Professional Documents
Culture Documents
Foreword
Steel Sector has been facing a lot of Challenges. Indian Institute of
Plant Engineers (IIPE) has been instrumental in creating platform for
the professionals The Indian in various industries and also for cross
industry exchange of views that have been instrumental in Plant
Productivity.
A seminar in Nov 2005 on Approaches to Zero Break Down
Maintenance at Steel Plants attended by over 150 delegates gave
an overwhelming response and the recommendations of the seminar
have become Industry guidelines. This seminar was not possible without the support of
SAIL, Bhilai Steel Plant.
A seminar titled War on Waste, inaugurated by Dr V Krishnamurthy, was organized in
Sept 2006, which covered Waste Management in various sectors. During the valedictory
function, chaired by the then Min. of State for Steel, it was recommended that the Industry
specic Waste Management should be organized at Plant locations. This seminar in Iron
& Steel Sector is the first in the chain of such Seminars to be organized eventually in
all industrial sectors including Oil & Gas, Fertilizers, Power (thermal, nuclear, hydro
etc) Mining, Textiles, Chemicals etc.
With the active support of SAIL (RSP), the present Seminar being organized at Rourkela,
will have Technical papers form all over the world including those from developed
and developing nations. The overwhelming response from Steel Entrepreneurs,
throughout the world, has already been demonstrated with participation of
delegates from USA, China, Nepal, Pakistan etc.
I am personally grateful to the Management of SAIL in general and the Managing
Director, RSP in particular for their wholehearted support.
J.S. Saluja
National Vice President, IIPE
& Chairman IIPE (Delhi)
Editorial
World Competitive standards, Rising input costs, Scarcity of raw
materials, Wastes generated like in other Sectors, have compelled
Mining, Iron & Steel Manufacturing Companies, to have a re-look
into their respective operations for all inclusive development and
sustainability in the operations. The Iron & Steel Industry is undergoing
a phase of uncertainty, volatility and speculation. Waste Management
in the Mining, Iron & Steel Industry has gained importance in view of
these dimensions.
The rapid advancement in technology, has made it possible to realize the task of Waste
Reduction, recycling in the Iron & Steel Industry on a sustainable basis.
This jointly organized by Steel Authority of India (SAIL) & Indian Institution of Plant
Engineers (IIPE) seminar, has been planned to share the experience, propagate and
recommend Waste Management potential of Raw Materials, socio economic and political
factors, which may have direct and indirect impact on the growth dreams of the Industry
among other relevant issues of strategic importance. The strategy of Wastes generated at
the Womb the mine to the Tomb - the Salable Product is to be conceptualized in total.
The papers presented are a product of extensive and in depth analysis with incredible
amount of time spent by various writers.
An attempt has been made to highlight some of proven and established technologies,
systems, processes, and attitudes etc., which are essential for continuous world wide
efforts being made towards achieving Waste Management Practices available for further
improving the same. The contributions from experts and practicing professionals have
great potential for implementing these practices.
YP Chawla,
Program Director
National Jt .Secy. IIPE
Program
Registration of Delegates - 9th May 2008 Friday 0800-1000 Hrs
International Seminar Waste Management in Iron & Steel Industry,
9-10 May, 2008, Rourkela
Inaugural Session
10.00-10.15
Welcome address
J S Saluja
10.15-10.30
10.30-10.45
BN Singh MD RSP
10.45-11.00
Inauguration
11.00-11.10
Vote of Thanks
ED (O), SAIL
Summing up
16.40-16.50
Journey Forward
16.50-16.55
Vote of Thanks
11.25 Tea
11.25
12.45 Session 1
12.45
13.30 Lunch
13.30
15.30 Session 2
15.30
15.50 Tea
15.50
18.00 Session 2
Contd
10.30 Session 3
10.30
11.00 Session 4
11.00
11.20 Tea
11.20
13.00 Session 5
Success Stories
13.00
14.00 Lunch
14.00
16.00 Panel
Discussions
16.00
16.20 Tea
16.20
16.55 Valedictory
Technical
Session
Paper
1.0
Topic
Base Paper
Author
YP Chawla
Session-1
1.1
V K Dhawan
1.2
1.3
R.K.Agrawal A.Sengupta
1.4
The Waste Management and Integrated Utilization
Wastes in Mining , Iron & Steel Industry
2.1
Use of Sub-Grade Ore- A case study
Session-2
2.2
2.3
Sajeev Varghese
2.4
S Roy Choudhury
2.5
2.6
2.7
2.8
Dr. B N Das,
B Vaidyanathan,
K K Manjhi, Dr. S P Kalia,
DD Patra,
DM Srivastava,
S.Ranade.
S.K.Bandopadhyay,
P.K.Ray Choudhury,
D.Ghosh, S.K.Vadher,
S.Chandrasekaran
K.K.Sanyal
2.9
Satyabrata Mishra
R.P. Singh
R.G. Segaran
S.Nanda,
D. Mohapatra,
Md. Islamuddin ,
3.3
Dr. B N Das,
V V R Murty
3.4
B. Sankar R.K.Dutta
P.K.Pani
3.5
Navin Kumar
VK Srivastava, AK Oli
Session-4
4.1
John H. Buddemeyer
4.2
TC Inc.
4.3
R.B. Gupta,
G.C Pattnaik
Position
IIPE
Patron
2
3
4
IIPE
Patron
IIPEPatron
President
National
Vice Pres.
National
Jt. Secy
Sl.
Position
Name &
Designation
Lt. Gen. SS Apte
PVSM (Retd)
Past NP, IIPE
Shri CK Varughese
Past NP, IIPE
Shri NP Gupta
Shri Rakesh Nath
Chairman
Shri J S Saluja
Director Project
Shri YP Chawla
CEO
.
Address
Phone (O)
Fax
Phone (R)
9810310233
011-26854525
011-26105997
011-26168627
9868553045
011-22779856
011-29211185
011-29219566
011-26102583
011-22150630
0120-6626666
9811101181
011-46591105
0120-6626690
011-26942660
011-46591100
011-25262517
011-25279434
Address
Phone (O)
Fax
Phone (R)
0120-6626666
9811101181
011-46591105
0120-6626690
011-26942660
011-46591100
011-25262517
011-25279434
Chairman
Secretary
2
3
4
Secretary
(Fin)
Manager
Name &
Designation
Shri J S Saluja
Director Projects
Shri YP Chawla
CEO
.
Shri Satish Bahadur
Shri A Bhatnagar
9811916962
011-26493252
9811319198
011-26493974
011-23710822
23319962
011-22629546
Steering Committee Intl Seminar on Waste Management in Iron & Steel Industry
Sl.
1
2
3
4
5
6
Position
Chairman
Vice
Chairman
Incharge
Co-ordn.
Resource
Person
Chairman
Progm.
Director
Name &
Designation
Shri NP Singh., ED
(Works),
Shri SS Mohanti,
ED - MM
Shri RK Mathur,
Sr DGM
Shri S Ranadey ,
GM ,
Shri J S Saluja
Director
Shri Y P Chawla,
CEO
Address
Rourkela Steel Plant , Rourkela
Orissa 769011
-do-
Phone (O)
Fax
Phone (R)
0661-2510641
2523241
0120-6626666
9811101181
011-46591105
2642111
0120-6626690
011-26942660
011-46591100
011-25262517
011-25279434
Coordinating Committee Intl Seminar on Waste Management in Iron & Steel Industry
Sl.
Position
Chairman
Incharge
Co ordn
Member
--Do--
--Do--
Shri JC Mohapatra,
COC,
Shri GN Mathur
Shri P. Bansal, SAIL
HQ
Shri Mahesh
Takhtani,
Shri Narayan Pati
DGM COP
1
2
In charge
Reception
Committee
In Charge
Seminar
Task Force
--Do--
--Do--
10
--Do--
Address
Rourkela Steel Plant , Rourkela
Orissa 769011
--Do-Ex. CBIP
--Do--
Phone (R)
2646306
011-25079178
0661-2510920
Shri BB Mishra
0661 2511288
094379 63741
Shri A M Pujari
Shri Satish Bahadur,
0661 2510395
President, Business Combine
094379 63732
9811916962
Fax
0661-250050
94370-85885
22531226,
2240 3564
094370 47402
Shri P Varshney,
Vice President,
Phone (O)
0661-2611140
98101 53223
98685 14255
0661-2642
402
011-23710822
23319962
Technical Committee Intl Seminar on Waste Management in Iron & Steel Industry
Sl.
1
2
3
4
5
6
7
Position
Chairman
Member
--Do---Do---Do---Do---Do--
Address
SAIL HQ Ispat Bhavan Lodi Rd.
New Delhi 110 003
Rourkela Steel Plant
Rourkela Steel Plant
Rourkela Steel Plant
D-II /2449, Vasant Kunj, ND-70
Phone (O)
2222388
2221023
Address
ADG, EME (ESM) AHQ, New Delhi
R-256, D.S., Arjun Vihar, Delhi Cantt.
D-II/2449, Vasant Kunj, ND-70
Phone (O)
011-23011423
9350040427
011-23019478
Fax
2510359
Phone (R)
2241777
2242339
2646326
011-26138209
Essar Group
A-5, Sector-3, Noida-201 301
GM In charge SAIL Burnpur
AMMP-Division
Sl.
1
2
3
Position
Chairman
V.
Chairman
Secretary
Fax
011-23018608
Phone (R)
011-25691904
011-26138209
011-23018461
011-24677784
Position
Member
A. Board
--Do---Do---Do---Do---Do---Do---Do---Do--
10
11
12
--Do---Do---Do---Do--
13
14
15
16
--Do---Do---Do--
Address
Chief Secy Delhi
Phone (O)
Fax
Phone (R)
011-26102583
011-26109212
011-22150630
9810131406
Cmn. Utrakhand Jal Vidyut
NTPC Ltd SCOPE Complex
Core V Lodi Road ND-3
CMD, BBMB
SAIL , Ispat Bhawan, Lodhi Road,
New Delhi 110 003
SAIL , Ispat Bhawan, Lodhi Road,
New Delhi 110 003
Ashok Steel Inds. Ltd Bhagmati
Chambers Milan Marg. Kathmandu
PO-121112,
KA-2-2/18
Sewa Bhawan RK Puram,
Sec-I, New Delhi-110 066
BHEL , Siri Fort, Asian Games
Village, ND-110049
Essar Group A-5 Sector 3, Noida
Shri V S Verma
Member
Shri K Ravi Kumar
CMD
Shri J Mehra
Director
Brig AK Adlakha
Executive Director
Shri NP Gupta
President
Ms Rita Singh
Dr A K Lomas
CMD
011-24360232
011-26493129
011-24363478
011-24692543
0124-4043679
011-24367105
011-24367250
011-26492434
011-24368094
011-24367015
011-26493004
9771-243148
9771-242395
011-26102583
009-7714226477
0097753520155
011-26197267
011-26492024
011-26001001
011-26492043
011-26493933
0120-6626602
0120-6626690
011- 51071555
51072555
9810039364
011-29211185
9810096139
011-51070555
0120-2430769
011-29219566
0712 2510289
0120-4260204
0712-2510338
Vice Chairman
Sl.
1
Position
--Do--
--Do--
--Do--
--Do--
Address
Desein Indure Group Greater
Kailash-II, New Delhi- 110 048
PGCIL, Corporate Centre
th
7 Floor, Plot No-02 Sec.29
Gurgaon- 001
SAIL, Ispat Bhawan, Lodi Road,
New Delhi
nd
PTC, 2 Floor, NBBC Tower 15
Bhikaji CamaPlace ND 66
Phone (O)
011-29223761
9810019907
0124-2571957
9811612124
Fax
011-29218393
0124-2571956
Phone (R)
011-26132279
011-26132193
011-26894118
011-24366740
011-24366470
0120-2771278
011-51659132
98101053223
011-51659145
011-26277936
--Do--
--Do--
Dr GS Yadava
03788-225832
09436068834
0129-2428574
011-26591272
9891334151
011-26591615
26856058
26861834
Category
Address
Phone (O)
Fax
Phone (R)
Convener
Power
Sctr.
Convener
Steel
Sectr.
Dr. KK Govil
Ex- Dir (P), PFC
9811165557
011-24367259
011-24367250
011-264925174
Fax
Phone (R)
011-26147514
Executive Committee
S.
No
1
2
Category
Address
Phone (O)
Member
--Do--
011-25089974
011-26843281
--Do--
AHQ
Simon India Ltd., Devika Tower,
Nehru Place, ND-19
ONGC Limited New Delhi
9810843739
9810492884
011224064651
0135-2720278
--Do--
--Do--
--Do--
--Do--
--Do--
10
--Do--
11
--Do--
Shri AG Ansari
Chief Engineer
Shri S Majumdar
Executive Director
(DMS)
Shri LC Jain
Vice President (P)
011-27941082
01991-255433
011-27941082
011-22624985
0129-2258834
0129-2272806
9810546695
0124-2571955
0124-2571956
011-26890926
011-30623740
9313980341
01126783278,
26781483
011-26511605
www.beekaycorp.com
Knowledge Partners:
SailCon
Rourkela
Bokaro
Bhilai
Pacific Sterling Inc. USA
Base Paper
[1.0 / 1 ]
This paper is intended to give some inputs and data that has been collected for
reference by our Paper presenters , delegates to work out the Strategies intended to be
developed in this seminar and come up with recommendations that will make this
Industry self sustained to the extent possible targeting Zero Waste. The reports and
data referred in this paper might have gone changes at the time of Seminar. These
have been updated at the time of Compilation and are intended for giving direction to
the process of interaction and to be referred as base paper during the Seminar.
The Steel Industry is presently vibrant due to demand as well as volatile due to
high cost of inputs. The World Steel industry has entered a new phase. Finished steel
consumption in the five years since the start of the millennium has increased by 233
million tonnes - an average annual rate of around 6 percent. This compares with a 1.2
percent average yearly rise in the previous three decades to 2000.
Large Steel inventory building has occurred around the world. The talk of
shortages of raw materials has possibly prompted buyers to carry higher stock levels
than previously considered necessary. Fluctuating interest rates at moderately low level
the world over (barring India) have made inventory building exercise less painful than in
the past.
On the other end, Chinese government is deliberating on avoiding overheating of
Chinese economy by attempting to reduce growth in key industrial sectors, including
steel.
Overall, the World has not seen so much demand in last 20 years as it is now. The
global steel demand is seeing the rise on the back of accelerated infrastructure activity
in China, CIS and India, housing boom in USA, and white goods resurgence in Europe.
During the recent recessionary phase, the industry has consolidated in terms of
ownership as well as mothballing of inefficient capacities. And the Steel prices continue
firming up.
The Demand of Steel in India, China and other Asian countries is led by emphatic
investment activities in infrastructure. While, the reconstruction work in Iraq is expected
to fuel further demand for steel over the next few years. China is consuming steel like
never before for its infrastructure with investments such as Three Gorges project on
Yangtze as well as part of its build up to the Beijing Olympics in 2008 and the Shanghai
Expo in 2010.
Base Paper
[1.0 / 2 ]
In Europe, there is demand from housing and white goods industry which is on
buoyancy, according to industry estimates.
The global metals and mining industry grew by 17.5% in 2007 to reach a value of
US$1,457.4 billion. In 2011, the global metals and mining industry is forecast to have a
value of $1,600 billion, an increase of about 12% since 2007.
The demand supply gap is expected to increase driving the steel prices
northwards, even as the global steel industry is not prepared for this demand onslaught.
Approx. 90 percent of global steel demand growth over the next two years will take
place in the emerging or developing nations of the world.
Steel is an input for Global Industry. Steel Sales account for 67 % of the global
industrys value.
The challenges that the Industry faces today are the requirement of a sustainable
development by meeting the needs of our present generation without compromising the
ability of future generations to meet their own needs. The Industry is required to
understand the importance of a sustainable approach to the operations of any company
across the entire value chain, from the extraction of raw materials from the Mine through
to the manufacture of finished steel products and the distribution to our customers.
(Womb to Tomb Approach)
Steel is an integral part of our developing world, both now and into the
future. As one of the most common materials we come in contact
with everyday, it is difficult to imagine a world without steel. The
reason for this is steels strength, versatility and ability to be
recycled. Steel can be used many times over with re-processing
techniques maintaining properties and qualities, something that
makes it unique from other materials.
Base Paper
[1.0 / 3 ]
The Challenge of the high energy Cost (Iron and Steel sector is the largest
energy consuming sector in the world, devouring 15% of world industrial energy)
coupled with a pressure on the Carbon emissions and, the employing Competitive
Specific Energy consumption pattern is the challenge to the Technology Providers.
The benchmarking of Energy Consumption is another challenge by India being a
net importer of Crude Oil. In India, average specific energy consumption in steel making
is in the range of 6.2 8.2 GCal/TCS (vis--vis international value 4-4.5 GCal/TCS)
Similarly
benchmarking
Co2
emissions, the average CO2emission is
in the range of 2.2 3.2 T/TCS in
India(vis--vis international value of 1.5
1.7
T/TCS)
CO2emissions
in
steelmaking stem from the intense
consumption of fossil fuels for thermal
energy,
coke
making,
process
requirement and electrical energy mainly
is another task to be considered.
Carbon dioxide emissions from steel
production, which range between 5 and
15% of total country emissions in key
developing countries will continue to
grow as these countries develop to cater
to global steel demand
Reducing energy intensity is
therefore not only beneficial in saving scarce resources but also in reducing carbon
emissions and thus mitigating global climate change.
With increasing energy prices, diminishing reserves of conventional forms of
energy, and increasing GHG emissions, it is a need of the hour for the iron and steel
industries of the developing world to a take sustainability approach for utilization of the
limited fossil fuel reserves of the earth.
Base Paper
[1.0 / 4 ]
GHG emission
reduction in iron and
steel manufacturing
facilities can be done
through
different
routes
like
replacement
/
switching of CO2
intensive fuel (e.g. oil
to gas, coal to gas),
energy efficiency in
the
process
technology, waste processing, waste heat recovery projects including power generation,
energy savings by elimination of reheating processes. Such technological initiatives for
curbing GHG emissions, requires substantial capital investment, because of which
India, with its mixed bag of plant and machinery (power + industrial) in terms of old,
outdated industrial and power generation equipment coexisting with the latest, most
modern machinery, is widely seen as a key CER supplier under CDM
Some steel companies in India have initiated Climate Change initiatives towards
improving its energy performance through fuel substitutes, modernization, recovery &
reuse of by-product energy. In integrated steelmaking, a major source of energy and
CO2 emissions is from the manufacturing of coke consumed in the blast furnaces. With
continuous inflation in global steel demand and supply, there will be a necessity for
increasing amount of coke production
In this Context the Waste Management in Iron & Steel Industry becomes important
, covering the complete cycle of Process from Mining Ore to Saleable Product has been
planned to debated on transiting the process from end - of - Pipe approach to
Reduction, Recycle & Reuse i.e. Cleaner Production leading ultimately to Zero
Emissions in continuing with Zero Philosophy .
Zero Defect (Total Quality Management) ; Zero Inventory- (Just in Time
Production)
Zero Emission (Total Productivity): Reengineering of the Manufacturing
Processes for fully Utilize the resources within Industry for higher Revenues and Jobs.
Zero Emissions extend as under :
Base Paper
End-of Pipe
approach
[1.0 / 5 ]
Cleaner Production
(Reduce, Recycle, Reuse)
Zero Emissions
(Total Productivity)
Adding New Industry in Up Stream,
Minimizing effects on Down Stream
Utilizing Wastes in existing Industry
Minimize Waste
Value Addition
Cost Reduction
Revenue Increase
Continuing with
Developing Industry Cluster for using
Existing
Modifying the Existing Unit Waste as Input to next Industry
Process
Production
Process
Measures at the
Outlet
of
the
Input- Output Analysis
Output- Input Connection
process.
Water,
Energy, Waste Minimization through
Wastes
Production
Process Integrated Approach- Holistic Approach
Modification
Industry is
presently
Transit Stage to next stage
Ultimate Goal
focused on the
above
Base Paper
[1.0 / 6 ]
Base Paper
[1.0 / 7 ]
Country
2007
Share each
Sl
Country
2007
Share each
0.20%
Total
15.3
Japan
3.364
22.00%
22
Chile
0.034
Brazil
2.418
15.80%
23
Saudi Arabia
0.027
US
1.551
10.10%
24
Sweden
0.022
Belgium
1.539
10.10%
25
Tanzania
0.022
India
0.977
6.40%
26
Argentina
0.021
Pakistan
0.687
4.50%
27
Indonesia
0.016
Turkey
0.64
4.20%
28
Malaysia
0.015
Holland
0.509
3.30%
29
Philippines
0.008
UK
0.481
3.10%
30
North Korea
0.008
10
France
0.451
3.00%
31
Norway
0.007
11
Taiwan
0.384
32
UAE
0.006
12
South Africa
0.382
33
Egypt
0.006
13
South Korea
0.382
34
Morocco
0.006
14
Iran
0.376
35
Russia
0.005
15
Kazakhstan
0.27
1.80%
36
Mexico
0.004
16
Italy
0.213
1.40%
37
Bengal
0.003
17
Canada
0.169
1.10%
38
Burma
0.002
18
Germany
0.096
0.60%
39
Algeria
0.002
19
Viet Nam
0.082
0.50%
40
Hong Kong
0.001
20
Australia
0.073
41
Sri Lanka
0.001
21
Thailand
0.038
42
Mozambique
0.001
2.50%
0.20%
0.10%
0.00%
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
European Union
152.9
160.0
156.5
156.7
154.4
162.1
164.1
167.0
167.3
166.5
European Union
128.6
132.6
129.5
127.4
137.4
144.1
145.4
146.9
146.9
146.2
Other Europe
18.2
22.1
20.6
20.7
24.1
26.0
27.0
28.0
29.7
30.5
Former USSR
31.0
38.8
41.2
38.3
43.4
47.0
50.0
52.0
53.5
55.0
NAFTA
142.4
149.2
132.1
135.1
132.9
152.5
153.5
157.5
157.5
155.5
S America
24.8
28.1
28.4
27.4
28.1
31.5
32.5
34.5
35.5
36.5
Africa
15.4
15.0
16.3
17.4
17.1
17.5
18.0
18.5
19.0
19.0
Middle East
16.6
18.4
19.1
20.9
21.6
23.5
25.0
26.5
27.5
28.5
PR China
122.6
124.6
153.4
185.6
230.8
257.4
291.4
302.0
310.0
322.0
Japan
68.9
76.1
73.2
71.7
73.8
75.5
76.5
76.8
77.0
76.8
Other Asia
109.0
119.5
118.9
129.5
133.3
141.0
143.5
145.7
147.0
149.2
6.7
6.4
6.3
7.1
7.5
7.5
8.0
8.0
8.5
8.5
708.5
758.2
766.0
810.4
867.0
941.5
989.5
1016.5
1032.5
1048.0
Region
1999
2000
2001
2002
2003
Totals may not be arithmetically correct because of rounding
2004
2005
2006
2007
2008
Oceania
WORLD TOTAL
Base Paper
[1.0 / 8 ]
Ref : MPES UK
Governmental Interventions on Iron & Steel:
China began to levy a 5% export duty on coke in November 2006. It raised the tax
rate to 15% on June 1st 2007. As the world's largest coke producer and exporter, the
country has a say in pricing for coke on international markets. Foreign buyers chose to
bear price rises based on the 15% export duty.
