This is a presentation from JSW Steel, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. TOTAL WATER MANAGEMENT
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2. 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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3. JSW : Process – Raw materials to finished steel
Non - coking coal
Lum ore Iron ore Coking coal Fluxes
Beneficiation Coke oven
re
mp
Lump or
Pelletization
Sintering LCP
HMDS
Corex Blast furnace Converter LHF CCP HSM
3
HOT METAL STEEL

4. 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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5. Industrial management system
Entire Integrated Steel Operation certified
BENEFITS DERIVED:
DERIVED
Consistent quality and quantity of water .
Continuous improvements in quality.
Lower Operational & Maintenance costs.
Reliability of water for critical systems.
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6. 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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7. 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%

8. Water Usage in Integrated Steel Plants
1. Cooling of Metallurgical equipment (ICW)
2. Gas l i
2 G cleaning & Fume flushing
F fl hi
3. Miscellaneous (Fire, drinking, gardening)
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9. Water usage – Company “Policy”
1.
1 Efficient use of available water
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 Discharge
2 Z 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.
9

10. Efficient Use of water
Fin-Fan heat exchanger Rain water harvesting
Higher COC in Cooling towers Seepage water pumping 10

11. Cascading use of water
GCP
4.Consumptive Blow Down
use 3.
DCW
Blow Down
1.DM/So 2. ICW Blow Down
ft
11

12. 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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13. Waste water discharge – ‘zero’
GUARD POND -1 GUARD POND -2
Slag & Coke quenching Ore washing Best Practices-Green belt
Greenery Development
13

14. Water conservation – ‘total involvement’
Employee involvement Awareness
A
Water Help-Desk: Call 33457
Help Desk: Call-33457.
Attend 15-20 calls per day.
Action taken within 6 hours. 14

15. Water – “Suggestion mela”
15

16. Water - MIS
Monitoring system
g y
Consumption:
Flow meters at TOP of Shops:165 Nos.
Daily readings at Production shops & Hourly reading readings at FFPHs.
Quality:
Hourly analysis of Raw water & Drinking water.
Monthly
M hl water analysis by external chemical laboratories.
l i b l h i ll b i
Reporting system
Reports:
Daily water consumption report (Enclosure3.xls).
Monthly water report (Enclosure-5.xls)
Monthly water cost (report)
Review:
Water consumption review in Daily HOD meeting.
p y g
Weekly water conservation meeting (Enclosure4.xls).
DQEC meeting (MOM-May 2008.doc).
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17. Specific water consumption
Year Annual Water consumption Specific fresh
Production in tons water
(April - 3 Source of Consumption
Quantity
Q antit (m )
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 River
Ri 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

18. 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
Improvement in the cycle of concentration by
I t i th l f t ti 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 g ard
Utili ation of guard pond water for VV Nagar
ater
f 2007-2008 8.76 15 5
township/Vidyanagar township/Plant horticulture/
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19. 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 of blow down water
R li f bl d t
e 2007-2008 2.6 13 50 46
to slag quenching at BOF-CCP
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20. 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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21. Conservation projects - highlights
A.
A Application of Chemical in Raw water pond to reduce Evaporation .
1. Name of chemical : Ceta styrol Alcohol.
2. Supplier : Aqua Savia.
3.
3 Cost (Rs/kg) : 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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22. 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

23. 516
515
514
513 2004
512 2005
Raw Water Pond level 511 2006
510 2007
509
508
507
Jan F b M A M
J Feb Mar Apr May J
Jun J l A
Jul Aug S
Sep O t N D
Oct Nov Dec
Fig-3: Comparison of Evaporation Rates in cm
2.5
E vap o ratio n rate in cm
2
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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24. Conservation projects - highlights
B.
B Re use of seepage water & blow down water .
Cable Tunnels constructed to collect seepage water .
There are about 12 cable tunnel structures- VS-1, VS-2…VS-10.
Entire seepage water is collected in VS-10(ventilation system).
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25. Cable Tunnel water is measured using Electromagnetic flow meter.
g g
Cable tunnel water is being pumped to consumer units.
About 150 to 200 m3/day water is being saved.
25

26. Conservation projects - highlights
C.
C Use of Guard pond water .
Capacity of Each Guard p
p y pond is 55,000 m3 .
,
There are two separate Guard ponds for 4 MT & 7 MT Stage.
26

27. Guard pond pipeline network
To 7MT ore
Beneficiation
plant
pump house
7 MT Guard
(1w+1s)
pond II Storage
Q= 300m3/hr
cap. 55000m3
taken to 7MT GP
Excess water
To Beneficiation plant 150m3/hr
VV Nagar
o
horticulture
h ti lt
s
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
Each cap. Q=250m3/hr
cap 1st Boosting
g
station at station at
t ti t
H=70mtr Air strip
RM Gate
Guard pond I
Storage cap.
25000 m3
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28. THANK YOU
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