Vizag Steel has implemented extensive water conservation and recycling measures to reduce water consumption. Total water recycling is over 155,494 cubic meters per hour with make-up water needs of only 3,750 cubic meters per hour. Various projects have been implemented since 2004 to reduce water usage, such as recycling blowdown water, installing ultra filters, repairing pipelines, and modifying cooling systems. These projects have resulted in annual water savings of over 4 million cubic meters and costs recovered in under 3 years. Vizag Steel's specific water consumption of 2.33 cubic meters per ton of liquid steel is lower than other major steel producers. Further schemes are planned to achieve zero discharge of water.

1. Excellence In Water Management
By V.S.Subra mani
DGM (WMD)/VSP
VIZAG STEEL - PROFILE
First shore-bas ed pl ant o f 3.0 MT liquid steel capacity - operating at 12 0 % .
Certi fi ed for all 3 Intern ation al stan dards o f ISO 90 01,140 01 & 180 01.
Set up with lat est C DM t echnolo gies like 100% LD gas recovery, dry
quenchi ng of coke,100% C ast Hous e Slag Granulati on and Torpedo L adl e fo r
trans po rting liquid hot m etal.
The Comp any is p rimarily m anu factu ring Long P rodu cts lik e Bars, Wire ro ds,
Reb ars, Roun ds, Chan nels, Angl es et c., which are mostly us ed in Con struction
Indust ry.
Company’s products enjoy p remium in the local Market. Maj or Production
cat ers to Dom estic M ark et.
Gross turnover duri ng 07-08 is 10,433 Cr & Net p ro fit after tax is 1,943 C r
ag ainst previo us year fig of 9,151 Cr &1,36 3 Cr res pectiv ely.
Gro wth: Phas e Capacity (Mt ) Invest ( C r) Cum Invest (C r)
I (09-10 ) 6.8 9192 9192
II 8.5 2220 11412
III 13.0 8400 19812
IV (BY 20 20) 16.0 6000 25812
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2. Water in steel industry
• Equipment cooling
• Absorption / removal of heat
• Steam generation
• Drinking and sanitary purpose
• Fire fighting
• Plant process
• Gas scrubbing / cleaning
TYPICAL WATER CIRCUIT IN VSP
YELESHWARA M
RESERVIOR
RAW WATER
KBR
DRINKING WATER TREATME NT
FOR TOWNSHIP
RWTP
TREATME NT TREATME NT
FIRE AND DRINKING MAKE UP W ATER
W ATER FOR INDUSTR Y FOR INDUSTRIAL
USE
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3. BASIS FOR REPORTING OF QUANTITIES
Ø INTAKE WATER INTO RESER VOIR IS M EASURE D FROM THE
PARSHALL FLUME READINGS RECOR DE D JOINTLY BY
STATE GOV T. & VSP
Ø M A KE U P W AT E R C O N S U M PT I O N F O R T H E PL AN T I S
R E CO R DE D F R O M T HE O N LI N E F LO W M E T E R I N S T A LL E D I N
MAKEU P WATER PUM P HOUSE
Ø CO N S U M PT I O N I N IN DI V I DU A L R E C I R CU L A T I O N PU M P
HO U S ES I S M EAS U R ED B Y O N LI N E F LO W M ETER AN D
M E AS U R I N G T I M E T O TI M E WI T H U LT R ASO N I C F LO W M E T E R
Employees/Community Involvement in
Water Conservation
èMass Awareness thr ough Individ ual Responsibility
ØScroll in Cable TV & Pam phlet Distributi on
ØAppeal through Recorded V oice i n teleph ones (dial tone) wide
publi city of Tel nos of contact pers ons for water leaka ges et c.
è Exte nsive re -cycli ng. Elimi nating all wasta ges, Expl oring additional
sour ces, Identifi cation of waste water s our ces for imme diate
implementation.
èDiscussions in depart mental uni on and samal ochana meetings
èSpecial suggesti ons dri ve thr ough s uggesti on melas
èFormati on of se parate Q Cs
èPropaga nda at sch ools
èMessage by CMD & Direct ors in various for ums
èFormati on of S pecial ins pecti on gr oups in vari ous depart ments
èMeetings with cantee n contractors
è Monitori ng by Hi gher Mana gement thr ough Prese ntation by
Envir onment M gmt De pt on all water wasta ge points i n ED (Wor ks) co-
ordinati on meetings.