India : Govt. of India in order to cool down the surge in steel prices in India by
improving availability is planning to duty cuts on raw and finished material and the
inflation and with a view to controlling prices exports would be disincentivised with levy
of export duty. Imposition of export tax , Reduction of custom duty on Iron & Steel
,Abolishing Countervailing duty on re bar imports etc.
Prospects for International Steel Industry
Present status of the International Steel industry Steel is primarily a raw material
based industry as for the production of one tonne of steel, an integrated plant consumes
4 tonnes of raw materials.
India with its abundant availability of high grade Iron ore, the requisite technical
base and cheap skilled labour for the development of steel industry and to provide a
strong manufacturing base for the metallurgical industries.
India presently accounts for less than 5% of the global output of Finished Steel and
1% of global trade. The per capita consumption of 27 kg. is also well below even the
Asian average of 128 kg. China on the other hand shall consume 280 million tonnes of
Steel, including 30 million tonnes through imports against the total consumption of 30
million tonnes by India.
Chinese Steel and metallurgical industries have provided a major thrust to the
economic development, GDP growth and generation of massive employment
opportunities.
In India , Non-integrated or the secondary producers accounting for over 50%
output of the Finished Steel but without any captive mines have not gained much due to
the sharp rise in the prices of Melting scrap, Sponge Iron, Coke, Iron Ore and other
inputs.
The growth has been mainly export based, boosted by the high global prices and
liberal export incentives.
The current status of the Indian Steel industry amply reflects the vast potential for
the future growth of steel and allied industries through integrated planning to exploit the
potential and the Indian steel is indeed poised for a quantum jump in the next decade.
Base Paper
[1.0 / 9 ]
Base Paper
[1.0 / 10 ]
manufacturing base for the metallurgical products. (iii) Development of rural markets
and providing requisite infrastructure support for fabrication and after sale service in the
rural areas. (iv) Promote construction of steel intensive commercial buildings and
domestic housing in collaboration with Architects and town planners.
To Resolve
Protection of the Biosphere
We will reduce and make continual progress toward eliminating the release of any
substance that may cause environmental damage to the air, water, or the earth or its
inhabitants. We will safeguard all habitats affected by our operations and will protect
open spaces and wilderness, while preserving biodiversity.
Sustainable Use of Natural Resources
We will make sustainable use of renewable natural resources, such as water, soils
and forests. We will conserve non-renewable natural resources through efficient use
and careful planning.
Reduction and Disposal of Wastes
We will reduce and where possible eliminate waste through source reduction and
recycling. All waste will be handled and disposed of through safe and responsible
methods.
Energy Conservation
We will conserve energy and improve the energy efficiency of our internal
operations and of the goods and services we sell. We will make every effort to use
environmentally safe and sustainable energy sources.
Risk Reduction
We will strive to minimize the environmental, health and safety risks to our
employees and the communities in which we operate through safe technologies,
facilities and operating procedures, and by being prepared for emergencies
****
[1.1 / 1 ]
Waste Management
Waste management is the collection, transport, processing, recycling or disposal of
waste materials, usually ones produced by human activity, in an effort to reduce their
effect on human health or local aesthetics or amenity. A subfocus in recent decades has
been to reduce waste materials' effect on the natural world and the environment and to
recover resources from them.
Waste management can involve solid, liquid or gaseous substances with different
methods and fields of expertise for each.
[1.1 / 2 ]
Waste management practices differ for developed and developing nations, for
urban and rural areas, and for residential, industrial, and commercial producers. Waste
management for non-hazardous residential and institutional waste in metropolitan areas
is usually the responsibility of local government authorities, while management for nonhazardous commercial and industrial waste is usually the responsibility of the generator.
3.
[1.1 / 3 ]
minimization programs,
prevention, and waste
Use the waste material as a raw material substitute for another process.
[1.1 / 4 ]
wastes of steel plants into wealth provide new business opportunities for prospective
entrepreneurs.
On an average about 400 Kg of solid by products is generated in the steel industry
per tonne of crude steel and the world steel industry in 2006 had produced about 1.239
billion tonne of crude steel, thereby generating huge wastes. Major share of this (7080%) consists of Blast Furnace Slag and Basic Oxygen Furnace Slag. These wastes
are an ecological hazard. The total steel production in India in 2006 was about 44
million tonne and the waste generated annually was around 14 million tonne with
associated ecological problems. There remain opportunities in utilization of the
generated wastes into commercial products. Technologies have been developed in
most of the developed nations of the world for utilization of the generated wastes. In
India though utilization of wastes has begun it is still quite some time before there is
total utilization.
The objective of this paper is to bring out the scope of waste management in steel
plants through waste auditing, yield loss improvements and by implementing zero waste
programs in respective areas for waste minimization and match with the corresponding
figures in the developed world and again identify measures to minimise generation of
wastes, maximise utilisation of generated wastes and achieve zero waste status.
Integrated steel plants usually consist of Coke oven, blast furnace, sinter plant,
steel melting shop and rolling mills. In addition to the above the plants may have
auxiliary units like oxygen plant and power plant and Engineering shops for their own
uses. In India, Steel Plants are facing the challenge to make and process steel without
adversely impacting the environment, from complying with the requirements of the law
to adopting environmentally friendly, clean technologies. The Ministry of Steel has been
emphasizing on the importance of solid waste management. More than 30 per cent of
solid waste generated in the countrys steel industry is being economically used and it
needs to be further improved.
Solid waste arising from different major shops:
Sl no
Major Shop
Co & BPP
Coke & Coal Dust, Tar sludge, Sulphur Muck, Acid sludge,
Refractory waste
Sinter Plant
GCP, Sludge
RMP
BF
SMS
Rolling Mill
[1.1 / 5 ]
Typically, in an integrated Steel Plant, to make one tonne of crude steel even with
good quality raw materials and efficient operation requires 5 tonne of air, 2.8 tonne of
raw materials and 2.5 tonne of water. These will produce in addition to one tonne of
crude steel, eight tonne of moist dust laden gases and 0.32 tonne to 0.5 tonne of solid
waste.
A Glance to typical Solid Waste utilization in a SAIL plant
000T
Solid Waste
Gen
2006-07
Actual
% Utilization
Generation
2007-08
Plan
Utilization
% Utilization
BF Slag
1743
41
1890
984
52
BF Flue Dust
62
100
55
55
100
LD Slag
397
78
485
403
83
Lime Fines
25
100
30
30
100
Mill Scale
76
100
80
80
100
Refractory
12
50
15
7.5
50
Carbide
Sludge
3.5
100
3.5
3.5
100
Taking clue from the waste utilization being done as shown above a holistic view point on
waste management in iron & steel industry is being conveyed in this paper.
4.
[1.1 / 6 ]
Identifies where, when, how and why these wastes are produced;
Identify the composition of the waste and the source of each substance
Focus on wastes that are most hazardous and techniques that are most
easily implemented
Evaluate the results and schedule periodic reviews of the program so that it
can be adapted to reflect changes in regulations, technology, and economic
feasibility.
[1.1 / 7 ]
steel as it is manufactured into steel products. Examples of these intrinsic losses are
excess scrap generated because of quality rejects, poor or inconsistent steel properties,
or corrosion; excess material consumption due to excessive corrosion and safety
factors; the misapplication of materials; and manufacturing rejects and excesses from
manufacturing operations.
For example yield loss improvements can be achieved through use of dusts,
scales and sludge as an input material in converter process but it has its own merits &
demerits.
5.
[1.1 / 8 ]
[1.1 / 9 ]
Zero waste option to develop new coking processes that reduce emissions at
the source.
Non-recovery coke making processes are technically viable for a lower quality
of Coking coal.
Evaluation of slag reuse is a low cost, high value option for steel plants.
The technology for reducing slag volume and increasing its value to other
industries exists. It is dependent more on steelmaking chemistry and
operating practices than on capital investment
Blast furnace slags are used for the manufacture of cement, road base,
railroad ballast, light weight concrete block, glass and artificial rock. Recycling
it to the blast furnace may raise the hot metal phosphorus content to
undesirable levels.
The processing of steel slags for metals recovery is important for reuse at the
steel plant and is also important to facilitate the use of the nonmetallic steel
slag as construction aggregate.
[1.1 / 10 ]
segregate spent refractories at the source of generation, use them for less
critical applications after necessary conditioning and use them as constituents
in manufacture of new bricks/mortars
Minimize Scale Generation. Direct rolling or hot charging and good reheat
furnace
Oil Separation. Oily sludge is slurry of water, oil and metallic which is difficult
to separate. It has been significantly demonstrated by North American Steel
Industry improved separation of the constituents can be obtained using
microwave technology and specially developed oil release agents.
6.
[1.1 / 11 ]
[1.1 / 12 ]
Based on the discussions in this paper some of the key R&D Opportunities that
may be taken up for Yield Improvements by the industry are given below. The lists of
opportunities are not meant to be exclusive; rather, they are representative of the kinds
of activities that could be included in the overall pathway for yield improvements.
Process Equipment
7.
Conclusion?
Waste Management requires a new attitude. Traditional thinking places all the
responsibility on a few experts in charge of for it. The new focus shall make waste
management everyone's responsibility. Waste management may be a new role for
production-oriented managers and workers, but their cooperation is crucial. It will be the
workers themselves who must make waste management succeed in the workplace.
Management commitment and employee participation are vital to a successful
waste management program. Management can demonstrate its commitment to pollution
prevention and encourage employee participation by:
[1.1 / 13 ]
[1.2 / 1 ]
Introduction
Essar Steel Ltd., Gujarat (India), is part of the Essar Group of Companies which
has established roles in other fields like Shipping, Oil, Power, and Communication. It is
involved in manufacturing of Hot Briquetted Iron (HBI) and Hot Rolled Coils (HRC),
through the Direct Reduced Iron (Hot Briquette Iron) Electric Arc Furnace (DC)
Ladle Furnace Vacuum Degassing / Vacuum Carbon Deoxidation - Continuous Slab
Caster Hot Rolled Coil Cold Rolling - Galvanizing route at its Hazira operation 1.
The steel plant generates by-products such as slags, fines and dust. Essar steel is
aiming to achieve the status of a Zero Waste Company through recycling and reducing
the by-product generations.
2.
[1.2 / 2 ]
These dusts are first processed for extraction of zinc and other metals (if scrap is used
during charging) and later pelletized. Research has found that it could be used as a
source of lime and phosphorous in fertilizers.
Slag produced during the processing of iron and steel poses risk as its utilization
possibilities are limited. Blast Furnace slag, due to the lower iron content and its glassy
nature has found bulk use in the production of slag cement and pozzolanic cement 4.
Basic Oxygen Furnace (BOF) slag has the useful components like CaO, MgO with high
basicities (CaO/SiO2) of above 3.0. BOF slag therefore has high fluxing capacity and is
being charged in the blast furnace due to easy melt and better utilization of calcium
values. In the European countries, 30% of such slags are recycled into the blast
furnace. However, the most harmful components in the BOF slag is Phosphorous
which needs to be accounted for before use either in sintering plant or blast furnace.
Electric Arc Furnace (EAF) slag owing to its high crystallinity and high iron content
has presently no well established method for potential recycling. The Basicity Index (BI)
of the slag is generally between 1.2-1.8 which comes under the low hydraulic Merwinite
group. Also the Grindability Index, which is a measure for the energy required for
grinding a particular material to a given size, is high due to high Iron oxide content. This
makes the further grinding and processing of EAF slag energy intensive. Research is
presently focused on investigating the partial replacement of clinker with EAF slag for
the production of slag cement. Some other researchers have tried to substitute standard
sand with EAF slag and have reported benefits like increase in the compressive
strength and lower consumption of water. Ecomaister Co. Ltd. of Korea has invented,
patented and commercialized Slag Atomization Technique (SAT) by means of which
molten slag is converted to small round balls which is later used as a blasting material
or in cement admixtures 5.
Most of the materials of sludge and dusts from steel industries are recycled
through sinter making. The recycled wastes also have some effect on sinter quality,
strength and productivity. The recycling is generally controlled depending on the
analysis of the waste material.
The process byproduct of mill scale from the rolling process containing >70% Fe is
generally recycled into the sintering plant. Generally, 70100% mill scale containing
high iron is being recycled through either briquetting or sintering route with out any
difficulties. In some cases, de-oiling of the material is required. Rolling mill sludge
contains fine particles, which take the oil portion along with the rolling cooling water.
Recycling of these particles are challenging due to very high oil content. The reduction
of oily mill scale sludge along with blast furnace flue dust in laboratory experiments and
in a pilot plant rotary kiln has indicated that it is possible to reduce oily mill scale sludge
to sponge iron in the rotary kiln.
[1.2 / 3 ]
3.
Source of
Generation
Lime fines
Lime plant
Dolime fines
Dolime plant
4.
[1.2 / 4 ]
Steel Making Plant (SMP): SMP generates various by-products such as scraps,
skulls, lime fines, dolime fines, slag and Fume Extraction System (FES) dust. Scrap,
skulls, all metallic wastes are directly being utilized/recycled for use in the Electric
Arc Furnace for steel making.
Lime fines generated during lime making process are binded along with
pulverized coal and fed to the Electric Arc Furnace. Trials of making pellets out of lime
fines and pulverized coal has been completed. These pellets will be part of the feed mix
to Electric Arc furnaces. Slurry made from lime fines is also used to coat pellets
before charging in the Hot Briquetted Iron (HBI) modules to prevent clustering at high
temperatures inside the module during operation.
5.
References
1. Electric Arc Furnace (EAF) Slag - An excellent substitute for materials of
construction in Essar Steel Ltd Internal report, Essar Steel Ltd.
2.
3.
Michael Fenton, Iron and Steel scrap, U.S Geological Survey, Mineral
Commodity Summaries, January 2003.
4.
5.
6.
[1.3 / 1 ]
Abstract
Indian steel industry is, though nearly 100 years old, has not been able
to cross the crude steel production figure of 100 MTPA even though the country
has vast reserves of iron ore, coal and other minerals. Of the total crude steel
production around 45.1 MTPA (2005-2006), nearly 49% production is from primary
steel producers and balance 51% from secondary steel producers. With the total
liberation of industry sector since 1990s, the country is aiming to achieve 100
MTPA crude steel production within a span of 12 to 15 years, based on clean
technologies, at par with the world standard. A large number of new process
technologies for iron making is presently available in the world, particularly in the
developed countries. The relevance of these modern clean technologies with regard
to the conventional technologies and their feasibility for introduction/adoption in
India have certain limitations in Indian conditions:Absence of suitable technologies for beneficiation of Indian raw materials ,
specially iron ore and coal, Tata Steel has adopted their coal beneficiation
technology to bring down ash level to 14%; but more reduction is required. Coal,
based DRI is forced to use high ash coal of 25 to 40%. VM content in coal is
high and fixed carbon in coal is low . Hence, they are limited to be used even in
the alternate clean route of iron making by COREX process in India.
Several Indian steel plants have adopted some of the modern technological
innovations such as pre and post-carbonisation techniques. Stamp charging for
coke making as well as partial briquetting are also being tried to use inferior
quality coal. Non-recovery coking with heat recovery is finding nowadays much
preferred option. Jindal Steel also has installed Non Recovery type coke oven.
As most of Indian iron ores are combination of hematite-goesthite and
hematite-limonite, the sintering technology has to be developed for high fusibility
characteristics of iron ore. Energy efficient sintering process technology having
least emission is in demand. India requires low capacity cost-effective pelletisation
plant.
For iron making, in Blast Furnace area, coke rate has been brought down to 475kg
/thm from earlier 550 kg/thm. This is an important area for Indian steel plants as
[1.3 / 2 ]
[1.3 / 3 ]
Introduction
Steel in its many forms plays a crucial role in shaping modern industrial society. It
is a decisive factor for the economic and social development of our global society.
However, in this global and highly competitive environment, we have to continue our
efforts to produce steel at less cost, fulfill the stricter quality demands and find solution
to the limitations of energy and raw materials as well as environmental constraints.
A time existed when there were limited options for producing liquid steel. This
situation has changed with recent technological advancements. Many technological
routes have been identified for making hot metal at different parts of the world to avoid
high capital cost of conventional Blast Furnace and make use of different types of
available raw materials to produce steel at lesser cost - depending on the regional
advantages, market demand and techno - economics. While many processes are under
pilot or demonstration scale, few of them have come up as commercial plant.
2.
Global crude steel production during the year 2006 accounts to 1240 Million
Tonnes, which shows a growth of 8.8 % over 2005. China accounted for most of the
[1.3 / 4 ]
At present, the primary sector consists of public sector integrated steel plants
under Steel Authority of India Ltd. (SAIL), Rashtriya Ispat Nigam Ltd. (Vizag Steel Plant)
and the private sector Plant of Tata Steel. In the secondary sector, major steel is being
produced through the Electric Arc Furnace route with some of the new generation plants
having captive DRI (Direct Reduced Iron) & COREX facilities. In addition, there are a
couple of induction furnace units for producing steel ingots. There are a few lone DRI
producing units also, who produces sponge iron as input material for the Electric Arc
Furnaces as substitute for scrap.
While the integrated steel plants in the primary sector have downstream rolling
facilities, the secondary sector has innumerable small, medium and large rolling
facilities which produce finished steel, using feed materials of semis from the primary
sector, EAF and IF units. However, there are many Induction Furnace and Electric Arc
Furnace units who have there own downstream rolling facilities.
[1.3 / 5 ]
Crude Steel Production in India shows an exponential growth in last few decades
which shows more than 100 % increase of production in last 10 years.
Growth in steel demand is highest in developing world. In India present per capita
consumption of finished steel is 30 kg/annum compared to worlds average of 170 kg
/annum. Per capita consumption in India shows a growth of about 46% in last 7-8
Years. The reason for increase in demand is due to more urbanisation and subsequent
change in life, style. This has subsequently lead to infrastructure development, demand
in automobiles and transportation sector.
3.
Raw Materials
Major raw materials used for Iron & Steel making industry are iron ore and coking
& non-coking coal. As per National Steel Policy, to produce 110 million tonnes of steel
by the year 2020, iron ore & coal (coking & non- coking) requirement will be around 190
million tonnes and 100 million tonnes, respectively. Keeping this in mind, review of our
raw material resources, particularly iron ore and coal have gained utmost importance.
Though India has abundant reserves of iron ore, beneficiation of ore to improve the
quality and increased recovery of Iron Ore fines are necessary for effective &
sustainable use of the resource. For this, various techniques like use of hydro-cyclones,
flotation, magnetic separation, jigging etc., can be used. Indian mining industry requires
modern washing and beneficiation techniques for effective utilization of our resources.
Presently most of the fines generated in Indian mines are being exported or
stocked at the mine site, as there is no demand from the Indian steel industries.
Pelletization of these fines can be done for direct use of fines as a feed material for iron
making. In the pelletization process, the iron ore fines are initially agglomerated into
green pellets by adding a binder, usually powdered bentonite. The green pellets are
hardened by drying & heating in an oxidizing atmosphere in the furnace / kiln. India
[1.3 / 6 ]
needs low capacity pelletization plant for effective utilization of ferruginous wastes like
iron ore fines / dust etc.
India has also huge coal reserves, but significant portions of the coal reserves are
characterized by high ash content. The estimated coking coal reserves in India is only
32 billion tonnes which is about 13% of the total coal reserves of our country, and
having high ash content. Hence Indian steel industry are mostly dependent on import of
coking coal, containing low ash. For effective utilization of the Indian coal reserves, high
efficiency coal beneficiation and washing methods are required which includes cleaning
of coarse coal in Jigs, Barrel or Heavy Media Bath and cleaning of fine coal using
flotation technique or Cyclone /Hydro cyclones, with closed circuit water recovery. This
will not only improve the utilization of the Indian coal but also reduce the dependency on
the import as well as less environmental problems.
4.
Coke Making
Most of the recovery type Coke Ovens of Integrated Steel Plants in India (except
few like RINL) were set up during 1950s to 1970s and were subsequently expanded
and modernized. During those days, the pollution control facilities were installed
basically aiming at process requirements rather than control of pollution. There were no
emission/ discharge standards except the standard of CO emissions (3 kg/ton of coke)
and Stack PM emissions standard. (50 mg/Nm3). In 1997, Govt of India notified the
[1.3 / 7 ]
[1.3 / 8 ]
[1.3 / 9 ]
6.
