Coke oven

1. Pollution and Pollution Control Performance and Measures in India COKE OVENS Reference: “Into The Furnace”. CSE, Delhi.2011 1 Monday, November 19, 2012

2. Coke Ovens is complex of distinct plants Coke Oven, By Product Plant, Effluent Treatment Plant 2 Monday, November 19, 2012

3. Presentation of CSE Report, June 2012 on the Iron and Steel Industry in India Susmita Dasgupta JPC, ERU Monday, November 19, 2012 3

4. Coke ovens Presentation I Monday, November 19, 2012 4

5. There is a variant to this complex in the form of Coke oven heat recovery/non recovery type. 5 Monday, November 19, 2012

6. India has 32 million tonnes of annual coke producing capacity 6 Monday, November 19, 2012

7. The basic processes are Coal is heated in Coke Oven in the absence of air to yield coke. Volatile matters wholly and partially combusted evaporate into CO Gas which is quenched and collected. Collected gas is then cooled and distilled to yield by products like tar, benzene, napthalene and clean of sulphur . Water from condensation and CO cleaning is collected and passed on to Effluent Treatment Plants. Treated water and solid waste is generated. 7 Monday, November 19, 2012

8. Three Basic Processes Monday, November 19, 2012 8

9. Pollution From Coke Ovens Monday, November 19, 2012 9

10. Coke oven by product recovery type 23 million tonnes of annual capacity 10 Monday, November 19, 2012

11. Kinds of Pollution Due to combustion of coal Particulate matter S02 CO Nox Due to incomplete combustion PAH compounds, carcinogenic During distillation of by product. During treatment of waste water. May be contained both in air as well as water. 11 Monday, November 19, 2012

12. Kinds of Pollution .. Fugitive Unintended waste due to leakages. They are PAH compounds found in air, water or sludge. Tar sludge, benzol sludge. Usually hazardous. Incomplete processes. They happen due to high pressure generated in the ovens and decanters. Process Generated out of processes like water, particulate matter, solid non hazardous waste. Usually non hazardous. Completed processes. 12 Monday, November 19, 2012

13. Kinds of pollution .. Air Water Solid sludge. 13 Monday, November 19, 2012

14. Pollution in coke ovens Usually air emissions. 14 Monday, November 19, 2012

15. Sources of Pollution in Coke Ovens Splutter when coal is placed in the heated oven, called charging emission . This contains both particulate matter and PAH compounds. Due to high pressure of volatile matter inside oven during heating gas leaks out. This is diffuse emission . When volatile matter is wholly burnt and coke remains, dust is emitted. This is combustion emission . When coke is done and is pushed out of ovens into the pusher car, soot blows out. This is called pusher emission . When Coke Oven Gas is quenched with water, water evaporates into steam with particulate matter, So2, Nox and CO. This is called quenching emission . 15 Monday, November 19, 2012

16. Charging emissions can be prevented by Increasing compactness in coal packing. Change from top charging to stamp charging. Increase the volume of coke ovens to reduce frequency of charging. Increasing height of chamber. 16 Monday, November 19, 2012

17. Diffuse emission can be prevented by Using self sealing doors. Use of magnetic lid. Use of screw tightened pipes. Water sealing of ascension pipes. Plugging charging holes. Containing build up of pressure in the oven through variable pressure controller. Increasing compactness of feed through stamp charging. 17 Monday, November 19, 2012

18. Combustion emission due to under firing of stack can be contained through Arrest of dust containing PM, So2, Nox , CO and CO2. Having larger oven sizes through increase in chamber height. Stamp charging. HPLA 18 Monday, November 19, 2012

19. When coke is done, and is pushed out of the oven into container cars on rails, soot can be controlled by Having a land based stationary emission control device instead of the suction hood and bag filter attached to the mobile car. 19 Monday, November 19, 2012

