Sustainable Practices in Iron and Steel Industry Environment Management Division STEEL AUTHORITY OF INDIA LIMITED ECAC, WBPCB, Kolkata23.11.2012

Sustainable PracticesSustainable Practices in in

Iron and Steel IndustryIron and Steel Industry

Environment Management DivisionEnvironment Management Division

STEEL AUTHORITY OF INDIA LIMITED

ECAC, WBPCB, Kolkata 23.11.2012

SustainabilitySustainability means living within the resources of the planet without damaging the environment now or

in the future.

What is What is Sustainability Sustainability ??

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Integration of industrial

development and protection of

environment is the essence of

Sustainable Sustainable DevelopmentDevelopment

What is What is Sustainable Sustainable DevelopmentDevelopment??

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Ancient Philosophy – Ancient Philosophy – Respect for EnvironmentRespect for Environment

In ‘Rig Veda’, it is stated:

Sky is like a father

Earth is like a mother

Space is as their children

It reflects that environment is to be valued like parents and loved like children

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Steel - a vital resource for Sustainable Steel - a vital resource for Sustainable DevelopmentDevelopment

• Steel as a finished product, is one of the most environment friendly products, owing to its excellent mechanical properties, versatility and its recyclability.

• The rapid and continuing growth of steel industry during last few decades bears testimony to the indispensability of steel, as a vital resource for sustainable development.

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• However, the process of steel making itself is highly energy and fossil fuel intensive and consequently a major GHG emitting process and therefore, the cause of environmental concern across the world.

• Locally steel making industry is normally perceived to be large, dirty and polluting by civil society and environmentalists.

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Environmental Aspects of Iron & Steel Environmental Aspects of Iron & Steel IndustriesIndustries

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Growth of Indian Iron & Steel IndustryGrowth of Indian Iron & Steel Industry

• In commensuration with the growth of Indian economy, steel industry in India has also grown accordingly.

• Presently, crude steel production is ~72 MT, expected to reach ~150 MT per year by 2016 – 17.

• Such perceived growth in steel production capacity can be achieved mainly through rise in steel consumption, particularly in rural sector.

• Enhancement of production capacity requires construction of new steel plants and expansion of existing plants.

• This would also imply increased extraction of natural resources and their processing.

Challenging Issues for todayChallenging Issues for today

• Over the years, the domestic steel industry has improved its technology and maintenance systems.

• However, globally, Indian Steel Industry is yet to fully match its competitors in the developed countries in all the areas pertaining to adoption of sustainable production technique.

• Unless there is reduction in the consumption pattern of the input materials as well as specific emission intensities, it may be difficult to achieve a balance between increased production and minimum possible damage to the environment by the industries.

• The increase in capacity needs to address environmental issues for long term sustainability.

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Sustainable Practices Sustainable Practices are the only way out to meet these challenges and for long term

viability of the iron and steel industry.

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Initiatives from GovernmentInitiatives from Government

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• Environmental Rules and Regulations, notified from time to time - recently harmonized the notification for iron and steel industries

• Charter on Corporate Responsibility for Environmental Protection (CREP), 2003 - to go beyond the compliance with the environmental standards

• National Environmental Policy (NEP), 2006

- promotes sustainable development

• National Action Plan for Climate Change (NAPCC), 2008 identified 8 National Missions, - to achieve sustainable development

• Sustainable Development / MOU Guidelines issued by Department of Public Enterprise- including Sustainable Development as a compulsory element for Central Public Sector Enterprises

Sustainable Practices in Iron and Steel Sustainable Practices in Iron and Steel IndustriesIndustries

Sustainable practice aims at: Resource Conservation Energy conservation Pollution Control

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Efforts towards Resource ConservationEfforts towards Resource Conservation

Conservation of Raw Materials

• Incorporation of appropriate beneficiation system to maximise use of ore reserve and to recover additional iron value from slime

• The slime loss has been drastically reduced to ~10 % from ~20% with the recovery of quality fines concentrate.

• Beneficiation to use lean ore and to recover iron ore fines from slime

12Being installed at Bolani, Gua, Barsua-Taldih, Chiria and Dalli Mechanised Iron Ore mines of SAIL


Advantages:•To transform fines concentrate generated during the iron ore beneficiation process into pellets, suitable to feed Blast Furnace or Direct Reduction plant or Corex.•Gainful usage of ultrafines, which other wise would have gone into slime.•Usage of agglomerated ore improves BF productivity

• Pelletisation of iron ore fines


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Pellet Plants of capacity 4.0 MTPA and 1.0 MPTA are under installation at Gua Ore mines and Dalli Mechanised Mines respectively.


• Adoption of ITmk3 technology for production of steel from iron ore fines

Advantages:

•Direct use of low grade material (e.g, fine ore and boiler quality coal) to produce nuggets

•Highly energy-efficient, low environmental load

Conservation of Raw materials

14A plant with 0.5 MPTA nuggets production capacity is being installed at Alloy Steels Plant premises at Durgapur


• BOF slag being used as flux supplement for base mix preparation in Sinter Plant

• Use of BOF sludge in base mix for Sinter Plant


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• Adoption of 3R’s (Reduce, Reuse and Recycle) for waste utilization. As a result, solid waste utilization at SAIL plants show consistent improvement over the years.