Iron Making
Iron Making through Blast Furnace route includes capital cost for a new Coke
Oven Plant and a new Sinter Plant. To avoid such high capital investment and to utilize
low grade coal and iron ore fines. Alternative iron making technologies have had been
tried and tested in India and were found successful. Some of the alternative Iron making
[1.3 / 10 ]
technologies are through Direct Reduction, Smelting Reduction along with combination
of EAF or BOF for production of steel.
6.1 Direct Reduction Processes
Presently India ranks 1st, amongst the producers of DRI, with an annual production
of 15 MTPA, (25 % of the world out put) followed by Venezuela 8.6 MTPA and Iran 6.9
MTPA.
Indias Ispat Industries Limited (IIL) is one of the leading integrated steel makers
and the largest private sector producer of hot rolled coils in India through DRI process. It
produces world-class sponge iron, galvanised sheets and cold rolled coils, in addition to
hot rolled coils, through its two state-of-the art integrated steel plants, located at Dolvi
and Kalmeshwar in the state of Maharashtra. Its 1,200 acre Dolvi complex, houses the
3 MTPA Hot Rolled Coils Plant, that combines the latest technologies - the Conarc
Process for steel making and the Compact Strip Process (CSP) - introduced for the first
time in Asia. The complex also has a 1.6 MTPA Sponge Iron (DRI) Plant, which was
commissioned in 1994 as the world's largest and most efficient gas-based single mega
module plant. Moreover, the Dolvi complex has a 2 Million Tonne Blast Furnace. Ispat is
the only steel maker in India and amongst a few in the world to have total flexibility in
choice of steel making route, be it the conventional Blast Furnace route or the Electric
Arc Furnace route. Its dual technology allows Ispat the freedom to choose its raw
material feed, be it pig iron, sponge iron, iron ore, scrap or any combination of various
feeds. It also has total flexibility in choosing its energy source, be it electricity, coal or
gas.
6.2 Smelting Reduction Process
The new smelting reduction processes are based on the use of coal together with
pellets or lump ore. One objective of these processes is to eliminate Coke Ovens and
Sinter Plants. Another goal is to achieve non agglomerated fine ore. The smelting
reduction processes can be divided into two groups, the indirect reduction or inbed
process and direct reduction or inbath process, which includes COREX, HISMELT,
ROMELT, DIOS etc. Compared with the traditional hot metal production through Blast
Furnace route, only the COREX process offers the possibility of produceing hot metal
without BF quality coke on industrial scale. The operation results achieved from the
operating COREX plants at POSCO, SALDANHA and JINDAL STEEL, India confirm
this.
JINDALs COREX Plant has 2C-2000 modules. Module -1 was commissioned in
August 1999 and Module -2 was commissioned in April 2001. This process has greater
flexibility in operation and uses various types of non-coking coals as a primary fuel and
requires raw materials of less stringent quality. The gas generated from the process is
[1.3 / 11 ]
used for power generation for the pellet plant and as a fuel in the integrated plant
complex. The special features of COREX hot metal are; high temperature (1480 - 1510o
C), low sulphur, low nitrogen and least amount of impurities. Finally, it is more ecofriendly compared to the conventional Blast Furnace route due to exclusion of Sinter
Plant and Coke Ovens.
[1.3 / 12 ]
achieved indirectly due to reduced coke consumption. The use of CDI along with
oxygen enrichment, saves coke and increases productivity of Blast Furnace.
7.
Steel Making
The performance of the technological routes of steel making in the steel plants of
our country is considerably inferior as compared to the technology at the advanced
countries. The inferior performance is due to the inefficient /obsolete use of technology,
mismatch of Indian input materials with imported qualities --- all leading to low
productivity of capital and labour.
Though the production of steel through secondary refining has been increased
over years in India but the quantum has been comparatively low with respect to other
advance countries. Technology is crucial to long term competitiveness. Some of the
Cleaner technologies for Steel making are energy recovery from the BOF gas, on-line
sampling and analysis of steel, secondary de-dusting, dust hot briquetting & recycling,
treatment of wastewater from wet de-dusting and treatment of wastewater from
continuous casting.
[1.3 / 13 ]
Until the early 70s, oxygen steelmaking plants were built without secondary dust
collection equipment. As a result, most of todays secondary and subordinate primary
source dust collecting installations are retrofitted. The efficiency of such systems is
highly dependent on local conditions. These play an important role when it comes to the
choice and design of the recovery system (enclosures, hoods, etc). Determination of the
waste gas flow rates often depends on local conditions and on the available space for
installing piping systems together with the possible size of the pipe cross-sections.
[1.3 / 14 ]
As per the CREP charter, Ministry of Environment and Forests, all the integrated
steel producers to install secondary de-dusting facility at the Steel Melting Shops by
2008.
8.
8.2 Contiarc
Mainly consists of a melting reactor with an inner electrode, holding and guiding
system inside a central water cooled shaft, which serves to protect the electrode. In this
process the off gas from the furnace is used to preheat the charge .
In the Indian context, there is a wide variation in the technological achievements in
the Arc Furnace Technology. There is limitation in the development of Electric Arc
Furnace Technology due to high energy cost and poor availability of scrap. However,
few secondary producers in India have done considerable progress (refer Ispat Industry
in the Iron making section) in this regard. Installation of proper secondary emission
control system, utilization of EAF dust & slag and control of high noise in the EAF
steel making processes have further scope of improvement . Electrode consumption
of Electric Arc Furnace need to be reduced to 1 kg/thm from the existing level of 6.1
6.9 kg/thm (Reference Plant: Alloy Steels Plant, SAIL) .
[1.3 / 15 ]
9.
ROLLING MILLS
Ingot casting is an obsolete technology and steel makers all over the world are
switching over to continuous casting. Continuous casting eliminate the primary mills and
produce much superior quality material with high surface finish. It saves about 20%
energy. Rolling Mill can be categorized as Hot Rolling and Cold Rolling operations.
Pollution from a Rolling Mills mainly includes mill scale, oily mill sludge, oil emulsion,
pickling acid sludge, emission from reheating furnaces, Noise etc.
9.1 Mill Scale
contains approximately 70 % Fe content. Presently approximately 100 % of the
total generation is either recycled or sold. Hence little pressure is there to develop
further technological improvement for the utilization of mills scale. Rolling Mill sludge
which generally comes out of the secondary treatment from the effluent from mills
mainly contaminated with oils and inorganic particles. As the mill sludge are fines
bonded with grease and oil, its utilization is difficult and presently being dumped in most
of the units. Technology to utilize this in the annealing zone of sinter bed has been
developed by Burns Harbour, technology transfer in this aspect is solicited as oily mill
scale have a great potential for air pollution.
9.2 Thin Slab Casting
The important thin slab flat rolling technologies developed in the world are
Compact Strip Production (energy savings 50% over conventional Hot Strip Mill) and Inline Scrap Process (energy savings 40% over conventional HSM). This is being
installed in the new generation Rolling Mills wherever feasible.
10. Waste Utilisation
In an Iron & Steel Plant, about 85 % of the wastes is slag from Blast Furnace and
Steel Melting Shop. Hence utilisation of slag is an area of concern. Cement Plants can
take Blast Furnace Slag as a input material in its blend. High capacity Steel Plants can
install captive cement plants for the utilization of BF Slag. This will also attract CDM
benefit.
Technology option for the utilization of other ferruginous and non ferruginous
wastes includes various pelletisation and rotary hearth furnaces. Fastmet process is
one such example.
10.1 Fastmet Process
Fastmet is a coal based DRI (Direct Reduced Iron) process developed by Kobe
Steel Ltd. and Midrex Technologies, Inc. Iron bearing materials viz. virgin iron ores and
waste oxides are thoroughly blended with a reductant like coal or waste carbon and
rapidly heated in a Rotary Hearth Furnace to produce 85-92% metallised DRI in 6-12
[1.3 / 16 ]
minutes. This DRI is directly charged to Electric Arc Furnace to produce hot metal. The
hot metal produced in this process is same as conventional hot metal produced through
Blast Furnace route. This process utilizes metal bearing wastes both ferrous and nonferrous. Integrated steel plants find it difficult to process this waste and achieve zero
waste concept. The waste which can be processed through this technology include
residue from iron oxide screening, bag-house dust, mill scale, ESP fines, radial settling
sludge. This process can also utilize stockpiled metal bearing fines from various mining
and processing operations. This is a cost effective, energy conservative and
environment friendly process for recycling of steel plant wastes. This process is one of
the Best Available Technologies converting Waste to Gold.
11. Energy / Green House Gas Emissions Reduction And Pollution Control
Steel industry is one of the highest consumers of energy. It is evident that even
slight improvement in energy consumption in the Iron and Steel sector would mean
considerable saving of money from national point of view. The last two decades have
witnessed an unprecedented increase in the prices of energy available for steel
industry. This has initiated a renewed impetus for introduction of energy efficient
process technology as further energy conservation measures. The major energy inputs
in a steel plant are through Coal (coking & non coking, both), Electricity, Petro- fuels
and Steam, etc.
The Indian Steel plants accelerated their focus towards energy conservation since
the oil crisis in 1973. Various energy conservation measures have been adopted
progressively in the Indian Iron & Steel plants. With the expansion plan of Iron & Steel
Industry, more thrust for energy consumption / conservation is solicited.
[1.3 / 17 ]
[1.3 / 18 ]
building and engine for development. Simple calculation reveals that even to catch up
the world average per capita consumption of 170 kg of steel, Indias production falls
short by 132 MT annually (which is almost three times of the present annual out put).
To achieve global competitiveness, major expansion/ modernization and new
installations of Indian Iron and Steel Industry is underway. This steel making process is
associated with severe environmental impacts, from mining through production process.
With increasing concern at global and local levels on environmental degradation,
existing regulatory measures are being tightened and new regulations are on the anvil.
Project proponents of the expanding steel industry, when contemplating new
installations or expanding/modernization of the existing facilities, must have to plan
environmental safe guards to meet the more stringent pollution norms. The proposed
technologies must envisage Quality improvement of prime raw materials, maximizing
utilization of inferior grade of raw materials, total recycling of other ferruginous and non
ferruginous wastes, maximum thrust of energy saving and reuse, reduced GHG gas
emission, complete control of secondary emission and low particulate and gaseous
emission from the stacks through superior air pollution control systems.
THE ULTIMATE OBJECTIVE IS, EVERY TONNE OF STEEL PRODUCED MUST
AIM AT IMPROVING THE QUALITY OF LIFE FOR EVERY ONE, NOW AND FOR
FUTURE GENERATIONS. IN ONE WORD SUSTAINABLE.
13. Acknowledgement
The author acknowledges with thanks to the management of Steel Authority of
India for the valuable support that have been provided for publishing this paper.
14. REFERENCES
1. Agrawal R.K. and B.M.K. Bajpai (1999), Solid Waste Recycling,
Reconditioning and Reuse, in Proc. of REWAS 99 Global Symposium on
Recycling Waste Treatment and Clean Technology, eds. I Gaballah, J Hager
and B.Solozabal, Vol 2, San Sabestian, Spain, pp. 1638-1646.
2. AISI, 2001. American Iron and Steel Institute, Steel Industry Technology
Roadmap, AISI Report
3. Ameling D (2000), New Developments in Integrated Steel Making in
Europe, MPT International, December-2000, 6, 36-42
4. Balajee S R, P E Callaway, L M Jr Kelman and L J Lohmen (1995),
Production and BOF recycling of waste oxide briquettes containing steel
making sludges, grit and scale at Inland Steel, Iron and Steel Maker, 22, 8,
51-55.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
[1.3 / 19 ]
[1.4 / 1 ]
Introduction
The harmonious development of resource, environment, energy and population is
a key social problem in China even in the whole world. Environmental protection and
ecological equilibrium are considered on the top of the list in Baosteel Group on the
basis of sustainable development. In the implementation of the strategy as quality steel
production, it is also put forward as a integrated utilization strategy that carry out the
environmental protection policies, industrialize the wastes or biproducts of steel
production such as slag, ash, water, gas, oil.
It has been making great progress in the management of waste in Baosteel Group
during 10 years of unremitting efforts. The integrated utilization ratio of the waste is
close to 100%. The integrated utilization of slag, ash, mud and oil is developping toward
the specialization and industrialization.
2.
[1.4 / 2 ]
follows the "3R" principal of reducing, recycling and reusing, which makes the economic
activity as a close cycling system of "resource producing consuming reclaimed
resource" and achieves a "win-win" result of the economy, enviroment and the society.
Therefore, the nature of the recycling economy is ecological economy, the core is the
integrated utilization of resources. The integrated utilization is the key part of the
recycling economy and it is also a path to the recycling economy and sustainable
development.
Baosteel as a example of metallurgy industry in China, attaches great importance
to environmental protection and integrated utilization of resources. We recycles wastes
through internal and external ways, minimizes waste discharge to achieve the "zero
release" for years, We make it true that the so-called waste is very the resources in
the wrong location.
3.
[1.4 / 3 ]
2000), which plays a guiding role on the development of the blast furnace slag powder
in China. At present, we have set up two grinding lines which produces 1 million tons of
slag fine powder each, the production has been widely used in many projects such as
bridges, Shanghai Grand Theatre, the Maglev project, and overhead roads. Blast
furnace slag fine powder promotes the utilization of wastes, not only greatly ease the
pressure of scarce resources, reduce the cost of concrete project, but also significantly
improved the performance of concrete in working ability, strength, durability and other
properties.
[1.4 / 4 ]
ratio has been 100% for 13 years in series. The integrated utilization of fly ash is
gradually on the way of resources recycling.
[1.4 / 5 ]
4.
It is certain that there are a lot to do in the aspect of integrated utilization according
to the demand of recycling economy. It is essemtial to strengthen international
exchange and cooperation. We can exchange successful application as well as
practical experience through communication. Lets make great effort to make the waste
management a prospective career.
[2.1 / 1 ]
Complete Paper
Steel Industry in India is on an upswing because of the strong global and domestic
demand. India's rapid economic growth and soaring demand by sectors like
infrastructure, real estate and automobiles, at home and abroad, has put Indian steel
industry on the global map. According to the latest report by International Iron and Steel
Institute (IISI), India is the seventh largest steel producer in the world.
The announcement of the 'National Steel Policy' in 2005 sets out the
Government's vision for future growth of the sector. The policy largely aims to develop a
modern and efficient steel industry of world standards, catering to the diversified steel
demands. It focuses on achieving global competitiveness not only in terms of cost,
quality and product-mix, but also in terms of global benchmarks of efficiency and
productivity. It seeks to enhance indigenous production of steel to 200 million tonnes
(mT) per annum by 2019-20 from the 2004-05 level of 38.1 mT. This implies a
compounded annual growth of 11.5 percent per annum.
[2.1 / 2 ]
India is the 4th largest producer of iron ore, producing around 154 million tonnes
annually, which is nearly 12% of the global output. Indias proven iron ore reserve at
25.2 billion tonnes is 7% of the world total at around 370 billion tonnes (of which high
grade >65 % Fe hematite is about 14 %).
India's largest iron ore deposits are located in Jharkhand-Orissa belt, which
accounts for 44% of the total reserves, followed by Karnataka-Goa (32%) and
Chhattisgarh Maharashtra (16%).
Of the many problems that beset the steel industry, one is that India is deficient in
raw materials required by the steel industry. Iron ore deposits are finite and there are
problems in mining sufficient amounts of it.
This problem can be tackled by optimum processing of raw materials, search and
use of low grade ores, beneficiation and sintering/pelletisation of iron ore etc.
The National Mineral Policy, 1993 has outlined certain key objectives in the area of
mineral conservation and use like
Utilisation of low grade minerals, mineral wastes and rejects shall also be
encouraged through appropriate incentives.
Bhilai Steel Plant, an integrated ore based steel works, was commissioned in 1959
with production capacity of 1.0 mT of steel. In successive phases, capacity was
enhanced to 2.5 and 4.0 mT in the year 1962 and 1984 respectively. Figure depicts
facilities available with Bhilai Steel Plant for 4.0 mt production. As of now this is the
largest steel plant in India with present capacity utilisation more than 100%.
[2.1 / 3 ]
Bhilais share in the 26 mT hot metal production earmarked for SAIL in 2009 -10 is
7.5 mT. The iron ore requirement in 2009 -10, vis--vis its current requirement is
tabulated below
Iron Ore Requirement of BSP
YEAR
07-08
08-09
12-13
17-18
Hot Metal
5700
5800
7500
7500
Sinter Production
7100
7100
9700
9700
Skip Sinter
5652
5652
8245
8245
900
900
Pellet
Net Lumps Required
4768
4847
3323
3323
5176
4952
7813
7813
4196
4465
4032
3324
4932
4604
6156
8399
-505
-382
709
2630
1641
-1656
586
% SINTER
58.0
57.6
67.5
67.5
%LUMPS
42.0
42.4
25.2
25.2
7.4
7.4
Mines Potential
Lumps
Fines
Surplus / Shortfall
Lumps
Fines
%PELLET
Note: For 2007-08 & 2008-09 short fall in the requirement of fines will be met from old fine
stocks.
The iron mines at Dalli-Rajhara have been in production since 1958 and have so
far produced more than 207 mT of iron ore. With nearly 50 years of mining the ore
reserves have started dwindling giving rise to numerous constraints in mining thereby
creating a shortage of iron ore to meet the future requirement of the steel plant. The
current reserve position is tabulated below
1.1 Constraints in Mining
Working at lower horizons in Rajhara Mech. Mine below ground water table.
Pit likely to go 130 m below water table.
Increase of Silica & reduction of Lump yield with depth as we are nearing the
BHQ basement
[2.1 / 4 ]
Fe %
SiO2 %
Al2O3 %
20.67
67.31
1.76
0.84
32.87
64.09
4.38
2.26
Jharandalli Mine
9.97
63.44
4.36
1.90
4.05
62.33
4.71
2.61
Mahamaya Mine
4.32
62.00
5.00
2.90
Dulki
7.66
63.67
3.60
2.76
Total
79.54
64.88
3.48
1.83
Installation of Slime Beneficiation Plant along with down stream Pellet Plant
for utilization of the tailings.
Benefits
Gain-full utilization of low grade fines for iron making after beneficiation. The
yield of beneficiated fines shall be about 60 65 % having +63 % Fe.
[2.1 / 5 ]
In future all the regular generation of low grade fines shall be directly diverted
to the proposed unit instead of dumping.
This concentrate will be the feed material for the Pellet Plant which would
employ Grate Kiln cooler process of pellet making (Annex. II). Pulverized
coal will be used as fuel for kiln firing.
The pellet thus produced will be used in blast furnaces. The quality of BF grade
pellets is envisaged to be as follows:Fe content
63.50 (Min)
Size
9 -16 mm
CCS
Reducibility
70% (Min)
Swelling index
18 (Max)
2.2 Benefits
Disposal of current slurry generation from the existing washing facilities and
also gradually reclaim slimes from Hitkasa tailing pond.
Gainful utilization of waste material (slime) for iron making in the form of
pellets.
Pellets will directly replace lump ore with additional advantage of improved
productivity and reduced coke rate at Blast Furnaces.
[2.1 / 6 ]
3.
Conclusion
Such initiatives will not only meet the Objectives of the National Mineral Policy but
also establish the techno-economic feasibility of use of tailing and other sub-grade ore
for iron making thereby opening avenues for installation of similar units in India attached
to iron ore processing/washing plants. Beneficiation and use of such type of low grade
(Fe) hematite slime lying unused at various mining units will lead to benefits like
There are possibilities that the rejects of beneficiation plant may also be utilized
gainfully in the form of new products. This needs to be explored.
Alternatively the rejects after slime beneficiation having very low Fe content can be
reclaimed and used for back filling of exhausted mine pits with subsequent afforestation.
[2.1 / 7 ]
[2.1 / 8 ]
[2.1 / 9 ]
2.
A. Mukerji Deputy General Manager (Tech.) Mines HQ, Bhilai Steel Plant had
joined BSP in 1980 after completing M. Tech. (Applied Geology) from Saugar
University. Qualified Lead Auditor for ISO 14001. Has visited Australia and
China.
[2.2 / 1 ]
Introduction
India is a fast developing economy with GDP growth rate exceeding 8% during last
4 years. This growth rate is likely to be sustained for the next 10-15 years.
Steel is the basic material for industrial development. Finished steel consumption
is likely to go to 74 Mtpa by 2012 and to a level of 120 Mtpa by 2018 from a level of 47
[2.2 / 2 ]
Mtpa in 2007. Production of 74 Mtpa finished steel would require about 125 Mtpa of Iron
Ore.
India has reserves of about 12 Billion tonnes of iron ore. However, with the
increasing mining activity and exports of high grade ores; high grade reserves are
slowly & steadily getting depleted. Moreover, existing high grade reserves are not
readily being made available to new steel projects due to a number of policy and
procedural issues.
Appropriate planning is required to have a consistent supply of Feed Material of
63.5+ Fe %. If we continue to consume High Quality Iron Ore Lumps, the resources in
the country will get depleted in a very short period. It is essential to utilize the fines to
full extent. The utilization of fines alone may not solve the resource problems. Hence
Beneficiation of Low grade fines is a must for sustaining steel industry in India.
Essar Steel Orissa Limited is putting up 8 Million Ton Iron Ore Beneficiation Plant
at Dabuna in Joda Sector to utilize the Low Grade fines of about only 58% Fe to up
grade to 63.5+ Fe% using Beneficiation Techniques. Essar Steel has already put up a 8
Million Ton Beneficiation Plant at Kirandul, Bailadila, Chattisgarh to produce 67+Fe %
Direct Reduction grade high Quality material from Ore of 62-63% Fe %.
2.
Magnetic Separation which uses the magnetic property of one material with
Respect to other.
