Water plays an important role for the operation of

the factory. Different units of the factory require proper water circulation to be in process. Hence proper resource management is taken into consideration to assure conservation of the resource.

 Blast Furnace Stove

Gas Cleaning Plant

Power Plant Raw Material Handling System

Steel Melting Shop

 Water is an important resource and should be

used wisely. Hence even the waste water should be recycled to avoid its scarcity and lower down the company`s investment on it.
This requires ETP( Effluent treatment process),

which needs a plant to be setup where water is made pure enough through a series of process so that it can be used for different purpose. This will also help the factory to overcome its loss mainly in iron ore washing sector.

 Although proper precautions have been taken to

minimise discharge of water but still ZERO DISCHARGE is a problem for the factory. Eg:

 Utilisation of water resource on the plant other

than its uses in different units . This includes the drainage water. It can also be recycled and used for different purposes.

 The boiler in the DM plant has to be maintained at a

certain temperature. Hence requiring a cooling system to do so. But there might be LINKAGE PROBLEM in the pipelines due to some leakage.
ION EXCHANGE- during regeneration of DM plant,

waste water produced can be recycled for further use.

ETP can play a good role here to minimise the loss.

 Due to evaporation concentration of

impurities/dissolve solids take place.

Hence part of water has to be removed to control

the COC( Cycle of concentration ) of impurities and dissolved solids in water.

ETP can help to reclaim that water.

 PCM- Pig Casting Machine waste water

The pig iron produced in the blast furnace has to

be moulded/casted in a given shape.

Thus water has to be sprayed to cool it down and

cast it into the desired shape. Hence loss of water takes place.

 The waste product slurry of the GCP( Gas Cleaning

Plant ) contains water . This water is also wasted along with the mixture of dust particle and chemical(polyelectrolyte) present in semi solid form.

 During rainy season, mud gets mixed along with

the IRON ORE. Hence water has to be used to remove the mud from the ore . But there being no recovery system for this sprayed water, results in a 100% loss of it.
Here ETP is a good measure for water recovery

and will help the factory to control its expenditure on it.

 The discharged water termed as EFFLUENT , from

the above process can be treated and made pure enough to be used for different purpose.
Its a process used world wide to reclaim this

discharged water. Although setting up this plant requires a huge investment but ROI(return of investment) is good enough allowing a factory to implant this and get over its losses due to the loss of water. Our main attention being on the loss in IRON ORE WASHING.

 Effluent treatment process involves various steps

Clarifier Ph NeutralisIng pit air blown Aeration tank Bacterial Treatment

Collection pit CLEAN WATER

Bio Sludge

 The iron ore comprises of Fe2O3 , Fe3O4(Oxides)

and mud, silt, suspended solids.

These impurities have to be removed from the ore

before it can be put into use.

The water spray system helps us in accomplishing

our job. This processed water or the washary water is Reddish brown in colour due to iron ore contaminations .

 Anionic polyelectrolyte is used in the chemical

treatment of this processed water.

Polyelectrolyte added Overflow water Process water Hopper PUMP Clean water

Dirty water( Sludge water )

 The clean water obtained can be put into various use.

It can be again used for iron ore washing, or

Clean

pH

water

correction pit

PSF

MGF

DM water Iron ore washing Drinking water

source

PSF- Pressure Sand Filter MGF- Multi Grade Filter

 The ETP helps us in reclaiming used water as well

as it brings a hold on company`s investment.

The ROI when calculated proves to be in favor of

planting ETP.
Let the efficiency be taken as 90%

 180 m3 of water consumption takes place/ day for total

ton of iron ore handling/day without ETP plant.

So with 90 % efficiency in ETP, 18 m3 of water will be

used/day.
Let 0.5 ppm polyelectrolyte be used on flow rate.
(0.5 * 180)/1000 = 0.09 Kg/ day poly consumption

Now let the poly cost be Rs 150/ Kg Hence total cost of poly used/ day = 150* 0.09 = Rs 13.5/ day

 If cost of water be Rs 2/m3 and as stated

consumption be

180 m3/day,

total cost=Rs 360/day

ETP plant cost = Rs 5,00,000 ( One time investment ) Now, if plant life is 25 yrs, the ROI for this period has to be

calculated.
Hence water cost( without planting the ETP ) for 25yrs if iron ore

washing take place for 3 months in a year = Rs ( 360 * 90 * 25 ) = Rs 8,10,000

 # If ETP is planted:
Poly cost for 25yrs = Rs ( 13.5 * 90 * 25 )

= Rs 30,375
Cost of water taking 90% efficiency of ETP

=Rs ( .1 * 180 * 2 * 90 * 25 ) =Rs 81,000

Hence total cost for 25 yrs = Rs ( 5,00,000+30,375+81,000 )

= Rs 6,11,375

 Hence the ROI in 25 yrs = Rs 8,10,000 6,11,375

= Rs 1,98,625
Hence stating how ETP proves to be beneficial both in

terms of conserving water resource as well to get a hold on company`s loss over it.