Waste Management in Steel Industry

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ForewordSteel 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

specific 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. SalujaNational Vice President, IIPE

& Chairman IIPE (Delhi)


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EditorialWorld 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


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International Seminar Waste Management in Iron & Steel Industry,9-10 May, 2008, Rourkela

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 9th May 2008 Friday

10.00-10.15 Welcome address J S Saluja

10.15-10.30 About the Seminar NP Singh ED Works RSP

10.30-10.45 Key Note Address BN Singh MD RSP

10.45-11.00 Inauguration SK Roongta Chairman, SAIL

11.00-11.10 Vote of Thanks SS Mohanti- ED (MM) , RSP

International Seminar Waste Management in Iron & Steel Industry,9-10 May, 2008, Rourkela

Panelists for Panel Discussions: 10th May 2008BN Singh MD RSP- Head of Panel

Ms. Rita Singh MD Mesco

R P Singh- Ex MD Bhilai Steel Plant , CEO JIndal Steels

PR Tripathi Ex CMD NMDC,

Om Narayan Sr.Vice President Tata Steels

PC Aggarwal Chairman / Hira Singh MD Ashok Steels , Nepal

SK Jain ED (O), SAIL

Ashok Kumar ED (W), B S P

Dr. Xia Sheng- Director Engg. Bao Steel, China

Oommen, Dilip- CEO / A K Das GM , Essar Steel

JS Saluja National Vice President, & Chairman, IIPE, Delhi.

Valedictory Function 10th May 2008 Saturday 1620 -1655 Hrs16.20-16.30 Welcome Balbir Singh ED P&A , RSP

16.30-16.40 Summing up NP Singh , ED Opns. RSP RSP

16.40-16.50 Journey Forward J S Saluja National Vice Pres. IIPE

16.50-16.55 Vote of Thanks YP Chawla National Jt. Secy

IIPE & Program Convener


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Program of International Seminar on Waste Management in Iron & Steel Industry

08.00 10.00 Registration Registration of Delegates and PaperPresenters

10.00 11.10 InauguralSession

Please See Inaugural Program Details

11.10 11.25 Tea

11.25 12.45 Session 1 Present Practices:An Overview * Please see Paper Details.

12.45 13.30 Lunch

13.30 15.30 Session 2 Wastes in Iron & Steel Industry * Please see Paper Details.

15.30 15.50 Tea

15.50 18.00 Session 2Contd

Wastes in Iron & Steel Industry * Please see Paper Details.

Cultural Program & Fellowship Dinner

Day 2 10thMay 2008 Saturday

0900 10.30 Session 3 Solutions to Wastes in Iron & Steel Industry * Please see

Paper Details.

10.30 11.00 Session 4 Business Opportunities in Waste Reuse in Iron &Steel Industry * Please see Paper Details .

11.00 11.20 Tea

11.20 13.00 Session 5

Success Stories

13.00 14.00 Lunch

14.00 16.00 PanelDiscussions Please see the List of Panelists

16.00 16.20 Tea

16.20 16.55 Valedictory

Please see Valedictory Program details


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TechnicalSession

Paper Topic Author

1.0 Base Paper YP Chawla

Present Practices An Overview

1.1 An Overview on Waste management In Steel industry V K Dhawan

1.2 Zero Waste Journey at ESSAR Steel Dr. A.K Das. T Bhaskar

1.3 Need for Indian Iron & Steel Industry R.K.Agrawal A.SenguptaSession-1

1.4 The Waste Management and Integrated Utilization Ming Kang, Bin Liu

Wastes in Mining , Iron & Steel Industry

2.1 Use of Sub-Grade Ore- A case study N.K. Mayson, A. Mukerji

2.2 Benefaction of Low Grade Iron Ore Fines S Madhavan, Saroj Jain

2.3 Waste management efforts in Iron Making zone (BF) Sajeev Varghese

2.4 Solid Waste Management in Coke ovens S Roy Choudhury

2.5 Effective Biological Treatment of Coke Oven ByproductPlants Effluent For Removal of Ammonia, Cyanide &Phenol

Dr. B N Das,B Vaidyanathan,K K Manjhi, Dr. S P Kalia,

2.6 Waste Utilization & Minimization- BF DD Patra,DM Srivastava,S.Ranade.

2.7 Recycle Management of Waste Refractory S.K.Bandopadhyay,P.K.Ray Choudhury,D.Ghosh, S.K.Vadher,S.Chandrasekaran

2.8 Management of Solid and Liquid Wastes at Coke Ovenand By Product Plant

K.K.Sanyal

Session-2

2.9 Challenges and solutions for upgrading indian iron oresto optimize mining and steel production

Satyabrata Mishra

Solutions to Wastes in Mining, Iron & Steel Industry)

3.1 BF Slag and SMS Slag utilisationR.P. SinghR.G. Segaran

3.2Management of Splinters in SMS

S.Nanda,D. Mohapatra,Md. Islamuddin ,

3.3Effective Solid Waste Management inIron & Steel industry

Dr. B N Das,V V R Murty

3.4Recycling of Wastes from Iron Steel Industries for SaferEnvironment & better productivity

B. Sankar R.K.DuttaP.K.Pani

Session-3

3.5 Waste Lubricating Oil ManagementNavin KumarVK Srivastava, AK Oli

Business Opportunities in Waste Reuse in Iron & Steel Industry

4.1 EAF Dust Recycling Through Vitrification John H. Buddemeyer

4.2 Recovery and use of steel mill In-Plant Wastes TC Inc.Session-4

4.3Use of Plastic Waste in Iron and steel Industries AnApproach for Energy Reduction

R.B. Gupta,G.C Pattnaik


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INDIAN INSTITUTION OF PLANT ENGINEERSOffice Bearers (2007-2008) - National

Sl. Position Name &Designation

Address Phone (O) Fax Phone (R)

1IIPE

PatronLt. Gen. SS Apte

PVSM (Retd)Past NP, IIPE

E-506, Soma Vihar Appts,RK Puram New Delhi- 110 022

9810310233 011-26854525 011-26105997011-26168627

2IIPE

PatronShri CK Varughese

Past NP, IIPEE-218, Mayur Vihar,Ph-IInd, New Delhi-91

9868553045 011-22779856

3 IIPE-Patron

Shri NP Gupta President Desein Indure Group, GreaterKailash II, New Delhi 110048

011-29211185011-29219566

4President Shri Rakesh Nath

ChairmanCEA, Sewa Bhawan, RK Puram, ND i 011-26102583 011-22150630

5National

Vice Pres.Shri J S SalujaDirector Project

Director ,Essar GroupA-5, Sector-3, Noida-201 301

0120-66266669811101181

0120-6626690 011-26942660

6NationalJt. Secy

Shri YP ChawlaCEO

.