20. Quenching emissions When water is sprayed on CO Gas to cool the fluid, water evaporates producing steam. The steam contains particulate matter, CO, So2 and Nox . Dry quenching with ammonia helps in reducing this type of emissions. 20 Monday, November 19, 2012

21. Emissions are of two kinds Fugitive Fugitive emissions happen due to gas leaks. This may contain both combusted and incompletely combusted matter. Incomplete combustion has traces of PAH levels measured by the concentration of benzene pyrelene in the emission. Pollution control rules pertain to equipment design. Process Usually wholly combusted matter in the form of dust, namely PM, Nox , So2 and CO. Pollution control rules pertain to emission norms and Pollution control devices. 21 Monday, November 19, 2012

22. The emissions from CO Plant is air emission We track particulate matter, So2, CO and Nox . We track the concentration of B(a)p, a PAH compound that contains poisonous cyanide and emanates out of improperly combusted volatile matter in coal. 22 Monday, November 19, 2012

23. Ministry of Environment and Forests have specifications for Emission norms and standards. Plant design equipment. Specification of pollution control equipments. 23 Monday, November 19, 2012

24. Comparison of Air Emission Standards For Coke Oven Recovery Fugitive Visible Emissions Units India Europe USA Percentage Leaked From Doors % 5 5 to 10 4 Percentage Leaked from lids % 1 1 0.4 Percentage laked from ascension pipes % 4 1 2.5 Charging Emissions seconds/ charge 16 20 14 Benzo(a)pyrene in the work area Units India Europe USA Battery area Top ug/m3 5 5   Other units in coke plant ug/m3 2 2   Ambient air standards ng/m3 10 6   Underfiring Stack Emissions Units India Europe USA Particulate Matter mg/Nm3 50 20 50 Sulphur dioxide mg/Nm3 800 200 to 500 500 Nitrogen Oxide mg/Nm3 500 350 to 500 750 Carbon Monoxide kg/tonne of gross coke 3 3 3 Other Stack Related Emissions Units India Europe USA Stamp Charging PM mg/NM3 25     Coke Pushing Emissions gm/tonne of coke pushed 5 5   Sulphur in Coke Gas Recycled mg/Nm3 800 300   Wet Quenching Units India Europe USA Particulate Matter from Tower gm/tonne of coke produced 50 (wet) 25 (wet) 20 (dry) mg/Nm3 Source: CSE, June 2012 24 Monday, November 19, 2012

25. Norms Provided by the GSR 46(E) Notification dated 3.2.2006 Fugitive Visible Emissions Units New Baterries for Greenfield sites Rebuilt Batteries Existing Batteries Percentage Leaked From Doors % 5 10 10 Percentage Leaked from lids % 1 1 1 Percentage laked from ascension pipes % 4 4 4 Charging Emissions seconds/ charge 16 (HPLA) 50 (HPLA) 75 Benzo(a)pyrene in the work area Units Green Field Rebuilt Existing Battery area Top ug/m3 5 5 5 Other units in coke plant ug/m3 2 2 2 Ambient air standards ng/m3 10 10 10 Underfiring Stack Emissions Units       Particulate Matter mg/Nm3 50 50 50 Sulphur dioxide mg/Nm3 800 800 800 Nitrogen Oxide mg/Nm3 500 500 500 Carbon Monoxide kg/tonne of gross coke 3 3 3 Other Stack Related Emissions Units Green Field Rebuilt Existing Stamp Charging PM mg/NM3 25 25 25 Coke Pushing Emissions (land based system applicable) gm/tonne of coke pushed 5 5   Sulphur in Coke Gas Recycled mg/Nm3 800 not specified not specified Wet Quenching Units Green Field Rebuilt Existing Particulate Matter from Tower gm/tonne of coke produced 50 50 not specified 25 Monday, November 19, 2012

