Download Status Of Sponge Iron Units In Orissa - Vasundhara

STATUS OF SPONGE IRON UNITSIN ORISSAPrepared by –Environment Conservation Team(Aruna Murthy, Himansu Sekhar Patra)September 2005Vasundhara, E-14, Gajapati Nagar,Bhubaneshwar

STATUS OF SPONGE IRON UNITS IN ORISSAINTRODUCTIONSteel market in India is in a rising phase as infrastructure development has been rightly given highpriority. The secondary sector of steel production has witnessed phenomenal growth in recent years.The steel production through the secondary sectors, which works only 21.39% in 1993-94, has goneup to 35.46% in the year 2001-02. The reasons are:1. Low investment2. Ability to produce quality steel economically through this process3. Availability of Sponge Iron both in quality and quantity, which is a major raw material forsecondary steel makers.In the secondary sector, the steel production is mainly by EAF and induction furnace. Inductionfurnace route is gaining importance due to low investment cost and ability to produce quality steelat lower cost. A number of induction furnace units have been established with varied productioncapacity. With the increasing demand of sponge iron as the major raw material for the secondarysteel makers, there is mushrooming growth of sponge iron units in the country, particularly in theeastern side. All of them have opted for coal based plants having rotary kilns.The process of sponge iron making aims to remove oxygen from iron ore. When that occurs, thedeparting oxygen causes micro pores in the ore body making it porous. The final product, whenobserved under a microscope, resembles a honey comb structure, looking spongy in texture, hence,the name “Sponge Iron”RAW MATERIALS REQUIREDSponge Iron manufacture is highly sensitive to raw material characteristics. Therefore, it is essentialto examine the chemical and physical characteristics of raw materials, both individually and incombination. The basic raw materials for the production of Sponge Iron are iron ore, non-cokingcoal, and dolomite.Coal: Important factors determining coal quality are:1. Chemical properties such as fixed carbon, ash-content, volatile material, etc.2. Physical properties such as reactivity, and ash-fusion temperature.

Iron Ore: In sponge Iron making, iron ore is reduced in solid state. Unlike in the conventional steelmelting process, the gangue content of iron ore cannot be separated as a slag. Therefore, it becomesimperative to select an iron ore with a high iron content and a low gangue content, to optimize yieldduring steel making. Apart from this, to ensure a better kiln campaign life and output, iron ore ismade to undergo a series of other tests such as – Shatter, tumbler and abrasion indices, reducibility,etc.Dolomite: It acts in the processes as a Desulphuriser removing sulphur from the feed mix duringthe reduction process. It is mixed in small proportion along with other raw materials beforecharging into the kiln.TECHNOLOGY INVOLVEDProduction of Steel through the conventional blast furnace requires coking coal of which India haslimited reserves. Therefore, evolution of a technology for the reduction of Iron Ore usingabundantly available non-coking coal was contemplated, giving birth to direct reduction IronTechnology (DRI).PROCESS

Iron ore (Hematite) and non-coking coal are the prime raw materials for the production of spongeIron. These are charged into a rotary kiln in a requisite proportion along with some dolomite. Coalplays a dual role in the process by acting as a reductant as well as a fuel for providing heat tomaintain the requisite temperature inside the kiln at 950-1050°C. The reduction process occurs inthe solid state. The crucial factor in this reduction process is the controlled combustion of coal andits conversion to carbon monoxide to remove oxygen from the iron ore. The overall process requiresa duration of approximately 10-12 hrs inside the kiln, during which iron ore is optimally reducedand discharged to rotary cooler for cooling below 120°C, before coming out into the finishedproduct circuit.