Zoom Developers (P) LtdA-9 A , Ground Floor,Green Park, Aurobindo Marg , ND 16

011-46591105 011-46591100 011-25262517011-25279434

Office Bearers - DelhiSl. Position Name &

DesignationAddress Phone (O) Fax Phone (R)

1Chairman Shri J S Saluja

Director ProjectsDirector Essar GroupA-5, Sector-3, Noida-201 301

0120-66266669811101181

0120-6626690 011-26942660

2

Secretary Shri YP Chawla

CEO.

Zoom Developers (P) Ltd

A-9 A , Ground Floor, Green Park,Aurobindo Marg , New Delhi-110016

011-46591105 011-46591100 011-25262517

011-25279434

3Secretary

(Fin)Shri Satish Bahadur Business Combine,

13 Babar Road, New Delhi- 110 0019811916962 011-23710822

23319962

4Manager Shri A Bhatnagar IIPE, 664 Kamaljit Sandhu Block, Asian

Games Village N D- 110 049011-264932529811319198

011-26493974 011-22629546

Steering Committee Intl Seminar on Waste Management in Iron & Steel IndustrySl. Position Name &

DesignationAddress Phone (O) Fax Phone (R)

1Chairman Shri NP Singh., ED

(Works),Rourkela Steel Plant , Rourkela Orissa 769011

0661-2510641

2Vice

ChairmanShri SS Mohanti,ED - MM

-do-

3InchargeCo-ordn.

Shri RK Mathur,Sr DGM

HRD, address as above

4 ResourcePerson

Shri S Ranadey ,GM ,

Iron Dept, address as above 2523241 2642111

5Chairman Shri J S Saluja

DirectorDirector Projects ,Essar GroupA-5, Sector-3, Noida-201 301

0120-66266669811101181

0120-6626690 011-26942660

6Progm.Director

Shri Y P Chawla,CEO

Zoom Developers (P) LtdA-9 A , Ground Floor, Green Park,Aurobindo Marg , New Delhi-110016

011-46591105 011-46591100 011-25262517011-25279434

Coordinating Committee Intl Seminar on Waste Management in Iron & Steel IndustrySl. Position Name & Designation Address Phone (O) Fax Phone (R)

1Chairman Balbir Singh ED P&A Rourkela Steel Plant , Rourkela

Orissa 7690110661-2611140

2InchargeCo ordn

Shri JC Mohapatra,COC, --Do--

0661-25005094370-85885

2646306

3 Member Shri GN Mathur Ex. CBIP 011-25079178

4 --Do--

Shri P. Bansal, SAIL

HQ

--Do--

5 --Do--Shri MaheshTakhtani,

Rep RSP Delhi 22531226,2240 3564

98685 14255

6In chargeReceptionCommittee

Shri Narayan Pati DGM COP

0661-2510920 094370 47402 0661-2642402

7In ChargeSeminar

Task Force

Shri BB Mishra 0661 2511288 094379 63741

8 --Do-- Shri A M Pujari 0661 2510395 094379 63732

9 --Do--Shri Satish Bahadur, President, Business Combine 9811916962 011-23710822

23319962

10 --Do--Shri P Varshney,Vice President,

Power Trading Corp., New Delhi 98101 53223


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Technical Committee Intl Seminar on Waste Management in Iron & Steel Industry

Sl. Position Name & Designation Address Phone (O) Fax Phone (R)

1Chairman Shri SK Jain ED

(Opns)SAIL HQ Ispat Bhavan Lodi Rd.New Delhi 110 003

22223882221023

22417772242339

2 Member Shri GS Bhatia, Rourkela Steel Plant3 --Do-- Shri MR Diwakar, GM Rourkela Steel Plant

4 --Do-- Shri D Pal GM , Rourkela Steel Plant 2510359 2646326

5--Do-- Shri Mohan Hirani,

Ex-GM, NTPCD-II /2449, Vasant Kunj, ND-70 011-26138209

6 --Do-- Shri SK Jain, VicePresident, Essar GroupA-5, Sector-3, Noida-201 301

7--Do-- Shri L N Sharma,

SAILGM In charge SAIL Burnpur

AMMP-DivisionSl. Position Name & Designation Address Phone (O) Fax Phone (R)

1Chairman Maj Gen S K Sharma

ADGADG, EME (ESM) AHQ, New Delhi

R-256, D.S., Arjun Vihar, Delhi Cantt.011-230114239350040427

011-23018608 011-25691904

2V.

