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Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 1
European IPPC Bureau
Review process
for the Iron and Steel Industry BREF
Rainer Remus
European IPPC Bureau
Sustainable Production and Consumption Unit
Joint Research Centre – Institute for Prospective Technological Studies
20 July 2011
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 2
European IPPC Bureau
Review process for the IS BREF
The original Iron and Steel BREF was adopted in
December 2001 and was one of the first BREFs in a
series of 33 documents. Consequently it was
foreseen as one of the first BREFs to be reviewed.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 3
European IPPC Bureau
Milestones in the review process for the IS BREF
October 2005 Activation of the TWG for the review of the Iron and Steel
BREF and submission of TWG wishes
September 2006 TWG kick off meeting
February 2008 First draft of the review of the Iron and Steel BREF (1250
comments received)
July 2009 Second draft of the review of the Iron and Steel BREF (1385
comments received)
January 2010 Third draft of the review of the Iron and Steel BREF
February 2010 Final TWG meeting
April 2010 Fourth draft of the review of the Iron and Steel BREF
October 2010 Fifth draft of the review of the Iron and Steel BREF
June 2011 Final draft of the review of the Iron and Steel BREF
September 2011 Forum opinion on the full BREF including BAT conclusions
November 2011 Adoption of the BAT conclusions by the Committee
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 4
European IPPC Bureau
Scope of the IS BREF
This document addresses the industrial activities specified
in Annex I to the IED, namely:
• Activity 1.3: coke production
• Activity 2.1: metal ore (including sulphide ore) roasting and
sintering
• Activity 2.2: production of pig iron or steel including
continuous casting, with a capacity exceeding 2.5 tonnes
per hour
• The document also covers some activities that may be
directly associated to these activities on the same site, i.e.
pelletisation plants.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 5
European IPPC Bureau
The two main IS production routes
Electric Arc Furnace scrap Casting/
Rolling/
Finishing
1
2
ores
fluxes
coal
Sinter Plant
Pelletis.
Plant
Coking Plant
Blast Furnace
hot blast
reductant injection
Basic Ox. Steelmak.
pig iron
Slag Processing
Casting/ Rolling/ Finishing
oxygen
Steel products
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 6
European IPPC Bureau
The share of the two main IS production routes
In 2006 in the EU-27:
• 60 % of the steel production was based on the blast furnace/basic oxygen
furnace route (123 Mio. tonnes)
• 40 % was based on the EAF route (83 Mio. tonnes)
Turkish steel industry:
• 2nd largest producer of steel in Europe (approx. 26 Mio. tonnes)
• 10th most important steel-producing country globally
• 28 % blast furnace/basic oxygen furnace route
• 72 % EAF route (EAF mills)
• Largest scrap consumer in Europe (25.3 million tonnes) in 2010
• World’s largest importer of scrap metal
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 7
European IPPC Bureau
The structure of the IS BREF
• Preface
• Scope
• Chapter 1: General information (Production, economics and key
environmental issues)
• Chapter 2: horizontal issues (horizontal matters which do not relate to one
steel process only)
• Chapter 3 to 8 provide information on particular iron and steel processes
(sinter plants, pelletisation, coke ovens, blast furnaces, basic oxygen
steelmaking and casting, electric arc steelmaking and casting), including
information on applied processes and techniques, current emission and
consumption levels and techniques to consider in the determination of
BAT. The latter consists of a catalogue of environmental techniques and
forms the heart of the BREF.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 8
European IPPC Bureau
The structure of the IS BREF
• In Chapter 9 are the BAT conclusions as defined in Article 3(12) of the
Directive for Chapter 2 to 8.
• Chapter 10 provides information on alternative iron making techniques that
are already being applied.
• Chapter 11 presents information on 'emerging techniques'
• Chapter 12 provides the concluding remarks and recommendations for
future work
• Chapter 13 are the annexes.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 9
European IPPC Bureau
The key environmental issues in IS Production
The key environmental issues are:
• the reduction of emissions to air and water
• efficient energy and raw material usage
• minimisation, recovery and the recycling of process residues
• effective environmental and energy management systems.
• nuisance by noise emissions.
The key polluting substances emitted to air are dust, nitrogen oxides
and sulphur dioxide. Carbon oxides, polyaromatic hydrocarbons,
polychlorinated dibenzo-p-dioxins and dibenzofurans, total organic
carbon, metals, hydrogen chloride and hydrogen fluoride are
emitted as well.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 10
European IPPC Bureau
IS production from ores: Sinter plants
1
ores
fluxes
coal
Sinter Plant
Pelletis. Plant
Coking Plant
Blast Furnace
hot blast
reductant injection
Basic Ox. Steelmak.
