TOTAL WATER MANAGEMENT

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 JSW Steel – Group Companies

SISCOL, Salem Tarapur

JSW Steel, Vijayanagar – 4.0 mtpa.

JSW Port, Goa VMPL, Iron Ore mining

JPOCL JSW Captive power

JSW Steel, Bellary

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 JSW : Process – Raw materials to finished steel
Non - coking coal
mp ore Iron ore Coking coal Fluxes

Beneficiation Coke oven

Lump orre
Lum

Pelletization
Sintering LCP

HMDS

Corex Blast furnace Converter LHF CCP HSM

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HOT METAL STEEL
 JSW Steel Products

Plates and Slabs

HR Coils
- Slabs
- HR coils
- Cold rolled coils
- Pre coated
- Galvanised
- Bars & Rods
- Structural etc.

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Industrial management system
Entire Integrated Steel Operation certified

BENEFITS DERIVED:
DERIVED
¾Consistent quality and quantity of water .
¾Continuous improvements in quality.
¾Lower Operational & Maintenance costs.
¾Reliability of water for critical systems.
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Water from Tunga Bhadra Reservoir (32 MGD)

Tunga Bhadra Reservoir Intake water pump house

Raw water pond(6.5 Mm3 capacity) Clariflocculators(22.8 x 3 MGD)

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Water usage at JSW Steel
Corex-1
4%
Corex-2
3%
BF-1
BF 1
3%
Others
17% BF-2
5%
SMS-1
8%
HSM
3%
CRM
2%
Coke Ovens I & II
2%
Power plants Pellet Plant &
38% Benification
plant.
8%
Sinter plant I
1%
RMHS
1%
FFPH 7
5%
Water Usage in Integrated Steel Plants

1. Cooling of Metallurgical equipment (ICW)

2 Gas
2. G cleaning
l i & Fume
F flushing
fl hi

3. Miscellaneous (Fire, drinking, gardening)

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Water usage – Company “Policy”
1 Efficient use of available water
1.
Reduction of evaporation rate
• Maximize use of alternate sources rain water &
seepage.
• Reduction of fresh water in closed circuits by
higher COC.
• Reverse osmosis plant for recovering good
quality water.

2 Zero
2. Z Discharge
Di h
Cascading usage of water
• Use of blow down of one process
as make up water in other processes.
• Equalization of final blow down water quality
and its use in less critical applications.
pp
• Treated sewage for gardening.
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Efficient Use of water

Fin-Fan heat exchanger Rain water harvesting

Higher COC in Cooling towers Seepage water pumping 10

 Cascading use of water

GCP
4.Consumptive Blow Down
use 3.
DCW

Blow Down

1.DM/So 2. ICW Blow Down

ft

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Water Cascading – Corex Plant

Corex –DM
Water Circuit

Corex –ICW
C ICW Corex –Slurry
Water Circuit to PP

Corex –GCP GCP Water

Water Circuit Clarifier

Blow down to
Ore
Beneficiation SLIME POND

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 Waste water discharge – ‘zero’

GUARD POND -1 GUARD POND -2

Slag & Coke quenching Ore washing Best Practices-Green belt

Greenery Development

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 Water conservation – ‘total involvement’
Employee involvement A
Awareness

¾Water Help-Desk:
Help Desk: Call
Call-33457.
33457
¾Attend 15-20 calls per day.
¾Action taken within 6 hours. 14
Water – “Suggestion mela”

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Water - MIS
Monitoringg system
y
Consumption:
¾Flow meters at TOP of Shops:165 Nos.
¾Daily readings at Production shops & Hourly reading readings at FFPHs.

Quality:
¾Hourly analysis of Raw water & Drinking water.
¾M hl water analysis
¾Monthly l i by
b externall chemical
h i l laboratories.
l b i

Reporting system
Reports:
¾Daily water consumption report (Enclosure3.xls).
¾Monthly water report (Enclosure-5.xls)
¾Monthly water cost (report)
Review:
¾Water consumption
p review in Daily
y HOD meeting.g
¾Weekly water conservation meeting (Enclosure4.xls).
¾DQEC meeting (MOM-May 2008.doc).
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 Specific water consumption

Year Annual Water consumption Specific fresh

Production in tons water
(April - 3 Source of Consumption
Q antit (m )
Quantity
March) Water
Industrial Domestic Industrial
59,28,810 7,06,050 River 1875148 3.16
2004– 05
67 48 791
67,48,791 10 85 670
10,85,670 Ri
River 2243509 3 01
3.01
2005 – 06
2006 – 07 85,51,293 11,38,490 River 2648359 3.23

2007 – 08 98,19,801 16,72,610 River 3159209 3.13

Year Industrial Township water consumption

Ave rage
Consumption Per capita Per capita
employe es per No of persons
m3 consumption Consumption
day
2004-05 7,06,050 25,000 77 3,500 557
2005-06 10,85,670 28,000 106 4,000 487
2006-07 11,38,490 30,000 103 8,500 225
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2007-08 16,72,610 35,000 130 18,700 124
 Water conservation projects
A. Efficient use of water.
Water Saving project implemented Payback
Invest.
Sl No Year Savings Period
3 Rs. Lakhs (Months)
m
Collection of seepage water from raw water pond
a by constructing check dams and pump it back to 2004-2006 43.8 15 1
reservoir
b Construction of guard pond-1 for 4 mtpa units 2005-06 1.8 6 12
c Construction of guard pond-2 for 7 mtpa units 2007-08 9
Construction of lake in Vidyanagar to harvest rain
c 2005-06 40
water
I
Improvementt in
i the
th cyclel off concentration
t ti by b 2004-2008
d improving water treatment measures 10.5 194 45
(continuous)
e RVDF project in RWTP 2005-2006 0.012 205 48
Collection of seepage water by Bore wells and
f 2007-2008 1.28 2 4
utilization in iron making zone.
Collection of seepage water along the RWP bund
g 2006-2008 52.56 5 1
area and pumping it back to pond
Utilization
Utili ation of guard
g ard pond water
ater for VV Nagar
f 2007-2008 8.76 15 5
township/Vidyanagar township/Plant horticulture/

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 B. Cascading use of Water.

