
15. PLATIUM SCRAP
16. RADIATIOR SCRAP

ITEMS DEALT IN DISPOSAL STORES

17. RUBBER SCRAP
18. SGCI ROLL SCRAP
19. SS SCRAP
20. STEEL ROLL SCRAP(BROKEN/UNBROKEN)
21. TC SCRAP
22. TELECOM SCRAP
23. TYRE SCRAP
24.USED ALUMINIUM/COPPER CABEL SCRAP
25.USED ALUMINIUM/COPPER CABLE SCRAP
26.USED BATTERIES
27.USED COMPRESSORS
28. USED LUB/TRANSFORMER OIL
29. USED PALLETS
30.USED REFRACTORY BRICKS
31.USED X-RAY FILMS
32. USED/DISCARDED EQUIPMENT/VEHICLES
33.WOODEN SLEEPER SCRAP

ITEMS DEALT BY EnMD

1.
2.
3.
4.
5.
6.
7.

POLYETHENE WASTE
BOTTLES
ELECTRICAL WASTE
RUBBER RELATED WASTE
OIL/GREASE SOAKED COTTON
E-WASTE
PAPER WASTE

THANK YOU