26. (a) air-cooled self-sealing doors; (b) the hydro-jet cleaning system shall be provided for the door and door frame cleaning with a facility of hydro jet pressure of 600 kg/cm 2 ; (c) the charging should be accomplished with hermetically sealed charging sleeves and screw feeder in charging car. The charging car should also be equipped with magnetic lid lifter and lid and frame cleaning mechanism (applicable to top charging batteries); (d) to provide aspiration through high-pressure ammonia liquor (HPLA) injection in goose neck and emission should be transferred directly to gas collecting mains; (e) water sealed AP covers should be provided; (f) computerized combustion control and moisture control systems. 26 Monday, November 19, 2012

27. Among the pollution control equipment it specifies Land based stationary precipitator. Norms for the use of effluent treated water for wet quenching. 27 Monday, November 19, 2012

28. Coke Oven Performance parameters Poor environment management also means poor economic efficiency 28 Monday, November 19, 2012

29. Fugitive Emission Standards Compliance Status 2009-10 Name of Steel Plant Battery No Compliance Vizag Steel Plant Battery 1 Yes Visakhapatnam Battery 2 Yes 50% Battery 3 No   Battery 4 No SAIL, Rourkela Battery 1 Yes 40% Battery 2 No   Battery 3 No   Battery 4 Yes   Battery 5 No Tata Steel Battery 3 No Jamshedpur Baterry 5 No 33% Baterry 6 No   Baterry 7 No   Baterry 8 Yes   Baterry 9 Yes JSW Steel, Vijayanagar Battery 3A Yes 100% Battery 3B Yes   Battery 3C Yes   Battery 3D Yes Neelachal Ispat, Orissa Battery 1 Yes 100%     Source: CSE 2012 29 Monday, November 19, 2012

30. Coke Oven Stack Particulate Matter Emission Coke Oven Stack PM Emissions 2008-09 and 2009-10 Plant mg/Nm3 Vizag Steel, 4 43.2 SAIL RSP,2 46 Tata Steel, 3 83 JSW Steel 10 Neelachal Ispat 56 SAIL BSP, 1 77.7 SAIL BSP, 2 75.4 SAIL BSP, 3 66.6 SAIL, BSP 7 80.3 SAIL, BSP 8 83.3 SAIL, BSP 9 89.3 SAIL, BSP 10 94.4 SAIL, DSP, 3 132.3 SAIL, IISCO, 8 113.68 SAIL, IISCO, 9 61.45 Source; CSE, June 2012 Improve quality of coal. Stamp charging increases bulk density. Variable pressure controller. 30 Monday, November 19, 2012

31. Coke Oven Gas Emissions Coke Oven Stack PM Emissions 2008-09 and 2009-10 Plant mg/Nm3 Vizag Steel, 4 43.2 SAIL RSP,2 46 Tata Steel, 3 83 JSW Steel 10 Neelachal Ispat 56 SAIL BSP, 1 77.7 SAIL BSP, 2 75.4 SAIL BSP, 3 66.6 SAIL, BSP 7 80.3 SAIL, BSP 8 83.3 SAIL, BSP 9 89.3 SAIL, BSP 10 94.4 SAIL, DSP, 3 132.3 SAIL, IISCO, 8 113.68 SAIL, IISCO, 9 61.45 Source; CSE, June 2012 High emissions indicate leakages. Can be corrected with self sealing doors. Stamp Charging. To improve bulk density of charge. Increase in coke oven chamber height. Increase in coke oven volume. Water sealed ascension pipes. Hydrojet cleaning. Magnetic lid Dry Quenching 31 Monday, November 19, 2012

32. BF to Gross Coke Yield Company wise BF Coke Yield to Gross Coke Plant Yield % Vizag Steel 83.2 SAIL RSP 88.8 Tata Steel 80 JSW Steel 91.9 Neelachal Ispat 87.8 SAIL, BSP 82.5 SAIL, BSL 83 SAIL, DSP 79 SAIL, IISCO 89 India's Average 84 Global Best 92 Source: CSE, June 2012 This parameter indicates the control of the company to raw material resources especially coal. 32 Monday, November 19, 2012

