Sesa Industries Limited, Goa


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This is a presentation from Sesa Industries Limited, 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.

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Sesa Industries Limited, Goa

  1. 1. Water Management at Sesa Industries Limited Pig Iron Plant-Amona, Goa 1 SIL-PIP 1
  2. 2. Com pany Pr ofile • Ses a Goa Limit ed is the largest pr oducer & exporter of iron or e, in t he privat e s ect or, in India wit h mini ng oper ati ons in Goa, Karnat aka & Oriss a. • In A pril 2007 the Ses a group was taken ov er by Vedanta res ources PLC. • Ses a Industri es, an 88% s ubsi di ary of Ses a Goa Li mit ed, was st art ed i n 1992 for manufacturing of pig ir on. • SIL manufact ur es basi c, foundr y and nodul ar gr ade pig iron for the st eel mills and foundri es. It als o s ells good quality sl ag to t he cement i ndus try. • The Company has dev el oped additional s peci al gr ades of pig ir on t o cat er t o the fast gr owi ng niche mar ket of ductil e iron castings i n India. HSE Vision and Strategies HSEC Vision To maintain pre-eminent position in health & safety, environment and social responsibility practices, and leveraging it for overall growth of the group companies. Strategies • HSE compliance • Obtainin g all statutory clearances in time, for existing and new projects. • Benchmarking of existing practices with the best in it’s class and devise the road map for HSEC excellence. 2
  3. 3. Process • Sesa Industries is the first compa ny to i ntr oduce l ow phos phorous foundr y gra de pig iron in India, in 1992. • The Com pany’s plant at Amona, strategically si tuate d on the banks of the Mandov i riv er, has tw o blast furnaces of 173 m3 v olume and a combi ned annual capacity of 292,000 metric tonnes. • Sesa’s pig iron pla nt manufactures special gra des of pig iron to meet di ffere nt customer require ments. – Low sulphur and l ow manga nese conte nt pig iron. – Nodular gra de pig ir on. QEHS S ystem cer tificati on 3
  4. 4. Water Mana gement •It is said tha t the “ Third World War w ill take place for w ater”. Sesa Industries Ltd. Pig Iron Plant appreciates the v alue of w ater and takes ev ery possible effor t to sav e & conserv e this resource. •Our 4R Water ma nageme nt strategy is: Reduce Re use Recycle Recharge (e.g. rainw ater harv esting etc.) Partnership with community in Water shed developmental work De-Silting of Nallah. • The company has signed an MOU with Betki Khandola Panlot Sangh and is in the process of signing an MOU with Amona Panlot Sangh. 4
  5. 5. Bandhara repaired for preserving water for paddy cultivation. Monitoring & Repor ting S ystem • The company has installed water meters at all the incoming points to measure the actual water used. • The company has formed a Water Con servation Cell in Sept. 2007, under the leadership of HOD P roduction, with members from the production and maintenance departments. • Every day the water con sumption is reported to the General Manager and all the HODs. They monitor the trend and deviation in the consumption pattern, evaluate it and take appropriate action as and when needed. • The status of our objective of 5% reduction in specific water consumption, is reported to the corporate HSE, monthly through HSE MIS and also discu ssed in the monthly operational review chaired by the Director. • Quarterly Vedanta HSE committee meeting, attended by the Group CEO and HSE heads of all the group companies, discu sse s the group’s objectives at the Vedanta headquarters. 5
  6. 6. Specific Wa ter Consumption. Sp. water consump tion 3.00 2.50 Sp. water in KL/THM 2.00 1.50 2.12 2.46 2.15 2.61 1.00 0.50 0.00 2004 -2005 2005-2006 2 006-2007 20 07-2008 Year * Note: The specific wat er c ons um ptio n is incr eas ed in2007-08 due to int ro ducti on o f cooli ng pl ates in bot h t he bl ast furnaces. Water Sav ing Proj ects • Automation of saline water pump for slag granulation. – Pumps are fitted at a distance of about 1 km. from the plant. Once sta rted, the pumps were running continuously, resulting in the overflow of the slag granulation tank, due to the delay in covering the distance to stop them. The automation of the pumps, based on the water level in the tank, has re sulted in saving the water which used to overflow and saving of energy. – Co st of the project: 4 Lacs • Water from the co ke shed roof is connected to the settling tank, thereby reducing the water requirement in the monsoon. • Other minor step s such a s arre sting the leakage s and diverting the water seal overflow to the two pond settling tanks , installation of sen sor ba sed taps, installation of water meters to the canteen etc, are taken up from 2007 to reduce the water consumption. 6
  7. 7. Specific waste water discharge • Water requir ement f or the blast furnace unit: – Process water f or gas cleaning sy stem, – Slag gra nulatio n – Cooling water f or PCM – Cooling of f urnace & other auxiliaries, – Domestic purpose Gas Cleaning 7
  8. 8. Slag Granula tion Water Recycli ng S yste m • Thi cke ner – To Re c ycle Proc ess Wat er 8
  9. 9. Cooling w ater for PCM • The molten metal is poured in the PCM, which is then cooled with water sp rays. After the pouring is over the pigs are cooled with water. This water is pre sently diverted to the slag granulation pit, which acts a s the make up water. • Future Project • PCM cooling water is mixed with lime & some metal chips. This water will be taken to a settling tank & then the clean water will be re-circulated in the system. The settled matter will be removed periodically to recover the mettalic chips. • This will result in saving of fresh water, which will reduce the fresh make up water requirement • The furnace shell is cooled externally & water is also circulated thru tuyere s. This water i s then passed through the cooling tower before re- circulating in the system. There is no treatment required for this water. The evaporation losse s are made up with fresh water. 9
  10. 10. Wastew ater Generate d fr om Domes tic Uses • The water used for gardening, floor cleaning, sanitary use etc. is termed as domestic water. • Total domestic water requirement for the entire complex is about 80 Kl/day, from which the waste water generation is very less only sanitary & washing. • The water used in the canteen & washing is used for gardening purpose, after treatment, • The sewage water generated from toilets & wash rooms, is collected and sent to the sludge soak pit. Sludge soak pit is the one in which the sewage effluents from the residential drain are directly discharged. The water in the accumulated sewage is soaked by adjoining pervious soil, while the sludge is digested in the pit. The pit is lined with masonry with open joints and the top is covered with a rigid slab. Per capita consumption per capita consumption (litres/ person / day ) 200 153 per capita consumption 150 135 126 106 100 50 0 2004 -2005 2005-2006 2006-2007 2007-2 008 Year * Per capita water consumption incl udes water f or gardening. 10
  11. 11. THANK YOU 11