pig iron
Slag
Processing
Casting/ Rolling/
Finishing
oxygen
Steel products
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 11
European IPPC Bureau
Sinter strand
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 12
European IPPC Bureau
Reduction of particulates in sinter plants • Sinter plants are the major source for dust, heavy metal and dioxin
emissions in IS production from ores
• Waste gases from sinter plants are characterized by:
• high fine particles
• high specific dust resistivity due to high alkaline content
• high concentrations of dioxins, mercury, SO2, HF and HCl
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 13
European IPPC Bureau
Technique Type Achieved emission levels [mg/Nm3]
Averaging period
Fabric Filter
Fabric Filter 1 – 15 DAV
<3 DAV
<2 DAV
<0.5 AAV
<10 n/a
Eletrostatic precipitator (ESP)
ESP 36 AAV
ESP 25 - 65 AAV
MEEP1) – ESP 25 – 56 DAV
ESCS2) – ESP 20 -37 n/a
Energy pulse superimposition3) – ESP 43 – 77 AV
ESCS2) – ESP 40 n/a
Most ESP 50 - 140 n/a
1) Moving electrodes electrostatic precipitator 2) Electrostatic space cleaner super 3) Energy puls superimposing
DAV = Daily average
AAV = Annual average
n/a = not reported
Dust abatement in sinter plants by advanced ESP and fabric filter
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 14
European IPPC Bureau
Control of dust, PDCC/F, HCl, HF and SOx emissions by
prededusting-additive injection-final dedusting
Additives
required:
pre - dedusting
Option:
• return to
sinter strand
• treatment
• disposal
sinter strand
waste gas suction
mixing drum
• Disposal
• treatment
• return to
sinter strand
Cyclone
ESP
Bag filter
required:
filter internal
dust return
optional: pre - dedusting
Option:
• return to sinter strand
• treatment • disposal
sinter strand
waste gas suction
mixing drum
• Disposal • Return to sinter strand
Cyclone
ESP
Cyclone
ESP Bag filter
required:
filter internal dust return
Additive
injection Stack
Lim
e
(HC
l, HF, p
reco
atin
g)
Ca
rbo
n a
dd
itive
(PC
DD
/F)
Wate
r, lime
(SO
2 )
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 16
European IPPC Bureau
Performance for dust from Jan – Oct 2008
(daily mean values)
0
1
2
3
4
5
6
01/0
1/20
08
15/0
1/20
08
29/0
1/20
08
12/0
2/20
08
26/0
2/20
08
11/0
3/20
08
25/0
3/20
08
08/0
4/20
08
22/0
4/20
08
06/0
5/20
08
20/0
5/20
08
03/0
6/20
08
17/0
6/20
08
01/0
7/20
08
15/0
7/20
08
29/0
7/20
08
12/0
8/20
08
26/0
8/20
08
09/0
9/20
08
23/0
9/20
08
07/1
0/20
08
21/1
0/20
08
du
st
co
nc. in
th
e t
reate
d w
aste
gas i
n [
mg
/m3]
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 17
European IPPC Bureau
Sinter strand primary dust emissions with ESP
Dust emissions from sinter strands
0
10
20
30
40
50
60
70
80
90
0 2 4 6 8 10
Installations
Diu
st [
mg
/Nm
3]
AAV
5th percentile
DAV
95th percentile
BAT-AEL
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 18
European IPPC Bureau
PCDD/F emissions with ESP and additive injection from sinter
strand
Dioxin emissions from sinter strand
0
0,1
0,2
0,3
0,4
0,5
0,6
0 1 2 3 4 5 6
Installations
PC
DD
/F [
ng
I-T
EQ
/Nm
3]
BAT-AEL
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 19
European IPPC Bureau
Upper
BAT-AEL
Sinter strand primary dust emissions with fabric filter
Lower
BAT-AEL
Dust emissions from 5 sinter strands with fabric filter
0
2
4
6
8
10
12
14
16
0 1 2 3 4 5 6
Installations
Du
st
[mg
/Nm
3]
DAV
95th percentile
Upper
BAT-
AEL
Lower
BAT-
AEL
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 20
European IPPC Bureau
Dioxin emissions from sinter strand
0
0,05
0,1
0,15
0,2
0,25
0 1 2 3 4 5 6
Installations
PC
DD
/F [
ng
I-T
EQ
/Nm
3]
PCDD/F emissions with fabric filter and additive injection from Sinter strand
BAT-AEL
Dioxin emissions with fabric filter and additive injection from 5 sinter
strands
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 21
European IPPC Bureau
BAT conclusion for dust emissions from the sinter plant
20. BAT for primary emissions from sinter plants is to reduce dust emissions from the
sinter strand waste gas by means of a bag filter.
BAT for primary emissions for existing plants is to reduce dust emissions from the
sinter strand waste gas by using advanced electrostatic precipitators when bag filters
are not applicable.
The BAT-associated emission level for dust is <1 – 15 mg/Nm3 for the bag filter and <20
– 40 mg/Nm3 for the advanced electrostatic precipitator (which should be designed and
operated to achieve these values), both determined as a daily mean value.
Bag Filter
Description: Bag filters used in sinter plants are usually applied downstream of an
existing electrostatic precipitator or cyclone but can also be operated as a standalone
device.