ChairmanShri Mohan Hirani D-II/2449, Vasant Kunj, ND-70 011-26138209

3Secretary Brig Kuljeet Singh DDG EME (ESM) , AHQ, ND 011-23019478 011-23018461 011-24677784

Advisory Board MembersSl. Position Name & Designation Address Phone (O) Fax Phone (R)

1MemberA. Board

Shri Rakesh Mehta Chief Secy Delhi

2--Do-- Shri Rakesh Nath

ChairmanCEA Sewa Bhawan,

RK Puram, New Delhi011-26102583 011-26109212 011-22150630

3--Do-- Dr PS Rana

Ex-CMD, HUDCO9810131406 011-26493129

4 --Do-- Shri Y. Prasad Cmn. Utrakhand Jal Vidyut

5--Do-- Shri Chandan Roy

Director (Oprn)NTPC Ltd SCOPE Complex

Core V Lodi Road ND-3011-24360232 011-24363478 011-24692543

6--Do-- Shri U C Misra

Director (Pers)CMD, BBMB 0124-4043679

7--Do-- Shri K K Khanna

Director (Tech)SAIL , Ispat Bhawan, Lodhi Road,

New Delhi 110 003011-24367105 011-24367250 011-26492434

8--Do-- Shri S K Roongta

Chairman, SAILSAIL , Ispat Bhawan, Lodhi Road,

New Delhi 110 003011-24368094 011-24367015 011-26493004

9

--Do-- Shri PC Aggarwal

Chairman

Ashok Steel Inds. Ltd Bhagmati

Chambers Milan Marg. KathmanduPO-121112,KA-2-2/18

9771-243148

9771-242395

009-771-

4226477009-

7753520155

10--Do-- Shri V S Verma

MemberSewa Bhawan RK Puram,Sec-I, New Delhi-110 066

011-26102583 011-26197267 011-26492024

11--Do-- Shri K Ravi Kumar

CMDBHEL , Siri Fort, Asian Games

Village, ND-110049011-26001001 011-26492043 011-26493933

12--Do-- Shri J Mehra

DirectorEssar Group A-5 Sector 3, Noida 0120-6626602 0120-6626690

13--Do-- Brig AK Adlakha

Executive DirectorAIREA ,81/2, Adchini, Sri Aurobindo

Marg, ND 110017.011- 51071555

510725559810039364

011-51070555 0120-2430769

14--Do-- Shri NP Gupta

PresidentDesein Indure Group , GreaterKailash-II, New Delhi-110 048

011-292111859810096139

011-29219566

15 --Do-- Ms Rita Singh MD , Mesco

16

--Do-- Dr A K Lomas

CMD

Mineral Exploration Corpn Ltd.,

Nagpur

0712 2510289 0120-4260204

0712-2510338

Vice ChairmanSl. Position Name & Designation Address Phone (O) Fax Phone (R)

1 --Do-- Shri RC GuptaVice President

Desein Indure Group GreaterKailash-II, New Delhi- 110 048

011-292237619810019907

011-29218393 011-26132279011-26132193

2 --Do-- Shri HL TayalExe. Director

PGCIL, Corporate Centre7

thFloor, Plot No-02 Sec.29

Gurgaon- 001

0124-25719579811612124

0124-2571956 011-26894118

4 --Do-- Shri V K DhawanED (Operations)

SAIL, Ispat Bhawan, Lodi Road,New Delhi

011-24366740 011-24366470 0120-2771278

5 --Do-- Srhi P VarshneyVice President

PTC, 2nd

Floor, NBBC Tower 15Bhikaji CamaPlace ND 66

011-5165913298101053223

011-51659145 011-26277936


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6 --Do-- Shri Digvijai NathED

Office of ED Subanisiri BasinProjects NHPC Ltd, Ziro, ArunachalPradesh-791 120

03788-22583209436068834

0129-2428574

7 --Do-- Dr GS Yadava IIT Hauz KhasNew Delhi & Chmn. Institution ofEngineers Delhi

011-265912729891334151

011-265916152685605826861834

Standing Committee-Industrial Sectors ConvenersS.No

Category Name & Designation Address Phone (O) Fax Phone (R)

1 ConvenerPowerSctr.

Dr. KK GovilEx- Dir (P), PFC

132 Vasant EnclaveNew Delhi- 110 057

9811165557 011-26147514

2 ConvenerSteelSectr.

Shri G Ojha Director SAIL, Ispat Bhawan, Lodi Road,ND-110003

011-24367259 011-24367250 011-264925174

Executive CommitteeS.No

Category Name & Designation Address Phone (O) Fax Phone (R)

1 Member Col Mahesh Mathur AHQ 9810843739 011-25089974

2 --Do-- Shri YK MattooSr Adviser

Simon India Ltd., Devika Tower,Nehru Place, ND-19

9810492884 011-26843281

3 --Do-- Shri Ashish JainDy. S.E.

ONGC Limited New Delhi 011224064651 0135-2720278

4 --Do-- Shri SK KailaConsultant Kaila Technical Services24/C-9, Sec-8, Rohini , ND 85 011-27941082 011-27941082

6 --Do-- Shri SK GoyalDy. GM (Mech)

National Fertilizer,Panipat

7 --Do-- Shri L N SharmaGM Incharge

SAIL,

8 --Do-- Shri A B AgrawalGeneral Manager

NHPC Ltd.,Salal HydroelectricProject PO Jyotipuram, Vai Reasi,

Dist Udampur J&KK

01991-255433 011-22624985

9 --Do-- Shri AG AnsariChief Engineer

NHPC Limited Sector-33Faridabad-121 003

0129-2258834 0129-2272806 9810546695

10 --Do-- Shri S MajumdarExecutive Director

(DMS)

PGCIL, Corporate Centre7

thFloor, Plot No-02, Sec.29,

Gurgaon-122 001

0124-2571955 0124-2571956 011-26890926

11 --Do-- Shri LC JainVice President (P)

M/s Flowmore Pvt Ltd A-292,Mahipalpur Extension, N.H.-8

New Delhi - 110037

011-306237409313980341

011-26783278,26781483

011-26511605


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International Seminar on Waste Management inIron & Steel Industry

Jointly organized by:

INDIAN INSTITUTION OF PLANT

ENGINEERS

Co Sponsored by :

BeeKay Engineering Corporation

www.beekaycorp.com

Knowledge Partners:

SailConRourkelaBokaro

Bhilai

Pacific Sterling Inc. USA

A Premier Project Development Company


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Base Paper [1.0 / 1 ]

Base Paper: YP Chawla CEO Zoom Developers P Ltd.

National Jt .Secretary IIPEIron Pillar Erected by King Ashoka before Christ

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.


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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 ofUS$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. Thereason 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.


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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 and15% 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 ofenergy, 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.