EXISTING SPONGE IRON UNITS IN ORISSASl. NoList of Sponge Iron Units in the state of Orissa as on 28.02.2005Name and LocationSUNDERGARH DISTRICT1 Agrasen Sponge (P) Ltd, Mandiakudar, Sundergarh2 Bajrang Ispat Pvt. Ltd, Kuarmunda, Sundergarh3 Govindam Project, Kalosihira, Kuarmunda, Sundergarh4 Jagannath Sponge Pvt. Ltd, Kuarmunda, Sundergarh5 Jai Balaji Jyoti Steels Ltd., Tainser, Lathikata, Sundergarh6 Jay Iron and Steels Ltd, Balanda, Sundergarh7 Kalinga Sponge Iron Ltd., Kalunga I.E. Sundergarg8 Khaderia Ispat Ltd., Kuarmunda, Sundergarg9 Maa Tarini Industries Pvt Ltd, Balanda, Sundergarh10 Mangalam Ispat Pvt Ltd, Usra Road, Kuarmunda, Sundergarh11 Meta Sponge Pvt Ltd., Kalinga I.E.Sundergarh12 Neepaz Mattaliks Pvt Ltd. Hariharpur, Kuarmunda Sundergarh13 OCL India Ltd.(Sponge Iron Division) Rajgangpur, Sundergarh14 Pawan Jay Sponge Iron Ltd., Bijabahal, kunjaharia, SUndargarh15 Pooja Sponge Iron Ltd., kalunga I.E. Sundergarh16 Prabhu Sponge Iron Pvt Ltd., Jhagarpur, Rajgangpur, Sundergarh17 Reliable Sponge Pvt Ltd. Jhaliaberina, Bonan Sundergarh18 Rexon Strips Ltd, Kumakala, Sundergarh19 Scan Sponge Iron Ltd., Ramabahal, Rajgangpur, Sundergarh20 Scan Steels Ltd.(Sponge Iron Division), Ramabahal, Rajgangpur, Sundergarh21 Seeta Sponge Iron Ltd, Kalunga I.E.Sundergarh22 Sri Balaji Metallics Pvt Ltd., Kharibandh, Sundergarh23 Sri Ganesh Metallics Ltd., Kuarmunda, Sumdergarh24 Srishti Ispat Ltd.(Sponge Iron Division), Bringatoli, Sundergarh25 Sponge Udyog Pvt.Ltd, Kalunga, Sundergarh26 Sri Mahavir Ferroalloys Pvt.Ltd., Kalunga I.E. Sundergarh27 Suraj Products Ltd., Barapali, Kesarmal, Rajgangpur, Sundergarh28 Swastik Ispat Pvt Ltd, Kuarmunda, Sundergarh29 T.R.Chemicals Pvt Ltd., Barapali, Kesarmal, Rajgangpur, Sundergarh30 Utkal Metalliks Ltd, Kalunga I.E., Sundergarh31 Veda Vyas Ispat Pvt.Ltd., Kuarmunda, SundergarhKEONJHAR32 Aditya Sponge and Power Pvt Ltd., Telkoi, Dubulpal, Keonjhar33 Beekay Steels and Power Ltd, Uliburu, Nalda, Keonjhar34 Crackers India Alloys Ltd. (Sponge) Govardhanpur, Deojhar, Keonjhar