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4. Total Water Management
• Water Balancing & Water Audit
• Treatment & Freezing the end user requirement
for various processes
• Supply and distribution of water through out the
plant at required quality & quantity parameters.
• Water Recirculation & conservation
• Complete chemical Treatment
• Converting Waste Water into Makeup water grade
• Recovery of metallurgical waste and recycling of
water
• Technological Discipline
• Cost economics at every step
• Periodic review of all step
WATER MAPPING FOR PLANT WORKS
RECIRCULATI ON IN Cu.M /Hr
ZONE CLEAR CONTAM INA TED TOTA L MAKE -UP WATER
COCCP 10052 980 11032 265
SP 900 1926 2826 70
BF 12865 9520 22385 270
SMS 5415 6160 11575 260
RM 5140 10680 15820 40
TPP 62700 --- 62700 1380
AS 432 --- 432 25
CWP-1 5250 --- 5250 10
CWP-3 4000 --- 4000 10
ASP 9920 --- 9920 80
CH-2 1000 --- 1000 10
SOFT WATER 2200 --- 2200 130
DM WA TER 5399 --- 5399 400
DRINKING --- 550
CONSTRUCTI ON --- 250
TOTA L 1,55, 494 3750
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5. VARIOUS WATER CONSERVATION MEASURES (IN
LAST 4 YEARS)
Ann ual Wa ter Inv est.
Title of Wa ter Sav ings Ma de Payback
Sl Year of
Sav ing proj ect Period
No Imple men tati on
imple men ted (Mo nth s)
Rs. Rs.
m3
Lakhs Lakhs
Recycling of
Secondary Sp ra y
1 Cooling water in Jun'04 2190000 131.4 296 27.03
SMS 250
Cu.mtr/H r
Utilizing Cooling
2 tower – 22 blow June 05 175200 10.5 2.5 2.8
down in Mills
Utilizing Cooling
3 tower – 21 blow Aug. 05 262800 15.7 2.5 1.9
down in S MS
Introduction of
4 Jan. 06 1752000 105 500 45
Ultra Filter plant
Installation of 2
nos of pumps in
5 diversion channel July 06 438000 165.7 470 34
to recove r rain
water
VARIOUS WATER CONSERVATION MEASURES (IN
LAST 4 YEARS)
Ann ual Wa ter Inv est.
Title of Wa ter Sav ings Ma de Payback
Sl Year of
Sav ing proj ect Period
No Imple men tati on
imple men ted (Mo nth s)
Rs. Rs.
m3
Lakhs Lakhs
Provision of side
6 stream Filters at Jan 07 438000 165.7 470 34
T PP PH-04
Replacement of
damaged pipe
7 Ma r 07 876000 131.40 200 18
lines in various
zones
Settling tanks for
recove ry of
8 Ma r 07 876000 131.40 585 54
metallurgical
waste
Diversion of
exhaust cooling
9 Dec 07 350400 52.56 2 1
water in BHS 1 to
PH -6
Renovation of all
10 cooling towers in Feb 08 438000 65.70 100 18
coke ove n area.
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6. RAIN HARVESTING
PROJECTS
-Vizag Steel has implemented Rain Harvesting
measures in a big way as mentioned below
:
¯Masonry Check Dams - 9 nos.
¯Percolation Pits - 94 nos.
¯Earthen Check Dams - 1 no.
¯Recharge Wells - 18 nos.
STREGTHENING COOLING
SYSTEM IN COKE OVEN
Problem Identification:
• High Temperature of recirculation water
• Huge Drift loss
• In effective Cooling
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7. STREGTHENING COOLING
SYSTEM IN COKE OVEN
Modification:
• Total renovation of cooling tower
includes
• Replacement of existing 2 layer fill
system to 3 layer
• Replacement of Asbestos Drift
eliminators by PVC waves and bushes
STREGTHENING COOLING
SYSTEM IN COKE OVEN
Result :
• Water saving incurred out of modification of drift
eliminators : 50 cum. /hr.