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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 forincreasing 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 :


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End-of Pipeapproach

Cleaner Production(Reduce, Recycle, Reuse)

Zero Emissions

(Total Productivity)

Minimizing effects on Down Stream Adding New Industry in Up Stream,Utilizing Wastes in existing Industry

Minimize Waste Value AdditionCost Reduction Revenue Increase

Continuing withExistingProductionProcess

Modifying the Existing UnitProcess

Developing Industry Cluster for usingWaste as Input to next Industry

Measures at theOutlet of theprocess.

Input- Output Analysis Output- Input Connection

Water, Energy,Wastes

Waste Minimization throughProduction ProcessModification

Integrated Approach- Holistic Approach

Industry ispresently

focused on theabove

Transit Stage to next stage Ultimate Goal

Wastes Recycling will lead to Minimization of exploitation of Natural Resources

The factors that require Measurement of the industries sustainability are to:

Develop indices of benchmark

Develop successful standards and labeling programs

To learn best-of-kind operation

To build a kind of Energy Code


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To facilitate technology deployment by gathering information on State-of-the-

Art technologies

The Technology of Manufacture is required to be examined for better productivity.

o 40 per cent of the worlds steel production takesplace through the EAF route, which manufacturessteel from scrap metal.

o Steel recycling is common practice and scrap steelhas become a valuable commodity because there

is a technology that can accept it. Engineers and Scientists to take on excitingroute to develop technologies and processes to be able to take into account allWaste Materials. The possibilities are endless!

o Enhancing existing processes to be able to use all kinds of Waste resources to

make the Sustainable Materials Processing, including recycling of waste insteelmaking, lowering of energy and emissions in processing, iron andSteelmaking technologies.

While debating various issues, the Industry Recent High Lights on the

Resource Position may also be examined:

o India's iron ore resources can increase significantly as per ICRIERo Iron Ore reserves can increase significantly from the current estimated level by

increasing investment & exploratory efforts.o Concerns over reserves in view of the proposed capacity additions need to be

dispelled, as significant share of steel gets recycled and efforts will made throughimprovement in technologies and waste recycling , demand for iron ore is to beattempted to be stable.

The studies have indicated that in the current scenario, export restrictions will

make it difficult to take care of excess fines. Restrictions on trade in iron ore will also

restrict the economies of scale to Indian mining Companies and they may remain

inefficient in global comparison forever. Such restrictions could also lead to closure of

some of the mines, leading to loss of direct and indirect jobs.

India's iron ore production in 2006-07 was around 181 million tonne, which was in

excess of the consumption level. India exported about 93 million tonne during that fiscal,

which is expected to come down to about 88 million tonne in the current fiscal. Nearly

80% of exported ores are fines, because those are not adequately used in India. India's

competitiveness in the Chinese market has already started falling, the study points out.


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World Scenario on Steel

SUMMARY OF APPARENT CONSUMPTION (Million Tonnes) OF FINISHED STEEL 1998 to 2008

Region 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

Euro ean Union 152.9 160.0 156.5 156.7 154.4 162.1 164.1 167.0 167.3 166.5

Euro ean Union 128.6 132.6 129.5 127.4 137.4 144.1 145.4 146.9 146.9 146.2

Other Euro e 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

Ja an 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

Oceania 6.7 6.4 6.3 7.1 7.5 7.5 8.0 8.0 8.5 8.5

WORLD TOTAL 708.5 758.2 766.0 810.4 867.0 941.5 989.5 1016.5 1032.5 1048.0

Re ion 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

Totals may not be arithmetically correct because of rounding

Sl Country 2007 Share each Sl Country 2007 Share each

Total 15.3

1 Japan 3.364 22.00% 22 Chile 0.034

2 Brazil 2.418 15.80% 23 Saudi Arabia 0.027

0.20%

3 US 1.551 10.10% 24 Sweden 0.022

4 Belgium 1.539 10.10% 25 Tanzania 0.022

5 India 0.977 6.40% 26 Argentina 0.021

6 Pakistan 0.687 4.50% 27 Indonesia 0.016

7 Turkey 0.64 4.20% 28 Malaysia 0.015

8 Holland 0.509 3.30% 29 Philippines 0.008

0.10%

9 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

2.50%

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 40 Hong Kong 0.001

20 Australia 0.073

0.50%

41 Sri Lanka 0.001

21 Thailand 0.038 0.20% 42 Mozambique 0.001

0.00%


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Ref : MPES UK

Governmental Interventions on Iron & Steel:

Chinabegan to levy a 5% export duty on coke in November 2006. It raised the taxrate 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.


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Structure of Indian Steel Industry Indian Steel Industry comprises of several

interdependent and interlinked segments for value addition, broadly classified as the

integrated or the majors producers and non-integrated or the Secondary Producers.

India has played a pioneering role in the recycling of scrap for the production of Steel

through EAF/Induction Furnaces and the rolling of both the Long and the Flat Products

in Mini/Midi Mills at highly competitive prices. The Secondary Sector accounted for over

50% of the total indigenous output of Finished Steel

The Secondary Producers focus on the production of high grade steels and

specialty products to meet the specific requirements of the industry and the

development plans must include the strengthening of the Secondary sector along with

the major producers.

Ample scope for the reduction of production costs by the Secondary Sector

through the technological up-gradation, particularly by the Electric Arc and the Induction

Furnace Producers, through the conversion of Electric Arc Furnaces to Twin shell

Furnaces.

Technological developments in the past decade, the non integrated producers and

the integrated compact Mills have emerged as low cost producers of Finished steel due

to low capital investment and breakeven points intense customer orientation and

flexibility in altering the product wise.

The Sponge Iron/Mini/Midi Rolling Mill route appears to be the appropriate for a

large country like India and the requisite support be provided to the Secondary

Producers on merits, for the modernization and expansion projects and these Mills

adopting Waste Recycling Techniques.