35 Deepak Steel and Power Ltd., Topadihi, Keonjhar36 Grewal Associates, Matkambeda, Barbil, Keonjhar37 Hima Ispat Pvt Ltd., Barpada, Guali, Keonjhar38 Kusum Power Met Ltd., Kutugaon, Chipinda, Keonjhar39 MSP Sponge Iron Pvt Ltd., Haladiaguna, Gohardhanpur, Keonjhar40 N.K.Bhojani Pvt Ltd, Rugdihi, Barbil, Keonjhar41 OMDC Sponge Iron Plant, Thakurani, Keonjhar42 Orion Ispat Ltd, Ramachandrapur, Keonjhar43 Orissa Sponge iron Ltd.palasapanga, Keonjhar44 Rungta Mines (Sponge Iron Division), Karakola, Barbil, Keonjhar45 Sri Ganesh Sponge Iron Ltd., Kutugaon, Keonjhar46 Sri Metallics Ltd., Loidapada, Keonjhar47 Sumrit Metallics Pvt Ltd., Soyabali, Barbil, Keonjhar48 Tata Sponge Iron Ltd., Bilaipada, Joda, KeonjharDHENKANAL49 Scaw Industries Pvt Ltd., I.E., Gundichapada, Dhenkanal,ANGUL50 Shree Metallics Ltd., Amalapada, AnugulJAJPUR51 Surya Sponge Iron Ltd., Kalkala, Budakendua, JajpurMAYURBHANJ52 Shiv Shakti Sponge Iron Ltd., Pandersil, MayurbhanjSAMBALPUR53 Maa Samaleswari Sponge Iron Ltd., Kattarbhaga, Rengali, Sambalpur54 T.R. Chemicals Ltd., Belpada, Bamara, SambalpurJHARSUGUDA55 Bahgavati Steels Pvt.Ltd., Badmal Jharsuguda56 L.N.Metallics Ltd., Siripura, Jharsuguda57 Pawan Sut Sponge Iron Pvt Ltd., badmal, Jharsuguda58 Sri Madhav Ispat Ltd., Siriapali, Parmanpur, Jharsuguda59 SMC Power generation Pvt Ltd, Hirma, Jharsuguda60 SPS Sponge Iron Ltd, Badmal, JharsugudaCUTTACK61 Shiva Metallics, Suniamuhan, Mancheswar, Cuttack

LIST OF SPONGE IRON PLANTS GRANTED CONSENT TOESTABLISH (NOC) As on 14.12.2005Sl. No Name of Industry Location Block District1M/s Shisti Ispat Ltd (Sponge Iron Budhakata,Div.)Bringatoli2M/s Sri Mahavir Ferro Alloys Pvt. Kalunga IndustrialLtd.Estate3 M/s Suraj Products Ltd.Barapali, Kesarmal,Rajgangpur4 M/s Mangalam Ispat (P) Ltd.Usra Road,Kuarmunda5 M/s Neepaz Metalliks Pvt. LtdChadrihariharpur,Kuarmunda6M/s OCL India Ltd., (Sponge IronDivision)Kiln No(Capacityin TDP)Sundergarh 2 X 100Sundergarh 2 X 100Sundergarh 3 X 50Sundergarh 1 X 100Sundergarh 5 X 100Lomloi Rajgangpur Sundergarh 4 X 1007 M/s Maa Tarini India (P) Ltd. Balanda, Kalunga Sundergarh 2 X 508 M/s T.R.Chemicals (P) Ltd. Barpalli Rajgangpur Sundergarh 3 X 509 M/s Prabhu Sponge (P) Ltd. Jhagarpur Rajgangpur Sundergarh 3 X 5010 M/s Sree Metalliks Ltd.11 M/s Shiva Metalliks (P) Ltd.12M/s Shree Jagannath MetalliksIndustriesMukundapur,AmalapadaSanuimuhan,MancheswarKhaprakhai,PalaspangaAngul 2 X 100Cuttack 1 X 50Keonjhar 1 X 10013 M/s Orion Ispat Ltd. Ramchandrapur Keonjhar 2 X 10014 M/s N.K.Bhojani (P) Ltd.15 M/s Surya Sponge Iron Ltd.16 M/s Pawanjay Sponge Iron Ltd.Rugudihi, Guali,BarbilBudhakendua,KalkalaBijabahal,KunjhariaKeonjhar 3 X 40Jajpur2 X 401X 100Sundergarh 3 X 5017 M/s Orissa Sponge Ltd. Palaspanga Keonjhar 1 X 35018 M/s Utkal Metalliks Ltd.Kalunga IndustrialEstateSundergarh1 X 501X 4019 M/s Shiva Shaki Sponge Iron Ltd Pandersil, Sukruli Mayurbhanj 2 X 10020M/s Ganesh Sponge MetalliksLtd.Chandrahariharpur Sundergarh 3 X 100

