Kirloskar Ferrous Industries Limited, Bevinahalli Village, Koppal Taluk & Dist Karnataka

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2 FORM V (See rule 14) ENVIRONMENTAL STATEMENT FOR THE FINANCIAL YEAR ENDING THE 31 ST MARCH-2017 PART A i. Name and address of the owner: Mr. R. V. Gumaste Occupier of the industry Managing Director Operation or process Kirloskar Ferrous Industries Limited, Bevinahalli Village, Koppal Taluk & Dist Karnataka ii. Industry category Primary - (STC Code) Secondary- (STC Code) : Large- Red iii. Production category Units Pig Iron : 2 x 2.5 lakh TPA Gray Iron Castings : 1, 50,000 TPA Power Plant BF Based : 3.5 x x 1 = 11.5 MW DG Sets : 4.5 x 2 = 9.0 MW Sinter Plant : 5, 00,000 TPA iv. Year of establishment: 1994 v. Date of the last environmental statement submitted. : Water and Raw Material Consumption: PART B Production during (1 st Aril 2016 to 31 st March 2017) i. Water consumption in m 3 /A Process: Sl. No. Unit Water consumption 1 Pig Iron 3,61,807 m3/a 2 Gray Iron Castings 1,11,271 m3/a 3 Sinter 46,477 m3/a 4 Power Plant BF Gas Based 2,76,328 m3/a 5 Power Plant DG Sets 18,422 m3/a Cooling : (included in the above list) Domestic : 2,06,829 m 3 /A 1

3 ii. Specific water consumption Name of Products Process water consumption per unit of products During the current During the current financial year ( ) financial year ( ) Pig Iron Plant 2.84 m3/mt 1.28 m3/mt Gray Iron Castings 3.51 m3/mt 2.39 m3/mt Sinter m3/mt Power BF gas based m3/kwh Power DG Sets m3/kwh iii. Raw material consumption Name of Product Pig Iron Sinter Plant Foundry Name of raw materials* Consumption of raw material per unit of output During the previous During the current financial year ( ) financial year ( ) (in tons) (in tons) Sinter Iron Ore Coke Fluxes Manganese Quartz Coke Fines Iron Ore Fines Dolomite Fines Lime Stone Fines Quick Lime Mill Scale Iron Ore Molten Metal Bentonite Coal Dust Fresh Sand Wet Sand Resin Sand * Industry may use codes if disclosing details of raw material would violate contractual obligations, otherwise all industries have to name the raw materials used. 2

4 PART.C Pollution discharged to environment/unit of output (Parameter as specified in the consent issued) Pollutants Quantity of Pollutants discharged (mass/day) kg/day Concentration of Pollutants discharged (mass/volume) mg/m 3 Percentage of variation from prescribed standards with reasons a. Water Zero Discharge of waste water b. Air RMHS % Below RMHS % Below TG & Boiler % Below TG & Boiler 1 & % Below ESP % Below Bag Filter % Below Rotoclone % Below Shot Blasting % Below Shot Blasting % Below FBDC % Below PART.D HAZARDOUS WASTES (As specified under Hazardous Wastes (Management & Handling Rules, 1989) Hazardous Wastes 1.From Process During the previous financial year ( ) Total Quantity (Kg) During the current financial year ( ) 1. Used Oil 2. Discorded Container 3. Paint Sludge 1470 Ltrs / A 9593 No s / A 0.94 MT / A 6600 Ltrs / A 9360 No s / A 1.76 MT / A 3

5 SOLID WASTES: Solid Wastes i) Pig Iron Plant PIG IRON: PART- E During the previous financial year ( ) in tons A. From process Total Quantity During the current financial year ( ) in tons Granulated Slag 1,01,287 1,12,196 Un-Granulated Slag 25,321 37,000 FOUNDRY: Rejected Moulding sand 35,886 44,182 Rejected Core Sand and Cores 1,888 2,325 B. From Pollution Control Facility GCP Dust ,453 GCP Sludge ,497 B. Quantity recycled or re- utilised within the unit 1) Sold Granulated Slag Un-Granulated Slag Skull Rejected Core Sand 2) Disposed/Stored Granulated Slag Un Granulated PCM Skull Rejected Moulding Sand 100% sold to cement plants 100% sold to cement plants 100% sold to recycling units 100% will be recycled though sand reclamation plant 2,63,716 tons stored at slag dump yard (it is being sold) 131 tons stored at UG slag yard 1,247 tons stored at UG slag yard 2,37,782 tons : disposed at secured land fill at Kerehalli site PART. F Please specify the characteristics (in terms of concentration and quantum) of hazardous as well as solid wastes and indicate disposal practice adopted for both these categories of wastes. A) SOLID WASTES: The solid waste generated from the process is reused, recycled and disposed properly in scientific way. The other domestic solid waste generated are paper, plastic, wood, scrap, garden waste etc., are segregated at source. The same will be stored at centralised scrap yard and sold to scrap vender. 4