[2.2 / 3 ]
According to the nature of Ore, the quality of final product required, the value of the
ineral & the overall economics one technique or combination of techniques are being
followed by different mineral industries.
4.
If the ore is contains Magnetite the process generally adopted is Low Intensity
Magnetic separation.
The number of stages depends on the Nature of Ore , Feed Quality & Product
Quality. If ROM is a mixture of Magnetite, Hematite & Geothite the process followed is
Low intensity Magnetic Separation followed by Gravity Separation. If very high Quality is
needed then Flotation is followed after Magnetic as well as Gravity separation.
In case of only Hematite & Geothite are present then Gravity separation followed
by High Intensity Magnetic Separation is normally the Beneficiation Route.
5.
[2.2 / 4 ]
The companys Beneficiation Process stopped from 1-1-2006 after Hon. Supreme
Court verdict to stop Mining operations. That was the only Magnetite deposit in India
being mined.
Gravity Separation
Magnetic Separation
Flotation
All the above methods requires de-slimed material as well as Liberation. In Mineral
Beneficiation, slime & liberation are two faces of the same coin.
Size in mm
- 10 +6
- 6 +2
- 2+ 1
- 1 +0.5
-0.5 +0.21
-0.21+0.1
-0.1 +0.053
-0.053+0.02
-0.02
[2.2 / 5 ]
% Retained
1.1
37.5
18.2
12.6
6.6
5.7
2.7
5.6
10.0
Fe %
61.5
60.5
60.0
59.5
60.5
58.0
57.0
50.0
45.0
The minus 0.02 mm finest fraction which is only Slime with 45% Fe. The coarse
fractions needs grinding to liberate the material first at 1mm & below for Gravity
separation & below 150 microns for Magnetic Separation. The grinding should generate
least slime for better yield & to improve the efficiency of Beneficiation equipments.
Primary Grinding of + 1mm Screen oversize in Ball Mill in close circuit with
Screen.
Treat the Gravity Separation Tail in Magnetic separation along with de sliming
cyclone under flow.
[2.2 / 6 ]
Slurry Transportation
Taking advantage of finer grinding our company decided to Transport the
concentrate in Slurry Form through 253 Km long Slurry Pipe line of 20 diameter. This is
a Eco Friendly way of transporting the concentrate. The advantages of this
transportation are:
The transported water is recovered in Pellet Plant after filtration & the same is
used in Pellet Plant as make up water.
Pelletisation
The Concentrate will be filtered at Paradeep & mixed with Bentonite & limestone to
produce pellets which is called as Green Pellets. The Green Pellets are heat hardened
in Indurating machine at 1320 Deg. C using Low Sulphur Oil as Fuel.
The pellet produced is to be used in Blast Furnace as a feedstock.
6.
Conclusion
It is possible to produce good quality Blast Furnace feed material Using Low
Grade Iron Ore Fines using proper Beneficiation techniques. The Concentrate
produced can be transported in Slurry form in an eco friendly & economical
way. The agglomeration techniques of Pelletisation helps to produce material
of correct size & strength material for Blast Furnace.
Utilization of low grade is also in the larger National interest. By utilizing low
grade ores, better quality material is being preserved for future generations.
[2.2 / 7 ]
RO
Scree
Roll
crushe
+1
Screw
Scree
Intermediate
thickener
Hydrocyclone
Hydrocyclone
Rougher
Spiral
Magnetic
separator
Cleaner
Spiral
Concentrate
thickener
Tailings
thickener
Tails
Conc.
[ 2.3 / 1 ]
[ 2.3 / 2 ]
2.
In Dalli mines of Bhilai Steel Plant, work has been carried out to decrease % SiO2
in the sinter fines from 4.4 to 3.9% to improve the functioning of the thickeners. It was
observed that the existing classifiers at crushing screening and washing plant can reject
fine silica particles through its overflow by operating with higher solid to water ratio.
Operating classifier at 20-25% pulp density increases the slime loss from existing 14%
to 19% and decreases silica content in iron ore fines by 0.5%. Increased slime loss was
also causing jamming of Radial settling tank and production loss. In order to reduce
silica content in iron ore fines & reduce slime loss, it is proposed to modify the Fluidized
Bed Classifier (FBC) system so that classifiers can be operated at higher pulp density
without thickener jamming.
This modified system was able to recover iron fines concentrate with 63% Fe with
about 4% SiO2. FBC system was stopped due to failure of dewateriser screen. Now the
[ 2.3 / 3 ]
damaged screen will be replaced by a slow speed spiral classifier (SSSC) unit to
recover the fine iron concentrate from the slime. It will thus ensure the slime loss to
remain at 14% level but improving the quality of sinter fines by decreasing 0.5% silica
content. As the faster settling iron particles would be recovered from SSSC unit, the
thickener jamming problem will be solved & clear process water will be recycled to the
Crushing Screening &Washing plant from the Radial Settling Tank pumping station
itself.
Annual consumption of sinter in blast furnaces is 7.1 million tones for the year
2007-08. A reduction in SiO2 of .5% can reduce slag rate by 2kg/t of hot metal. Thus
annually we can save around 4000t of slag generation. The process flow diagram of
FBC and the proposed modification is given in Fig. 3. The civil work of the proposed
modification is almost complete & unit may start by Jan. 2008.
-10 mm ore fines
Slime 0.2 mm
Fe:50%
SiO2-14%
Duplex Spiral
-10 +0.2mm
Sinter fines
(avg.SiO2-4.4 %)
Fluidised Bed
Classifier (FBC)
Slime beneficiation
system
Slurry Pump
Hydro cyclone
Existing Fines
Conv. Belt
3.
[ 2.3 / 4 ]
5.
[ 2.4 / 1 ]
1.
Introduction
Metallurgical coke making in by product recovery oven is one of the major source
of solid waste generation in an integrated steel plant where coke& coke oven gas are
the major source of energy. Right from the receipt, unloading handling, crushing
carbonization and subsequence coke handling dust & breeze is generated. The process
of coal charging of inside the oven, pushing & coke quenching operation generates lot
of waste into kind of hot air forms, dust, breeze, coke smaller freedom. Energy
requirement of this Steel Plant for heading purposes is mostly supplied by coke oven
gas, tar & pitch mixture.
In the early nineties environmental regulation for coke oven emission was nonexistent, except for co emission (3Kg / ton of coke) & particulate emission (50Kg / m3).
1.
3.
4.
[ 2.4 / 2 ]
2.
[ 2.4 / 3 ]
[ 2.4 / 4 ]
6.
Cause
Spillage
Pusher car
Spillage of coal
Dust emission
during pushing
Spillage of coke
Action
1). All pocket opener for drawing
coal are in automode &
2).All Pocket opener are
interlocking with long travel of m/c.
Spillage at oven top P/S & C/S
telescope bunker charged at a
time & then middle bunker coal
changed & in middle bunker
sleeve with ring provided for
reducing spillage.
Timer introduced in middle
bunker pocket opener for full
charging of oven.
1). All pusher car
Leveling System in auto mode has
been installed.
2). All pusher car spillage chute tie
rod system provided for reduce of
coal spillage, earlier counter chain
system in flexible chute are there.
3). Leveler bar stand straightened
was done so that during leveling of
each. Oven, spillage coal came out
(nearly300kg) in coal spillage
bunker for reuse, which eliminates
coal spillage.
Battery no. 10 Door Extractor
machine (DE-3&4) hoods are
modified for dust emission
control.
chain system has been provided
in cage of door extractor.
In coke oven Battery NO-3 both coal charging cars, screw feeder charging system
has been installed for complete elimination of coal spillage at oven top level.
[ 2.4 / 5 ]
[ 2.4 / 6 ]
In screening area all 25mm grizzly 12 rolls has been provided for better screening
& in continues vibrating screen, double spring has been installed & angle of screen has
been changed from150to 221/20, for better screening. More over the convergent of
grizzly chute has been modified for effective utilization of grizzly rolls & as well as at the
end of grizzly roll, socket has been provided for eliminating coke breakages (which
causes coke disintegration.
In these specific area by modifying CSP equipment BF grade coke generation has
been increased by 1%, and in Bf coke bunker coke fines has been decreased. More
over coke (-25mm) size fraction has been decrease from 3.3 T/Oven to 2.26 T/oven.
All conveyers width has been increased from 1200mm to 1400mm & trough angle
has been changed from 250 to 350 & some leveler arrangement has been installed for
complete elimination of coke Spillage. Special type scrapper has been provided for
separating coke fines from conveyor (non carrying side).
In Tripper care for coke feeding in Bf coke bunker limit switch has been installed
for complete elimination of break down & Spillage of coke.
7.1 Management of Waste
In coke oven starting from coal to coke feeding, waste of different type are
managed differently.
7.2 Waste in Coal Plant
All solid waste generated in coal plant has been reused in cycle by cleaning
manually
7.3 Waste In Coke Oven Battery
Solid waste generated in coke oven Battery has been reused in two ways.
Mechanized / manually mode used in battery area
Manual mode in coke sorting area.
Manual cleaning has been done for coal Spillage, & coal dust & reuse them in coal
plant.
Mechanized mode like coke thrower used in coke pusher & JCB are being used for
coke Spillage occur during coke production, which is recycle with coke at stock yard.
7.4 Manual cleaning Process
4 truck each having 6 Ton capacity regularly engaged for total territory cleaning
specially coal / coke dust / breeze, coke particle. Nearly 4x6x5 = 120 Ton coal dust are
being generated & reused in their system.
[ 2.4 / 7 ]
CSP-1
CSP-2
CSP-3
+25 mm to 80 mm
BF 1 to 4
Bf 4,5/6
+20 mm to 25 mm
SP-3
SP-3
Sp-3
-20 mm
SP1
SP-2
SP-3
Sintering Plant I
Sintering Plant I
Sintering Plant I
Coke dust
K-0
K-0
K-0
Coal dust
CHP
CHP
CHP
Coke particle
Conclusion
Coke oven Batteries are considered to be one of the major contributors towards
waste generation & atmospheric pollution in the Steel industry. The coal preparation,
oven charging, pushing & quenching & coke screening operation causes lot of wastes in
kind of dust, coke particles, coal spillage, coke breeze, coke fines, that are considered
to be the harmful to the human system & this generation & their handling also
considered to be prime important for smooth production of coke oven. Due to large
number of emission sources, their transient nature, long life of coke oven batteries etc.
Control of emission from coke oven is a difficult task.
[ 2.4 / 8 ]
Over the years a large number of different type control measures in the coke oven
have been introduced by the SAIL BSP in the different areas of coke oven Batteries to
improve significant working environment in the operating batteries.
9.
Reference
1. Bandopadhyay s.s et al 1992 Modification of coke oven doors with heat shield
to reduce gas emission.
2. nashan G (1987) Coke making international volume no. 1 1987.
3. Mr. Ghosh. RDCIS in EFCI, 2002 Production of BF Coke in Cleaner
Environment.
4. Abhijit Misra, in EFCI, 2002 Coke plant at Tata steel a technologies model for
environment construction.
[ 2.4 / 9 ]
BATT-1
BATT-2
BATT-3
BATT-4
BATT-6
CSP-1
SY-1
BF-1
BATT-7
BATT-8
CSP-2
BF-2
BF-3
BF-4
BF-5
BATT-9
CSP-3
BF-6
BF-7
SY-2
BSP
Coke Quality
M10 (MAX)
M40 (MIN)
CSR (MIN)
S (MAX)
CRI (MIN)
MOISTURE (MAX)
+80 mm(MAX)
-40 mm
CSP-1
2006-07
8.2
80.4
64.8
0.55
22.0
4.0
8.5
22.0
CSP-2
2006-07
8.2
80.4
64.8
0.55
22.0
4.0
8.5
22.0
CSP-3
2006-07
8.0
80.4
64.8
0.55
22.0
4.0
8.5
22.0
BSP
[ 2.4 / 10 ]
COKE Quality
M10
M40
CSR
CRI
MOISTURE
+80 mm
-40 MM
SULPHUR
MEAN SIZE
CSP-1
2006-07
8.0
80.7
65.4
22.6
3.5
8.6
0.51
54.6
CSP-2
2006-07
7.9
80.9
65.3
22.7
3.6
8.1
17.0
0.51
-
CSP-3
2006-07
8.0
80.5
65.3
22.7
3.8
7.9
21.8
0.51
54.0
BSP
CSP-1
5
CSP-2
5
CSP-3
10
25 MM GRIZZLY
NO. OF ROLL
CONTINUOUS
VIBRATION
SCREEN SIZE
IVS SCREEN
12
28.5 MM
28.5 MM
28.5 MM
20 MM
20 MM
20 MM
BSP
[ 2.4 / 11 ]
BATTERY
BATTERY
BATTERY
SYSTEM
1-8
10
---
---
CONVENTIONAL
TOP QUENCHING
(STAGGER)
SIDE
QUENCHING
BSP
AVERAGE %
+100 MM
2.1
+80 MM
10.2
+60 MM
19.4
+40 MM
40.1
+25 MM
19.8
+ 10 MM
5.6
- 10 MM
2.9
BSP
[ 2.4 / 12 ]
SIZE
CSP-1
CSP-2
CSP-3
+100 MM
NIL
NIL
NIL
+80 MM
8.4
8.6
7.4
+60 MM
25.5
25.6
23.1
+40 MM
43.8
43.0
45.9
+25 MM
21.2
21.0
22.5
+10 MM
1.1
1.0
1.1
BSP
CSP-3
EQUIPMENT
CHANGING
FREQUENCY
80MM GRIZZLY
ROLL
80MM CRUSHER
SEGMENT
25MM GRIZZLY
ROLL
CVS SCREEN
IVS SCREEN
COKE MOISTURE
ANALYZER
PRESENT STATUS
POST CARBONIZATION PROCESS
CSP-1
CSP-2
CSP-3
6 MONTH
6 MONTH
6 MONTH
6 MONTH
6 MONTH
6 MONTH
2 MONTH
2 MONTH
40 DAYS
3 MONTH
3 MONTH
---
3 MONTH
3 MONTH
---
3 MONTH
3 MONTH
INSTALLED &
WORKING
BSP
[ 2.4 / 13 ]
BSP
BSP
[ 2.4 / 14 ]
MOISTURE
3.5%(MAX)
VM
0.8
M 10
8.0(MAX)
M 40
81 (MAX)
CSR
BSP
4 inputs for
DOE
PHASE-4 CONTROL
RESULT
BEFORE PROJECT
AFTER PROJECT
MONTH
MOISTURE %
MONTH
NOV04
5.8
JAN06
DEC04
5.6
FEB06
JAN05
4.3
MARCH06
FEB05
5.01
APRIL06
MARCH05
4.81
MAY06
APRIL05
5.06
JUN06
MAY05
4.66
JULY06
JUN05
5.29
AUG06
JUL05
6.03
SEP06
AUG05
5.32
OCT06
SEP05
5.26
NOV06
OCT05
5.24
DEC06
NOV05
5.5
JAN07
DEC05
5.58
FEB07
MARCH07
APRIL07
MAY07
JUN07
[ 2.4 / 15 ]
MOISTURE %
4.7
4.8
4.9
4.6
4.5
3.9
3.8
3.8
3.8
3.7
3.7
3.7
3.7
3.7
3.6
3.6
3.7
3.8
BSP
[ 2.4 / 16 ]
BSP
STATUS IN 2005-06
TARGET
RESULTS (DEC.06 MAY 07)
LOCATION
METHODOLOGY APPLIED
TIME OF COMPLETION
OF PROJECT
SIX MONTHS
BENEFITS : -
BSP
[ 2.4 / 17 ]
BEFORE PROJECT
AFTER PROJECT
MONTH
40MM
MONTH
40MM
Oct 05
23.5
Oct06
22.5
Nov05
21.8
Nov06
22.3
Dec05
21.8
Dec06
21.3
Jan06
21.8
Jan,07
20.6
Feb06
21.4
Feb07
20.7
March06
23.2
March07
20.7
April,06
23.2
April07
21.1
May,06
22.8
May07
22.0
June06
22.8
July06
22.1
Aug06
22.2
Sept06
22.2
BSP
Table: Comparative productivity figures for different size ovens
Parameters
Small
Large oven
oven
(Orghishima)
Dimension (Usable),Height,m
4.50
7.65
7.85
7.10
7.63
Length, m
11.7
16.4
17.2
15.9
18.0
Width, m
0.450
0.435
0.550
0.590
0.610
22.1
52.2
70.0
62.3
78.9
Productivity, Coke/Oven, t
12.7
32.0
43.0
39.8
48.7
No. of ovens
322
123
120
142
120
2898
984
1080
1278
1080
10.5
5.1
6.0
6.2
5.5
No. of pushing/day
430
171
128
138
115
3870
1368
1152
1242
1035
14.0
7.0
5.0
6.6
5.3
Useful volume m
cleaned Km/day
(Capacity: Coke, 2Mt/year)
Huckingen
Prosper
Kaiser
Stuhl III
[2.5 / 1 ]
Introduction
The Iron & Steel Industry in general is one of the major contributors of
environmental pollution due to the complex and diversified nature of raw materials and
by-products handled and various waste products, discharged into the surrounding ecosystem. Starting from mining of iron ores and fluxes and their beneficiation to coke
making, iron making, steel making and rolling, various solid, liquid and gaseous
pollutants are liberated which contribute to air, water, land and noise pollution which call
for proper treatment and disposal for better environmental management.
One of the major pollution problem encountered in steel industry is treatment of
wastewater generated from various process. The waste water generated from Coke
Oven By Product Plant is the most polluted water arising from any Integrated Steel
Plant. This wastewater contains toxic chemicals like Phenol, Cyanide & Ammonia,
which are harmful to receiving water bodies when discharged, untreated.
Rourkela Steel Plant is an integrated Iron & Steel Plant which was set up in the
year 1959 and modernised in early 90s to a production capacity of 1.9 MT of crude
steel. About 5000T of coal is carbonised daily to produce coke, which is an important
raw material for making hot metal along with iron ore. While making coke, lot of raw
gases are generated in Coke Ovens which will be cleaned and number of by products
like Tar, Benzol, Naphthalene, Carbolic acid, Pitch, Anthracene oil are separated in
Coke Oven By Product Plant commonly known as Coal Chemicals Department. The
cleaned coke oven gas is used as a main source of energy for various operations in the
steel plant.
Lot of water is used in various operations in Coal Chemicals Department for
purification of coke oven gas and production of various byproducts. During the process,
wastewater is generated to the tune of 150 to 175 m3/hr. This wastewater is highly toxic
and contains high concentrations of Phenol, Cyanide & Ammonia.
[2.5 / 2 ]
There are various methods to treat the wastewater arising from Coal Chemicals
area. The various processes can be categorised into two i.e concentration process and
oxidation process. In concentration process the pollutants are removed from the effluent
by concentration of pollutants into a small volume of waste that itself requires same
form of treatment of disposal. The concentration processes include adsorption of the
pollutants on activated carbon or ion exchange media, osmosis solvent extraction. In
oxidation process, the pollutants are oxidized to relatively harmless end products by
either chemical or bio-chemical means. Chemical oxidation includes, oxidation by
ozone, chlorine, electrolytic action. Biochemical oxidation methods include oxidation of
pollutants by using microorganisms. Biological oxidation is the most widely practiced
method and is generally followed by some other processes as a Polishing step. For
complex wastes generated in the carbonisation process, it is difficult to find a single
process that offers complete treatment. BOD (Biological Oxidation and Dephenolisation)
is the most common and preferred root through out the world because of its simplicity in
operation and easiness in maintenance. In all steel plants including SAIL plants, the
BOD plant was is being operated which was installed earlier and revamped recently.
There is certain variations in process and equipment in different steel plants but the
essential principle is the same.
Principle of BOD plant: The pollutants present in the waste water are removed
due to oxidation/digestion by micro organisms. A common BOD plant consists of
various units and its flow chart of BOD plant is given in Annexure-1.
The waste water arising from Coal Chemicals department generally consists of
various pollutants viz., tar, oil, phenol, cyanide & ammonia. The microorganisms are
highly sensitive to shock loads. To eliminate shock loads, equalisation tanks are
provided generally to make the influent, homogeneous. These equalisation tanks also
act as a place for settling tars and other suspended solids present in the influent. The
presence of oil in influent badly inhibits the growth of microorganisms. Oil is first
removed by means of dissolved air floatation (DAF) system before putting in for
biological oxidation. The wastewater, which is uniform in nature, is admitted into first
stage aeration where oxygen is supplied by means of mechanical aerators. The
required nutrients like phosphorous is supplied by addition of 5% phosphoric acids and
Nitrogen portion of nutrients are met through ammonia present in the wastewater. The
presence of Pseudomonas bacteria in aeration tank where sufficient oxygen is
maintained (>4 mg/lit) by aerators, help in multiplying their population by taking phenol
as food and come to an equilibrium as per food to mass ratio (F:M) of 0.4 so that no
nitrification can take place in the first stage aeration. After reduction of Phenol in first
stage, the liquor is admitted into a clarifier where the sludge is allowed to settle and the
supernent liquor is send to Trickling filer for removal of Cyanide.
[2.5 / 3 ]
The liquor is sprayed on filter media and allowed to pass through it. During passing
through the filter media, Cyanide and thiocyanide are oxidised by the microorganisms
present on the surface of the filter media and form into a layer called slime layer. The
microorganisms will grow by taking Cyanide as food oxygen from the ambient air. The
microbial growth will increase thickness of the slime laver on the filter media till the inner
most layer of the microorganisms will die due to non availability of oxygen. This will lead
to slashing of the slime layer and the dead microorganisms will fall down along with
flowing water. The liquor is recycled to maintain sufficient hydraulic loading on Trickling
filter.
After removal of Phenol, Cyanide & Thiocyanide, the liquor is treated in second
stage aeration, where Ammonia is removed. The ammonia is converted into nitrite by
Nitrosomonous microorganisms and nitrite is converted into nitrate by Nitrobacter
microorganisms. The nitrification reactions tend to make the medium highly acidic which
inhibit the growth of microorganisms. The growth of microorganisms is given in
Annexure-2.
