This document outlines Balasore Alloys Ltd.'s Dust Generation Mapping and Control Plan initiative to achieve a dust-free environment at their plant. It includes an introduction to dust and standards, timelines for the initiative, sources of dust generation from material flow, transportation and environmental factors, the importance of dust mapping to measure and control dust, proposed equipment for dust mapping, the dust mapping process, and potential elimination and control plans for material flow, transportation and environmental sources of dust. Control plans provide detailed suggestions and considerations for engineering teams to reduce dust from various areas and processes.

1. BALASORE ALLOYS LTD.
Dust Generation
Mapping
Elimination &
Control Plan
Sustain
Dust
Mapping
&
Control Plan.
Prepared By :
Deepak Kumar Sahoo
Under the guidance of
Mr. S V Bhavani Varma
& Mr. J S Verma
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Cover Page

2. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -i
Objective
Achieving
Dust Free Environment
in Plant Premises
through
Dust Mapping &Control Plan
[DMCP] Initiative.

3. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page –ii
Table of Contents
S/N
Contents
Pg. No.
1
Introduction
-: 01:-
2
DustGeneration [Source]
-: 03 :-
2.1
1. Material Flow
-: 04:-
2.2
2.Transportation
-: 06:-
2.3
3.Environment
-: 08:-
3
Dust Mapping
-: 09:-
4
Elimination & Control Plan
-: 12:-
4.1
1. Material Flow
-: 13:-
4.2
2.Transportation
-: 14:-
4.3
3.Environment
-: 15:-
5
ROI for DMCP Initiative
-: 16:-
6
Sustain
-: 17:-

4. Authority
Measured as: 24 hrmean
Relevance
UK Air Quality Standard
50 μg/m3
Air quality in relation to public health
SPCB, Orissa
100 μg/m3
Industrial
190.6 -238.2 μg/m3
Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -01
Introduction
Dust:Itconsistsofparticlesintheatmospherethatcomefromvarioussourcessuchassolidparticlesfromrawmaterials,soildustliftedbyweather/Windflow,FlueGases,vehiclemovementetc.
DustLevelStandard

5. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -02
Time Line for DMCP Initiatives
Initial
Assessment
Dust
Mapping
Elimination,
Control Plan
& Implementation
Sustain &
Improvement
2 Month
3 Month
9 Months
Kick off
Completion of Initial Assessment
Receiving the Dust Measuring Instrument.
Completion of Dust Mapping.
Finalization of Elimination & Control Plan
Will reach final stage of execution –
Control Plan
Sustain & Scope for improvement

6. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -03
Source of Dust generation
Therearevarioussourcesofdustgeneration;butinBALPlant,weidentifiedmainlythedustcamefrom3majorSources.
Material flow
Transportation
Environmental

7. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -04
Material Flow : Flow Diagram
RM Storage
UG Bunker
Day bin Bunker
Weigh Hoppers
F/C Chutes
Material Charging
Smelting
Tapping
Casting
Loading
Breaking yard
Slag Yard
Sales
Cooling
Loading truck
MRP plant
Loading truck
Return Dust
Weigh mint
Storage area
Recycle
UG Bunker
Screen House
Detailed Process Map for Material Flow

8. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -05
Dust Generation : Material Flow

9. Gate Entry
Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -06
Transportation: Flow Diagram
RM Store Area / Br.plant
Weigh bridge
UG Bunker
Weigh bridge
Storage Area
Casting Metal/Slag loading
Slag Yard
MRP plant
Weighing
Break yard
Weighing
Sales yard
Weighing
Material loading & Weighment
Raw material feeding
Product handling movement
Raw Material Entry
Weighment
RM yard at unloading point
Weighment
Exit
Exit

10. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -07
Dust Generation : Transportation

11. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -08
Dust Generation : Environment
Open Raw Material Stock Yard
Chimney ( BAL Plant & Br. Plant )
Under Construction
Open Conveyer System
More Fines Generation
Internal Road Conditions

12. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -09
Dust Mapping : Why ?
IfyoucanMEASUREit,
youcanCONTROLit.
We can reduce 30% of the current dust generation, if we are able to measure the dust level continuously.

13. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -10
Dust Mapping : Measuring Device
HAZ-DUST Real-time Area Dust Monitor
P311
DT-9881
P611
$ 1763
£1.764,00
£847
£2425
SKC Inc.
PCE Instruments UK Ltd.
PCE Instruments UK Ltd.
PCE Instruments UK Ltd.
The Avg. Cost of Dust Measuring Device is costing around 2 LacsINR and the lead time Maximum 15 days. [Date of Payment to Equipment received @ BAL Plant.]

14. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -11
Dust Map : Area Wise
AfterreceivingthetheDustMeasuringdevicewewillmeasurethedustlevelwitheachindividualareaandmonitorthedustlevelonweeklybasis.
1.InitialAccessthedustlevelinsidetheplant
2.PreparetheDustMAPinthewholePlant.
3.WeeklyDustTracking–Areawise.
4.TrendAnalysisforDustlevel.

15. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -12
Elimination & Control Plan
EliminationandControlPlanmaybeoutsourceordevelopinhouse.
In House Develop
Consultant or Expert

16. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -13
Control Plan : Material Flow
Dustisgeneratingduringmaterialflowdueto
1.Leakage.
2.Spillage.
3.WrongDesign.
4.PoorMaintenance.
5.OpenconveyorSystem
Suggestion and possible cause : Material Flow

17. Doc. No : BAL/DS/DMCP/A11-02Dec’ 13 | Page -01
Dust Mapping And Control PlanControl Plan Material Flow.
INDEX
Dust Generation
Mapping
Elimination &
Control Plan
Sustain
Dust
Mapping
&
Control Plan.
Control Plan
Material Flow

18. Doc. No : BAL/DS/DMCP/A11-02Dec’ 13 | Page -02
Suggestion
During material unloading some of the materials drops to the platform; that material went to UG Bunker
S1: Platform Can be checker plate.
S2 : Increase the height of side wall so no material will fall in the platform
S N Padhi
15.01.14
Discussion with Engineering team.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

19. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -03
Suggestion
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

20. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -04
Suggestion
If we can arrange the uniform water spray near bunker the dust level can be reduce; also at the same time we need to take care the moisture level in the raw materials.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

21. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -05
Suggestion
Some of the materials are came through conveyor.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

22. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -06
Suggestion
Raw Materials falling one corner of the conveyor.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

23. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -07
Suggestion
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

24. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -08
Suggestion
GAP between Conveyor and bunker can be reduce so that dust particle will go to the bunker.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

25. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -09
Suggestion
GAP can be reduce so that dust particle will go to the bunker.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

26. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -10
Suggestion
Conveyor can make close type by using PVC screen arrangement just like airport luggage x-ray machine entrance.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

27. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -11
Suggestion
Conveyor brush required during return so that raw material can’t transform.
KAM
Target Date
Support Required
Dust Mapping And Control PlanControl Plan Material Flow.

28. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -14
Control Plan : Transportation
Dustisgeneratingduringmaterialflowdueto
1.HighVehiclesmovement(MotionStudyrequired)
2.InternalRoadconditionsarenotuptothemark.
3.LeakageinTrucks
4.SpeedyMovement.
Suggestion and possible cause : Transportation

29. Doc. No : BAL/DS/DMCP/A11-02Dec’ 13 | Page -1
Dust Mapping and Control PlanControl Plan Transportation.
Dust Generation
Mapping
Elimination &
Control Plan
Sustain
Dust
Mapping
&
Control Plan.
Control Plan
Transportation

30. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Transportation.

31. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Transportation.

32. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Transportation.

33. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -15
Control Plan : Environment
Dustisgeneratingduringmaterialflowdueto
1.OpenRawMaterialStockYard
2.Chimney(BALPlant&Br.Plant)
3.UnderConstruction
4.OpenConveyerSystem
5.MoreFinesGenerationduringprocess.
6.OpenLandSpace–bothinsideandoutsidetheplantpremises.
Suggestion and possible cause : Transportation

34. Doc. No : BAL/DS/DMCP/A11-02Dec’ 13 | Page -1
Dust Mapping and Control PlanControl Plan Environment.
Dust Generation
Mapping
Elimination &
Control Plan
Sustain
Dust
Mapping
&
Control Plan.
Control Plan
Environment

35. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

36. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

37. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

38. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

39. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

40. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

41. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

42. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

43. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

44. Doc. No : BAL/DS/DMCP/A11-05Dec’ 13 | Page -3
Suggestion
KAM
Target Date
Support Required
Dust Mapping and Control PlanControl Plan Environment.

45. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -16
Control Plan : ROI of DMCP
Duringthepre-assessmenttheROIofDMCPwillbecalculated.
1.Directfinancialbenefits
1.Yield–RawMaterials.
2.Productivityimprovement.
2.Furnaceprocessstabilizationforlessdustgeneration.
3.Man-hoursinvolve.
4.Brandimpactinsocioeconomylife.
5.Employeeshealthimpact.
6.Intangiblebenefits.

46. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | Page -17
Sustain
1.DustMappingAudit:AreaWise
2.DustMappingScoreinterlinkwithPMS.
3.Reward&RecognitionSchemeforDustMappingandControlPlan.
4.RawMaterial(FromBrqt.ToFurnace) Yieldtobemonitoredandanalyzedperiodically.
5.ExternalConsultantforperiodicalassessment.
6.PeriodicallyvisitforgoodmanufacturingpracticeFerroalloysplant.

47. Dust Generation
Mapping
Control Plan
Sustain
Doc. No : BAL/DS/DMCP/A11Dec’ 13 | END
BALASORE ALLOYS LIMITED.
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DEEPAK KUMAR SAHOO
Email : dksahoo2@gmail.com