Key role of the domestic market The expansion of the domestic market in a huge

country like India holds the key to the future growth of the steel industry and the basic

input like Steel should obviously be utilized for the industrial and the economic

development of the country. Besides, the export prices and markets are subject to wide

ranging fluctuations triggered by economic and political developments in different parts

of the world.

Targets of the SeminarThe major responsibility for the implementation of the development plans and

strategies shall however rest on the industry through (i) Benchmarking with the leading

global steel producers in term of the production costs, quality and service, to meet the

global competition in the low tariff regime. (ii) Customer orientation and collaborative

research and development with the metallurgical industries, to develop cost effective

products for the domestic and export markets and to develop India as a low cost global


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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, soilsand 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

****


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Present Practices An Overview [1.1 / 1 ]

AN OVERVIEW ON WASTE MANAGEMENT IN STEEL INDUSTRY

V.K. Dhawan ED (SAILCON)Steel Authority of India Limited

New Delhi

1. Waste Management: For Sustainable Development

Development of an industry in the present age of Sustainable Development is

synonymous with the concern for environment along with its social and economic goals.

Steel is the driving force of economic progress. The intrinsic ability of steel to be

completely recycled offers good prospects for Sustainable Development of the steel

industry. The challenge for steel in the new millennium is no longer to prove its capacity

to create growth, but to show that it is a material with a future, resolutely adaptedthrough recycling /reuse of wastes to the integrated concept of Sustainable

Development. When the steel industry is to remain committed to Sustainable

Development, there is no option for the industry other than gainful utilisation of all the

wastes.

One of the major concerns of world steel industry is the disposal of wastes

generated at various stages of processing. The global emphasis on stringent legislation

for environmental protection has changed the scenario of waste dumping into waste

management. Because of natural drive to be cost-effective, there is a growing trend of

adopting such waste management measures as would convert wastes into wealth,

thereby treating wastes as by-products. This has led to aiming at development of zero-

waste technologies. The technologies developed to economically convert wastes of

steel plants into wealth provide new business opportunities for prospective

entrepreneurs. Such technologies are divided in two categories, namely technologies

for gainful utilization of wastes in manufacture of conventional products and those for

gainful conversion of wastes into altogether new products.

2. 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.


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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 non-

hazardous commercial and industrial waste is usually the responsibility of the generator.

3. The Waste Hierarchy

The waste hierarchy refers to the "4 Rs" reduce, reuse and recycle, restore which

classify waste management strategies according to their desirability in terms of waste

minimization. The aim of the waste hierarchy is to extract the maximum practical

benefits from products and to generate the minimum amount of waste. The waste

hierarchy remains the cornerstone of most waste minimization strategies.

In general by reducing or eliminating wastes an industry can:

Solve the waste disposal problems created by land bans

Reduce waste disposal costs

Reduce costs for energy, water and raw materials

Reduce operating costs

Protect workers, the public and the environment

Reduce risk of spills, accidents and emergencies

Reduce vulnerability to lawsuits and improve its public image

Generate income from wastes that can be sold.


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3.1 Waste Minimization Techniques

Waste minimization includes any source reduction and/or recycling activity

undertaken by a waste generator (i.e. any business that produces waste through theiroperations). These activities result in a reduction of waste produced and/or a reduction

in the toxicity of the waste. Some examples of waste minimization techniques are listed

below.

3.2 Source Reduction Techniques

Change the composition of the product to reduce the amount of waste

resulting from the products use.

Reduce or eliminate hazardous materials that enter the production process.

Use technology (including measuring and cutting) to make changes to the

production process; equipment, layout or piping; or operating conditions. Purchase what you need to avoid waste from unwanted materials.

Good operating practices such as waste minimization programs,

management and personnel practices, loss prevention, and waste

segregation help to reduce waste at their source.

3.3 Recycling Techniques

Return waste material to original process.

Use the waste material as a raw material substitute for another process.

Process waste material for resource recovery.

Process waste material as a by-product.

Investigate contractors to recycle waste material.

3.4 Waste Management In Steel Industry

Metallurgical industry is both capital and energy intensive and its production

volumes are very high. Process chains within the industry are long. Many different

technologies are applied and the industry has a significant impact on the environment.

Steel industry is a mature industry with overcapacity as well as the strongly cyclic nature

is a problem. In the future, the competitiveness of the steel industry depends on

reducing the production time-to-market time, lowering the production costs, increasing

the performance of products and minimizing the environmental impacts. One of the

major concerns of world steel industry is the disposal of wastes generated at various

stages of processing. Because of natural drive to be cost-effective, there is a growing

trend of adopting such waste management measures as would convert wastes into

wealth, thereby treating wastes as by-products. This has led to aiming at development

of zero-waste technologies. The technologies developed to economically convert


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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 industryper 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 (70-

80%) 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 withoutadversely 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 Major Solid Wastes

1 Co & BPP Coke & Coal Dust, Tar sludge, Sulphur Muck, Acid sludge,

Refractory waste

2 Sinter Plant GCP, Sludge

3 RMP Lime fines, ESP dust

4 BF BF Slag Flue dust, BF GCP Sludge, Refractory wastes

5 SMS LD Slag, GCP sludge, Refractory wastes

6 Rolling Mill Mill Scale, Scrap, oil sludge


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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

2006-07Actual

2007-08PlanSolid Waste

Gen % Utilization Generation 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

CarbideSludge

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. Scope of Management of Steel Plant wastes involves

Waste Audit-- Quantification, characterisation and management of all types

of wastes in a steel plant, analysis of the wastes and characterisation of

hazardous wastes,related Ecological problems

Yield loss improvements--Reduce, Reuse, Recycle and Restore- The

Four Rs, Reduce, Reuse, Recycle and Restore, all contribute to saving

energy and natural resources

Zero waste program- Present practices of steel plant waste management

vis--vis best practices, Envisage new products from wastes, their market

scope, project cost estimate for implementation, preliminary evaluation oforder of investment and running cost of implementation of a feasible

technology.

