With the then state of art technology
7 M Tall Coke Oven Battery
--Vizag
3200 cum Blast Furnace (still biggest in the country)
Steel
100 % Continuous Casting (Only plant in India)
---- A Systematic & Integrated Approach
WATER SUPPLY & DISTRIBUTION FEATURES IN VSP
Complete Water Audit
Cost Economics at every step
! Kanithi Balancing Reservoir (KBR) with 12 Million Cu.M storage capacity for 100 days requirement. ! 250 KM length of industrial water and F & D water pipeline network.
Technological Discipline
Periodic Review of all steps
! Combined recirculation rate of 1,55,000 Cum/hr with 3600 cum/hr of Make up water addition. ! 30 pump houses, 8 treatment plants, 4 Overhead
Complete Chemical Treatment
tanks, 22 cooling towers, 10 Sewage pump houses, STP & ETP. ! 12 Recirculation systems under chemical treatment
Freezing end user Spec
Cascading use of Blow Down Converting WW to MUW grade
Total Water Management
TOTAL WATER MANAGEMENT IN VIZAG STEEL
WATER WASTAGES IDENTIFIED S No
Water Audit: A complete water balance: – a) Intake water – b) Process consumption, Evaporation etc. – c) Process-waste: Blowdowns, Leakages, Overflows, once thro etc. – d) Boundary outfalls: Effluents.
Source
QTY. IN M3 / hr.
1
SMS-GCP Water wastage at TP-3
350
2
Fresh Water Usage in SMS Slag Yard
50
3
BF-SGP overflow water
80
4
TPP filter backwash water
30
5
TPP Acidic Effluents
100
6
GCP- Sludge water
200
7
Pump House 28 Filter back wash Water
20
8
Pipe line leakages and wastage in buildings etc
400
9
.CoCCP-CDCP overflows from HRWPH
60
10
Cooling Tower Drift losses
200
11
Sec. Spray – Once Through wastage
250
12
Town Ship Excess water Consumption TOTAL
200 1940
TOTAL WATER MANAGEMENT EFFORTS (in last 2 years)
Total Water Management Freezing End User Specifications:S No
Source
!Equipments supplied long back- Water Quality Requirements no longer matching with latest trends in Water treatment.
1
2 3
!End User Water Quality parameters redefined, e.g.:- ASP, TPP, BF-GCP, SMS-GCP etc.
M3 / hr.
SMS-GCP Water wastage at TP-3 – Recycling introduced
BF-SGP overflow water – Recycling introduced.
!Package Air Conditioners > 5 TR water to nearest CTs. !Water from all sample coolers to nearest CTs.
TPP filter backwash water – Recycled
30 100
Recycling of sludge water to Ash pond – Zero Makeup for Ash handling
1
Recycling of Secondary Spray cooling water in SMS 250 Cu M/hr.
2
Recycling of Township Sewage Treatment Plant Water 250 Cu M/hr.
3
Additional Treatment facilities in SMS water system
4
MBC Plant Effluents
Value
Remarks
2.96 Crores
5 Crores
Under process (AMR)
60 890
SPECIAL CHEMICAL TREATMENT " Improved COC of R.C. Systems from the range of 2 – 3 to 4 – 5.5. " Reduction in blow down water by 1500 cu.m/hr. " 12 recirculation systems under special chemical treatment . " Rs 8.6 crores savings through water conserved every year. " Scaling, Corrosion, MicroMicro-biological fouling, Nozzle chockages, chockages, GCP performance etc are kept under strict control.
SMS – SECONDARY SPRAY WATER SYSTEM •
• • •
2.08 Crores
20
10 .CoCCP-CDCP overflows from HRWPH - Recycled
•
4.6 Crores
200
Pump House 28 Filter back wash Water Recycled
PRESTIGIOUS WATER CONSERVATION MEASURES S. No. Source
80
TPP Acidic Effluents – Sent To Ash Pond
TOTAL
!Power Plant CT Blow Down Water to Ash Slurry Pump House (300 M3/Hr) !Oxygen Plant CT Blow Down Water to SMS (45 M3/Hr) !Chilled Water Plant CT Blow Down Water to Rolling Mills ( 30 M3/Hr )
50
water
5
7
CASCADING USE OF BLOW DOWN WATER
350
Water saving in Slag Yard by using Secondary Spray
4
6
!Quality and Process Efficiency kept in mind
QTY. Saved in
System strengthened, heavy pipe deposits cleared by chemical cleaning. High rate deep bed filtration oil skimmers and chemical treatment for recirculating water has been introduced. Saving = 250 cu.mtr/hr. of water Cost of Implementation : Rs. 3 Crores Commissioned : June ‘04
RAIN HARVESTING PROJECTS
RAIN WATER HARVESTING PROJECT
Vizag Steel has implemented Rain Harvesting measures in a big way as mentioned. • Masonry Check Dams - 9 nos. • Percolation Pits - 94 nos. • Earthen Check Dams - 1 no. • Recharge Wells - 18 nos.
INNOVATION #INTRODUCTION OF ULTRA FILTER IN SEWAGE WATER SYSTEM #FIRST OF ITS OWN KIND IN STEEL INDUSTRIES IN INDIA
ULTRA FILTER SKIDS
TOWN SHIP SEWAGE SYSTEM
• A tertiary treatment scheme has been worked out with a clarifier, multi grade filter, ultra filtration and two-stage chlorination using Electro chlorinator. The treated water shall be used in Rolling Mills and steel melt shop. • Savings: 250 Cu.Mtr/Hr • Cost of Implementation: 4.6 Cr. (approx.) • Target : End March ’05(work under Progress)
Total Water Management Technological Discipline:1) Reduction in Township Water Consumption - By mass Awareness 200 CuM/Hr 2) Repair of Cooling Tower Drift Eliminators- 200 CuM/Hr 3) Repair of U/G pipes, fixing of float valves & press type valves, orifice plates etc. - 400 CuM/Hr 4) Annunciation systems for system abnormalities strengthened. 5) Introduction of Automation in remote areas. 6) Training on Water Conservation & Waste Management included and imparted at T & DC.
COST BENEFITS ( RECURRING)
BENCHMARK
IN LAST TWO YEARS ON ACCOUNT OF WATER CONSERVATION
$ Foremost in water conservation among the steel producers in India.
" Reduction in make up water cosmn.
$ Comparable in Specific water consumption with the major steel producers in the world.
" Savings in energy by way of reduced pumping hours
3.0 CuM/TLS against 3.52 CuM/TLS of Pohang Steel Works, S.Korea & 3.43 CuM/TLS of Gwagyonk Steel works in S.Korea.
" KBR storage increased by 25% with respect to plant consumption.
Sp.Water Consumption per Ton of Liquid Steel
12
SPECIFIC WATER CONSUMPTION 10.7
10
Bench Mark < 2.5 7.8
8
6.33 6
4.88 3.96
4
3.31
2.76
2 0 98-99
99-00
00-01
01-02 Year
02-03
03-04
-- Rs 14.0Crores
04-05
-- Rs 5.0 Crores
" Reduction in effluent discharges. " Amount invested in water conservation measures during 2002-03 " Amount invested during 2003-04
$ To achieve and maintain specific water consumption at less than 2.5 CuM/TLS.
-- 1800 CuM/Hr
-- Rs 30 lakhs -- Rs. 300 lakhs