6 A) HAZARDOUS WASTES: Used Oil, Discarded Container & Paint Sludge are considered as hazardous waste as per Hazardous and Other Wastes (Management and Transboundary Movement) Rules, E-wastes like, waste bulbs, tubes, electrical and electronic parts and computer peripherals are collected in a segregated manner and sold to approved e-waste recyclers. Used batteries are collected and return to the vender on buy back basis. Used oil /waste oil is generated from process and sold to CPCB / SPCB authorized re- Processors / recyclers. The Quantity of Hazardous wastes generated like Used Oil, Discarded container and Paint Sludge is as given in Part -D. PART.G Impact of the pollution control measures taken on conservation of natural resources and consequently on the cost of production. Water is used in various processes are mainly for cooling and quenching purpose, hence there were no generation of trade effluent. Through reuse and recycling technique waste water generated from one process will be used in other process and zero liquid discharge policy is adopted. Water conservation is practised by rain water harvesting. Bore wells are provided with rain water filtration and recharge system through filtration media and recharge techniques. Building roof top rain water is made to channelized to this pits to recharge the bore wells. This year we have completed 7nos. bore wells with a cost of 7.0 lakh rupees. We have also planned to construct bore well recharge system for another 13 nos. of bore wells. We have also provided guard ponds (Lake-A & B) where all the storm water is channelized to collect in these ponds. The water collected by rain water will be used in the process for slag granulation and quenching purposes. This water is also utilised for dust suppression on the unpaved roads inside the raw material yards. Domestic water is being treated in STP with 250KL installed capacity and the treated water is used for garden development and green belt watering. KFIL has taken Water, Energy, Hydraulic Oil, Coolant Oil and Lube Oil conservation under ISO 14001:2004, Environmental Management System. Company has fixed the specific consumption target for all resources and continuous follow-up is made for improving process efficiency to reduce the specific consumption, thereby controlling on the cost of production. A) RE-USE OF SOLID WASTE: The type of solid wastes generated from the Pig Iron and Foundry Unit has been already tabulated in Part "E". Re-use of solid wastes generated is summarized as below. Iron ore fines and Coke fines generated from Pig Iron plant are reused for sinter making in sinter plant as raw material Granulated Slag generated from Pig Iron Plant is reused as raw material in Cement Industries and tiles manufacturing industries. 5

7 Rejected Core Sand & Mould Sand generated from Foundry stored in identified area. Installed sand reclamation plant to reuse core sand through crushing and screening. Process wastes like sludge from Gas Cleaning Plant & dry dust are being utilized in the SINTER PLANT. The skull and UG slag generated from MBF process are also sold to KSPCB authorised buyers for recovery of iron, through crushing and screening. The left out material is also used in cement industry. The black sand generated from foundry process are reused and recycled to the maimum extent, the remaining waste sand which is not usable in foundry process is being dumped in land fill site at Kerehalli village which is approved from KSPCB. B) RE-USE OF AIR POLLUTANTS: Blast Furnace Gas generated from Blast Furnaces contains 25-28%of Carbon Monoxide (CO), which has a calorific value of about kcal. This is being cleaned in Gas Cleaning Plant and used as a fuel in hot blast stoves for preheating the air and Turbo- Generator Boilers for Power generation respectively. The dust collected from the bag filter, ESP and multi tube pollution control equipments are reused back in sinter plant for sinter making. The dust collected in bag filters of fettling shop are having iron content, which is sold to the scrap venders. PART-H Additional measure / investment proposal for Environment Protection including abatement of Pollution. Investment made towards Pollution Control / Environment Management, Kirloskar Ferrous Industries Limited is committed to protect and upkeep the surrounding Environment clean and green. The management commitment towards environmental protection has been incorporated in our Environmental Occupational Health and Safety Policy. Adopted costeffective methods for waste management, adopted best available technology for prevention & control of pollution and resource conservation in all its areas of process, operations & services. KFIL has implemented and certified for ISO 14001: EMS and OHSAS 18001:2007 Certification through IRCLASS, Mumbai. PART-I Any other particulars in respect of environmental protection and abatement of pollution Following are the measures taken for Environment protection and abatement of pollution: Towards Clean & Green Environment: 6