R&D opportunities:- Technology development efforts required to be carried

out with special context to the wastes from steel plants


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4.1 Waste Auditing

A waste audit:

Defines sources, quantities and types of wastes generated;

Identifies where, when, how and why these wastes are produced;

Identifies areas of wastage and waste problems; and

Establishes targets and priorities for waste reduction.

The waste audit can be used to:

ensure external regulatory compliance;

develop base-line data; and

evaluate alternatives to minimize wastage of resources

To conduct a waste audit, the following steps may be followed:

List all generated wastes

Identify the composition of the waste and the source of each substance

Identify options to reduce the generation of these substances in the

production or manufacturing process

Focus on wastes that are most hazardous and techniques that are most

easily implemented

Compare the technical and economic feasibility of the options identified 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.

4.2 Yield Loss in the Steel Industry

From the available information, in a typical year, the U.S steel industry consumes

approximately 120 million tonne of raw materials and ships approximately 100 million

tonne of products. Roughly 53% of these shipments are produced by integrated

steelmakers, i.e. blast furnace and BOF operators, and 47% via the electric furnace

route. This represents a total yield loss of about 20 million tonne each year. The lossesare realized throughout many different operations in a steel mill. They appear in the

form of home scrap and waste oxides; integrated producers also lose a small

percentage of coal and coke. Yield losses also reduce the overall energy efficiency of

steelmaking. The steel industry consumes about 18.1 million Btu per ton of product,

22% more than the practical minimum energy consumption of about 14 million Btu/ton.

These energy losses about 4 million Btu/ton are a result of the energy embedded

in yield losses and process inefficiencies. Additional losses are generated in the use of


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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. What Steel Industry should do for yield loss improvements

The steel industry should strive to make improvements in yield losses in order to

become more competitive through better waste management. Yield loss in steelmaking

is a function of waste oxide production, slag formation, and in-plant scrap returns. Inaddition, any off-specification steel that may be returned from the customer will be a

substantial yield loss. Finally, the yield loss associated with the use of finished goods

cannot be ignored; improvements in steel processing techniques that improve steel

quality and the development of new materials and their implementation by customers

have the potential to save up to substantial amount of energy required to manufacture

the steel used in the product.

The steel industry needs more precise knowledge of steelmaking processes, feed

stocks, and products in order to address the complex combination of inefficiencies that

lead to yield losses. Better understanding and control of iron making and steelmaking

manufacturing processes will help reduce these inefficiencies. Advanced technologies,

operating practices, and materials that increase steelmaking productivity and yield will

also generate sizeable energy savings.

Improvements in operating techniques and practices can reduce the yield losses

associated with in-house scrap returns, waste oxide production, excess slag formation,

lower throughput, and reworking. In-house scrap and the produce that returns due to

non conformity of specifications from customer must be reprocessed. Both kinds of

scrap represent significant yield loss since the energy consumed in the production of

these is lost.

The operation of electric arc furnaces, for example, presents an opportunity for

improving yield by optimizing charging practices, reducing furnace heat time, and

optimizing operating cycles. The productivity of many finishing processes can also be

increased by minimizing process times and adopting practices that reduce defects.

Other examples are scaling due to improper atmosphere control and excess soaking

time in the reheat and annealing furnace. Lack of chemical control produces excess

slag volume and iron losses in the blast furnace, BOF, and EAF.


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5.1 A Step Towards a Zero Waste Plant

Globally, steel industry has made tremendous efforts in the past decade to

drastically reduce its operating costs and to comply with environmental requirements.Given this situation, the promotion and acceptance of a "zero waste" philosophy in

environmental circles may appear to be an unwelcome challenge for the industry,

involving more up front exploratory work than continued operation with a pollution

control/compliance philosophy.

5.2 The Zero Waste Concept

A zero waste approach should -

1. Be a structured approach to minimize -waste generation, energy

consumption, emissions

2. View wastes & emissions as potential raw materials to be conserved orreused rather than wasted.

3. Clearly identify appropriate manufacturing processes and ensures bottom line

cost savings.

4. Implement the identified projects which

reduce process wastes,

convert waste to economically beneficial material

develop new processes that eliminate waste.

For example, the value of EAF steelmaking slag is greatly increased if it ismodified for use in cement-making operations.

Redesign or develop a process which produces no unusable by products. For

example, the COREX iron making process eliminates the need for coke

making and coke oven gas byproduct recovery plants.

5.3 Potential Zero Waste Process for the Steel Industry

Economics for every plant is uniquely determined by its location, age, product mix,

equipment, cost structure among other factors. It is neither reasonable nor economical

to attempt to make every process within a steel plant into a zero waste process, since

the thermodynamics and kinetics of some reactions mitigate against achieving absolutezero waste.

Some zero waste approaches and technologies in these areas are provided below.

5.4 Coke making

Waste can be minimized by improving up the operation and maintenance of

existing processes.


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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 qualityof Coking coal.

The combination of COREX and a Non-Utility Generator NUG is a reasonable

option in areas with an inadequate power supply grid

5.5 DRI Production

Iron oxide fines generated during the screening of ore and pellets are a process

waste for which there is no current economic use. Many DRI plants buy pellets and it is

not economical to return fines to the pelletizing plants that supply their raw materials. A

DRI technology that uses iron ore fines is a zero waste complement to the two DRI

technologies widely used. There are several processes like the DIOS coal basedprocess (Japan) uses iron ore fines, which are pre-reduced in a fluidized bed, to

produce liquid iron from a bath smelting reduction process. The FIOR natural gas based

process (Venezuela) uses 100% fines in a multiple stationary fluidized bed. The Lurgi

Circofer (coal based) and Circored (hydrogen based) processes use iron ore fines to

produce DRI.

5.6 Slags

Evaluation of slag reuse is a low cost, high value option for steel plants.

Opportunities for waste minimization include the reduction of slag volume

through better control of lime input to the furnace and improved control of

silicon and sulphur in blast furnace hot metal.

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 steelslag as construction aggregate.

Slag processors to be developed in the vicinity to handle a variety of

materials such as steel slag, ladle slag, pit slag, and used refractory material

to recover steel metallics.