21 M/s Hima Ispat Pvt. Ltd. Barpada, Guali Keonjhar 1 X 30022 M/s Grewal Associates (P) Ltd. Matkambeda Barbil Keonjhar23 M/s Pawansut Sponge (P) Ltd.Badmale,KukurjangaSambalpur2 X 1001X 10024 M/s L.N. Metalliks (P) Ltd Siripura Jharsuguda 1 X 10025M/s Golden Trexim (P)Ltd.(Beekay Steels and PowerLtd.)Ulliboni, Nalda Keonjhar 1 X 30026 M/s Khedaria Ispat Ltd Kuarmunda Sundergarh 1 X 5027 M/s Cracker India Alloys (P) Ltd. Gobardhanpur,DeojharKeonjhar 1 X 10028 M/s Sponge Udyog (P) Ltd. Jaibahal, Kalunga Sundergarh 1 X 10029 M/s Sumrit Metalliks (P) Ltd Soyabali, Barbil Keonjhar 1 X 5030 M/s Aarati Steels (P) Ltd31M/s Rungta Mines Ltd., (SpongeIron Division)Ghantikal,AthagarhCuttack 2 X 500Karakolha Barbil Keonjhar 4 X 50032 M/s Agrasen Sponge (P) ltd Mandiakudar Sundergarh 2 X 5033 M/s Bajranga Ispat (P) Ltd.Naikinbahal,KuarmundaSundergarh2 X 401 X 10034 M/s Vedvyas Ispat (P) Ltd Gobira, Kuarmunda Sundergarh 1 X 1003536M/s Sri Ganesh Sponge Iron (P)Ltd.M/s Tata Sponge Iron Ltd.(Expansion)Kutugaon, Chipinda Keonjhar 1 X 100Bileipada, Joda Keonjhar 2 X 37537 M/s Kusum Power Met (P) Ltd Kutugaon, Chipinda Keonjhar38 M/s Meta Sponge (P) Ltd.39 M/s Gobindam Project (P) LtdKalunga IndustrialEstateKalosihira,Kuarmunda2 X 501 X 100Sundergarh 1 X 401 X 10040 M/s OMDC Ltd Dalki, Thakurani Keonjhar 1 X 10041 M/s Puja Sponge (P) LtdKalunga IndustrialEstateSundergarh 1 X 10042 M/s SMC Power Generation Ltd. Hirma Jharsuguda 1 X 30043 M/s Kalinga Sponge Iron Ltd.Kalunga IndustrialEstateSundergarh 1 X 10044 M/s Rungta Mines Ltd. Kamando Sundergarh

45 M/s Scaw Industries (P) LtdGundichapadaIndustrial EstateDhenkanal 1 X 30046 M/s Bindal Sponge Ltd. Sunakhani, Talcher Angul 1 X 30047 M/s Jagannath Sponge (P) Ltd. Kuarmunda Sundergarh 1 X 5048M/s Maa Samaleswari SpongeIron ltd.Katarbagha,RengaliSambalpur 1 X 10049 M/s SMS Sponge Iron Ltd. Badmal Jharsuguda 6 X 10050 M/s Sree Madhab Ispat (P) Ltd Siriapali Jharsuguda 2 X 10051 M/s Swastik Ispat Pvt. Ltd.Naikinbahal,KuarmundaSundergarh 1 X 5052 M/s Jyoti Iron & Steel Ltd. Tainsar, Lathikata Sundergarh 2 X 10053 M/s Nixon Steel & Power Ltd54 M/s Seeta Sponge LtdKalunga IndustrialEstateKalunga IndustrialEstateSundergarh 1 X 350Sundergarh 1 X 5055 M/s Bhushan Steel Telkoi, Rengali Sambalpur 2 X 50056 M/s MSP Sponge Iron (P) Ltd57 M/s Scan Sponge Iron Ltd58 M/s Atcom Metalliks Ltd.Balisuan,Haladiaguna,GobardhanpurRamabahal,RajgangpurGundichapadaIndustrial EstateKeonjhar2 X 402 X 50Sundergarh 1 X 50Dhenkanal59 M/s Agarwal Minerals Rugudi Keonjhar60 M/s Aditya Sponge & Power Ltd. Telkoi, Dubulapal Keonjhar 2 X 10061 M/s Deepak Steel & Power Ltd. Tapadihi Keonjhar62M/s Sumasankar Sponge Iron (P)Ltd63 M/s Ganesh Sponge (P) Ltd.KhuntaketaKrushnachandrapur,ParangKeonjhar64 M/s Bhushan Steel & Strips Ltd. Meramundali Dhenkanal6566M/s Dinabandhu Steel and PowerLtd.M/s Samaleswari Ferro Metals (P)Ltd67 M/s Maa Shakumbari SpongeKalinga Nagar,Industrial GrowthCentre2 X 502 X 100Angul 1 X 100JajpurBisalkhinda, Sasan Sambalpur 1 X 100Naikinbahal,KuarmundaSundergarh 1 X 100