33. Gross Coke Yield Improves Company wise Gross Coke Yield 2009-10 Plant Gross Coke Yield % Vizag Steel Plant 74.4 SAIL, RSP 74.6 Tata Steel 75.6 JSW 72 Neelachal Ispat 75.6 SAIL, BSP 74 SAIL, IISCO 76 India's Average 74.5 Global Best 81 Source: CSE, June 2012 If quality of coal is better. Bulk density improves through stamp charging. Coke chamber height increases. Variable pressure monitor is installed. 33 Monday, November 19, 2012

34. Coke Oven Gas Collection Rate Company wise Coke Oven Gas Collection Rate 2009-10 Plant Nm3/tonne of dry coke Vizag Steel 340 SAIL RSP 318 Tata Steel 310 JSW Steel 320 Neelachal Ispat 332 SAIL, BSP 317 SAIL,BSL 310 SAIL, DSP 290 SAIL, IISCO 299 India's Average 316 Global Best Practice 388 Source: CSE, June 2012 Would improve if Wet quenching is replaced by dry ammonia quenching. HPLA rather than Gas Burning Chamber is installed. Water sealed ascension pipes are used. Coke yield in the oven improves. Low levels of particulate matter is emitted. Coal has low sulphur content. 34 Monday, November 19, 2012

35. Specific Thermal Efficiency Specific Thermal Energy Consumption 2009-10 Coke Oven kcal/kg gross coke Vizag Steel Plant 813 SAIL, RSP 786 Tata Steel 794 JSW Steel Total 885 JSW 3A and 3D 900 Neelachal Ispat 764 SAIL Bhilai Total 662 SAIL Bhilai 5 546 SAIL, IISCO 781 India's Average 764 Global Best 496 Source: CSE, June 2012 Dry quenching helps in heat recovery. Proper sealing of doors, lids, pipes improve thermal efficiency. Stamp charging improves thermal efficiency. 35 Monday, November 19, 2012

36. List of Clean Technologies Increase in coke oven chamber height. Move over from top to stamp charging to increase density in bulk. Self sealed doors. Magnetic lids. Hydrojet cleaners. Water sealed ascension pipes. HPLA Land based ESP 36 Monday, November 19, 2012

37. Technology #1 Increase in Chamber Height This increases the volume of the oven and reduces the need to repeatedly open the doors. Reduces leakage/diffuse emissions. The number of bushings is reduced. Decreases pushing emission. Global best practice = height of 8.3 metres . India’s average 4.3meters. Volume of coke oven increases. 8.3 m height = 70 tonne of oven volume. 37 Monday, November 19, 2012

38. Technology # 2 Stamp Charging Top charging accommodates 765 kgs /m3 volume. Stamp charging accommodates 1150kg.m3 volume. More coal can be pushed at a time and this reduces charging and pushing emissions. Stamp charging improves coke strength and this helps BF productivity. Combustion emissions/stack emissions are reduced due to increased coke strength. 38 Monday, November 19, 2012

39. Technology #3 Self sealed Doors Gas pressure is kept at a minimum inside the oven so that tar sealing gaskets are formed along the doors. Spring loaded stainless steel doors. GSR 46(E) notification of 3.2.2006 specifies self sealing doors. Of the 45 ovens studied, only 18 have self sealing doors. This is 40% compliance. 39 Monday, November 19, 2012

40. Technology #4 Magnetic Lid In order to minimise leakage/diffuse emissions, magnetic lids are prescribed. GSR 46(E) dated 3.2.2006 specifies magnetic lids. 40 Monday, November 19, 2012

41. Technology #5 Hydrojet Cleaners Technology # 6 Water sealed ascension pipes Hydrojet cleaners helps clean gas exit zones to help declog . GSR 46(E) 3.2.206 has specified the use of such cleaners. Since gas tends to leak through ascension pipes due to high pressure built up in the oven, water sealed ascension pipes are recommended. 41 Monday, November 19, 2012