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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/mortars5.7 Hot Rolling

The hot rolling operation generates scales and sludges with high iron content,

contaminated with significant amounts of oil and grease.

The zero waste approach in this area may have three elements:

Minimize Scale Generation. Direct rolling or hot charging and good reheat

furnace

management can reduce scale loss.

Reduce Oil Contamination: One of the primary sources of oily scale isleaking bearings. Reductions in oil losses through the use of sealed bearings,

thus reducing maintenance, operating costs, and the quantity of oil in sludge.

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. R&D opportunities in Waste Management in Steel Industry

The steel industry can improve its fuel efficiency and productivity by capturing the

heat value of by-product gases and optimizing its mix of fuels and feedstock. In a similarfashion, efficient use of iron and steelmaking by-products can improve yield by

maximizing the industrys use of its iron-bearing feedstock. Recycling scrap may

consume less than half the energy required for iron ore reduction. R&D to increase

recycling includes improved measurement technologies to classify scrap and

processes.

The reliance of iron making on coke is a productivity barrier that can be overcome

by increased use of coke alternatives such as coal and natural gas. Research have

shown Iron-bearing by-products generated within the steel mill can also be used as

feedstock to the blast furnace. Waste oxides contain iron units plus lime, coal and coke

fines.

Research leading to increased internal recycling of these residues will increase the

steel industrys primary yield while reducing disposal costs and saving energy.

Advanced refractories and other improved materials can reduce the frequency of both

scheduled and unscheduled downtime for furnaces and ladles. The development of


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rolling and finishing technologies with reduced maintenance requirements or faster

operating speeds can eliminate bottlenecks that inhibit productivity in these stages.

R&D in the Material properties can optimize steels in ways that minimize the yieldloss in manufacturing. For example, appropriate alloying, rolling, and heat treating

practices must be determined as well as weld ability, forming, and annealing schedules.

R&D opportunities to improve microstructure control and reduce defects include

better sensors for chemistry, cleanliness and defect detection systems. Half of the

Waste oxide generation in steelmaking furnaces contains iron. A major barrier to

reducing this loss is maintaining reliable process control and furnace stability. Potential

R&D opportunities to overcome this barrier include sensors for critical chemical and

physical parameters in the BF, BOF, and other furnaces; real-time chemistry adjustment

technologies; and advanced combustion control systems.

6.1 Viewpoint

It is proposed that to ensure Zero Waste in steel industry, waste management

departments should be created mandatory in every steel industry and then steel

industry should have an apex body comprising of personnel of waste management

department/environment/safety with a mission to promote steel as the material of choice

and to enhance the competitiveness of steel industry by targeting for sustainable waste

management programmes through more and more R&D in this area with an ultimate

aim for zero waste implementation in steel industry.

As part of its strategy for achieving the goals, the body should create an extensivehigh-risk R&D program to develop new technologies and reduce the lead time between

discovery and commercialization. The program should be highly leveraged by steel-

producing companies, steel users, and equipment suppliers. Because the waste

management apex body R&D accomplishes a public purpose as well as the industrys

objectives, the local/central Government may share cost of the R&D projects taken up

by this body. The other part of the strategy of this body should be to ensure the

implementation of Zero Waste program.

The waste management apex body and steel companies in individual capacity and

Steel sector as a whole will share several common goals, including maintaining a

globally competitive manufacturing sector, increasing energy efficiency, reducingenvironmental impact, and creating and saving jobs.

The numerous benefits of this collaborative partnership of the industry and

Government are summarized below.

Increasing Energy Efficiency and Improving the Environment:

Leveraging High Risk Research


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Maintaining Globally Competitive Manufacturing

Delivering Safe, Low-Cost Consumer Goods

Utilizing Government Resources and Expertise

Accelerating Technology Development

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.

Modeling, Measurement, and Control

Operating Techniques and Practices

Process Equipment

Fuels, Feedstocks, and Recycling Material Properties and Manufacturing Technologies

6.2 Zero Waste Implementation

Waste minimization and recycling is widely perceived to require more initial

exploratory work. An organized approach to waste minimization is required to identify

and economically justify opportunities to reduce environmental costs and/or make a

valuable product from waste.

A zero waste program will be successful only when it has five key factors:

1. Total commitment from the highest levels of management.

2. Cross discipline teamwork.

3. Clear-sighted identification of areas which provide environmental and

economic opportunities.

4. Objective process evaluation.

5. A continuous improvement outlook.

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 wastemanagement 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:


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Training employees in waste management techniques

Encouraging employee suggestions

Providing incentives for employee participation Providing resources necessary to get the job done.

Waste management projects may be selected & strategies developed for new

installations right from the design stage during the expansion/modernization going on in

the Steel industry.A systematic approach will produce better results than piecemeal

efforts. An essential first step is a comprehensive waste audit. Areas that pose a

significant problem with respect to environmental compliance and/or costs are good

places to start.

The zero waste concept can be applied to both integrated and mini-mill steel

plants. Waste Management does not end with project implementation, follow-up andcontinuous improvements are crucial to waste management. Measurement and

reporting of waste reduction and cost saving goals achieved will help to justify future

projects and indicate areas for further work.


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ZERO WASTE JOURNEY AT ESSAR STEEL

Dr. A.K Das

Senior Vice-President

Essar Steel Limited

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 isaiming to achieve the status of a Zero Waste Company through recycling and reducing

the by-product generations.

2. Global trends of waste utilization

The iron and steel industry represents one of the most energy intensive and waste

generative sectors within the Indian economy and is therefore of particular interest in

context of both local and global environmental discussions 2. The present day scenario

demands a balance in the productivity as well as the reduction in the wastes expelled

from the Industry. Hence there is a great drive among steel giants as to find a way for

proper utilization of various wastes and energy in order to maintain a clean sheet inthe global market.

Scrap is one of the primary waste materials which are now being effectively

recycled.Recycled iron and steel scrap is a vital raw material for the production of new

steel and cast iron products. Recycling of scrap plays an important role in the

conservation of energy because the remelting of scrap requires much less energy than

the production of iron or steel products from iron ore 3.