68 M/s Reliable Sponge Pvt Ltd. Jhaliaberena, Bonai Sundergarh 1 X 10069 M/s B.R.Sponge & Power Ltd.Bad-Tumkela,Rajamunda70 M/s Rana Sponge Ltd. Kulei DhenkanalSundergarh 2 X 10071 M/s Maheswari Ispat Ltd. Rampei, Khuntuni Cuttack 2 X 10072 M/s Jay Iron & Steel Ltd. Balanda, Kalunga Sundergarh73 M/s Ores ispat Pvt. Ltd. Gurundipalli Sundergarh74 M/s Balajee Metalliks (P) Ltd. Khairabanda Sundergarh 1 X 5075 M/s Bhagabati Steel (P) Ltd76 M/s T.R.Chemicals (P) Ltd.Kukurjanga,BadmalBelpara, Basra,BonaiJharsuguda 1 X 50Sambalpur 1 X 10077 M/s Rexon Strips Ltd. Kumkela Sundergarh 2 X 10078M/s Scan Steels Ltd.(Sponge IronDiv)Rambahal Rajgangpur Sundergarh 1 X 5079 M/s Sree Metalliks Ltd. Loidapada Keonjhar80M/s Maa Vaishnavdevi SpongeLtd.Kalunga IndustrialEstate81 M/s Vasundhara Metalliks (P) Ltd Podajalanga,Bilaimunda, Himgir2 X 504 X 100Sundergarh 2 X 50Sundergarh 1 X 5082 M/s Singhal Enterprises Hirma Jharsuguda 1 X 10083 M/s B.R.G.Steel (P) Ltd. Kurunti, Puspanga Dhenkanal84 M/s Mahakali Ispat (P) Ltd. Gurundipali, Bonai Sundergarh8586M/s Sree Sai Sradha Steels (P) Bijabahal,Ltd.KunjhariaM/s Bhaskar Steel & Ferro Alloys Bad-Tumkela,Ltd.RajamundaSundergarh 1 X 25Sundergarh 1 X 30087 M/s Surendra Mining Ind (P) Ltd. Bakhamusa, Bonai Sundergarh88 M/s Shyam DRI Power Ltd. Pandloy, Rengali Sambalpur89 M/s Deepak Steel & Power Ltd. Kuliguna, Nalda Keonjhar90 M/s K.J.Ispat Ltd.Jakhapura,KalinganagarIndustrial ComplexJajpur91 M/s Sri Hari Sponge (P) Ltd. Kendrikela, Bonai Sundergarh

92 M/s Shiv Metalliks (P) Ltd. Gurundipalli, Bonai Sundergarh 1 X 10093 M/s Ocean Ispat (P) Ltd. Basantapur, Joda Keonjhar94 M/s Deo Mines& Minerals Thiberna, Bonai SundergarhM/s Maa Samaleswari Industries95Lapanga Sambalpur 2 X 100(P) LtdRaghunathpalli,96 M/s Jai Hanuman Udyog Ltd.Jharsuguda 1 X 100KolihiraKalinga Nagar, Ind.97 M/s Maithan (Mal) Industries Ltd. JajpurComplex, Duburi98 M/s Aryan Ispat & Power (P) Ltd Rengali Sambalpur99 M/s Monica Holdings (P) LtdBad-Tumkela,BonaiSundergarh100 M/s Vishal Metalliks (P) Ltd Barhamusa Sundergarh101 M/s Vikram (P) Ltd. Tumkela Sundergarh102 M/s Action Ispat & Power (P) Ltd Pondaripathor &MarakuttaJharsuguda103 M/s B.R.G. Iron & Steel Co. Ltd. Kurunti, Kuspanga Dhenkanal104 Kaushal Ferro Metals (P) Ltd.Badbahal,KundukelaSundergarh105 R.B.Sponge Iron (P) Ltd. Kenghati, Jayantpur Sambalpur