42. Technology #7 High Pressure Liquid Ammonia Aspirator This helps capture emission by reducing the pressure of gas through ammonia cooling. Used in dry quenching technology for gas collection. Used in stamp charging to reduce charging emissions. Very useful for capturing PAH emissions emanating out of incomplete combustion. GSR 46(E) 3.2.2006 notification exists. 42 Monday, November 19, 2012

43. Technology #8 Land Based Stationary Air Filter Coke is pushed out in container cars on rails equipped with suction hood and bag filters. GSR 46(E) 3.2.2006 recommends the use of land based stationary precipitator for control of dust during coke pushing. 43 Monday, November 19, 2012

44. Design of Coke Ovens In India Name of Plant Battery Gross Coke Capacity in million tonnes per annum Number of ovens/ batteries Chamber Height in metres Type of Charging Coal Holding Capacity (dry coal) in tonnes/ oven Vizag Steel Battery 1 0.8 67 7 top 31.6   Battery 2 0.8 67 7 top 31.6   Battery 3 0.8 67 7 top 31.6   Battery 4 0.8 67 7 top 31.6 SAIL, RSP Battery 1 0.48 70 4.5 top 17   Battery 2 0.48 70 4.5 top 17   Battery 3 0.48 70 4.5 top 17   Battery 4 0.56 80 4.5 top 17   Battery 5 0.56 80 4.5 top 17 Tata Steel Battery 3 0.3 54 4.5 top 17   Battery 5 0.5 30 4.5 Stamp 24.3   Battery 6 0.48 60 4.5 Stamp 24.3   Battery 7 0.48 54 4.5 Stamp 24.3   Battery 8 0.5 70 4.5 Stamp 24.3   Battery 9 0.5 70 4.5 Stamp 24.3 JSW Vijaynagar Battery 3A 0.38 56 4.3 Stamp 27   Battery 3B 0.38 56 4.3 Stamp 27   Battery 3C 0.38 56 4.3 Stamp 27   Battery 3D 0.38 56 4.3 Stamp 27 Neelachal Ispat Battery 1 0.8 67 7 top 17 SAIL DSP Battery 1 0.4 78 4.45 top 17   Battery 3 0.4 78 4.45 top 17   Battery 4 0.4 78 4.45 top 17   Battery 6 0.4 78 4.45 top 17 SAIL BSL Battery 1 0.57 69 5 top 20.7   Battery 2 0.57 69 5 top 20.7   Battery 3 0.57 69 5 top 20.7   Battery 4 0.57 69 5 top 20.7   Battery 5 0.57 69 5 top 20.7   Battery 6 0.57 69 5 top 20.7   Battery 7 0.57 69 5 top 20.7   Battery 8 0.57 69 5 top 20.7 SAIL, BSP battery 1 0.4 65 5 top 16.8   battery 2 0.4 65 5 top 16.8   battery 3 0.4 65 5 top 16.8   battery 4 0.4 65 5 top 16.8   battery 5 0.4 65 5 top 16.8   battery 6 0.4 65 5 top 16.8   battery 7 0.4 65 5 top 16.8   battery 8 0.4 65 5 top 16.8   battery 9 0.8 67 7 top 30   battery 10 0.8 67 7 top 30 SAIL, IISCO Battery 8 0.4 78 4.5 top 18.8   Battery 9 0.4 78 4.5 top 18.8   Battery 10 0.4 78 4.5 top 18.8 Source: CSE, June 2012 Monday, November 19, 2012 44

45. Technologies Adopted in Indian Coke Ovens 45 Monday, November 19, 2012

46. By product plant Sulphur is removed, by products are retrieved 46 Monday, November 19, 2012

47. New technologies for sulphur removal Sulphur content in CO Gas prior to treatment is 1800-4000 mg/Nm3. In ammonia scrubbing, sulphur content comes down to 800 mg/Nm3. In wet oxidative system, sulphur content comes down to 200 mg/Nm3 47 Monday, November 19, 2012