Applicability: For existing plants requirements such as space for a downstream
installation to the electrostatic precipitator can be relevant. Special regard should be
given to the age and the performance of the existing electrostatic precipitator.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 22
European IPPC Bureau
BAT conclusion for dioxin prevention and reduction in sinter plant off-gas
25. BAT for primary emissions from sinter strands is to reduce emissions of
polychlorinated dibenzodioxins/furans (PCDD/F) and polychlorinated biphenyls (PCB)
by using injection of adequate adsorption agents into the waste gas duct of the sinter
strand before dedusting with a bag filter or advanced electrostatic precipitators when
bag filters are not applicable.
The BAT- associated emissions level for polychlorinated dibenzodioxins/furans
(PCDD/F) is <0.05 – 0.2 ng I-TEQ/Nm3 for the bag filter and <0.2 – 0.4 ng-I-TEQ/Nm3
for the advanced electrostatic precipitator, both determined for a 6 – 8 hour random
sample under steady-state conditions.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 23
European IPPC Bureau
IS production from scrap: Electric Arc Furnace
Electric Arc Furnace scrap
Casting/
Rolling/
Finishing
2
Steel products
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 24
European IPPC Bureau
Electric Arc Furnace
Charging the furnace
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 25
European IPPC Bureau
Typical off-gas collection and treatment system in an EAF
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 26
European IPPC Bureau
Overall view of the
activated lignite dosing
system
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 27
European IPPC Bureau
Daily averages for dust from an EAF over three years
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 28
European IPPC Bureau
Dust emissions from various EAF plants
Dust emissions from EAF
0
2
4
6
8
10
12
14
16
0 2 4 6 8 10 12 14 16 18
Installations
Diu
st
[mg
/Nm
3]
DAV
Min
Max
AAV
AAV 2004
AAV 2008
AAV 2003
BAT-AEL
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 29
European IPPC Bureau
Dioxin emissions from various EAF plants
BAT-AEL
0
0,05
0,1
0,15
0,2
0,25
0 5 10 15 20 25
Installations
PC
DD
/F I
-TE
Q n
g/N
m3
lower range
upper range
DAV
BAT-AEL
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 30
European IPPC Bureau
BAT conclusion for dust emissions from the electric arc furnace
89. BAT for the electric arc furnace (EAF) primary and secondary dedusting (including
scrap preheating, charging, melting, tapping, ladle furnace and secondary metallurgy)
is to achieve an efficient extraction of dust emissions from all emission sources by using
one of the techniques listed below and to use subsequent dedusting by means of a bag
filter:
I. a combination of direct off-gas extraction (4th or 2nd hole) and hood systems
II. direct gas extraction and doghouse systems
III. direct gas extraction and total building evacuation (low-capacity electric arc
furnaces (EAF) may not require direct gas extraction to achieve the same
extraction efficiency).
The overall average collection efficiency associated with BAT is >98 %.
The BAT-associated emission level for dust is <5 mg/Nm3, determined as a daily mean
value.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 31
European IPPC Bureau
BAT conclusion for dioxin emissions from the electric arc furnace
90. BAT for the electric arc furnace (EAF) primary and secondary dedusting (including
scrap preheating, charging, melting, tapping, ladle furnace and secondary metallurgy) is
to prevent and reduce polychlorinated dibenzodioxins/furans (PCDD/F) and
polychlorinated biphenyls (PCB) emissions by avoiding, as much as possible, raw
materials which contain PCDD/F and PCB or their precursors (see BAT 6 and 7) and
using one or a combination of the following techniques in conjunction with an
appropriate dust removal system:
I. appropriate post-combustion
Applicability of BAT I: In existing plants, circumstances like available space, given off-
gas duct system, etc. need to be taken into consideration for assessing the applicability.
II. appropriate rapid quenching
III. injection of adequate adsorption agents into the duct before dedusting.
The BAT-associated emission level for polychlorinated dibenzodioxins/furans (PCDD/F)
is <0.1 ng I-TEQ/Nm3, based on a 6 – 8 hour random sample during steady-state
conditions. In some cases, the BAT-associated emission level can be achieved with
primary measures only.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 32
European IPPC Bureau
Concluding remarks
• The BREF process followed a defined and demanding exchange information process.
• Lot of information and expertise of many stakeholders from industry, Member States and NGOs were included.
• This BREF can be considered as a good description of the current best available techniques and their associated emission levels in the iron and steel production.
• It will be used as the reference for setting permit conditions where the BAT-AELs should not be exceeded.
• The revised BAT Reference Document for Iron and Steel Production can be considered a driver towards improved environmental performance.
Workshop on the implementation of BAT under new Directive 2010/75/EU – Ankara, 20 July, 2011 33
European IPPC Bureau
All BREFs can be downloaded free of charge
from the EIPPCB website
http://eippcb.jrc.es/reference/
Thank you for your attention Rainer Remus
European IPPC Bureau
Tel.: +34 954 488 290
http://eippcb.jrc.es