• Increased deltaT by 2 – 3 degrees improved the
performance of various heat exchangers of coke ovens.
• Elimination of water spillage to the surroundings.
• Cost benefit analysis:
• Investment made against procurement of fills and drift
eliminators and execution : Rs. 100 Lakhs
• Hence direct Tangible savings : Rs. 65.70 lakh per
annum
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8. WATER CONSUMPTION
w.r.t. PRODUCTION
PRODUCTION CONSUMPTION
YEAR
(MT Liq steel) (MGD)
DESIGNED 3.0 70
00-01 2.91 40
01-02 3.08 35
02-03 3.34 31.4
03-04 3.51 27.0
04-05 3.56 26.0
05-06 3.60 25.0
06-07 3.61 24.5
26.0
07-08 3.31 ( Due to Co nstruction Activity –
1. 5 MGD Ad dtl cons. )
10.7
7.8
6.33
4.88
3.96
3.31
2.76
2.56 2.29 2.33
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9. SPEC. WATER CONSUMPTION IN VSP
AS COMPARED TO STEEL MAJORS
Vizag Steel’s
speci fi c As com par ed to
w ater
consum pti on
(cubi c meter /
ton of liquid Bluescope Thyss en Chi na Corus,
steel) steel - Krupp - POS CO
Steel, UK
Australia Germany
Tai w an
2.33 2.5 3.2 3.6 4.5 4.7
Source : collec ted By Sri Ramesh Prasad AGM / Vizag S teel at
interna tional for um “IISI” held at Amster dum, CO RUS STEE L.
SCHEMES TOWARDS ZERO DISCHARGE
Qty of wa ter to Estima ted
Source be rec ycle d in Type of treatmen t Cost i n Rs in Remarks
cum/ hr crores
Tre ate d wa ter will be use d
Ph ysical trea tm ent in the expa nsi on area for
like misc. us es like fire
Balacher uv u 300-350 20.1
settli ng/clarri ficati on, figh tin g, d us t su ppressi on,
Oil se parati on e tc. garde ning, toilet flus hing
etc.
500 (incl udi ng Tre ate d wa ter will be use d
Appik on da expansi on Rev erse Osm osis 43.15 as make up i n TPP S ys tem
units) and i n so ft water ne twork
Sewage fro m Tre ate d wa ter will be use d
the exis ting 80 Rev erse Osm osis 21.5 in C OCCP recirc ula tio n
plan ts sys tem
Sewage fro m
the Tre ate d wa ter will be use d
80 Rev erse Osm osis 18.6
expansi on in so ft water network
units
To pu mp ou t wa ter fr om
Mari ne
MB C,C OC CP leaka ges,
Dischar ge 300 - 450 Collec tin g Ta nk 11.5
rej ects from RO pla nt
Pipe Li ne
(S TP-!)
Tota l E xpected Water R ecove ry = 1050 cu m / hour
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10. VSP – OTHER AWARDS
Ø CII – EXIM Bank awar d 2007 for Signific ant Ac hievement .
Ø Gol den Peac oc k award for Environmental manag ement by world Envir onmental
Foundation – 2006
Ø Nati onal energ y c ons er vati on award – 2006 (7 times i n row) for Energ y effici enc y
(First priz e for 3 c ons ec uti ve years and also a s pecial award for ac hievi ng this).
for
Ø Nati onal awar d for excell ence i n Water M anagement by CII– 2006 (three
CII–
consecuti ve year s).
Ø Commendati on priz e for str ong commi tment to Exc ell enc e - C II Exi m Bank
Awar d for Business Excell enc e 2006 for Overall Exc ellenc e i n all ac ti viti es of the
company.
Ø Str ong C ommit ment - CII HR Exc ellenc e Awar d 2006 for Exc ellenc e i n HR
proc es ses and practic es.
Ø Organi zational Exc ell enc e Awar d for Effici ent s ugges tion sc heme operation gi ven
by INSSAN – 2006
Ø Best Industri al Producti vi ty Award (Jawaharl al N ehru Sil ver R oll ing Trophy) fr om
olling
FAPC CI for Outstandi ng pr oducti vit y in steel producti on.- 2006
on.-
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