Blast furnace flue dust is a solid waste material from the integrated steel plant. The

flue dust is a mixture of oxides expelled from the top of the blast furnace, whose major

components are iron oxides and coke fines. It also contains silicon, calcium, magnesiumand other minor elemental oxides in lesser amounts. The direct recycling of flue dust is

not usually possible since it contains some undesirable elements (like zinc, lead and

alkali metals) that can cause operational difficulties in the blast furnace. As these

undesirable elements are in very low quantities it is not economically feasible to extract

them on an industrial scale.. The same is seen in Electric Arc Furnace dust also called

Fume Extraction System (FES) dust, which contains a large amount of iron oxide.


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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.


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3. Scenario at Essar Steel

Essar Steel Ltd. With a current capacity of 4.6 million tones per annum, generates

various materials as by-products from the steel melting plant and other plants. Some ofthe major by-product generations are given in the Table 1. Electric Arc Furnace slag

and Ladle Furnace slag are the predominant by-products that need immediate attention.

Understanding this, the management as well a key professionals have focused their

attention and also have chalked out several projects for their effective utilization.

Table 1:By-product generation at Essar Steel Ltd.

By-productSource ofGeneration

Lime fines Lime plant

Dolime fines Dolime plant

Slag (Electric Arc Furnace & LadleFurnace)

Steel Making Plant

Fume Extraction System Dust Steel Making Plant

4. Waste utilization at Essar Steel

A Sinter plant with a capacity of 1.32 million tons located on an area of 120 m 2

has been commissioned. The main function of this plant would be to sinter the iron ore

fines generated from the calibrated lump ore degradation as well as from the broken

pellets. A 12 ft diameter disc pelletizer is a part of the plant. Essar is planning to utilizethe sludge pond fines, mill scale and fume extraction system dust for making

micropellets using this pelletizer and hence increase the amenability for these materials

to sinter. The sinter produced would be then utilized for making hot metal in the blast

furnaces and later charged in the Electric Arc furnaces.

EAF slaggenerated at SMPafter necessary characterization with respect to the

chemical and physical properties has been effectively utilized for filling the low lying

areas in and around the plant. The slag has also been used as an effective aggregate

for road making within the plant premises as well as in surrounding areas. Trials have

been completed in joint collaboration with Surat Municipal Corporation and Reliance

Industries Ltd. Essar has also initiated collaborative research work along with CentralGlass and Ceramic Research Institute (CGCRI) Calcutta to make vitrified ceramic

tiles from the slag. Prototypes have been prepared; field trials of the tiles will be taken

up shortly. Trials of recycling ladle slag as a source for lime is also being carried out.

Characterization studies of Fume extraction system dust is being carried out to find

other potential route for its recycling/reuse.


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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 Furnacefor 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 ofconstruction in Essar Steel Ltd Internal report, Essar Steel Ltd.

2. B.P.Radhakrishna, Boom in Indias Iron and Steel Industry, Current Science,

Vol: 92, No.9, May 2007.

3. Michael Fenton, Iron and Steel scrap, U.S Geological Survey, Mineral

Commodity Summaries, January 2003.

4. B. Das, S. Prakash, P.S.R. Reddy and V.N. Misra , An overview of utilization

of slag and sludge from steel industries, Resources, Conservation and

Recycling, Volume 50, Issue 1, March 2007, Pages 40-57.5. Slag Atomizing Technology (SAT): Strategic management of electric arc

furnace slags, Global Slag Magazine, June Issue.

6. Luckman Muhmood, Slag utilization possibilities at Essar- Internal Report,

Essar Steel Ltd.


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NEED FOR INDIAN IRON AND STEEL INDUSTRY

R.K. Agrawal & A.Sengupta

E-mail: [email protected]

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 andhematite-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


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coking coal stock is very limited. Technological innovations on BF are continuing by

modernisation. In the secondary sector, DRI (Direct Reduced Iron) based steel Plants

are coming in the area where coal and gas availability is abundant. To day India is the

highest producer of DRI in the world. Jindals COREX plant is one of the pioneers of

Iron making by smelting reduction process.

In the steel making process, many technological development have been taken

place through out the years including secondary refining, still a lot more to be done to

be competitive in the world. On line sampling of steel, installation of secondary de-

dusting facilities, maximising continuous casting, etc are the emerging trend now.

Electric Arc Furnace Steel Making sector, there is wide variation in the

technological profile . Few Indian plants are of world class but others still suffer

with technological obsolesces . Electrode consumption of the order of 1 kg/ton

needs to be adopted. Fume emission control devices need improvement in

accordance with national environment policy-2006.

Steel makers around the world are switching over to continuous casting. In India

Steel Production through continuous casting route is only 66% which is much less

compared to the world average of 91%. India also need to enhance the continuous

casting facility, Thin Slab casting etc. Utilisation of Rolling Mills sludge and oily Mill

Scales also need to be increased .

For Energy/GHG Emission Reduction, Energy Audit for all the plants has become

almost mandatory. All the steel plants, particularly, primary steel producers, are

striving hard to bring down the energy consumption level by waste heat recovery

from all the practicable sources . Energy savings has government bearing on the

operational cost of the plant. The report of the expert committee on integrated

energy policy of planning commission has recommended for creation of national

energy fund to finance energy research and development which inter alias include

technology up gradation as well as to reduce energy and GHG emission.

In accordance with the National Environmental Policy-2006 and for the

sustainable growth of the society, Indian steel industry being one of the core

contributors towards GDP, technological-cum-financial assistance are needed in

some of the key areas like quality improvement of prime raw materials, utilisation ofinferior quality of raw materials, dust pollution reduction to a level of 1 kg per ton of

crude steel or even below, SOX/NOx pollution reduction to a level below 1.2 to 1.5

kg per ton of crude steel, complete treatment of phenol, cyanide, ammonia and

other eco-toxic mater

Waste Management in Steel Industry

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