2 NH4+ + 3O2
NITROSOMONOUS
2 NO2- + 4H+ + 2H2O
2 NO2- + O2
NITROBACTOR
2 NO3-
NH4+ + 2O2
NITRIFIERS
[2.5 / 4 ]
STATIONARY PHASE
GROWTH CURVE OF MICRO ORGANISMS
LOG (BACTERIAL DENSITY)
3.5
3
2.5
2
1.5
1
0.5
0
1.75
4.25
TIME
[2.5 / 5 ]
in toxic substances viz., Phenol, Cyanide & Ammonia are bio chemically oxidised by
uni/multi cellular organisms like autotrophic bacteria, crustaceans by consuming part of
it to build their own cell tissues and part of it to produce energy for their survival and
producing CO2 and water as end products which are harmless to environment.
The BOD plant has the following units for treatment of wastewater in stages;
a) Equalisation tank
b) Dissolved air floatation unit for removal of Tar & oil
c) First stage aeration tank (AT#1) for removal of Phenol
d) First stage clarifier
e) Trickling filter for removal of Cyanide
f) Second stage aeration tank (AT#2) for removal of Ammonia
g) Second stage clarifier
h) Sludge thickener
i) Sludge drying bed
Biological Oxidation and Dephenolisation is a near natural treatment of
wastewater by various types of microorganisms like Pseudomonas bacteria for removal
of Phenol, Nitrosomonous & Nitrobacter for removal of Ammonia. The
oxidation/digestion of the pollutants take place in aeration tanks where oxygen is made
available to microorganisms from air to breakdown the toxic substances. This is a
techno-economically viable solution for treatment in confirmation to IS2490-1982.
The BOD plant was designed for influent water with the following characteristics.
Over a period of time the influent wastewater characteristics were changed due to
closing down of some units in CCD. This resulted in irregular feed of wastewater to
BOD plant which badly affected the growth of microorganisms and efficiency of
treatment of BOD plant. The design data, present level of pollutants at inlet and outlet of
BOD plant with norms are given below;
SN.
PARAMETER
INLET
DESIGN (mg/L)
PRESENT LEVEL
ATINLET
NORM
(mg/L)
1.
150 - 175
80 - 100
2.
Ammonia
300 - 350
157
50
2.
Phenol
400 - 500
167
1.0
3.
100 - 150
0.2
4.
BOD
1700
410
30
5.
30 - 40
Traces
10
[2.5 / 6 ]
The wide difference in design data and the present influent characteristics resulted
improper growth/inhibited growth of microorganisms at various stages of treatment in
BOD plant. This has resulted in improper reduction of Ammonia and cyanide and failed
to meet the statutory norms.
3.
4.
2.
3.
Constant pumping of waste water from all 3 catch pits of CCD to maintain
constant hydraulic feed to BOD plant - The pumps are maintained properly
and constant vigil is kept at all catch pits for continuous pumping of waste
water to BOD plant.
Extending the inlet of equilisation tank up to its bottom for thorough mixing &
equilisation. Earlier the inlet and outlets of equalisation tanks are at same
horizontal plane which resulted in short circuiting and the main purpose of
equalisation tank was defeated. The extension of inlet up to the bottom of
equilisation tank, made uniform mixing of liquor in the tank and short circuiting
is prevented.
Revival of DAF unit and using FeSO4 as coagulant in place of alum. - The
presence of Cyanide & Thiocyanide prevents growth of Nitrosomonous and
Nitrobacter micro organisms. Ferrous Sulphate removes Cyanide present in
the wastewater. Earlier Alum was used as coagulant for removal of
suspended solids. Now alum is replaced by Ferrous Sulphate, which acts as
coagulant as well as helps in removal of Cyanide. It is established that
cyanide is removed with the dosage of Ferrous Sulphate with a dosing rate of
15 ppm.
[2.5 / 7 ]
Fe (CN)2
Fe(CN)2 + 4CN-
[Fe(CN)6]4-
6.
SN
PARAMETER
1.
2.
3.
4.
5.
Phenol
Cyanide
Ammonia as NH3-N
Tar & Oil
COD
DURING TRIAL
NORM
(mg/L)
0.06 - 0.32
0.08 - 0.70
24.2 - 236
NOT TRACEABLE
70 - 143
0.06 - 0.10
0.14 - 0.20
1.28 - 35
NOT TRACEABLE
65- 137
1.0
0.2
50
10
250
Conclusion
The removal of Phenol is very good. Cyanide and Ammonia reduction is achieved
first time since inception after implementation of the action plan. Dosing of Ferrous
Sulphate at inlet to DAF, maintenance of optimal pH & MLVSS concentration at second
stage aeration were given maximum thrust to improve removal of Cyanide & Ammonia
so that statutory norms are met. The treated effluent is recycled back to Coke Ovens for
quenching purpose there by there is no discharge from BOD plant to drain.
[2.6 / 1 ]
Abstract
Blast Furnaces being a processor of mineral, generates a number of waste
material during production of hot metal, Slag being the major waste product. Actually
something is termed as waste as long as it has not found a use. Since the ages several
mountains of slag has been created in absence of a viable use. But now not only BF
Slag (granulated) has been an important raw material for Portland slag cement but also
it has found use in several other areas such as marine aquaculture, construction
industry& for insulation purpose (as ground granulated slag). Similarly another waste
product of BF process, the flue dust, recovered during cleaning of BF top gas is used in
basemix the feed for sinter making. A number of actions were taken at R.S.P Blast
Furnaces to minimize waste generation as well as in recycling the waste. Use of
imported coal in blend, increasing HBT, installation of HTP and improving process
parameters to name a few have resulted into lower waste generation where as
installation of CHSGP, Belt Press Filter and improvement in GCP has improved the
recycling of the waste generated. RSP is also implementing an ambitious modernization
plan where waste generation shall be further reduced and all the waste shall be
recycled.
1.
Introduction
Any industrial unit using natural resources generates a byproduct during
processing which is termed as a waste as long as an use is not found for this product. It
is a fact that no system can be perpetually perfect to prevent generation of a waste, but
the system can be improved to reduce the waste generation to a bare minimum level.
Further, effort must be made to find a use for the byproducts of the system, so that they
can be used as a resource for some other product.
Blast Furnace is a major consumer of natural resources such as Iron Ore, Coking
Coal, Lime stone, Quartzite etc., besides Air for its Oxygen requirement. It also uses
millions of gallons of water for its process. BF slag is one of the major waste products
of BF, which comes from the gangue material of Iron Ore & Ash of coke. Also the fines
carried over by BF gas & Cooling water is another waste product of BF. Since the ages,
no body knows how many mountains of Iron Ore the Blast Furnaces have swallowed
[2.6 / 2 ]
world over and how many mountains of environmentally detrimental slag mountains
they have created. But the
scenario is now changed, natural resources are fast
depleting and no one can have the liberty to throw any thing to the surrounding affecting
our environment. As the old saying goes, necessity is the mother of invention or
scarcity brings austerity, soon people have started taking up a number of measures for
optimum utilization of resources, minimum generation of wastes or waste recycle
measures and finding a number of use for its waste products. Rourkela Steel Plant Blast
Furnaces have also done its part in minimising waste generation or recycling of its
waste products.
A large number of measures were undertaken at BF shops in minimizing
production of slag or otherwise converting the slag to usable form to be used as a
resource for cement plants. Also measures were taken to minimize & recover the solid
waste lost through BF gas & from Cooling water to the maximum possible level. All
attempts have been put to minimize & re-circulate the cooling water in such a way that
the unit is almost self sustaining on water requirement.
A number of actions were also taken to minimize the return fines arising from the
raw material conveying system and recycling of the same through the system. Details
of waste generation, minimization measures & their recycle are enumerated in this
paper.
2.
[2.6 / 3 ]
3.
675
650
625
600
575
550
97-98
Coke Rate
98-99
97-98
678
99-00
98-99
663
00-01
99-00
668
01-02
00-01
656
02-03
01-02
647
03-04
02-03
611
Figure-1
03-04
633
04-05
04-05
633
05-06
05-06
607
06-07
06-07
577
07-08
07-08
578
[2.6 / 4 ]
97-98
Gague
97-98
47.8
98-99
98-99
48.4
99-00
99-00
48.6
00-01
00-01
48.1
01-02
01-02
48.1
02-03
02-03
46.2
03-04
03-04
46
04-05
04-05
47.7
05-06
05-06
45.1
06-07
06-07
43.6
07-08
07-08
44.57
Figure-2
The above efforts have resulted into reduction in slag generation (slag rate) per ton
of hot metal to ~ 395 Kg/THM from ~ 410 Kg/THM over the years as shown in Fig.3.
(b)
[2.6 / 5 ]
the coke fines to launder by a vibrator. Improving the strength & hardness of input
materials particularly that of coke & sinter reduces fines generation thereby reduces the
flue dust carried over by the outgoing BF top gas. Use of more imported coal in blend
and use of PBCC has helped us to improve the coke hardness ( i.e. M10 value) over the
years. Similarly, improvements in sinter plants has resulted into sinter having good
strength ( DTI value). The coke M10 value & sinter DTI value over the years are given in
Fig.5 &6.
SLAG RATE TREND (Kg/THM)
430
405
380
97-98
98-99
97-98
slag rate 400
99-00
98-99
410
00-01
99-00
414
01-02
00-01
409
02-03
01-02
432
03-04
02-03
411
04-05
03-04
404
05-06
04-05
402
05-06
393
06-07
06-07
394
07-08
07-08
406
Figure-3
% SINTER SCREENED
110
105
100
95
90
85
80
97-98
%Sint Screen
98-99
97-98
82.8
99-00
98-99
84.1
00-01
99-00
95
01-02
00-01
96.25
02-03
01-02
97.68
03-04
02-03
93.85
Figure-4
04-05
03-04
95.94
05-06
04-05
98.73
05-06
98.37
06-07
06-07
98.99
07-08
07-08
99.21
[2.6 / 6 ]
9.2
8.8
8.6
8.4
8.2
97-98
98-99
97-98
M-10 8.85
98-99
9.05
99-00
99-00
8.84
00-01
00-01
8.67
01-02
01-02
8.67
02-03
02-03
8.44
03-04
03-04
8.57
04-05
04-05
8.76
05-06
06-07
05-06
8.56
07-08
06-07
8.44
07-08
8.65
Figure-5
DTI
97-98
98-99
99-00
00-01
97-98
70.2
98-99
70.1
99-00
70.1
00-01
71.9
01-02
01-02
71.5
02-03
02-03
71.3
03-04
03-04
73.1
04-05
04-05
71.1
05-06
05-06
70.7
06-07
06-07
70.7
07-08
07-08
71.3
Figure-6
[2.6 / 7 ]
35
30
25
20
15
10
97-98
Fluedust
98-99
97-98
26
99-00
98-99
20
00-01
99-00
30
01-02
00-01
18
02-03
01-02
15
03-04
02-03
18
03-04
15
04-05
04-05
7
05-06
05-06
9
06-07
06-07
7
07-08
07-08
7
Figure-7
c)
[2.6 / 8 ]
clean gas line and increasing gas pressure in stove gas line has contributed to
increased consumption of BF gas & less bleeding.
BF GAS YIELD(NM3/TSC)
3000
2950
2900
2850
2800
2750
2700
2650
2600
97-98
97-98
BFG Yield 2628
98-99
98-99
2719
99-00
99-00
2706
00-01
00-01
2900
01-02
01-02
2811
02-03
02-03
2893
03-04
03-04
2826
04-05
04-05
2630
05-06
05-06
2734
06-07
06-07
2883
07-08
07-08
2879
Figure-8
d)
[2.6 / 9 ]
1300
1100
900
700
500
300
97-98
98-99
97-98
Makeup water 1438
99-00
98-99
1276
00-01
99-00
1037
01-02
00-01
801
02-03
01-02
794
03-04
02-03
559
04-05
03-04
480
05-06
04-05
431
05-06
411
06-07
06-07
401
07-08
07-08
377
Figure-9
Among the major initiatives taken for reducing water losses is, the installation of
highly efficient and environment friendly Belt Press filter in place of vacuum disc filter
for filtering the clarifier underflow water. Efficient removal of sludge by belt press filter
has eliminated frequent draining of clarifier underflow water thereby substantially
reduced the water losses on this count. Revamping & up gradation of 6 cooling towers
in last 2 years has gone a long way in reducing additional water requirement as well as
minimizing the losses also. After connection of a pipe from BF cooling tower inlet pipe to
High Pressure pump # 1,2 & 3, excess water overflow from BF cooling towers could be
diverted and overflow/wastage avoided. This has resulted into saving of substantial
mount of water wastage. Besides the above steps, replacement of leaking valves &
repair of leaking pipes was carried out regularly to save water.
Efforts to convert the waste into a recyclable form :
As mentioned above earlier, as soon as a waste finds an user it is no more a
waste, it has become a resource. Therefore, it shall be a beauty if all the waste is
converted into a resource & is put to use. With this philosophy in mind, all tempts have
been made to convert our major waste i.e. BF slag into granulated slag which is a major
raw material for cement plants. The actions taken at our plant over the years to increase
the percentage of slag granulated is detailed below:
[2.6 / 10 ]
1.
97-98
97-98
%chsgp 62.15
98-99
98-99
89
99-00
99-00
99.4
00-01
00-01
94.5
01-02
01-02
94.1
02-03
02-03
97
Figure-10
03-04
03-04
94.2
04-05
04-05
97.3
05-06
05-06
87.8
06-07
06-07
97.8
07-08
07-08
88.1
[2.6 / 11 ]
Liquid slag from BF #2&3 still continues to be sent to external SGP for granulating
the slag. A number of action have been taken to improve the % of slag granulated at
SGP from a level of 40 to 50 during the 90s to ~ 70% in 2007-08. Introduction of water
dumping of skull slag pots instead of knocking, has brought in revolutionary changes in
improving slag pot availability, providing clean slag pots for casting, avoiding cracking
of slag pots & damage to slag cars & their tilting drives . This has facilitated availability
of pots for proper lime coating & enhanced slag pot carrying capacity resulting into more
slag pouring per pot at SGP.
Besides the above, introduction of super finish steel slag pots and & improved
lime coating by using CP#II lime fines and 5 coats of lime instead of earlier 3 coats has
increased the % of slag poured at SGP considerably. Introduction of CHSGP at BF#1 &
#4 also ensured quick disposal of slag loads to SGP (because of few slag load
generation) thereby minimizing hard crust formation & maximum pouring. Dumping of
cast house mucks in slag pots has also been discontinued since 2004 which helped in
preventing hard crust formation & the slag loads are now easily pourable at SGP.
Improved cast house practice such as minimum 3 casts/shift, minimization of slag
pot pushing during castings and higher metal/slag temperature has helped in avoiding
hard crust formation and therefore, more % of slag pouring at SGP.The trend of % slag
granulated at SGP in the last decade is shown in Fig.11. It is heartening that the above
actions have yielded good dividend and % of over all liquid slag granulated at BF has
been increased to above 80% & that of INBA at SGP to more than 95% as shown in
figure-12.
% OF SLAG GRANULATED IN SGP
100
90
80
70
60
50
40
30
SGP
97-98
98-99
99-00
00-01
97-98
36.5
98-99
41.3
99-00
57.5
00-01
54.4
01-02
01-02
42.9
02-03
02-03
44.7
Figure-11
03-04
03-04
45.5
04-05
04-05
49
05-06
05-06
57.7
06-07
06-07
81.7
07-08
07-08
70.6
[2.6 / 12 ]
100
90
80
70
60
50
40
97-98
98-99
99-00
97-98
%slag granulated 48.3
98-99
57.2
00-01
99-00
74
01-02
00-01
72.1
02-03
01-02
64.4
03-04
02-03
62.4
04-05
03-04
60.2
05-06
04-05
63.2
06-07
05-06
70.9
06-07
89.4
07-08
07-08
87.5
Figure-12
2.
[2.6 / 13 ]
down considerably from 15-16 mg/Nm3 to 5 mg/Nm3. Similarly, whatever flue dust was
washed through washers / scrubbers & ESPs is also recovered by settling in clarifiers &
then by filtering. The efficiency of recovery of dust from the clarifier water has been
enhanced by introduction of chemical dozing along with installation of Belt Press filter in
place of vacuum disc filter. Recovery of dust from Belt Press filter is now 15T/day in
comparison to 5T/day in case of Disc filter. Revival of clarifier #3which was down for
several years by in-house innovative method has also helped in the effort for recovering
more dust from washing water and has also enhanced clarifier availability. Strict
implementation of clarifier cleaning schedule ( i.e. cleaning of each clarifier once in a
year) has also helped us in increasing the dust recovery. The trend of cleanness of BF
gas & dust recovery is given in Fig.13 which reveals that there is tremendous
improvement in recovery of flue dust from top gas.
17
15
13
11
97-98
BFG Dust
98-99
97-98
12.6
99-00
98-99
14.8
00-01
99-00
11.7
01-02
00-01
8.7
02-03
01-02
7.8
03-04
02-03
9
03-04
15.9
04-05
04-05
7.7
05-06
05-06
7.6
06-07
06-07
6.9
07-08
07-08
5.8
Figure-13
Measures to recover & recycle the wastes in stock house
The common wastes in raw material handling system & stock house are the belt
return fines and the D.E system recovery dust. Fixing of modified scrappers & a reliable
fines handling system enabled us to recover the belt return fines which is then recycled
through base mix feed in OBBP.In absence of an effective DE system, lot of dust is lost
by polluting the air. Revamping & upgradation of DE system in our BF #4 stock house in
2005 has not only helped us to recover substantial amount of dust but also made it
easier to re-use in base mix feed. This year too the DE system of BF#1,2 &3 Stock
House has been revamped & made effective. While the proposal for installation of dry
4.
[2.6 / 14 ]
fog system for suppression of dust in stock house is under implementation the proposal
for implementation of cast house de-dusting system is under active consideration of
management.
5.
Measures to recover & recycle the Cast House runner losses & metal kishes
Cast house waste generation is largely due to the runner loss and muck generated
while preparing the Cast House. Metal kisses generated during casting is also another
metallic waste. The earlier practice at Rourkela had been to collect all the iron jams in
scrap boxes and rest of the generation in muck boxes. Iron jams were taken by
dumpers to scrap & salvage unit for processing the same to be used in SMS, whereas
the muck boxes were either emptied into slag pots for dumping outside the plant or
taken by tippers to be dumped in Scrap & Salvage unit. The practice of sending mucks
through slag pots has been stopped since 2004; all the iron jams and slag mucks
generated in Cast House is sent to our Scrap & Salvage department where metallic
portion is reclaimed from the waste and used in Blast Furnaces as BF fines.
While effort is made to recycle the Cast House wastes a number of steps have
been taken to reduce muck generation of Cast House. Important among them ; use of
high life trough mass which made it possible to repair the trough once in a month in
comparison to 2 to 3 times in a month earlier. Holding of bypass continuously for over a
month has eliminated bypass runner losses. Use of castable iron runner, and tilting
runner in BF 3 & BF #4 has reduced iron runner losses to almost zero.
Splash
guards are provided by the side of iron tracks to catch metal splashing which is then
recovered in large pieces to be used as scrap. Metal kisses on the Cast House or from
the ground is dosed and sent to SSD for reclamation.
6.
[2.7 / 1 ]
[2.7 / 2 ]
[2.7 / 3 ]
done due to lack of available space and manpower. Moreover, all generated spent
refractories of different suppliers are to be stored separately and also dealing of
unknown material for recycling may be difficult. In the absence of dedicated recycling
plant at RSP, most of the spent refractories generated are either sold or dumped
outside.
[2.8 / 1 ]
The waste management is an industry makes it cost effective and its productivity
increases by recycling wastes. Thus approaches to ZERO WASTE. By proper waste
management pollution reduces & in turn helps social & economic development.
Various liquid and Solid Waste (Hazardous and non-hazardous) are being
generated in CO & BPP of Bokaro Steel Plant. The secured engineering landfill ( Fig
1) of 125 meters x 30 meters x 4 meters has been made for disposal of hazardous
wastes of CO & BPP and mill area. Liquid wastes are Ammoniacal liquor generated
during coke oven gas condensation and waste water generated during scrubbing of C.O
gas in other units of By-product Plant.
Ammonia rich waste water is treated in Ammonia still to take out free ammonia
which goes into saturator for enhancing Ammonium Sulphate production. Other waste
water with ammonia, phenol , cyanide, tar oil and grease is treated in B.O.D plant &
treated water is used in coke quenching. Thus waste water is re-used fully in the coke
making process only. Table 1 & 2 shows the characteristics of waste and treated water
of B.O.D plant.
In Table 3 solid waste materials gives an idea of solid wastes management
system either by re-cycling/ re-using and earns revenue by selling to outside parties,
thus approach to ZERO Waste. For some wastes , market is being explored. Damaged
conveyor belts generated are cut into small lengths & sell to market . Metallic wastes
are being charged in Steel making system in SMS converter. Refractory bricks
generated are being used inside
plant for some secondary purposes. We have
developed lubricating oil recycling system where no waste generated & it also satisfies
ISO 14001 : 2004 EMS guidelines. ( BSL already certified ).
Thus we the collectives of CO & BPP of Bokaro Steel Plant are improving in
wastes management system, we will continue till we achieve ZERO WASTES.
Table-1
Ammonia
: 400 mg/liter
: 500 mg / liter
Cyanide
: 2 mg / liter
PH
:8-9
Phenol
: 400 mg/liter
Table-2
Ammonia
[2.8 / 2 ]
: 50 mg/liter
: 5.0 mg/liter
Cyanide
: 1.0 mg/liter
PH
: 7-9
Table-3
S.no
Wastes
2400
Management
System
Mixed
with
blend
Sale to parties
Regenerated Acid
sludge
250
Market to search
4.