For ensuring proper and complete management of solid waste, SAIL has taken up following projects on environment under Research & Development (R&D) Master Plan;

A. Utilisation of Slag

• Dry granulation of BOF slag

B. Utilisation of Sludge

• Almond briquetting of sludge for use in converter

• Micro-palletisation of sludge for use in sinter plant

Management of Solid waste

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• For further reduction in water consumption, “Zero Discharge” scheme is under different stages of implementation at plants.

Conservation of Water

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• Efficient local re-circulation systems and plugging of leakages, resulting in reduction of sp. water consumption drastically.

Efforts towards Energy ConservationEfforts towards Energy ConservationEnergy-efficient Technologies have been implemented/are being implemented under on-going expansion/modernization projects in different processes of steel making to achieve reduction in specific energy consumption and specific CO2 emission.

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Higher Higher Capacity Capacity

COBCOB

CDQ

CDISinter Waste Heat Recovery

Hot Stove Waste Heat Recovery

TRTTRT BLTBLT

Multi-Slit Burners Continuous Continuous CastingCasting

Recovery Recovery of BOF of BOF

GasGas

Walking Walking Beam Beam

FurnaceFurnace

Sec. Sec. EmissioEmissio

n n ControlControl

CCCS

Efforts towards Energy ConservationEfforts towards Energy Conservation

Coke Making

• Coke Dry Quenching (CDQ)

• Computerized Combustion Control System (CCCS)

• High Pressure Liquor Aspiration (HPLA) System

• Modern Leak-proof Doors

• Higher Capacity Coke Oven Battery

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Coke Dry Quenching (CDQ)Coke Dry Quenching (CDQ)

Features & Benefits:• Better coke quality• Reduces emissions• Recovers sensible heat of coke• Generates electricity• Water conservation

Disadvantages:• High initial cost • Space constraints• Difficult for retrofitting

Under installation with new Coke-Oven batteries at BSP, RSP & ISP under on-going expansion cum modernization in SAIL plants 20

Computerised Combustion Control System (CCCS)Computerised Combustion Control System (CCCS)

Features & Benefits:• Optimise battery heating• Fuel and energy efficiency• Maintain good and uniform coke temp.

Disadvantages:• Difficulty in retrofitting in running batteries• High initial cost

Installed at Coke-Oven batteries at BSP, RSP and BSL and under installation with new Coke-Oven batteries under on-going expansion cum modernization in SAIL plants

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High Pressure Ammonia Liquor Aspiration System (HPALA)

Features & Benefits:• Emission control• gainful recovery of carbonaceous material• Energy-efficient

Disadvantages:• Integration with up and downstream facilities• Difficulty in retrofitting in operating batteries

Progressively introduced during rebuilding of coke oven batteries at various plants and also being incorporated at new batteries at BSP, RSP and ISP under modernisation cum expansion project of SAIL

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Clean Technologies - Coke MakingClean Technologies - Coke Making

Modern Leak-proof DoorModern Leak-proof Door

Features & Benefits: • Minimise emission from doors• Regulation-free operation• Less maintenance-prone

Disadvantages:• High initial cost


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Progressively installed at all SAIL plants and also being installed at new batteries at BSP, RSP and ISP under modernization cum expansion project of SAIL


Higher Capacity Coke Oven (7 m tall) Higher Capacity Coke Oven (7 m tall) BatteryBattery

Features & Benefits: • Energy efficiency• Less pollution prone• Better maintainability

Disadvantages:• High initial cost•machineries can not be shared amongst a batch of old batteries

Installed at BSP and also under installation at BSP, RSP and ISP with new coke oven batteries under modernisation cum expansion project of SAIL 24


Sinter Making

• Waste Heat Recovery from Sinter Coolers

• Multi-slit Burners in Ignition Furnace

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SINTER MACHINE

SINTER COOLERS

CYCLONE

Hot Air

Clean Hot Air to Furnace

Sinter Furnace

Comb. Gas

Hot Air Extraction Hood

Hot Air Extraction Hood

Features & Benefits: •Achieving energy efficiency through recovery of waste heat•Reducing emissions•Fuel savings

Disadvantages:•High initial cost•Difficulty in retrofitting in the existing plant

Installed with Sinter Plants at BSP and DSP and under installation with new Sinter Plants at ISP & BSL and Sinter Machines at BSP, under on-going modernization cum expansion project of SAIL

Waste Heat Recovery from Sinter CoolerWaste Heat Recovery from Sinter Cooler


Multi-Slit Burners in Ignition FurnaceMulti-Slit Burners in Ignition Furnace

Features & Benefits: • Fuel savings• Less emissions

Barriers:• High initial cost

Installed at all plants and also being installed at various plants under under modernisation cum expansion project of SAIL 27


Iron Making

• Coal Dust Injection (CDI)

• Waste Heat Recovery from BF Stoves

• Top Gas Pressure Recovery Turbine (TRT)

