Management of Wastes: DR - Kishore Chenna Asst. Gen - Manager Environment Mgt. Dept

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
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%

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

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MANAGEMENT OF WASTES

DEVELOPMENT WHICH MEETS

Global Environmental Issues

Steel production and environment

3-4 T Raw Materials

4-10 Cu. M Water

1-2 T solid wastes

What does it mean ?

Steel production and environment

It means that a ton of steel:

water equivalent to daily consumption of 200 people

What is waste minimization ?

It is a new and creative way of thinking

It is achieved by continuous application of

NEED FOR WASTE MINIMISATION

To reduce the consumption of process inputs like raw material,

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

BENEFITS OF WASTE MINIMISATION

TYPICAL CAUSES OF WASTE

Poor Process / equipment design

WASTE MINIMISATION TECHNIQUES

Film on Consumerism and Waste

SOLID WASTES (Resources) AT VSP

AIR POLLUTION CONTROL

Bag house in RMHP

Air Pollution Control (DE) Systems in VSP

Note: Data excludes ventilation systems in VSP

Dust from DE Systems

Sludges from Water Treatment Plants

Process Solid Co-Products

Status of LD utilisation in VSP

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

Microbial leaching of phosphorous from LD slag

Title: Microbial removal of Phosphorous

Phosphorus reduction was about 40% in lab scale

Microbial removal of Phosphorous

Results were not consistent

Looking for alternative methods

Title: GCP sludge briquetting

Briquettes were made using GCP sludge

96 tons of briquettes were produced during

No adverse effects were observed

GCP sludge briquetting

38 tons briquettes were produced and used

Title: Briquetting of Metallurgical Waste

Research partner: IMMT , Bhubaneswar

8 types of wastes were used in different

Title: Briquetting of Metallurgical Waste

Iron ore fines

Mini pond sludge

Title: Briquetting of Metallurgical Waste

Making of briquettes is under progress