Invest.
Year of Annual Water Made Payback
Title of Water Saving
Sl No Implement Savings Period
project implemented
ation 3 (Months)
m Rs. Rs.
Lakhs Lakhs Lakhs
Utilization of blow down of
a GCP water of Corex, BF 1&2 2007-2008 7.58 3.79 10 32
for make up in ore
beneficiation plant
Conversion of open circuit ID
b fan cooling to closed circuit 2007-2008 2.73 13.65 15 14
cooling
Utilization of blow down water
c from CPP-2 for coke 2007-2008 6.57 32.85 6 3
quenching in to Coke oven-1,2
Collection of seepage water
d from MSDS cable tunnel and 2007-2008 4.97 24.82 10 5
use in scale pit, of BOF.

Recycling
R li off blow
bl down
d water
t
e 2007-2008 2.6 13 50 46
to slag quenching at BOF-CCP

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 Water usage - analysis
Cement Plant
LCP
Boilers
RMHS
Corex-1
utiltities
Sinter plant I
(25 TPH)
Pellet Plant & Corex-2 HSM FFPH
Benification BOC-1
plant.
BF-1 CPP-2 JSWEL
Corex
Coke Ovens I
& II
FFPH
FFPH.
BF-2
CRM BF-2 FFPH
CPP-1
JPOCL
HSM
Cokeoven
SMS-1
FFPH

Chart-1,4 MT Production units Chart-2, Fire fighting pump houses Chart-3, Power Plants

Turbidity Chart
Boilers utiltities
Water to
(80 TPH) Shankar Gudda
colony IST steel plant 12 NTU
WRM
New batching
SMS-2 VV Nagar
plant

T u r b i d i ty
Coke Ovens III Vaddu village 7 NTU
Crushing plant
Water supplied
to Township 7 MTPA Labour
Hort. Colony/Drinking
water For BF-3.
Water from
BF-3 Drinking water
Sinter plant II RWP to Lake
supplied to O NTU
Water to plant.
overhead tank
Hour
in Vidyanagar.

Chart-4,7 MT Production units Chart-5,Miscellaneous units Chart-6 SPC

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 Conservation projects - highlights
A Application of Chemical in Raw water pond to reduce Evaporation .
A.

1. Name of chemical : Ceta styrol Alcohol.

2. Supplier : Aqua Savia.
3 Cost (Rs/kg)
3. : 120 Rs/kg
Rs/kg.
4. Application rate (kg/day) : 64 kg/day.
5. Cost of application per day : 8500 Rs/day.
6. Potential saving of water at
50% efficiency : 8000 m3/day.
7. Savings due to reduction. : Rs 20,000/day

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Evaloc is being mixed with water Solution is poured into a container
Water Consum ption - March 2007 Water Consumption - March 2008
Evaporation loss
17% Evaporation loss
13%
Others
Others
5%
4%

JSW
56% Ancillary units JSW
Ancillary units
20% 57%
19%

Drinking water Drinking water

4% 5%
Total consumption = 2815.66 X 1000 m3 Total consumption = 2397.44 X 1000 m3 22
 516
515
514
513 2004
512 2005
Raw Water Pond level 511 2006
510 2007
509
508
507
J
Jan F b Mar
Feb M Apr
A May
M J
Jun J l Aug
Jul A S
Sep O t Nov
Oct N Dec
D

Fig-3: Comparison of Evaporation Rates in cm

2.5
E vap o ratio n rate in cm

1.5 With & without

1
Evaloc application.
0.5

0
Jan Feb Mar Apr May June July Aug Sep
Month
Without Evaloc With Evaloc
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 Conservation projects - highlights
B Re use of seepage water & blow down water .
B.

¾ Cable Tunnels constructed to collect seepage water .

¾ There are about 12 cable tunnel structures- VS-1, VS-2…VS-10.
¾ Entire seepage water is collected in VS-10(ventilation system).

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¾ Cable Tunnel water is measured using
g Electromagnetic
g flow meter.
¾ Cable tunnel water is being pumped to consumer units.
¾About 150 to 200 m3/day water is being saved.

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Conservation projects - highlights
C Use of Guard pond water .
C.

¾ Capacity
p y of Each Guard ppond is 55,000
, m3 .
¾There are two separate Guard ponds for 4 MT & 7 MT Stage.

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 Guard pond pipeline network
To 7MT ore
Beneficiation
plant
pump house
7 MT Guard
(1w+1s)
pond II Storage
Q= 300m3/hr
cap. 55000m3
o 7MT GP
s water

To Beneficiation plant 150m3/hr

VV Nagar
taken to

h ti lt
horticulture
Excess

30 m3/hr Plant
2.

Horticulture 20
m3/hr
300 m3 Vidya Nagar
200 m3 township /Air
port
Horticulture
Pump house (1w+1s) 2nd Boosting 50m3/hr
cap Q=250m3/hr
Each cap. 1st Boosting
g
station at station
t ti att
H=70mtr Air strip
RM Gate
Guard pond I
Storage cap.
25000 m3

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THANK YOU

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