Innovation through Recycling / Minimizing Waste through... · 2/24/2017 · Innovation Forum 7th...

Innovation Forum 7th Feb 2017

Innovation through

Recycling / Minimizing Waste

Presented by Mr. N.A. Ansari

CEO

A presentation from Jindal Shadeed Iron& Steel

Innovation Forum 7th Feb 2017 2

Who are we?

• First & Largest Integrated Steel Plant in Oman

Waste–an opportunity for innovation

• JSIS efforts

• Future plans

Support Required

• Government support

• Regulations

Agenda


Who are we?

• First & Largest Integrated Steel Plant in Oman

Agenda


First & largest integrated steel plant in Oman

1.5 MTPA

DRI Plant

(HBI/HDRI)

2.0 MTPA

SMS Plant (Square /

Round Billet)

1.4 MTPA

Rolling Mill (8 – 40 mm

Rebar)

771 employees

USD 1.2 Billion Investment

300 Acres

Part of the US $ 18 billion OP Jindal Group

Chairman


Our Journey

July 2010

Acquisition

Dec 2010

DRI Plant

commissioned

April 2014

SMS Plant

commissioned

April 2016

Rolling mill

commissioned

1

2

3

4


Waste–an opportunity for innovation

• JSIS efforts

• Future plans

Agenda


Most favored

Least favored

Reduce

Reuse

Recycle

Disposal

Waste Pyramid


Steel in the Circular Economy


Steel and Sustainability

•Steel industry (next biggest to Oil & Gas industry) strictly adheres to environmental responsibility.

Strict Adherence to environment policy

•Steel is the world’s most recycled material & 100% recyclable.

100 % Recyclable

•100% compliance with local/international environmental norms.

•Oman’s first Plant sharing real time data of Continuous Ambient Air

Monitoring Station with Ministry of Environment and Climate Affairs

(MECA)

•Follows world’s most stringent EU BAT Norms i.e.10 mg/Nm3 for dust

against Omani norms 100 mg/Nm3.

•Only plant in GCC treating Slag from EAF for recovery of the metal from

Slag and other uses strongly pursued.

•Recycles different types of by products.

Jindal Shadeed efforts - Going beyond norms


Principle

Principles of Reduction, Reuse, and Recycling (3’R’s) in Waste Management

Environment friendly

Reuse and Recycling aims at clean, green and zero waste technology

Cost Saving

• Reduce the cost of waste disposal

• Provide substantial amount of iron, flux /other materials

• Fuel rate benefits to the existing process.

Waste Management in Integrated Steel


Current Initiatives


EAF Dust and

Bagging

Expected Savings : OMR 30,000 p.a.

Classified as Hazardous due to heavy metal content

Most challenging in handling, transportation and disposal due to cost & environmental concerns.

EAF Dust cannot be directly charged in the furnace.

EAF Dust is agglomerated by mixing definite proportion of dust with bentonite and water to produce 8-18mm Pellets having adequate strength and moisture suitable to be recycled in Electric Arc Furnace

Jindal Shadeed initiated production and recycling 25% EAF dust in Electric Arc Furnace with a target of 100% in next few months.

EAF Dust Recycle


Refractory Waste - Reuse

Magnesia – Carbon Bricks

Sorting and Crushing of Magnesia-Carbon Bricks to below 50 mm size

This can be used as a substitute to

“Dololime” in Electric Arc Furnace.

Dololime is used as a slag forming material to remove the impurities in Electric Arc furnace.

Expected Savings : OMR 24,000 p.a.


JSIS is the only

company in Oman

undertaking metal

recovery by HARSCO

Road Aggregate

Fine Aggregate in Precast

Engineering

Cement Application

Engineering Fill

EAF Slag – Recycle / Reuse

Non Hazardous

Future expected Savings : OMR 500,000 p.a.

Under development

Other benefit : Clean Environment


Energy / Resource Saving initiatives

Hot DRI Gravity Feeding System

• First of it’s kind in the world, less space utilization

• Reduction in Electrode Consumption/ handling loss • EAF productivity increases up to 20%

• Energy savings of 15 KWH/Ton of DRI

Optimizing Hot DRI to SMS Plant Reduction in NG Consumption/Ton of DRI from 10.0 to 9.35 MMBTU/Ton & reduction in power 120-140 Kwh/T

Hot charging of Billets to Rolling Mill Substantial savings in NG consumption up to 40% by hot charging.

Commissioning of Liquid Ring compressor

Energy savings of 1.95 kWh/Ton of DRI Production.

Increased the system pressure from 300 mbar to 500 mbar

Savings in power consumption of Process gas compressors in DR Plant of 7kWh/Ton of DRI production.


Help the neighbor / create SME

Help the neighbour (Sohar Aluminum)

Trial usage of Spent pot Liner (Cathode) / Spent Anodes which is in SMS

Hazardous Waste - 25,000 Tons in stock

SPL can substitute carbonaceous raw material in the

Electric Arc Furnace for steel making process.

JSIS and Sohar Aluminium are working together to reuse it in the Electric Arc Furnace at Jindal Shadeed.

Creation of SME

Crushing industries for various crushing activities


Future Plans


Formed during Continuous Casting and Rolling Mill processes when steel is subjected for thermal gradients in oxidant atmospheres, which promotes the growth of iron oxides layer at the surface of steel

50% Reduction in generation of Mill Scale:

1. Ramp up the production with minimum stoppages in Rolling Mill.

2. Proper balancing of the pressures inside the Reheating Furnace.

3. To maintain minimum required oxygen in reheating furnace.

4. Increase the hot charging % of Billets to Rolling Mill.

Mill Scale Reduction


Various Future Initiatives

•Briquetting oxide fines, sludge fines and quench fines as “Direct Reduced Briquettes” (DRB) for its use in DR Plant as a partial substitute to “Oxide Feed”.

Fines Briquetting

• Injection of lime dolo fines (or) Briquetting of lime dolo fines, bag filter dust and settling chamber dust for its use in SMS as a partial substitute to flux.

Lime dolo briqueting

•Electrode Waste - After crushing can be utilized as a carbon material in Electric Arc Furnace .

Electrode waste

•CO2 Utilisation in making methanol and other CO2 sequestration.

CO 2 Utilization


Energy / Saving initiatives

Modification to Extract Power from Flue Gas:

To Generate Power from the Waste Flue Gas (8 -10 MW)

Installation of Turbo Expander:

To generate power from the pressure of Incoming Natural Gas (1-2 MW)

Modification in Ladle Preheating System:

Modification in ladle Preheating system being planned shortly which saves substantial reduction in Natural Gas up to 50% (presently 7750NM3/day).


Support Required

• Government support

• Regulations

Agenda


1. Support from Be’ah for Testing /

certification of usage of Slag.

2. Support from PEIE / universities

research on innovation for future

slag application.

3. Support from Government for

incentivizing energy saving

initiatives.

4. Support from Government to stop

wastages due to frequent start up

(which is due to forced shut down

during peak demand in view of CRT)

22

Government Support Requested


1. MECA approval based on Be’ah

certification for usage of slag.

2. One stop shop for approval as

against Multiple agencies for

approval

23

Regulation Support Requested


THANK YOU

Innovation through Recycling / Minimizing Waste through... · 2/24/2017 · Innovation Forum 7th...

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