48. Sources of Pollution in By Product Plant Water is generated when the CO gas condenses. Water may contain PAH. Water may also contain sulphur . Sulphur sludge. Tar sludge Benzol sludge. 48 Monday, November 19, 2012

49. Effluent treatment plant Here waste water enters for treatment and cleaning. Also sludge from distilled by products are cleaned into non hazardous solid waste. 49 Monday, November 19, 2012

50. Steps in Effluent Treatment Plant Tar is removed. Suspended solids captured. BOD,COD removed. Sludge is thickened. Water released. Ammonia is removed. Cyanide is removed. Clean water flushed. Solid waste disposed. 50 Monday, November 19, 2012

51. Water Treatment Parameters in ETP Waste Water Treatment Plant Parameters Parameter Units Tata Steel SAIL, RSP JSW, Vijaynagar pH   7.8 8.5 to 9.5 8.2 to 8.7 Ammonia Nitrogen mg/litre 150 300 to 350 120-348 Phenol mg/litre 330 400 to 450 264 to 725 Cyanide mg/litre 4.8 to 5.6 20 7.4 to 262 Oil and grease mg/litre 5 to 10 30 to 40 7.7 to 24.6 BOD mg/litre 1150   COD mg/litre 2400 1939 to 2931 Total Suspended Solids mg/litre 50 138 to 569 Mixed Liquor Suspended Solids 4000     3248 Source: CSE, June 2012 51 Monday, November 19, 2012

52. Water Consumption in Coke Oven Coke Ovens consume 13% of all water required in the steel plants. Water is used for cooling ovens, quenching off gas. Cleaning plant and machinery. Water is condensed out of coal, out of the Coke Oven Gas while recovering tar and other products. Also during cyanide dilution. 52 Monday, November 19, 2012

53. Dry Quenching reduces water consumption. Coke Oven Plants 2009-10 Plant m3/tonne gross coke Method of Quenching JSW 0.55 dry SAIL, RSP 0.72 wet Tata Steel 2.3 wet Source: CSE, June 2012 Waste Water in ETP 2009-10 Plant m3/tonne gross coke Vizag Steel Plant 0.2 Tata Steel 0.27 SAIL, RSP 0.44 JSW 0.5 Global Best 0.3 Source: CSE June 2012 53 Monday, November 19, 2012

54. Solid waste can be Non hazardous Coal dust as spillage from carts, storage and handling areas. Undersize particles of coke. Spillage during coke pushing. All are collected and recycled. Hazardous Tar decanter sludge from by product plant. Coke activate sludge from ETP. Benzol muck. Sulphur muck. Waste oil and grease with cyanide. 54 Monday, November 19, 2012

55. Hazardous Solid Waste Generation and Disposal c Hazardous Solid Waste Disposal in 2009-10 Vizag Steel Plant SAIL RSP Tata Steel JSW Steel Hazardous Solid Waste quantity generated in tonnes Method of disposal quantity generated in tonnes Method of disposal quantity generated in tonnes Method of disposal quantity generated in tonnes Method of disposal Tar Decanter Sludge 2956 100% recycled 60 100% recycled 3180 100% recycled 300 100% recycled Other tar wastes 77.7 100% recycled 96 waste pit         Benzol muck 468.17 100% recycled             Coke Oven ETP activated sludge/tarry waste 751.37 100% recycled 8 100% recycled 47.5 100% recycled 365 100% recycled Sulphur waste none   10 sold to authorised agencies               300 waste pit     330 sold to authorised agencies Source: CSE, June 2012 55 Monday, November 19, 2012

56. Overall Performance of Coke Ovens, By Product Recovery Vizag Steel 3 leaves Tata Steel 2 leaves JSW 2 leaves Neelachal Ispat 2 leaves SAIL, RSP 1 leaf SAIL others: non performers. 56 Monday, November 19, 2012