1200
Disposal to HAZ. W.
PIT
5.
6.
7.
B.O.D
POY JAR
Sulphur sludge
Used Conveyors
8.
9.
----48,000 Kg
10.
360 MT
11.
12.
Pond Breeze
1.
Decanter sludge
2.
Acidic
Tar
from
Sulphate plant
3.
Qty/Yr
MT
6000
Amn.
1200 Nos.
300 MT
------
coal
----
2000
MT
Rev.
(Rs.in Lakh)
---12 .00
No waste
No
Waste
No
Waste
---
No
Waste
No
Waste
[2.9 / 1 ]
Challenges
[2.9 / 2 ]
Solutions
provide the steel industry with the - follow the required classical steps
demanded quantity and quality
quality becomes one keypoint for - evaluate the results regarding possible
improving the productivity of steel
quality and yields as well as associated costs
making
- mineralogical characterization
[3.1 / 1 ]
Abstract
Environmental legislation and regulations and the economics of disposal are
directing the steel industry to look for ways of minimising the generation of wastes and
maximise recycling and reuse of collected wastes. The biggest part (about 70% - 80%)
of solid waste arisings in an integrated steel plant, is metallurgical slag, which is utilised
to a large extent in the cement industry and for road and civil constructions.
At BSL , presently the 51 % BF slag is granulated and sold to nearby cement
industries. However , nowadays the cement industries prefer dry flyash fom power
plants for making blended cement, to cut the cost of grinding of Granulated BF slag .
Thus there is a need to look for other alternative routes for increasing BF slag
utilization.
Production of Ground Granulated BF Slag (GGBFS) and Air cooled BF slag
aggregates for construction industry are the promising avenues for enhancing the BF
slag utilization. Government should encourage everyone; Steel Industry , ready-mix
concrete companies, builders, contractors, engineers, and architects; to use GGBFS,
thus producing better concrete as well as saving energy and reducing the CO2
emissions in the environment.
BSL has achieved 96 % utilization level in SMS slag . BSL is processing the SMS
Slag in various fractions. 0-5 mm slag is being charged into Sinter Plant replacing
equal amount of flux . Similarly 10-40 mm size are being used in SMS and BF. The
entire road of Plant and Township are being repaired by 5-10 mm and 10-40 mm size
LD slag. BSL is having around 400 Kms of Railway Track for which 20-65 mm size LD
slag is being spread replacing conventional stone ballast . BSL is also supplying
processed LD slag to IISCO Steel Plant, Burnpur which is being charged in Blast
Furnace, inturn cutting down fresh flux consumption.
Directions to the concerned in Central Govt and in State Govts. Agenicies like
CPWD, PWD, NHAI, Railways , etc, to specify the use of Slag Cement / GGBFS/ BF
[3.1 / 2 ]
and SMS slag aggregates, etc; in construction activities, will go a long way in meeting
the utilization targets of metallurgical slags from Integrated Steel Plants in India.
1.
Introduction
Environmental legislation and regulations and the economics of disposal are
directing the steel industry to look for ways of minimising the generation of wastes and
maximise recycling and reuse of collected wastes.
The biggest part (about 70% - 80%) of solid waste arisings in an integrated steel
plant, is metallurgical slag, which is already utilised in the cement industry and for road
and civil constructions. The chemical analysis of the above stated Metallurgical Slags
(BF slag and SMS slag) are given in Annexure-1.
The Generation and Utilization of Solid Waste in the financial year 2006-07 at
Bokaro Steel Plant is given in Table-1.
Tabe-1
Solid Waste Generation and Utilisation in BSL ( 2006-07)
Solid Wastes Generation (T)
Utilisation (T)
% Utilisation
BF Slag
17,43,345
7,11,471
41**
SMS Slag
3,97,420
3,30,631
83**
Mill Scale
76,393
76,393
100
ESP Dust
25,377
25,377
100
Flue Dust
62,205
62,205
100
Acetylene Sludge
3,546
3,546
100
Coke Breeze
3,92,053
3,92,053
100
Refractory waste
12,000
6,000
50
** Note : Utilization of SMS slag & BF slag has reached to 96% & 51 % in Nov 2007.
2.
Efforts are made at BSL to reduce coke ash % by judicial blending of different
indigenous and imported coals and increased use of washed low alumina Iron Ore in
Sinter Plant and in Blast Furnaces, so as to reduce the Metallurgical Slags from the
process units.
Coke rate also reduced by introducing Coal Dust Injection (CDI) and Coal Tar
Injection (CTI) system in BF which not only reduces specific energy consumption but
also reduces BF slag arising and also reduces environmental pollution in coke ovens
by reducing the coke making requirement for the given hot metal production. BSL has
[3.1 / 3 ]
CDI installed in BF 4 & 5 and CTI in BF 1 . Rest of the Furnaces will be fitted with
CDI in phased manner . This will also help to reduce BF slag arisings, appreciably in
the coming years.
BSL has on site Cast House Slag Granulation Plant (CHSGP) in BF 4 & 5. BSL
is also having Offsite Slag Granulation Plant for granulating BF slag from BF 1, 2 & 3.
CHSGP will be installed in BF 1, 2 & 3 in phased manner, which will help in increasing
BF slag utilisation .
At present the Granulated BF slag is sold to cement industry which produces
Portland slag cement (PSC). PSC is obtained by mixing Portland Cement Clinker,
gypsum and granulated slag in suitable proportions and grinding the mixture to get a
through and intimate mix between the constituents .
It may also be manufactured by separately grinding portland cement clinker,
gypsum and granulated slag and then mixing them intimately . The resultant product is
a cement which has physical properties similar to those of ordinary portland cement . In
addition, it has low heat of hydration and is relatively more resistant to soils and water
containing excessive amounts of sulphates of alkalied metals, alumina and iron, as well
as to acidic waters, and can, therefore, be used for marine works with advantage . Mass
concrete works like large foundations, dams, port-and-harbor structures such as jetties,
break-waters, warfs; floating structures, sewerage and underground structures, pipe
lines and mines, also can be built using slag cement. It is also suitable for shore
protection works such as blocks, tetrapods, machine foundations, piling, caissons, piers,
wells, effluent and sewerage treatment plants, buildings, industrial structures, cooling
towers, silos and storage structures.
Slag being available in Eastern India, Slag cement is quite popular in Eastern India
and many important structures like Second Hoogly Bridge, Underground Metro system
at Calcutta, etc. have used Slag cement.
At BSL presently about 51% BF slag is granulated and sold to near by cement
industries. However cement industries in and around Bokaro area are very few, leading
to stock piling up of granulated BF slag happens, particularly since the cement
industries prefer dry flyash for making blended cement, to cut the cost of grinding of
Granulated BF slag. Thus there is a need to look for other alternative routes for
increasing BF slag utilization at BSL. Production of Ground Granulated BF slag
(GGBFS) and Air cooled BF slag aggregates for construction industry are the
promising avenues for enhancing the BF slag utilization at BSL.
[3.1 / 4 ]
3.
[3.1 / 5 ]
[3.1 / 6 ]
4.
Conclusion
With growing shortages of energy and materials, waste is now seen as a potential
resource. Environmental legislation and regulations and the economics of disposal are
directing the steel industry to look for ways of minimising the generation of wastes and
maximise recycling of collected wastes.
Environmental Friendly Slag Cement ( made using BF Granulated slag and Steel
Making Slag ), Ground Granulated BF Slag (GGBFS) for using in Construction Industry
should be preferably promoted in India by necessary economic incentives and
legislative mechanism by MoEF in line with US EPAs scheme and should be
enforced by Administrative Set up in India.
[3.1 / 7 ]
Annexure-1
BF Slag
BF Slag
SILICA
32.89
14.70
ALUMINA
13.54
3.25
OXIDE OF IRON
21.40
22.20
FeO
1.28
12.71
LIME
25.16
36.15
MgO
0.81
1.50
LOI
0.60
4.21
(3.2 / 1)
1.
Introduction
Prevailing conditions affecting splinter (dust) generation
Like most of the BASIC oxygen furnace shops operating in India, SMS II
department of Rourkela Steel Plant has also adopted the conventional way of making
steel that is desiliconisation, dephosphorization, decarbonization, and some
desulphurization is done upto the removable levels of the individual constituents in the
converter alone.
Hence, generation of total dust is affected inside the converter only. As the hot
metal received from blast furnace normally contains silicon, phosphorus, and sulphur on
the higher side as well as manganese in small amounts, available lime of largely
compromised quality is used in higher quantities. Other constraints of converter
operation like lining protection with shortage of scrap etc. have imposed the adoption of
the use of iron ore and dolomite in optimum quantities. Briefly, we make steel in the
condition of slag in higher viscosity and the liquid metal with lower surface tension. We
also blow with a six-nozzle lance for improving the process of steel making. All these
factors facilitated the process of dust making in higher quantities. That is why against
the normal expectation of 3.5 to 4 tons of dust generation per blow, all our previous
assessments have shown a generation level in excess of 4.5 tons in slurry form only i.e.
excluding higher size grits.
2.
Dust Management
In RSP, a Gas Cleaning Plant designed and commissioned by DAVY MCKEE
LTD. UK manages dust. It is a modified form of OG(Off Gas/ Oxygen gas) process
developed in Japan in 1975. As usual, it has two functional sections:
Cooling section.
Cleaning section
Cooling section is an absolutely necessary and problematic section in all BOF gas
cleaning plants just to facilitate safe use of water as the cleaning medium owing to the
following parameters:
(3.2 / 2)
1. Wet scrubbing system is suitable for BOF gases as no strong acid forming
gases are generated during steel making. Hence, rapid corrosion does not take
place due to use of water for scrubbing.
2. Only the venturi type wet scrubbers have the capability and reliability to perform
in severe fluctuations of dust quantity and size. The size distribution varies from
0.008 m to 250. m under normal conditions and upto 500 m or even beyond
under abnormal conditions, but about 60% dust by mass remains in 1 to 60
microns range by the time it reaches the cleaning section.
3. Water cannot be sprayed to gases directly when gases are at temperatures far
beyond 800 C as water in steam phase at 800 C (water gas) may dissociate
forming explosive hydrogen. Thus, gases have to be cooled from about 1700 C
at converter mouth to about 900 C.
4. The cooling section also serves the most important function of dust preparation
and separation. It flocculates most of the fine dust to bigger agglomerates and
returns back many bigger/heavier particles to converter.
Right from the converter vessel mouth, gasses along with all splinters are
guided through the skirt to cooling hood. Dust is mechanically entrained
upwards along with the gases. Turbulences inside the hood are avoided by
design upto the cleaning section so that flocculation is facilitated.
In RSP, the cooling section has some special features uncommon to many
others.
1. System has been designed for atleast 50% more gas load than normally
working.
2. Much care has been taken in all the equipments to minimize erosion and
ensure smooth flow of fluids.
3. Pressure drop in fluid flow has been ensured to be bare minimum with
adequate compensation.
4. All the susceptible pockets have been adequately taken care of against
locked in hazardous gases.
3.
Cleaning Section
In the cleaning section, two stages cleaning has been provided. The first stage
cleaning starts with a quencher which cools the gases and dust from about 900 C to
about 75 C. The quencher is designed to trap all the heavier particles and some of the
smaller particles. The quencher is followed by the primary venturi scrubber and the
primary separating elbow where contaminated water is collected and drained off to the
flume.
The gases with residual fine particles are then guided to the secondary cleaning
stage, which is provided with a high energy venturi scrubber. The secondary scrubber is
supplied with clarified water from wastewater treatment plant, which gets partially
(3.2 / 3)
contaminated after cleaning. This partially contaminated water is then separated from
the gas stream at the secondary separating elbow just below the secondary scrubber
venturi and pumped to quencher for final use before sending to waste water treatment
plant.
The wastewater contains dust particles almost of all sizes starting from submicron
to about 500 microns. Almost 99.5% of the dust generated in the converter basin are
captured by the inside gas cleaning plant and the flare stack normally exhausts some
dust in the invisible or mild color sizes.
4.
Sludge/Slurry Management
The wastewater treatment plant (WWTP) receives highly contaminated water by
the flume (launder). The flume discharges water to a screw classifier where a few
seconds settling time is available. Almost all the bigger particles and granules settle on
the floor and swept by screw classifier. These granular dusts is then conveyed and
discharged for onward utilization in sintering plants.
(3.2 / 4)
incorporated so that while one is in operation, the other two can be left for drying/
disposal as per requirement.
The pits have been constructed at an average distance of 1200 meters from
wastewater treatment plants. The ground was leveled and earthen embankments of 2.6
meter height were constructed. NB125 size slurry handling pipes (2 lengths) have been
laid for discharging slurry at the rate of 75 m3/hour.
Originally, the scheme was to draw slurry from thickeners to sludge holding tanks
from where it was to be pumped to the pits. The scheme was found to be facing some
capacity mismatch problems for pumping. Higher temperature and fluctuating density of
the sludge in the sludge holding tanks led to operational problems for the pumps. It was
decided to try direct pumping from under the thickeners so that slurry density remains
quite low and higher positive suction is ensured irrespective of temperature. The trial
was successful and consistent behavior of the pumps was observed.
The project has been running successfully since March 2006 and that is the major
reason why we have been able to cope up with high level of production. Now the
system is running for only three hours every shift and still able to manage the whole
dust load.
5.
Observations
Some of the observations in the system are noteworthy.
1.
After about two hours of operation in every shift, the slurry density at
discharge point is very low indicated by a drop in discharge line pressure as
well as color of the slurry.
2.
3.
The settled sludge made a gradient of almost 1 in 125 in the pit whereby the
sludge touched the discharge pipe while covering half the length of the pit
only. It has necessitated multiple feed points per pit for full utilization.
4.
5.
Permanent water accumulation has occurred in the unused pit which were
previously drier. Minor leakage has also been observed on the base of one
side embankment. The water quality of the leakage is surprisingly very good
(compared to water after sedimentation).
(3.2 / 5)
6.
PH very near to 10
7.
TH< 10
8.
9.
Some snakes and small insects have been found swimming in this water.
10. It may be one consolation that even the ground water may not be getting
polluted owing to this project.
11. Pit no. 3 which is much deeper compared to other pits has become a lake
with clear water of the above quality. We may think of using this water for
suitable purposes.
6.
Conclusion
Seepages through embankments or ground may require some changes in layout
etc to ensure drying of the sludge in pits when nearby pit is in operation.
Use of dried BOF sludge is normally a challenge for conventional sintering plants.
Many steel plants prefer to make briquettes by using PVC, polyethylene or
polypropylene as binders and use them in blast furnaces. Process of direct use in BOF
converters after briquetting is also available. Portland cement has never been
successful in binding the sludge for making bricks and the last use as land filler is
neither economical nor devoid of other controversies. In this situation, many steel plants
have adopted processes, which have reduced generation of total dust by about 50%.
We may have to resort to some similar ways in the future.
[3.3 / 1 ]
Synopsis
The quantity of waste generation and its quality are the indicators of Steel Plants
operational efficiency and quality of input raw materials. Waste generation is a threat to
environment protection and sustainable development. Basically two types are wastes
viz., ferruginous wastes (iron bearing) and non ferruginous wastes are generated from
different processes during the Iron & Steel making. The ferruginous wastes can be
gainfully utilized by proper recycling, back to process, for steel making where as proper
method of usage is to be identified for the non ferruginous wastes for maximization of
their utilisation . The principle of 4R (Reduce, Reuse, Recover & Reuse) is adopted as
baseline for Solid Waste Management in Rourkela Steel Plant . Disposal of wastes
confirming to statutory requirements is a last resort in effective solid waste
management.
No one is waste in this nature. It is the responsibility of the technocrats to identify
the various alternate uses of the wastes to make them as by products. Recovery,
recycling and reuse of wastes in steel making not only earn revenue in terms of saving
of basic raw materials replaced but also conserves natural minerals from depletion.
Recycling and reuse of wastes have their own limitations hence disposal of wastes has
become inevitable. Disposal of wastes on land is a big threat to environment. Use of
different slags as pavement material, railway ballast and use of fly ash in cement
manufacturing are already established by research organisations. Governments
support and stringent directives are the need of the hour to support steel industry in
effective management of wastes .
1.
Introduction
In an integrated steel plant, 5 tonnes of input raw materials in the form of Iron Ore,
Coal, Fluxes, Ferro alloys & Refractory are required for making 1 tonne of Crude Steel .
In the process of steel making around 3.5 tonnes of wastes like slags, dusts, sludges,
[3.3 / 2 ]
fly ash, mill scales etc., are generated. The general flow of materials in iron and steel
making is given in Fig.(1) . The main reasons for high quantity of waste generation are
poor quality of raw materials i.e., Iron ore and Coal. High alumina content in Iron ore
and poor coke quality lead to high coke rate in hot metal production resulting in high
quantities of Blast Furnace slag generation. High ash content in boiler coal results in
high fly ash generation in captive power plants.
OXYGEN
PLANTS (TOP#1
& 2)
COKE
OVENS
SINTER
PLANT#1
SINTER
PLANT#2
BLAST FURNACES
PIG
CASTING
MACHINE
STEEL MELTING
SHOPS (# 1 & 2)
SWPP
PLATE
MILL
HOT STRIP
MILL
ERWPP
CRM
SSM
[3.3 / 3 ]
neutralisation of acidic water, broken refractory bricks for pavement making, and
acetylene plant sludge for white washing.
2.
Ferruginous Wastes
The iron bearing wastes, generated at different stages of steel making are suitable
for recycling back to steel making process and reusing in place of raw materials after
suitable processing. The recycling of ferruginous wastes back to process is not only
replacing iron ore but also other raw materials like Iron Ore (Fines), Lime stone and
Coke breeze (coal) . The different types of ferruginous wastes generated at different
stages of steel making in Rourkela Steel Plant, their quality and quantity of generation is
given in Table-1.
2.1 Mill Scale
The mill scale which is nothing but oxides of iron, is generated when the hot slab,
plates, coils are cleaned with water during rolling. Mill Scale is generated from Steel
Melting Shops, Hot Rolling Mills and Cold Rolling Mills. Mill scale is generated at a rate
of 2% of steel rolled in rolling mills . The mill scale coming along with wastewater is
separated in wastewater treatment plants. As mill scale is nothing but iron oxides having
Fe upto 98.5%, its recycling back to Ore bedding and blending plant is replacing Iron
ore (fines) to an extent of 115% . All the mill scales generated in Rourkela Steel Plant
are recycled back 100% and gainfully utilised.
2.2 Blast Furnace Flue Dust
The dust coming along with Blast furnace gas is first separated in dry form at Dust
Catchers, is called Blast Furnace Flue Dust . The BFc. Flue dust is generated at a rate
of 50 gms per one Tonne of Hot Metal production. The chemical composition of BFc.
flue dust shows that these wastes can replace Iron Ore (Fines) and Coke when it is
recycled back for making base mix . Recycling of 1 T of Blast furnace flue dust is
replacing 0.63 T of fresh Iron Ore(Fines) and 0.37 Tonnes of Coke . All the Blast
Furnace Flue Dusts are recycled back and gainfully utilised in Rourkela Steel Plant for
making base mix.
2.3 BFc sludge/SMS Sludge
The micro fine particles separated from Blast Furnace Gas and BOF gas at Gas
Cleaning Plants in the form of sludge is called BFc sludge/SMS sludge. The rate of
generation of sludge is 0.018 T of Tonne of crude steel . The composition of sludges
shows that, they can replace Iron Ore (fines) and Lime Stone, when the sludges are
recycled back for making base mix in Ore Bedding Blending Plant. One tonne of sludge
replace 0.62 T of Iron Ore(fines) and 0.38 T of lime stone, when it is recycled back for
making base mix for sinter making.
[3.3 / 4 ]
[3.3 / 5 ]
Acetylene sludge
Lime fines
Dolomite fines
Fly ash
[3.3 / 6 ]
neutralisation purposes. This sludge can also be used for white washing purpose.
Presently the acetylene sludge is being sold out.
3.3 Dolomite & Lime Fines
In Calcining Plant#2 & LDBP of Rourkela Steel Plant, lot of dolomite & lime fines
are generated during calcination of dolomite and lime stone. These fines are mostly
arising from material handling operations, screening and are captured in various dust
extraction systems in the plant. The CaO content of these lime fines is ranging from 8587% and can be gainfully utilised for neutralisation purposes as well as for white
washing. These lime fines are also gainfully utilised as trimming addition in Sinter Plant.
The lime fines are also being used for neutralisation purposes in water treatment plants
for township, neutralisation units of Cold Rolling Mill . All the fines are gainfully utilized
to 100% in Rourkela Steel Plant.
3.4 Fly Ash
RSP is having a coal based Captive Power Plant. The ash generated during the
burning of coal, called fly ash is disposed off by dry & wet methods. The fly ash
generation is 36000 T/month . Presently most of the fly ash is disposed off in wet
condition in Ash ponds. The disposed fly ash is presently used only for raising dyke
height of ash ponds . Dry fly ash is also disposed to cement manufactures from MP
boiler#3 presently. Arrangements are being made for direct disposal of dry fly ash from
captive power plant HP boilers of RSP.
4.
Conclusion
The management of Solid wastes from steel making is a major environmental
issue to be tackled properly as the quantities are very large . Consistent efforts are
required to maximize the utilisation of these solid wastes. Whatever unuilised wastes
are left behind are to be properly disposed on the ground in a systematic way. The
[3.3 / 7 ]
dumping sites are also developed systematically. Devising means to reduce, recycle
recover and reuse of solid wastes can only solve the problem. While substantial
progress has been made during last few years these areas, yet much more remains to
be done.
Table-1
Solid Wastes Generation & Utilisation in Rourkela Steel Plant
SN
SOLID
WASTE
SOURCE OF
GENERATION
QUANTITY OF
GENERATION
(T)
(2006-07)
1.
