Sources of Pollution

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Sl.No. Units Operation Emission released/ Waste generated Types of Pollution 1 Raw Material Handling

Stock piling, crushing, screening, conveyor transfer & charging, etc Temperature: Ambient - Fugitive Dust emission - Noise - Air - Land - Noise 2 Induction Furnace & LRF treatment Charging, melting, de carb. de-phos ,etc followed by LRF treatment - CO, NO2, SO2 - Dust - Slag - Air - Air /land -Land - solid waste

3 CCM Plant Casting of liquid steel into solid billets,

- Steam - Scale, grease & lubricant in hot water - Cooling water (closed circuit) - Tundish slag - Air / thermal - Water / land - Thermal 4 (2 x 90TPD) Kiln for Sponge Iron

Reduction of Iron Ore CO, NO2, SO2

Char Ash

Air / thermal Noise

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The existing flue gases from the kiln arrest in ESP, the stack height of ESP is 30 m. The same setup will be installed after installation of additional 1 x 90 TPD kiln.

Fumes generated in the Induction Furnace shall be captured through a roof mounted suction hood which will be of swiveling type. Provision for secondary emission control from IF during charging/tapping will be provided by side hoods.

Similarly, fumes generated in the LRF shall be captured through an overhead/side hood.

The gases from the Induction & LRF shall be mixed before passing through Spark Arrestor to catch any burning particle before entry to Pulse Jet Bag Filter provided for dust cleaning purpose. Due to ingress of ambient air into suction hoods of Induction furnace and LRF and forced draft coolers, the temperature of the gas before inlet to Bag filter shall be around 140deg C. The bag house shall be efficient for filtration of dust by high pressure compressed air pulses. Dust content in the exhaust air shall be limited to 50mg/Nm3 _{or less.}

Dust collected in the Spark Arrestor & Bag House shall be transported to an overhead storage bin through screw conveyors and bucket elevator. The discharge end of dust storage bins shall be provided with air lock valves. A pug mill shall be provided for converting the dust to pellets/balls for further handling & disposal.

The clean & cool gas from the bag house shall be exhausted through a chimney by an Induced draft (ID) fan. The height of the self supporting chimney shall be 30 m and will be provided with lightning arrestor, aviation lightings, and stair ways with provision of measuring dust level in the exhaust gas.

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Another bag filter system has been provided for dust and fumes generated in ladle repair shop and raw material handling area.

(A) Air Pollution Control

Table 2.11: Existing & Proposed Pollution Mitigation System Existing

(90 TPD Kiln) ESP

with stack height- 30 m

Proposed

(2 x 90 TPD Kiln) ESP

with stack height- 30 m Particulate Matter concentration in discharged gases will remain <50 mg/Nm3

2 x 12T Induction Furnace and LRF)

Primary & Secondary emission Bagfilters, with stack height-- 30 m

Particulate Matter concentration in discharged gases will remain <50 mg/Nm3

Material handling area Dust extraction/ dust suppression system

The measures to control the air pollution will ensure the ambient air quality standards as laid down by Central Pollution Control Board (CPCB) for industrial and mixed-use areas.

The systems proposed for the air pollution control will provide acceptable environment condition in the working areas. The technological equipment and process have been selected with the above objective. However, the ambient air pollution in the surrounding area will depend on other industries in the area. Depending upon the quality of emission from different sources, suitable air control systems will be provided.

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Noise is generated from drives, fans, compressors, vibrations from rotating machines and from furnaces. Noise level shall be 75dB (A) maximum at 1 m distance from the noise emitting unit.

Many operations in the plant will produce objectionable level of noise, which may not be practicable to eliminate entirely, but in most areas it can be brought down to the acceptable level. Various measures proposed to reduce the noise pollution include reduction of noise at source, provision of acoustic lagging for an equipment .Some areas where due to technological process, it is not feasible to bring down the noise level within acceptable limits, personnel working in these areas will be provided with noise reduction aid such as ear muffler and also the duration of exposure of the personnel will be limited as per the norms.

Guidelines for Noise Control Measures are:

• Providing insulating caps and aids at exit of noise source on the machinery.

• Using material like thin rubber or lead sheets to wrap work places like, DG sets etc.

• Adopting efficient flow techniques for noise associated with high fluid velocity and turbulence.

• Acoustic sealing, providing shock-absorbing techniques, inlet and outlet mufflers.

• Providing absorbing material on roofs, walls and floors to reduce reflected noise.

• Isolation of noise emitting unit in a separate acoustic proof premises such as in case of compressors, blowers, etc.

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The measures envisaged for water pollution are expected to contain the water pollution as no discharges are anticipated. By adoption of the following schemes in general:

Re-circulation water in the process

Providing adequate treatment units for removal of the suspended and colloidal matter.

Neutralization of acidic water by lime

Treated and cleaned water is then reused for green belt/dust suppression/slag cooling.

(D) Solid Wastes

The char generated from kiln will be sold to power plant operator for using char as a fuel. Slag generated from induction furnace & LRF will be cooled, solidified and crushed to recover steel and balance reused/sold to Contractor for filling of low lying lands, etc. All other dust generated in the plant including raw material handling system and steel plant will be dumped for disposal Steel scraps generated in steel melting shop, continuous casting plant will be recycled for melting.

Extensive pollution control measures have been envisaged for minimizing the dust pollution of the plant. Debris and muck generated in the plant will be collected and dumped in the dumping area for periodic disposal. This point is further elaborated in Table-2.11.

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Table 2.12: Quantity of Solid Waste and their mode of disposal (for