57. Main sources of deviation COD, Nitrogen, cyanide control. B(a)P concentration high. Leakage, charging and pushing emissions. Stack PM emissions. Hazardous waste disposal. CO gas collection rate. Dry quenching technology. Coke oven chamber size. 57 Monday, November 19, 2012

58. Changes Needed Plant and equipment Dry quenching. Taller chambers. Self sealing doors, magnetic lids, water sealing. HPLA system. Variable pressure monitor. Land based stationary precipitator. Operational Better cleaning. Better draining. Keener COD, BOD practices. Improved tar decanting. Improved solid hazardous waste disposal. 58 Monday, November 19, 2012

59. Non recovery ovens 59 Monday, November 19, 2012

60. CO oven serves the following functions Provides coke for Blast Furnace. Recovers by products like tar with economic value. Recovers Coke Oven Gas which is a source of heating for the steel plant. 60 Monday, November 19, 2012

61. However, the recovery type coke ovens also produces PAH PAH emanates due to the attempt to recover by products. PAH is carcinogenic and the US has banned the recovery oven for future ovens. 61 Monday, November 19, 2012

62. In the non recovery coke oven CO oven gas is wholly burnt without any possibility of recovery of by products. Instead, more heat is recovered from the process. No waste water discharge. No need for elaborate ETP. PAH is negligible. More coal holding capacity. 62 Monday, November 19, 2012

63. But, the flip side Less coke yield as coke is also burnt. Air emissions tend to be high due to high pressure as the volatile matters are burnt inside the coke chamber. Takes up more space. 63 Monday, November 19, 2012

64. Performance can be improved through Stamp charging. Dry quenching. 64 Monday, November 19, 2012

65. Comparative Gross Coke Yield Company wise Gross Coke Yield 2009-10 Recovery Coke Oven Plant Gross Coke Yield % Vizag Steel Plant 74.4 SAIL, RSP 74.6 Tata Steel 75.6 JSW 72 Neelachal Ispat 75.6 SAIL, BSP 74 SAIL, IISCO 76 India's Average 74.5 Global Best 81 Source: CSE, June 2012 Company wise Gross Coke Yield 2009-10 Non recovery Oven Gross Coke Yield % Visa Steel 68.3 JSPL 68.3 Bhushan Steel 72.9 JSW 71 India's Average 70.2 Global Best 76 Source: CSE, June 2012 65 Monday, November 19, 2012

66. BF to Gross Coke Yield Recovery Ovens Company wise BF Coke Yield to Gross Coke Plant Yield % Vizag Steel 83.2 SAIL RSP 88.8 Tata Steel 80 JSW Steel 91.9 Neelachal Ispat 87.8 SAIL, BSP 82.5 SAIL, BSL 83 SAIL, DSP 79 SAIL, IISCO 89 India's Average 84 Global Best 92 Source: CSE, June 2012 Non recovery Ovens Company wise BF Coke Yield to Gross Coke Non recovery Yield % Visa Steel 87 JSPL 90 Bhushan Steel 90 JSW 87.6 India's Average 88.6 Global Best 92 Source: CSE, June 2012 66 Monday, November 19, 2012

67. Sources of Air Pollution in Non recovery ovens Stack emissions connected to Waste Heat Recovery Boilers. Fugitive Emissions due to charging and pushing. During wet quenching of coke. All CPCB norms of air pollution limits are the same. No suggestions on plant and equipment. 67 Monday, November 19, 2012

68. Other emissions Negligible waste water discharge. Almost no hazardous solid waste. 68 Monday, November 19, 2012

69. Performance of non recovery coke ovens Plant Bhushan Power and Steel, Odisha Visa Steel, Kalinganagar , Odisha JSPL, Raigarh JSW Vijaynagar Grades Two leaves Two leaves One leaf One leaf Monday, November 19, 2012 69

70. Major Areas of Deviances Unable to match up in waste heat generation. Unable to match up to BF coke yield. Unable to instal dry quenching. Stack emissions poor. Monday, November 19, 2012 70