Being a process industry that consumes and generates considerable amount of fine sized inputs & outputs, proficient waste management in terms of its methodical disposal and value addition, wherever possible is an absolute necessity. Failing this, the company may face serious consequences resulting in even its future growth restriction. At Tata Sponge, a number of initiatives have helped in proper waste management…
- A clear water pump ensures continuous cleaning of contaminated water for its reuse in operations.
- A large waste-dumping yard has been developed at a safe distance between the plant and the township to dispose off waste materials generated during sponge iron production. To avoid pollution, a thick layer of sweet soil covers the waste heaps and grass is grown to make the area clean and green.
- Concrete flooring has been laid inside the plant in areas. Continuous water spraying cleans the floors and helps the dust to flow into nearby drains from where the sludge is collected and disposed off in the waste yard.
- Separate disposal yards have been earmarked for dumping biodegradable and non-degradable rejects. These are disposed as per company procedure. Regular inspection by the Environment Cell ensure nonoccurrence of any lapse in this regard.
- Brick plants have been commissioned to convert the waste fly ash generated in the power plant into bricks, by adding sand, lime and gypsum. The strength of such bricks is 4 times greater than conventional clay bricks while the shape is far better and flexible due to the moulds used for their making.The Company has extensively used these bricks for constructing boundary walls, residential flats, and buildings inside the plant. The encouraging demand for these special bricks is being met by four brick making machines. The management of this unit has been given to a charitable trust formed by the wives of employees. The profits thus generated is meant to be used for charitable activities.
- Generation of power: Tata Sponge has installed Waste Heat Recovery Boilers (WHRB) to generate power from the hot gases of its 3 kilns.
This converts the latent heat of kilns into productive electrical energy. The electrical energy thus generated not only caters to the entire plant requirement and township, but also earns the company profits by selling the surplus power.
Thus, this unconventional route of generating power has acted as a substitute for fossil fuel (coal) which would have been otherwise consumed to produce energy for meeting company needs. Besides, this has also helped the company to become the first sponge iron company in India to avail CDM benefits.