8 Plantation of tall growing and thick foliage trees inside the premises, planted 4 rows of plantation along the periphery of the Plant and all along the compound wall inside and outside. Out of 282 acres, more than 38 % is covered under green belt with total plantation of 1,53,628 nos. covered with an area of 107 acres. Plantation development is a continued process, every year KFIL is planting to improve Greenery. This year 20,000 tree saplings are proposed to plant within and outside the factory premises. Towards prevention and control of pollution: Commissioned Fume Extraction System with Bag Filter Technology for MBF 1 & 2 to control fumes, smoke and Kish graphite emission. Installed Dust Extraction system with Bag Filter technology in RMHS 1 and 2 to control dust emission. Installed Sinter plant for reusing of our MBF solid waste (Iron Ore fines & dust, Coke fines and other fluxes) Provided Porous Fence/ Mesh of a stretch of 480m with a height of 12 m. North, East and western side of the raw material yard boundary, to arrest the spread of fugitive emission to the neighbouring area. Provision of Concrete Roads of length1650 m inside plant premises to control dust emission Provision of Jet Type Fixed Sprinkler system in raw material yards to control dust emission. Installed 2 Stoves each MBF s for reducing the 30% coke consumption. Installed Fan less cooler in Compressor House to reduce the power consumption. Provided additional conveyor belt below Truck Tippler Hopper, to avoid handling activity, which help reduce fugitive emission. Towards resource conservation: Taken initiatives to eliminate wastage of water by training employees & arresting leakages in their work areas. Provision of centralized air conditioning system for new administrative building for power conservation. Installation of 50 KW roof top solar power generation unit for new administrative building. Towards cost effective methods for waste management: Most of the solid wastes / by-products like coke fines, iron ore fines and GCP dust are being reused in Sinter making process. In order to adopt recycle / re-use practices, as a part of commitment to our Environmental Policy, Rain water & other wastewater is collected in the Lake-B and re-used for Plantation and sprinkling purposes. Above all, KFIL is incurring about Rs. 18 Crores annually, towards operation & maintenance of various pollution control equipments provided in the industry and other Environmental Protection measures. All key characteristics as per legal requirements are monitored periodically, results submitted to concern Departments and records maintained. 7

9 Complying with all applicable Environmental laws as part of commitment to our Environmental Management System. All observations made by the officers of the Karnataka State Pollution Control Board, Ministry of Environment & Forest, during their visit and the suggestions given by them are implemented. An Environmental Management Department has been established comprising of a qualified Environmental Engineer, headed by Vice President - HRM & General Administration. Water, treated Wastewater and Wastewater samples are analyzed through recognized external laboratories. The World Environmental Day celebrated on June 5th of every year to create awareness among the Employees towards maintaining pollution free Environment. Organizing a four days Film Festival called VASUNDHARA showcasing documentaries on environment, wildlife, energy, air, water to create awareness to school & college students and general public. Increasing awareness among the Employees by nominating to attend the external training Programs, as and when organized / conducted by the Pollution Control Board or other agencies and also organizing In-house training programmes. 8

10 Photographs showing view of the plant 9

11 Plantation on the occasion of World environment day celebration 10

12 Water Sprinkling System in open yards and roads 11

13 Porous Mesh constructed around the North boundary of RMHS to control fugitive emissions. 12

14 Plantation along the railway siding Plantation is in progress (Aug 2017) along the compound wall 13

15 Healthy growth of Plantation planted in the year 2016 even with arid rain fall Healthy growth of Plantation planted in the year 2016 even with arid rain fall 14

16 Constructed storm water collection and collection pond to harvest the rain water and enrich the ground water by percolation. 7 nos. of bore wells are provided with rain water recharge filtering and system, with an expenditure of 7.0 lakh rupees. Many building roof top rain water is diverted to this bore wells to enrich the ground water. 15

17 Sewage treatment plant of capacity 250KLD is revamped to improve the treatment efficiency. Sewage treatment plant of capacity 250KLD is revamped to improve the treatment efficiency. 16

18 New Dust Extraction (DE) Systems are installed to foundry shake out unit New Dust Extraction (DE) Systems are installed to foundry Sand plant and sand cooler area 17