BFc slag
Blast
Furnaces
827575
2.
SMS slag
Steel Melting
Shop
366933
3.
Blast
furnace
flue dust
Blast furnace
dust catcher
14883
4.
SMS
sludge
5.
Mill Scale
6.
7.
8.
Total
Acetylen
e Sludge
Calcined
lime
Fines
Used
refractory
/ fire clay
bricks
Waste Water
treatment
plant of SMS
Rolling Mills
waste water
treatment
plants
Acetylene
plants
Calcination
Plant#2 &
LDBP
From relining
of converters,
furnaces and
ovens
Steel Plant
35919
UTILISATION
(%)
2006-07
QUALITY
Fe= 46-52-%; CaO= 22-30%;
MgO= 4-10%; MnO= 2-6% &
SiO2 = 26-31%
Feo= 18-21%; Sio2= 16-18%;
CaO= 47-53%
C=16.6-33.4%;
LOI=
19.443.6%; Fe= 30-40.5%; SiO2 =
7.4-11.6%;
CaO=
2.3-4.6;
MgO= 0.5-1.2%
C= 2.13%, Fe= 51.8% ; MgO=
2.0; S= 0.21%; SiO2= 2.1;
CaO= 12.8; LOI = 6.7%
90.75 %
47.92%
100 %
0.39 %
37836
2244
SiO2=4-6%;
Al2O3=
CaO= 60-70%
32231
Cao=70-80%;
MgO=3.5%;
SiO2=1.7%; Al2O3= 3.5%
100%
2946
100%
1321722
100%
1-3%
100%
77 %
[3.4 / 1 ]
Introduction
With the revival of Industrial scenario all over the world, the Iron steel plants are
growing anything like mushroom, with the emergence of no of plants also posed a big
challenge among the manufacturer to recycle the waste coming out of the process. It is
not only the disposal of the waste but it has a necessity also to keep the environment
clean as well as increase the productivity. The rapid growth along with their
technological limitations a severe problem is being faced by the industries in the area of
environmental pollution leading to ecological imbalance for the society. The problems
become much grimmer as they are placed in a situation of stiff competition with
enormous quantity of generated waste and their handling, disposal, elimination or reutilization. As day-by-day the Govt. of India become more conscious about the
environment we all have to think seriously about the above matter. With the growing
price of steel the raw materials cost is also going high so by recycling of the waste will
help in bringing the production cost down.
Steel industry has been transformed into a dynamic industry within many
fundamental ways the steel is produced, fast to adopt new technology and at the same
time these changes have made new challenges to be solved. Even though steel makers
traditionally had recycled a good amount of by-products they produce .A new process a
better social awareness and more restrictive legislation have generated new ideas and
new technologies for better re-using of all of them. Most of the times, compliance with
environmental regulations has been a burden for the steel makers, adding extra cost to
steel products .It seems that only economic solutions to the environmental problems are
when the by-products are considered as raw material for some other process, thus
obtaining an economic value and not been considered as waste product.
The most common and economical route for making steel with low initial
investment is Induction caster route with own sponge iron plant and captive power
plant many of the mini steel plant have this set up .The major waste material generated
in this set up are
Sponge Iron plant (i) Iron ore fines (ii) coal fines (iii) bag filter dust
(iv) Waste flue gas (v) Accretion material (vi) Sponge iron Fines
[3.4 / 2 ]
(vii) Char
Power plant
Steel Plant
Waste Mangement
The disposal of waste generated from the industrial processes is the major
concern Reduce, reuse and recycle philosophy and efficient waste management has
to be prompted.
The material generated in a process which is unused and rejected in that process
is considered as a waste.
Iron ore fines and Coal fines
Iron ore and coal are the two major raw materials for the Iron & steel industry but
the process required certain size of raw material. There fore crushing and screening is
required. During crushing of iron ore lumps normally 30% fines (-3mm) are generated of
total lumps ore. From chemical analysis it has been seen that it contain >65% Fe (T).
Similarly in case of coal. The generation of coal fines is very high in dry season as
compare to the cosumption. These excess fines coal are required to be disposed off in
dry season.
2 to 5 mm of the ore can be used in rotary kiln sponge iron process directly by
adjusting coal size and process parameters.
0 to 2 mm ore fines can be used by pelletisation in other iron making process such
as BF-BOF route, Oxicup, gas based sponge iron process.
Bag filter dust
High capacity bag filter are installed in dust emission area the dust generated from
bag filters are considered as waste .The dust generated from coal bag filters have the
proximate analysis report VM=2%, ASH=75%, FC=23% similarly the iron dust also
contain .65%Fe (T).
It could be used in the AFBC of the power plant.
It could also be used in the brick-manufacturing unit for construction job for which
they are using the top soil of the earth
[3.4 / 3 ]
CO2 = 19%
H2O = 17%
O2 = 1%
CO = 0.5%
SO2 = 0.05%
CH4 = 0.8%
N2 = 61.65%
The temperature of the flue gas can be utilized in power generation through waste
heat recovery boiler
Accretion Material
Accretion materials which we are getting out of the kiln are mainly comprised of:Al2O3 + SiO2 = 70-78%, Fe2O3 = 20 28%, rest is TiO2, CaO, MgO, Fe (M).
It can be used in the Oxicup furnace.
It can also be used in the land filling in the mining areas
It can also be thought of to extract the 30% hematite from the amount through
the mineral beneficiation process.
Char
Char generation in the rotary kiln is approximately 25%to 30%.
Having proximate analysis report of:
V.M = 1% to 2%.
ASH = 68 %( Approx.)
FC = 30% (Approx.)
[3.4 / 4 ]
CV = 2000 Kcal/Kg
Chemical analysis of char:
LOI = 31.72
SiO2 = 38.64
Al2O3 = 17.12
Fe2O3 = 10.67
CaO = 1.13
MgO = 0.15
Na2O = 0.09
K2O = 0.48
Char can be utilized in AFBC for power generation. And its chemical composition
suggests it can well be used as a cement raw material replacing siliceous material
having potential heat value around 2000 Kcal/Kg, which can save some fuel during
burning in cement kiln also.
Slag
Slag is a by-product from the foundry process. The type of slag produced by a
foundry will depend on the Processes used. Common ferrous foundry slag includes:
n cupola slag (air-cooled or water-quenched);
n induction furnace slag;
n electric arc furnace slag;
n desulphurisation slag.
The physical and chemical characteristics of slag make it ideal for re-use in a
range of applications. Its chemical Composition makes it suitable for use as a source of
various minerals. Physically, its mineral-like properties make it particularly suitable as
an aggregate replacement...
Use Of Iron & Steel Making Slag
Reuse of iron & steel making slag largely depends on slag chemistry and the
methods used for its cooling. With increase in production of steel, production of slag
also increased significantly. So, several new areas have been explored for reuse of
slag. Slag has been used since ancient time for construction purposes.
[3.4 / 5 ]
The use of slag increased significantly in asphalt blends for smooth road paving.
Air-cooled blast furnace slags are used for road construction after crushing and
screening. Water cooled blast furnace slag are widely used for cement making because
of its cementations properties which develops with lime and water.
Reuse of slag generated from foundry process
1.) Cupola slag: The air-cooled cupola slags are used in asphalt, ballast, bricks, mineral
wool, and road base construction. The water-cooled cupola slags are used in
blockmaking, bricks, mineral wools, soil modifier, and abrasives running surfaces.
2.) Induction furnace slag : Road base construction, abrasives.
3.) Electric arc furnace slag : Ballast, road base construction.
4.) Desulphurization slag : Soil modifier, slaked lime replacement, blast furnace slag,
and
Cement manufacture.
Mill scale
Mill scales are the oxides of iron produced during hot fabrication of the steel.
During continuous casting of near about 0.6 -0.7% of mill scale generated of the
finished steel billet.
Mill scale having composition of
Fe (T) = 70 %( Approx.) , Oxygen by weight 25%
Other gangue material = 8%
Sulphur = 0.1%
VM = 4.5%
The use of mill scale as an oxidizing agent results in improving the yield of process
but it needs thermal energy to dissociate it self and make oxygen available for refining
reaction.
These materials can be utilized as oxidizing agent in the melting furnace, which
can remove phosphorus as P2O5 and reduce the carbon content in the molten bath also
this can be used in thermit welding process.
Fly Ash
Fly ash is generated in the AFBC boiler and it is about 70% of the charge into it
.Fly Ash is composed of: -
[3.4 / 6 ]
Al2O3 = 20-25%
Fe2O3 = 8-10%
TiO2 = 1-1.5%
CaO = 1-1.5%
MgO = 1%(Approx.)
SiO2 = 60-65%
Na2O = 0.05%
K2O = 0.5 -1%
Fly ash can be used in the cement plant for making PPC.This fly ash can also be
used for bricks making for building construction
ESP Dust
The residual dust particle from flue gas exited from the kilns are collected by the
TR set of Electrostatic precipitator are receipted in the hopper. These dust particles are
termed as ESP dust. The ESP Dust generated could be used for brick manufacturing.
It could also be used in the AFBC boilers as a potential fuel.
Modern Recycling technology
[3.4 / 7 ]
(ii)
[4.1/ 1 ]
[4.1/ 2 ]
IRC process, dust is mixed with other raw materials, melted, then cooled and formed
into recycled products that meet customer specifications.
Fig. 1 400X magnification of current IRC product showing various crystal forms.
[4.1/ 3 ]
depending on the way the material is thermally treated. Glasses are, generally
speaking, super-cooled liquids of extremely high viscosity. When heated to a specific
temperature, glass becomes low enough in viscosity that the atoms cannot order
themselves sufficiently to become crystalline. However, if cooled slowly enough, they
can become ordered (crystalline), as shown schematically in Figure 3.
The most common glasses, e.g., window glass, in use today are based on a
silicate structure (Si02), the same material used in many ceramics, e.g., dinnerware.
Silicon dioxide in pure form can make a very fine optical glass called fused silica;
unfortunately, the temperature required to form it is very high, restricting its use to areas
where a very low thermal expansion material of high optical quality is required. The
more common glasses use fluxing agents, like Na20 or K20, Figure 4, which reduce the
processing temperature, making the glass easier to form. Silica has often been referred
to as the universal solvent, by glass and ceramic manufacturers, due to its ability to
accept most other ions into its structure while remaining quite stable in the presence of
water, acids and bases, HF being the exception. Additions of other oxides are made to
glass for many reasons; however, they are generally added to increase resistance to
chemical corrosion, increase or decrease optical transmission, to obtain various colors,
and to vary mechanical properties. Glass is also used as a coating for other materials to
provide environmental protection or provide a decorative effect. Glass coatings on a
metal are called enamels and on ceramics, they are referred to as glazes .. In each,
relatively large amounts (1-10 weight percent) of transition metal ions are added to give
a particular color and/or opacity.
(1a)
(1b)
Fig. 3 Schematic representation of (a) ordered crystalline form and (b) random network .
glassy form of the same composition (Kingery, 1960).
[4.1/ 4 ]
Si++
O 2Na + or Metal
Ions
[4.1/ 5 ]
network structure. When the glass cannot accept additional metal ions, the metal
precipitates out of the glass and forms oxides that are insoluble or nearly insoluble in
water and acids
ARKANSAS BLACK GLASS ANNEALED SPECIMEN #1 MICROHARDNESS TESTING
DATA Vickers Indentor (200 gf Load)
400Z Magnification
PHASE I
882.5
922.5
806.0
PHASE 2
646.5
686.1
652.0
PHASE 3
908.9
1083.6
970.3
Environmentally Sound
The Inorganic Recycling process has been fully evaluated and determined to be a
legitimate recycling activity by the U.S. Environmental Protection Agency and every
state regulatory agency with jurisdiction over Inorganic existing full scale or pilot
operations. As a recycler, Inorganic is authorized to process any inorganic wastes at its
facilities upon completion of the testing Protocols outlined in the initial U.S. Environmental
Protection Agency authorization letter of April, 1990.
[4.1/ 6 ]
By consistently demonstrating that any waste that passes the testing protocols established by
U.S. EPA can be effectively managed through the Inorganic process, the agencies were assured
that neither the initial characterization of those wastes nor the means by which they were
generated are material considerations. Whether such wastes are cast off from chemical
manufacturing, industrial processing, commercial use, incinerator ash, spills arising from
transportation or processing accidents, or residues in pits, ponds or lagoons, all inorganic
hazardous wastes can be legally recycled. Inorganic has commercially demonstrated the
environmentally sound re-cyclability of various plating sludge, Incinerator ashes and residues in
un-permitted pits, ponds and lagoons. Recycling of these wastes by Inorganic results in
environmentally non-hazardous commercial products sold into commerce. Commercial contracts are
in place for sale of IRC material primarily into blast media and asphalt shingles. The prime attribute
of the Inorganic product, over and beyond its unique color and hardness characteristics, is the fact
that the product itself, even at the molecular level, is non hazardous based on U.S. EPA's toxicity
characteristic leaching procedure test ("TCLP").
As illustrated in Figure 6, based on U.S.
EPA's recycling regulations, wastes lose their "hazardous" label at or before the
time they are placed in Inorganic receiving hoppers at its fully enclosed recycling
facilities. If the recycling facility is located on the site of the generator of the hazardous
waste, those wastes lose their "hazardous" title and become hazardous raw materials
immediately upon movement into the recycling process, whether from the generator's
initial collection unit or upon excavation and transport to the Inorganic facility. Because
[4.1/ 7 ]
of this shift in legal characterization of these materials, Inorganic is willing to take title to
the materials early in the recycling process.
Once within the Inorganic facility, these once "hazardous wastes" are managed as
hazardous raw materials. Upon entering the Inorganic thermal processing unit, the
materials lose their hazardous characteristics through the crystal and chemical bonding
that occurs with additives chosen specifically for the incoming material's chemistry.
Through further refinement of these additives, Inorganic is able to "tailor" its product to
meet the unique chemical specifications of Inorganic's customers.
Throughout the whole process, records are kept on the results of initial testing
protocols, the quantity and chemistry of the incoming materials and the quantity and
chemistry of the outgoing products to assure that the transformation of the "wastes" into
nonhazardous commercial products has been successfully completed. Any spills or off
specification products produced can be reintroduced into the mixing vessels within the
Inorganic facility.
Under U.S. EPA's recycling guideline, any "hazardous waste" that is recycled and
incorporated into a commercial product, losses its original label as a "hazardous waste"
as a matter of law, and is therefore no longer regulated as a waste. Having severed the
legal and chemical "liability trail" normally associated with hazardous waste operations,
both Inorganic and the original generator of the wastes are thoroughly and completely
isolated from future hazardous wastes liability associated with commercial products
shipped. Once in commerce, the Inorganic products are regulated merely as a function
of normal industry guidelines, including compliance with manufacture safety date sheet
specifications.
Generators doing business with Inorganic are invited to periodically inspect the
Inorganic operations and records maintained to confirm the complete recycling of the
original wastes into the products and assure themselves of the legal and chemical
sufficiency of the recycling process. Any dusts generated in the course of hazardous
material processing are collected in approved air pollution control devices and
introduced back into the recycling process with the initial hazardous materials. Any
product that does not completely satisfy the customer's specifications could be simply
reprocessed back through the kiln.
Inorganic Recycling has been active in the true recycling of inorganic materials
since 1988. Chrome plating waste was the first material approved by the EPA for this
method of recycling. The first EAF dust recycling unit was started in 1992 in Arkansas
and it is also approved by the Federal and State EPA as true recycling.
[4.1/ 8 ]
ROOFING
Face
granule
12/30 mesh
angular
Backing
coIor
unimportant
angular to
spherical
500,000
tons per
year
The IRC recycling process has now been proven in full scale commercial
operation. It has demonstrated the ability to recycle a continuous flow of EAF dust into
salable products since May, 1995. For over eighteen months, with the exception of a
few planned outages, IRC has recycled EAF dust every day, and has sold all products
as originally produced. Every pound has been "right" the first time.
EAF dust and other feedstock materials, custom engineered to produce' products
meeting customer standards, are mixed and fed into the recycling kin and molten
material is tapped out, continuously. The molten glass ceramic products is routinely
sized to customer requirements and shipped. Due to proximity to the Mississippi River,
barge shipment provides low cost transportation. Shipments are made approximately
once every six weeks. All dust sent to the IRC facility is recycled and sold. No materials
are buried. No materials are returned to the mill. Currently, virtually all IRC products are
used as roofing granule materials and provide home owners with a consistent, more UV
resistant product.
[4.1/ 9 ]
All products, without exception, produced by IRC have passed the EPA's TCLP
test and of equal importance, have met more rigorous customer specifications. We have
no reason to doubt that record will continue well into the future.
No other on-site EAF dust recycling system can match the IRC record as a proven
process. Except for the few well established dust disposal alternatives, no other dust
handling system can match the IRC record as a proven process.
One reason for this success is that the IRC process simply adds special know-how
to well understood glass-ceramic processing methods. Basic methods are highly flexible
and well able to meet the challenge of different sources and dust composition, normally
encountered. Custom engineered feed stocks are added to EAF dust in a manner
designed to assure that all product specifications are met. The melting process is
designed to accommodate dark glass and to accept changes while continuing to meet
specifications. Both dry and wet scrubbing systems are in place to address any off
gases from the kiln that may contain sulfur, chlorides and fluorides.
The current unit processes dust at a rate of 12,000 TPY. A new unit (one kiln) is
designed for 20,000 TPY dust and will come on stream in late 1997. The new unit will
incorporate both oxyfuel and electrical resistant heating. The new unit will also'
incorporate various methods of forming the end product that will allow such steps as
beading, forming, fiber forming, coating, annealing, shapes, etc. both Alternatively
and/or simultaneously.
[4.1/ 10 ]
50 to 65%
39 to 25%
1.5 to 2.5%
0.8 to 0.6%
0.3 to 0.7%
1.0 to 1.5%
2 to 3%
Slag
CaO
Si02
Fe203
MnO
MgO
Cr203
A103
47%
23%
20%
4.5%
3.5%
.5%
1.0%
Plate
73.25
13.45
8.58
Flint
73.21
13.45
10.332
MgO
3.77
1.04
Fe203 0.356
0.081
A1203 0.28
1.34
S03
0.19
0.16
K20
0.11
0.40
PbO
0.0037 .
Cr203 0.0023
0.0026
Amber Emerald
72.45
72.26
13.01
13.11
10.48
10.47
0.68
0.31
1.95
0.03
0.44
0.78
0.205
2.05
0.08
0.93
0.12
[4.1/ 11 ]
[4.1/ 12 ]
This Paper is Printed with Permission from: Pacific Sterling Technologies, Inc. USA
For Plant Set up, please contact:
Mr. Shankar Chowdhury, President BD & Proj.
Zoom Developers P Ltd.
Poonam Building, 3rd Floor ; 5/2 Russel Street ; Kolkata - 700 071,
Phone : +91 33 22263669/70 ; Fax : +91 33 22263668
Director (Projects & Business Development), Steel
Mobile : +91 9831899469 ; E mail : shankarc@zoomdevelopers.com
[4.2 / 1 ]
[4.2 / 2 ]
The iron and steel industry in the U.S. has issued criterion for a Direct Iron and
Steel making process, for the future, that should be developed over the next 20 years.
The process criterion, uses coal directly, eliminates wastes, reduces emissions, reduces
costs and energy and uses iron ore fines.
A new process that meets all the criterion has been developed which provides for
an agglomeration of iron bearing materials fines, premixed with coal or other carbon
sources and fed directly to a smelter, eliminating the need for coke, pre-processing of
feed materials, sintering and pelletizing and eliminating air pollutants and energy
consumption from those processes, while also recovering iron bearing wastes and
utilizing other wastes from iron and steel making processes.
The technology, called the RBI Process, for which T.C.Inc. has been issued a U.S.
Patent, includes the agglomeration of feed materials, mixed with a carbonaceous fuel,
to produce a self reducing feed to a smelter. The selected agglomeration technique is a
hydraulic ram briquette machine, which will produce feed material to withstand any
handling, maintain strength and integrity during processing, penetrate any slag barrier
and maintain strength during the reduction. The ram briquette machine was also
selected to reduce or eliminate use of binders due to its inherent ability to make an
agglomerate of high density. The research phase of the RBI Process was completed in
the 80s. Technology and designs now developed include the methods to make hot
metal from the waste and ore fines, use of coal instead of coke, operating a steel mill
100% waste free, reducing capital costs, reducing or eliminating in some cases,
greenhouse gases, reducing energy and building an iron making or steel making plant
from 50,000 TPY and up on a competitive scale with large capacities.
While the selection of a smelter for Direct Iron Making will follow the route of an
oxygen furnace, the technology will utilize any existing melter/smelter for the recovery of
waste, since most wastes recycling has to be site specific.
Additional technology is also being developed to utilize this processing method for
the non-ferrous and ferrous alloy industries, such as directly making stainless from as
mined materials, such as nickel laterites, and using any waste carbon sources such as
wood from forest fires and other sources of wastes.
Review Of Technology
In the 1980s in the US, it became apparent that iron and steel plant wastes,
emissions and effluents were a cause of concern due to, ground water contamination
from stockpiling or land filling, air born particulates were contaminating soils in
surrounding plant areas and there was concern of the greenhouse effect from gas
emissions. As a result, restrictions were put on land filling and stockpiling of wastes
and air born emissions from plants and a new era of monitoring and control was
[4.2 / 3 ]
established. The added cost to iron and steel making then dictated that new
technologies be developed for collecting the emissions and effluents and treating the
collected materials to reduce leaching into groundwater and potential health hazards.
The iron and steel industry, since, has incorporated new technology in reducing
particulate emissions from air born sources and in collecting wastes. Some methods
have also been incorporated to recycle, through existing processes, the sinter plant for
example, wastes that have no ill effect on production capacity or quality from
contaminants. Greenhouse gas emissions have also been reduced with increased plant
efficiencies. However, no technology had been implemented, en-masse, to recover and
use waste materials.