ENVIRONMENTAL IMPACT OF SPONGE IRON UNITSRight from the raw material yard to disposal of the final product (Sponge Iron), at every step of itshandling there is pollution. Sponge Iron Plants have the following pollution hazards:1. Dust emission during raw material preparation and product discharge and handling:A definite size of iron ore and coal is required for the production of sponge iron. Thesuppliers are not adequately equipped to cater to the needs of the sponge iron industries.Therefore, the industries crush and size the raw materials at their plant premises. Duringsuch crushing and sizing operations, generation of fugitive dust and discarded ore fines andcoal fines in inevitable. Major dust emitting areas include areas such as product dischargefrom cooler to conveying system, magnetic separator, and raw material preparation unit.2. Reduction: The gaseous products of reduction contain mainly raw material dust, and gaseslike CO 2 , CO, H 2 , NO X , O 2 , unreacted hydrocarbons, and SO X3. Waste water discharge: The dusts from the gaseous emissions are separated through ESPor Gas quenching system. In either case, the disposal is done by converting the dust to aslurry form to avoid flying of the same in ambient air. In order to recycle the water, theslurry is allowed to settle in a clari-flocculator, from where the settled solid particles arepumped out. The polluted slurry water is then allowed to settle in settling ponds, or lagoonsfrom where the clear water is pumped back for reuse. Such water is polluted with dissolvedsolids.4. Gaseous emissions: The exhaust gas emerges out of DRI kilns at a temperature of about900°C having some quantities of combustibles. This gas is used to produce steam in wasteheat boilers, which in turn is used to produce power. The dust coming from exhaust gas iseither quenched to make slurry for easy disposal or is collected in dry condition or in wetcondition from the ESP. So far, no utilization of this dust have been found out which causesair pollution (due to dust) in the near by areas.5. Char: The partially burnt coal called char is discharged from the reactor along with spongeiron. After the magnetic separation, the char is separated as waste.PROBLEMS DUE TO SPONGE IRON UNITS IN ORISSAIn many of the sponge Iron Units in Orissa, ESP has not been installed and where it is installed,these units switch off their ESPs during the nights for a few hours. Thus, the area becomes a hugesmoke bowl. In some sponge iron units in Sundergarh, it was found that the precipitators were notrunning in several of the units. Smoke and soot from the plants carried by the wind cause wheezingproblem in kids, and cows and cattle to become restless. The smoke is sometimes so thick thatvision even at a distance as close as 1 meter becomes difficult. The clothes worn by peopleimmediately become smeared with coal dust. Even cooking utensils are covered with soot. InKormunda (Sundergarh) where Neepaz Metallics (a 1.4 lakh tonnes sponge iron plant) is set up, thedrinking water becomes covered with black soot. The emissions also cause irritation and wateringof eyes in human beings.