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Efforts towards Energy ConservationEfforts towards Energy ConservationCoal Dust Injection (CDI)Coal Dust Injection (CDI)

Features & Benefits: •Uses thermal coal which in turn reduces coke rate and hence reduces energy consumption and emissions in CO battery•Reduces dependency on costly coking coal •Increases BF refractory lining life

Disadvantages:•Difficulty in achieving required burden characteristics and blast temp.•Achieving uniform transfer of pulverized coal

CDI / CTI installed at 16 out of 20 BFs at SAIL plants. Facility is being installed with new BFs under on-going modernisation cum expansion project of SAIL

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Blast Furnace Heat RecuperationBlast Furnace Heat Recuperation

Being installed with new BFs at BSP, RSP and ISP under on-going modernisation cum expansion program of SAIL

Features & Benefits: • Energy Saving

Disadvantages:• High initial cost


Top Pressure Recovery Turbine (TRT)Top Pressure Recovery Turbine (TRT)

Features & Benefits: •Generates electric power, utilizing top gas pressure, which was getting wasted otherwise•Excellent operational reliability

Disadvantages:• Suitable for larger furnace with higher temp. & press. only• High initial cost

Being installed with new BFs at BSP, RSP and ISP under on-going modernisation cum expansion program of SAIL 31


Steel Making

• Recovery of BOF gas

• Continuous Casting

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Recovery of BOF GasRecovery of BOF GasFeatures & Benefits: •Energy saving through utilization of heat value of by-product gas• Reduction in emissions• Reduction in quantity of flue gas

Disadvantages:• High initial cost• Increased operational and maintenance cost • Retrofitting in existing system Installed at all steel plants and being installed with new

BOFs at BSP, RSP and ISP under on-going modernisation cum expansion program of SAIL 33


Continuous CastingContinuous Casting

Features & Benefits: • Energy saving• Emission reduction• Resource conservation• Enhanced yield and quality

Disadvantages:• high initial cost• Space and layout • Retrofitting in existing system

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Installed at BSP, DSP, RSP and BSL, and being installed at ISP under on-going modernisation cum expansion program


Walking Beam FurnaceWalking Beam Furnace

Features & Benefits: • Highly energy efficient• Uniform heating• Enhanced quality

Disadvantages:• High initial cost• Retrofitting in existing system

Installed at BSP and being installed at BSL under on-going modernization cum expansion program of SAIL

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RollingRolling

Efforts towards Pollution ControlEfforts towards Pollution Control

SAIL has identified a two-pronged approach:

Adoption of Clean Technologies and

Implementation of Cleaning-up Technologies

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Clean Technology Clean Technology refers to the technology that is refers to the technology that is economically competitive & productive, uses less economically competitive & productive, uses less material and/or energy, generates less waste, and material and/or energy, generates less waste, and causes less environmental damage than the causes less environmental damage than the alternatives.alternatives.

Cleaning-up Technology refers to the technology that reduces environmental damage by retrofitting, modification and adding end-of pipe pollution abatement measures to an established plant and process.

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Coke Making•Control of stack emission through latest technology like ceramic welding etc.

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• Introduction of screw-feed charging cars with HPLA system

• Installation of water sealed AP caps, modern leak-proof doors

• Installation of Dry Fog Dust Suppression (DFDS) system at Coal Handling and Coke Handling Plant to arrest work-zone emission

• Installation of BOD Plant for efficient treatment of phenolic CO-BP effluent


Raw Material Handling•Dry Fog Dust Suppression (DFDS) systems at Wagon Tipplers•Dust Extraction (DE) systems at transfer points

Sinter Making•Efficient de-dusting system for improved work-zone environment at Material Handling Area

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• Process emission control and area de-dusting through installation of ESP


Iron Making•Gas Cleaning Plant with Belt filter•Cast House De-dusting System

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• Dry Fog Dust Suppression (DFDS) for control of work-zone emission at Highline/Stock House


Steel Making•Gas Cleaning Plant with Vacuum Drum filter•Control of secondary emission through installation of Dog House•Bag filters for work-zone emission control at Flux Handling Area

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Rolling •Effluent Treatment Plant for treatment of effluent generated during rolling process

Others

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• Sewage Treatment Plant and utilization of treated effluent for industrial use

• Concord Blue Technology for treatment of Municipal Solid Waste (MSW)

To sum upTo sum up

• Adopting sustainable practices for iron & steel making is the only option to counteract the associated maladies at this juncture of growing demand.

• Along with the Industry, concerted efforts are needed from all the major players e.g. the Govt., Policy makers, Media, Consumers etc.

• Multidisciplinary research work is essential for exploring newer application and optimising use of existing technologies for a sustainable and environmentally sound management.

• SAIL is committed to Sustainable Development through progressive adoption of energy efficient technologies, resource conservation and pollution control.

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Crude Steel Production

There’s a little bit of SAIL in everybody’s life

Documents

Sustainable Practices in Iron and Steel Industry Environment Management Division STEEL AUTHORITY OF INDIA LIMITED ECAC, WBPCB, Kolkata23.11.2012