Iron and steel plant wastes are normally categorized into iron bearing materials,
refractories and carbonaceous materials. Methods to recover any or all of the wastes
needed to be developed. Waste materials from iron and steel making plants were
studied. This included mining and beneficiation and pelletizing operations, material
shipping , sinter plants, coke oven plants, integrated iron and steel plants and EAF and
DRI operations. The physical characteristics of the wastes revealed that, with the
exception of slag, most iron bearing materials were in the form of minus inch, most
refractories were in the form of brick or large particles, carbonaceous materials were
liquid, dust or breeze or in the form of graphite rods. The chemical or elemental form of
wastes, especially the iron bearing materials from various iron and steel plants each
had compositions specific to those iron and steel plant operations and products. The
refractory waste and carbon graphite needed to be separately reviewed due to size and
potential reuse. The major emphasis was put into finding a means to handle iron
bearing wastes of all the various operations for a case by case and site specific
scenario.
Handling the fines and dust and collecting them was not the issue, as technology
and equipment was readily available to do this. Making the iron bearing wastes a
reusable product or in some cases a non-hazardous product became the objective. To
do so various technologies were reviewed:
a. Pelletizing and induration and cold bonded pelletizing. These required the
materials to be ground to normal pelletizing grade feed, required the addition
of unwanted binders, and added an element of handling in induration or
curing. The product pellet still generated dust and fines and added to
chemical constituents undesirable in further processing. The cost associated
with any site specific case could not be justified. Shipping materials to a
central location for a more economically sound project only added to the cost
in handling the materials and the materials would then be mixed and
unacceptable to any specific site for reuse.
[4.2 / 4 ]
b. Roll type briquetting or brick making This technology provided that any
materials of less than inch could be used without grinding. However,
binders were required far in excess of pelletizing adding to the unwanted
chemical constituents in further processing. The briquettes also had to be
cured to increase the strength, but, handling and shipping still caused
generation of fines and dust. Again, the cost of briquette operations and high
maintenance costs of machines eliminated the justification for commercial
use.
In both type technologies, pelletizing and briquetting, or brick making only
integrated iron and steel plants could reuse the materials for recycling. EAF operations
waste iron bearing materials contained hazardous materials not suitable for recycling
and the EAF operations are not an iron making or iron reduction facility.
c. Pre-reduction studies were then made in order to provide a feed material that
was of more value to the iron and steel maker. Processes were developed to
use the technology of pelletizing or roll briquetting for a cold bonded feed to
rotary kilns, rotary hearths and shaft furnaces with carbon added to the pellet
or briquette.
The technology was adapted in some operations and
subsequently shutdown due to high operating costs, high capital costs with
few benefits to the iron and steel maker. The technologies also required
carbon sources of the highest quality, coke, and added the same chemical
constituents from binders, defeating any benefits to steel making.
d. Pre-reduction and smelting, as a combined process was also studied, not
only for recovery of in-plant wastes but to directly make iron from fines. This
technology also requires the highest quality feed and carbon sources,
pelletizing and major capital investments. Operating costs can only be
justified with large scale plants, therefore contributing to added iron and steel
overcapacity. The only recognized benefit is the use of coal instead of coke.
Later developments abandoned the recycling of wastes.
e. Direct steelmaking has been considered, to use fines and coals, not of coke
quality, and smelt/reduce materials directly. This had been considered as the
most viable technology under development, which could use recycled iron
units, dust and fines, directly, however, no studies are being conducted to use
waste materials. The technology also is limited to only large scale operations
to justify operating and capital costs and is not viable for site specific cases in
recycling wastes. Material losses from fume exhaust also reduce efficiency
and carbon additions are far in excess of the requirements of stoichiometric
reduction. Fines and dust feed do not penetrate slag barriers without injection
systems.
Process Development
The requirements to handle the iron bearing wastes and fines had the following
criterion:
[4.2 / 5 ]
Hydraulic ram briquetting was then reviewed and it met all the criterion listed.
Historically, the ram briquette machine had been used commercially since the 1930s for
the punch pressing of machine shop turnings and borings for feed to a foundry. This
practice has been continued through today. Tests were then conducted on various iron
and steel mill wastes, singularly without binders. Both iron bearing wastes and carbon
sources were tested, then in combinations, simulating typical site specific cases. In
some instances refractory material was crushed and added. If dust collection material
was used, only, the product briquette was somewhat weaker. This was compensated
for by the addition of a tar or pitch or coal and in some cases ground refractory. By
mixing dissimilar sized particles, no binders were required. However, by adding a
carbon source of some waste materials or coal, it was found that the material had an
inherent binder. It was also found that oxides would be self reducing upon feed to a
smelter.
Since the ram briquetter is a known technology, can produce an agglomerated
product from fines with mixtures desirable to the iron and steel maker, can utilize and
agglomerate any iron and steel wastes and can provide a self reducing feed material, it
was expected that the technology meets the criterion for direct iron and steel making,
ahead of its time. The technology is viable, in that it can be utilized at any site specific
plant, in any size to meet the requirements of capacities. The only inputs required,
other than feed equipment apparatus are cooling water for hydraulic cooling and power,
making it also environmental friendly, as compared to any other process which may
require induration, pelletizing or pre-reduction and therefore use of hydrocarbon fuels
with resultant gaseous emissions. This process can claim total use or recovery of all
iron and steel wastes.
[4.2 / 6 ]
The process also will utilize direct feed of as mined iron oxide feed, not ground to
meet pelletizing or concentrated feed to sinter plants. The material feed will be mixed
with coal fines or waste carbon sources and ram briquetted to provide a smelter with a
feed material that is self reducing. This will eliminate the need for pelletizing or sintering
and the use of coke making plants. As compared to pelletizing, sintering and coke
plants, no fuels are used, no gaseous emissions are experienced, there are no losses of
materials, capital expenditures and operating costs are reduced.
Other benefits are derived from using the ram briquetted technology, in that
imports of feed materials can be reduced and curtailed, or an area of low need for iron
or steel goods can build a micro plant, suitable for its local needs and using low quality
ore and carbon sources.
The potential application to the iron and steel industry is the recovery and use of all
iron bearing wastes, the potential application to replace sinter and pellet plants, the
potential of replacing coke ovens and using coal directly.
The research objective addressed the specific need for improvements in the iron
and steel industry to; increase efficiency through recovery of iron and steel wastes and
through the use of iron oxide fines in making iron, decrease the dependence on coke by
using coal directly, decrease the gaseous emissions in pre-processing, sintering,
pelletizing of iron oxides and coke making plants and decrease the energy consumption
in pre-processing, sintering, pelletizing, coke making and energy losses due to waste
materials. In 2005, over 1000 trillion Btus were invested in energy to produce waste
iron bearing materials and over 1500 trillion Btus were used to pre-process, pelletize
and sinter iron oxide fines. The goal is to recover the energy invested in wastes by
utilizing the waste and to reduce the energy consumption in pre-processing, pelletizing
and sintering.
The objective is to use coal directly, eliminating the need for coke
making. Additionally, it is the objective to eliminate the gaseous emissions by
eliminating some steps in pre-processing and to eliminate sintering, pelletizing and coke
making.
These goals will be accomplished by using an alternate method of
agglomeration, iron oxide mixed with a carbon for direct feed to a smelter and feeding
any type smelter that hot metal can be produced. It will not be necessary to develop a
new machine for agglomeration as the process technology uses a well know hydraulic
ram briquetting machine.
Technical Feasability
To make iron and subsequently steel, carbon is used, under heat, to chemically
extract the oxygen from the natural oxides of iron. Most processes convert some sort of
carbon source or hydrocarbon source into a reductant CO and/or H2 to be introduced
as a gas, externally to the iron oxide and extract the oxygen from the iron, by forcing the
gas through the iron oxide particle, producing somewhat of a pure iron, then the iron is
[4.2 / 7 ]
melted. The process is more complex as there are also other elements combined with
the iron and carbon sources that are dealt with separately and there are major
considerations as to how to get the gas into the iron oxide material. However,
simplistically, this is what occurs. In order to make this processing as efficient as
possible, iron oxides have been meticulously beneficiated, such that, a maximum value
of other materials is reduced, but, the iron oxide is then in a form that cant be used
unless it is agglomerated, normally by sintering or pelletizing. Shaft furnaces, namely
the blast furnace also has been designed for the purpose of accepting iron oxides in the
form of sinter and pellets. In order to have a carbon source for reduction in the blast
furnace, efficiency dictated that coal could be used but it had to be beneficiated by
removing the volatiles and other matter that would interfere with quality of hot metal
and the coal had to be more permeable to achieve efficiency, resulting in the processing
of coal to coke. It is the intent of using a ram briquetted mixture of iron oxide particles
and coal particles, tightly bound through compression as feed to a smelter. At elevated
temperatures in a smelter the carbon will oxidize by the extraction of oxygen from the
iron in the particle next to it. Gas flow and bed permeability is, therefore not a concern,
only heat. The ram briquette becomes a self reducing material and in the smelter,
within minutes is reduced of oxides and melted into hot metal. Since the reduction
takes place inside the ram briquette, it is anticipated that close to stoichiometric carbon,
plus carbon equilibrium, can be achieved
Reducing current energy usage, recovering iron and steel making wastes and
eliminating steps in pre-processing, sintering, pelletizing and coke making, using coal
directly and reducing gaseous emissions were the achievements desired. Selecting the
type smelter to achieve the desired hot metal results will be a goal as well as type of
heat input. It will be a goal to review the potential of heat recovery in off gases for
cogeneration of power based on various types of carbon input. Another goal, and
considered in the developmental phase, is to apply the technology to the non-ferrous
and stainless industries, such as nickel laterites and aluminum bauxites and others.
Benefits
The energy consumption for the RBI process to recover the worlds 100 million
tons of iron bearing wastes is 30 trillion Btus/yr, as compared to 1000 trillion Btus used
to make the waste. The per unit energy consumption is calculated at 40 kWh per ton
electrical power input. (per unit installed process is an engineering calculation of a ram
briquetting facility, including all materials handling, mixing, feeding mechanisms and the
machine requirements of a hydraulic system.) There is no comparable or competing
technology that is used to recover and use iron and steel plant wastes. Some captive
sinter plants are feeding some acceptable wastes into the process, however, sinter
plant energy use is about 1.6 million Btus per ton of combined energy consumption.
[4.2 / 8 ]
Therefore if wastes were recycled through sinter plants the energy required would be
about 160 trillion Btus.
Processes that use iron oxide agglomeration and pre-reduction, such as rotary
hearth technologies or other techniques before feed to a smelter will consume a
minimum of 15 million combined Btus per ton. In recovering the iron bearing wastes
the energy consumption is 1500 trillion Btus. As compared to ram briquetting the
energy savings with RBI is 98%.
To replace coke ovens, sinter and pellet plants, the blast furnace would also have
to be modified or replaced with an alternate smelting/steel making technology, for
example an oxygen furnace. Overall benefits to the iron and steel industry are in the
preparation of materials, the development of a site-specific technology, reduction of
effluents and total recovery of wastes.
The technology is designed to recover iron and steel plant wastes in the form of
iron bearing materials, carbon products and other wastes, such as refractories or lime
dust. Through this technique, about 10% of total steel production can be recovered and
reused, improving the productivity and cost of making steel. The proposed technology
also has the potential of replacing processing steps in iron and steelmaking in materials
preparation for smelting. It is anticipated that by using the patented process of ram
briquetting, hot metal can be produced at a significant savings over conventional
methods through energy savings alone.
If capital costs, operating costs and
maintenance costs of conventional equipment were included, it is anticipated the
savings in costs per ton of prepared materials would be in excess of one half.
Environmental Benefits
There are no wastes associated with using ram briquetting technology as a feed
preparation for materials to the iron and steel sector. 100 million tons per year of iron
bearing wastes associated with the iron and steel sector are already being produced
which can be recovered with ram briquetting. With existing technologies, sintering or
pelletizing of iron oxides and coke making,, CO2 emissions would be eliminated by
using ram briquetting technology. Currently the amount of CO2 emissions are
calculated from sintering (assuming pelletizing uses the same relative amounts of fuel)
and pelletizing at 69 pounds/ton of steel and coke making at 102 pounds/ton of steel. .
Wastes and by-products of coke making are also eliminated, but, with new smelting
technologies, effluents now that exist will be changed and have to be studied. It is
suspected that the selection of the smelting furnace with the ram briquette will greatly
enhance the use of all carbon and hydrocarbon products in coal and reduction of NOX
with the use of enriched air.
[4.2 / 9 ]
[4.2 / 10 ]
instead of pellets, sinter or sized lump and using coal instead of coke. The only
water for RBI is cooling water for the hydraulics. Manpower costs are at a
minimum since there is no special training involved and no IT degree required
nor expansive instrumentation. Care can also be given to total recycling
therefore no landfill, 100% free of waste, and most importantly reduce your
materials purchases by 10%.
G. Care can also be given to total use of all in-plant waste materials or use of fines
and local coals, a steel mill 100% free of waste. A total sustainable operation.
Elimination of material preparation high cost operations and green house gas
emissions.
References cited
1. Energy and Environmental Profile of the U.S. Iron and Steel Industry, August
2000, by Energetics, Inc., prepared for the U.S. DOE, OIT.
2. Steel Industry Technology Roadmap, December 2001, published by the AISI in
cooperation with the U.S. DOE.
3. Theoretical Minimum Energies to Produce Steel, March 2000, Carnegie Mellon
University, Published for the U.S. DOE
4. Energy Use in the U.S. Steel Industry, September 2000, John Stubbles,
Published for the U.S. DOE
5. U.S. Patent # 4,917,723, issued to applicant, Thomas J. Coyne, jr., assigned to
T.C.Inc., April, 1990.
T.C.Inc. is an international project development and consulting firm dealing in iron
and iron bearing materials in the fields of agglomeration, beneficiation, pelletizing and
reduction. The makeup of T.C.Inc. includes associates and associated companies with
expertise in iron and steel making technologies, gas reforming and burner systems and
syngas technology.
T.C.Inc. provides services in technology development and
evaluation, project evaluation, process evaluation and application, project, construction
and operations management, plant commissioning and training and operations
optimization. T.C.Inc. also offers patented technology in Direct Reduction of Iron
Oxides with any fuels, Increase in Capacities with a Shaft Furnace DRI Technologies of
20%, DRI and the Rotary Hearth and Rotary Kiln and the patented RBI Process for
Direct Iron and Steel Making and Waste Recovery.
Thomas J. Coyne, Jr., the author has published papers in iron and steel making
technology that cover such areas as raw materials for iron making and direct reduction,
direct reduction plant operations, shipping and reoxidation of direct reduced iron,
pelletizing of magnetite, gas flows and pressure considerations in shaft furnaces, shaft
furnace balances and assumptions, raw material plants mass balances, international
project development and management.
He has also been involved in technology
transfer of these technologies to developing nations for the past 40 years in the iron and
[4.2 / 11 ]
steel industries from mining to finished products and has developed a free email
advisory service for these areas, specifically for deserving third world nations coming
into their own.
This paper is a product of T.C.Inc., copywrited by T.C.Inc. and the technology
displayed may not be used or copied without the express approval of T.C.Inc. and
follows applicable law of the US Patent offices and US Dept. of Commerce.
[4.2 / 12 ]
[4.3 / 1 ]
Abstract: The major Iron and steel producers in the world, as their voluntary
energy saving action plan, proposed a more than 10% energy reduction by 2010 with
1990 as the basis. Further, some steel major has put forward an additional more than
1.5% energy by the use of waste plastics as a metallurgical raw material. Coke
making process and Blast furnace process of Iron making are considered to be
promising area to which the thermal decomposition of waste plastics is applicable
because the process involves coal Carbonization in a light temperature, reducing
atmosphere. Some plants in Japan has started using waste plastics in coke oven and in
Blast Furnace injection. In coke oven 1% addition of waste politics in raw coal did not
deteriorate the coke strength. In Blast Furnace addition of plastics in injection process
improves the thermal regim of the furnace and results in coke rate, reduction in slag
volume also. In India there is too much scope of recycling waste plastics in steel
Industries as the plastic waste generation is more than 6 million tones and this can
solve some extend the shortage of coking coal problem for Iron and steel Industries
particularly for Blast furnace process of Iron making. This paper outlines technology of
recycling businesses that make the best use the iron and steel making process of the
steel works.
Introduction
As the advent of the 21st Century, mankind is facing global environmental problem,
causing the industrial sector to take initiatives in establishing recycling for the efficient
utilization of our natural resources. By effectively utilizing the synergistic effects of Iron
and steel making technology and engineering technology built up through its long
history. In the world due to energy crises, major steel makers tackling issues related to
conserving energy and resources as well as protecting the environment throughout the
world. The plastic is most commonly used in many plants of world for sample India
during 2003 about 4 million tones of plastic waste were discharged and in Japan this
figure was as high as 9-8 million tones (1999) in USA. This was many times than Japan
and India. Out of the world total plastic waste only 33% is effectively used and balance
were disposed of by land filling. See Table No.1, plastic waste generation in India. The
[4.3 / 2 ]
growth of plastic industry is more than 17% against the population of about 1 billion and
this growth is further expected to rise due to mineral water bottles.
Table No. 1 : Plastic Waste generation in India (2007)
1995-96
2001-02
Total polymers
1889
4374
Process waste
38
87
(2%)
Post Consumption
870 (46%)
1966 (45%)
Waste
2006-07
8054
161
3624 (45%)
The trend of plastic use in India has been shown in Table No. 2
Table No. 2 Plastic uses in India (2007)
Polymer
1995-96
Polyethylene (PE)
823
Polypropylene (PP) 340
Polyvinyl Chloride 489
(PVC)
Polyethylenetero
34
phthalate (PET)
Others
203
Total
1889
Plastics packaging 976
% of packaging
52%
2001-02
1835
885
867
2006-07
> 3500
> 1800
> 1400
140
> 300
647
4374
2272
52%
> 1500
> 8054
4037
> 50%
2000
6 million
2006
In many parts of the world 50% plastic waste collected as general waste is
recycled today. Recycle waste is used as or for raw material around (4%), chemical
resources (3%), solid fuel (1%), waste power generator (35%) and heat source (7%),
However, the remaining half is disposed of at landfill causing environmental hazards.
Basic question how to put plastics in a recycle net, So that like steel recycling, plastics
also can be recycled in 100% productive use without affecting the economy and the
environment for this purpose. Iron and steel Industries has shown the ways to use
recycle plastic as partial substitute of coke in Blast Furnace and in coke oven also.
Recycling of waste plastics in Iron and steel Industries
[4.3 / 3 ]
[4.3 / 4 ]
Specially in the developing countries like India, when not sufficient presence of coking
coal is existing.
Fig. No.-1, Schematic flow for converting domestic waste plastics to Blast Furnace
Material
Recycling of waste PET bottles
Several companies in the world have started the business of recycling waste PET
bottles since 1990 PET bottles are widely used as contains for soft drinks, soy sauce,
mineral water, eatable Oil, other for example domestic consumption of PET bottles in
Japan is increasing each year and reached almost 70,0000 tons in 2005, of which about
270000 tons were collected by municipalities. The process flow treating waste PET
bottle has been shown in fig no. 2, Based on keihin works. This plant processes
transparent waste PET bottles into PET resin flaken. Waste PET bottles collected by
municipalities contain coloured bottles, caps and label. The most important issue in this
operation is how to remove these foreign objects efficiently and accurately. For sorting
purpose, combination of mechanical sorting, manual sorting, automatic bottle sorting
and label and cap separation equipment are used. After removal of foreign object, the
waste plastic is processed as per chart and part of this as per pre-design action injected
in the blast furnace as substitution of coke. Similar pattern recycling and utilization of
used electrical appliances is also done as per fig No 3. The major features of used
electrical appliances recycling is that most of recovered materials can effectively used in
Iron and steel industries as being done in Japans keihin works. Its unique advantage is
that the recovered plastics, which account for nearly 30% of home electrical appliances,
are directly used in the blast furnace waste plastic feeling operation.
[4.3 / 5 ]
Fig. No.-2, Schematic flow of the recycling for waste PET bottles.
[4.3 / 6 ]
Ash (mass % )
72.6
9.2
0.3
0.04
5.0
PS
PP
PVC
PVDC
PET
Others
21.4
24.8
13.7
52
0.4
15.5
19.0
Fig. No.-5
Fig. No.-6
[4.3 / 7 ]
Process : Fig No. 8 shown the process flow of the waste plastic recycling by the
coke oven from waste plastics to chemical raw materials method. After waste plastic
containers and packaging are pre treated for crushing, removal of foreign matters and
briquetting, they are mixed with blended coal, charged into coke ovens, and
decomposed at 12000C at the maximum without oxygen supply to yield 20% of coke,
40% of tar and light oil and 40% COG (a Hydrogen rich gas), approximately. The
collected material is used as a chemical raw material. The recovered coke is used to
reduce the iron ore in a Blast furnace, the tar and light oil are used as raw materials for
[4.3 / 8 ]
plastics etc. and the COG gas is used at power plant etc. as a clean energy source. The
waste plastics recycling by the coke oven from waste plastics to chemical raw material
method is most popular in Japan and many steel plants has adopted. These methods of
plastic recycling to reduce the energy consumption in Iron and steel plants.
Conclusion
Many parts of the world business development and R&D activities on resource
recycling were outlined many steel plants. Recycling business are making the best use
of the advantage of etc steel works located in the urban area, where huge accounts of
industrial and municipal wastes are generated. Thus providely the steel works with new
social value. Existing facilities are being effectively used to turn waste into Iron and steel
making material. The future shortage of coking coal effectively can be solve by use of
waste plastics in blast furnace and in coke oven.