LEGISLATION, RULES AND REGULATIONS STIPULATED FOR SPONGEIRON UNITS IN ORISSAGovernment of Orissa, Forest and Environment Dept has stipulated the following regulations for theestablishment of sponge iron plants in the state of Orissa.A. In six sensitive blocks (Kuarmunda, Lathikata, Rajgangpur and Bonaigarh block ofSundergarh district, Jharsuguda Block of Jharsuguda District and Rengali block ofSambalpur district) including 25 Km from block boundary –‣ No new sponges iron & integrated steel plant will be allowed.‣ Cases which had been received by the state pollution control board before the Governmentdecided on a prohibition on establishment of sponge iron plants in the state may beconsidered individually un merit. These proposals can be considered on case to case basiswith the condition that they set up a WHRB with a Power plant within 1 year‣ Proposals of establishment of integrated steel plant where MOUs have already been signedwith the state government may be considered on merit‣ Expansion proposals received by the SPCB before the decision on prohibition onestablishment or expansion of sponge iron units was made by the government may beconsidered on merit within a condition to install WHRB and/or steel plant.‣ Expansion of existing plant will be allowed for 25/50 TPD to 100TPD for the purpose ofinstallation of WHRB and power plant.B. Outside the six sensitive zones‣ Cases which had been received by the state pollution control board before the governmentdecision on prohibition to establish sponge iron plant in the state may be considered. Theseproposals can be considered on case to case basis with the condition for installation ofWHRB power plant within 1 year.‣ Cases where MOUs have been signed with the State Government may be considered.‣ Cases other than the above 2 shall not be considered till an environmental impact study ofthe existing units as well as proposed units is done and it is examined by the SPCB inconsultation with steel and mines and industries department.‣ Expansion proposals of existing sponge iron units may be considered to facilitate installationof WHRB with CPP or expansion to integrated steel plant.‣ Proposal for integrated steel plants through DRI route may be considered by sSPCB on thebasis of merit.C. The pending cases (i.e. Proposals received before the Government’s decision on theprohibition on establishment of sponge iron) may be cleared with stipulation of installationof ESP, with separate energy meter, automatic change over to DG set and other pollutioncontrol measures as decided earlier or, recommended by the state pollution control board. Inaddition, explicit stipulation for installation of Waste Heat Recovery Boiler (WHRB) withCPP or upgradation of the unit to steel plant within a period of 1 year from the date of issueof the NOC shall also be made.D. The existing sponge iron units shall be required to install WHRB with CPP within 1 yearand take immediate steps for installing equipments for automatic changeover to DG set incase of power breakdown and for installation of separate energy meter as well as otherpollution control measures as per the direction of SPCB.

MITIGATORY MEASURES – VASUNDHARA’S APPROACH1. Study the utilization of Char as Activated Carbon:It has been found that the reactivity of char is high. So, in some cases, a limited quantity ofchar can be recycled back to the rotary kiln with good results. Char can be used tomanufacture activated carbon and as domestic fuel.2. Study of utilization of Char Fines in Fuel Briquettes formation:The briquettes manufactured from coal char mixed with coal fines are used as a fuel in brickkilns. The rejects and wastes of bricks have been reduced considerably with the use of thesebriquettes, besides reduction of cost of fuel.3. Study of utilization of Exhaust Gas Dust for building bricks:Exhaust Gas Dust can be used for building bricks for construction purposes.4. Establishment of Waste Heat based power plants:Suggest the establishment of Waste Heat based power plants to encourage utilization ofwaste gases. Suitable amendment to the state legislation has already been proposed - Properimplementation and execution must be ensured.5. Research on DRI Plant Waste:The research organizations of the state must rise to the occasion to find methods forutilization of the DRI Plant Waste; because the growth potential of DRI plants in the countryis quite high and steel production through DRI and induction furnace route is the cheapest ofall the processes in the world today.6. Ensure control on the pollution from the DRI plant through: Installation of suitable de-dusting/ dust extracting equipments at dust emitting points. Suitable gas cleaning equipment such as ESP or gas quenching system should beinstalled. Ensure suitable methods of storing of raw material waste (raw material fines) anddisposal of the same. Suitable disposal of the sludge of waste water and reuse of wastewater. The mosteffective way is to save all waste water for reuse without allowing them to mix with anyother waste stream. Utilization of waste char for water purification, making domestic fuel briquettes, and asactivated carbon. The stockyard should be judiciously planned to avoid flying of dust inair.CONCLUSIONIt is a fact that the gainful utilization of the generated wastes plays a vital role in the profitability ofany organization. From the foregoing discussions, it is clear that the utilization of DRI plant wastesneed to be strengthened in order to abate future threat to the environment, besides generating profitsfor the organization.