international conference on indian steel industry: “challenges and opportunities” 23 rd -24 th...
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
STEELMAKING THROUGH EAF ROUTE AND ITS EFFECT ON ENVIRONMENT
BYDURBA TALUKDAR & SOMNATH GUPTA
M.N.DASTUR & COMPANY (P) LTD,
KOLKATA
INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
CO2 EMISSIONS BY GLOBAL STEEL INDUSTRY
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
ENERGY INTENSITY OF STEEL INDUSTRY
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
SPECIFIC ENERGY CONSUMPTION (Unit : GCal/TCS)
Plant 2007-08 2008-09 2009-10 2010-11(Apr – Dec 2010)
SAIL 6.95 6.74 6.72 6.82
BSP 6.72 6.5 6.56 6.66
DSP 6.94 6.5 6.55 6.78
RSP 7.39 7.09 6.97 6.89
BSL 6.89 6.83 6.74 6.88
ISP 8.14 8.18 8.18 8.23
RINL (GCal/TLS)
6.21 6.54 6.09 6.18
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
SPECIFIC ENERGY CONSUMPTION(Unit : GCal/TCS)(Continued)
Source: 1. Sail News – February – June 2010
2. Annual report 2010-11, Ministry of Steel, Govt. of India
Note: **BF and Sinter Plant were under capital repair for approx 6 months.
Plant 2007-08 2008-09 2009-10 2010-11(Apr – Dec 2012)
TaTa Steel 6.555 6.587 6.173 (Apr-Dec 2009)
NA
JSW Steel 6.847 6.704 6.495 6.31
JSPL 7.68 7.25 7.14 6.98
Essar Steel 5.99 5.81 NA NA
IIL 5.73 5.42** 5.46 (Apr-Sept 2009)
Merged with JSW
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
STEEL PRODUCTION THROUGH ELECTRIC FURNACES IN INDIA
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Total CrudeSteel Production(Million tons)
27.291 28.814 31.779 32.626 45.780 49.450 53.468 57.791 63.527 68.321
ProductionOf CrudeSteel in Electric Furnaces(Million tons)
9.980 10.850 12.680 14.300 24.780 27.650 31.300 34.800 36.200 41.300
% of SteelProduction in Electric Furnaces
36.5 37.7 39.9 43.8 54.1 55.9 58.5 60.2 57.0 60.4
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
MAJOR WASTE GENERATED FROM EAF
• Solid waste Slag Dust Sludge Refractory debris Skull
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
MAJOR WASTE GENERATED FROM EAF ( Continued)
• Gaseous waste Carbon-monoxide Carbon-dioxide Sulphur-dioxide Oxides of Nitrogen Particulate matter
• Liquid waste Polluted water
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
EAF SLAG
• COMPOSITION Main constituent – Calcium Oxide and Iron Other minor constituents - Magnesium, Manganese, Silicon, Aluminium
• APPLICATION Land Filling Road Construction Aggregate for concrete Clinker Kilns as a replacement for mined limestone Reuse in internal processes Soil conditioner Making prefabricated shapes for sewerage
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
EAF DUST
• COMPOSITION Main constituent – Iron Other constituents – Zinc in the form of oxide/sulphide/chloride
Lead as oxide, Cadmium, other metals, halides and fluxes
• Treatment Recycling back into the furnace High temperature metal recovery processes Hydrometallurgical and pyro-metallurgical processes
• APPLICATION Reuse in EAF Landfilling Extraction of Zinc Use in rotary hearth furnace
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
GASEOUS EMISSIONS
• Harmful SubstancesOxides of carbon Oxides of nitrogen Oxides of sulphur Cyanides Fluorides
• Measures adopted Improved Fume extraction system and control
technologies Furnace off gas analysis system
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
DEVELOPMENTS IN EAF PROCESS ROUTE
• Development of Shaft Furnace, Consteel Process and other processes
• The processes developed lead to : Lower noise level Lower dust content in off gases Reduced off-gas volume Full heat incineration of carbon-monoxide
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
TECHNOLOGICAL DEVELOPMENTS IN EAF
Period Technological Development
Tap-to-Tap Time
Electricity Consumption
(kWh/t)
Electrode Consumption
(kg/t)1965-70 Oxygen lancing 180 630 6.5
1970-80 -Water cooled panels-High power operation (UHP)
105 490 3.5
1980-85 - Ladle furnace- Foamy slag- Eccentric bottom tapping - Scrap pre-heating
80 450 2.5
1985-95 -Oxygen carbon injecton ( lance manipulator)- Pneumatic bath stirring
60 410 2.0
1995-2005 -Oxygen carbon/oxyfuel side wall injection-Use of hot metal as charge material
55 250-300 1.6
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd
TECHNOLOGICAL DEVELOPMENTS IN EAF (Continued)
• The technological developments lead to : Reduced energy consumption Resource savings Reduction of carbon footprints Cost savings
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”
23rd -24th MARCH 2012
M.N. Dastur & Company (P) Ltd 15
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