ToR on OG System NISCO - World Bank...GB700 JIS, G3101 Coil, plate:2.3-50 x16 00~3520x6000-1 8000 10.0 10.0 Total 1 00 1 00 ToR on OG System NISCO Table 2: Product variety and specification

ToR on OG System NISCO

Supplemental EIA on OG System

120T Converter Gas Recovery Project

Nanjing Iron & Steel Co., Ltd

April 2005

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AdministratorE1153v3


Table of Contents

Chapter 1 General Description…………………………………………………..3

Chapter 2 Main Pollution Source, Pollutant and Control Measures…………11

Chapter 3 Introduction of the New 120t Converter……………………………15

2


Chapter 1 General Description

120 t converter will be installed in the Heavy Plate Mill which is affiliated to

NISCO. See the following attachment for the details of NISCO.

Location:

It is located at DACHANG district, in the north of Nanjing City in a distance of

25 km from the central of the city (the straight-line distance is approximately 16

km). This plant faces the Yangtze River in the South and is close to Ningyang

motor way in the north. In the eastern side it neighbors with Nanjing Thermal

Power Plant, Nanjing Power Plant of North China Energy & Source Co. as well

as Nanjing Chemical Industry Co. The region & location map of NISCO is

shown hereinafter.

Product, output and working staff:

A new 120t top & bottom blown converter will be built with a liquid-steel output

of 1,090,000t/a. The products include on-line sheared plate, plate sheared with

dividing unit and hot rolled coil. The product specification and production

distribution on each steel grade is shown in the following tables.

3


1. General

Nanjing Iron & Steel Co.,Ltd. (hereinafter abb. as NISCO). is a province-level

enterprise group established on the basis of Nanjing Iron & Steel Group Corp.

Ltd. Through the development and construction for more than 40 years, it has

become a large iron & steel complex with a comprehensive productivity of

2,000,000t pig iron, 3,500,000t liquid steel and 4,000,000t steel product. It is

one of the key enterprise groups in Jiangsu province. In 2002, the sales

revenue of NISCO is 14.5 billion Yuan, ranking No. 69 among the “Top 500”

enterprises in China.

Nanjing Steel is located at Jiangbei Industrial Development Area in Nanjing

City along the Yangtze River. It enjoys favorable conditions in transportation. A

special railway is provided in plant area which is connected with

Beijing-Shanghai railway. An available 5000-ton plant-owned pier at Yangtze

River can provide convenience for loading/unloading.

In 2002, steel output of NISCO is 2,532,000t, the pig iron is 1,886,000t. The

profit & tax realized is 750 mil Yuan, in which the profit is 410 mil Yuan. In the

end of 2004, the original value of fixed assets is 3.75 billion Yuan and the net

value is 2.01 Yuan. The main product is medium or small sized section steel

and wire/rod, heavy plate, pack rolling sheet and steel strip, etc. All the steel

products are of carbon steel and low-alloy structure steel except the heavy

plate which are used as ship-building plate and boiler plate.

The configuration of existing production system

In coking, sintering and iron-making system there are two 42-battery coke

ovens with productivity of 580,000 t/a; two 39m2 sintering machines and two

24m2 sintering machines with productivity of 2,500,000 t/a; two oxidized pellet

shaft furnaces with the productivity of 800,000 t/a, one 300m3 blast furnace

and four 350m3 blast furnaces with the productivity of 1,850,000 t/a.

In steel-making plant there are three 20t BOF converters with the productivity

4


of 1,700,000 t/a; one 70t ultra high power EAF and one ladle refining furnace

with the productivity of 700,000 t/a; one R6m 4-strand billet caster, one

R5.25m 5-strand billet caster, one R5.7-21m ultra lower-head single-strand

slab caster, and R8m 5-strand billet caster with a total productivity of 1,700,000

t/a.

In steel-rolling system there are one medium-sized blooming mill with

productivity of 400,000 t/a, three small-sized section mill, wire / rod mill, heavy

plate mill, steel sheet mill, strip mill per each with the rolling productivity of

2,600,000 t/a. in NISCO a complete quality assurance system has already

been built up and successfully certified with IS09000 and ISO 2000 quality

system. The products namely thread steel, medium plate and high wire rod

were awarded with “Gold Cup Prize”.

In August 8, 2004, Nanjing Iron & Steel Complex Ltd. was established based

on the joint-venture between NISCO and Shanghai Fuxing Group. It indicates

that NISCO has been transformed from a pure state-owned enterprise to a non

state-owned enterprise.. During the “tenth five-year plan” period, NISCO plans

to invest twelve billion Yuan in technical updating for maximization and

modernization. Now a “wide medium plate (coil) project” and its associated

project has been implemented which will need investment of more than seven

billions Yuan to readjust the product structure. This project has been approved

by the State Council, and will be recorded as the one with the biggest

investment so far in the history of NISCO and Nanjing area in the field of

industry. After the commissioning of the project (in the third quarter of 2005 as

per schedule), the productivity of plate (coil) per year will be up to 1,500,000 t.

We also decide to build another plate production line recently by utilizing the

fund through joint-venture combined with bank loan, in order to gain an

additional steel output of 2,000,000t. The commissioning of this production line

is expected to be finished at the beginning of 2006. Till then the total

production capacity including the existing plant and the new production line will

5


be up to 6,500,000 t. Through the capital-fund operation and involvement in

the asset regroup with other steel mill at home and abroad, the productivity will

be approximately 6,000,000 t~7,000,000t under the investment and share

holding. By 2010, NISCO will reach the productivity of 15,000,000t in steel and

fifty billions Yuan in sales revenue.

6


figure 1: General layout of plate/coil project in NISCO

7

8

Figure 2: Geography location map of the project


ToR

on

OG

Sy

stem

NIS

CO

9

Tabl

e 1

Plat

e Pr

oduc

tion

Plan

Bas

ed o

n St

eel G

rade

N

o Q

ualit

yTy

pica

l st

eel g

rade

St

anda

rds

Si

ze (m

m)

Pr

oduc

tion

(104

t/a)

(%

) 1

Shi

pbui

ldin

g pl

ate

AH

32, D

H32

, EH

32,

AH

36, D

H36

, EH

36G

B71

2 cr

iterio

n in

re

late

d cl

assi

ficat

ion

soci

ety

Pla

te: 4

.8-5

0x16

00-3

520x

6000

-180

00

38.0

38

.0

2 P

ipel

ine

stee

l

X42

-80

AP

l5L

Coi

l, pl

ate:

6.4～

30x1

600-

3520

x600

0～18

000

20.0

20

.0

3

Low

-allo

y st

ruct

ural

15

MnV

S

M40

0, S

M49

0 A

572,

A57

3

GB

/T15

91

JlS

, G31

06

AS

TM

Coi

l, pl

ate:

2.3~

50x1

600～

3520

x600

0～18

000

12

.0

12

.0

4

Boi

ler p

late

20

g, 1

6Mn,

S

B41

0, S

B45

0 19

Mn6

GB

713

JIS

, G31

03

DlN

EN

100

28T2

4.

5

4.

5

5

Pre

ssur

e-ve

ssel

pl

ate

16M

nR

SP

V23

5, S

PV

315

A20

2, A

515,

A53

7

GB

6654

JI

S, G

3115

A

STM

Coi

l, pl

ate:

6.0

-50x

1600

～35

20x6

000-

1800

0

5.

0

5.

0

6 B

ridge

-bea

m p

late

16

Mnq

, 15M

nVq

SM

400,

SM

490

YB

(T)1

0 JI

S, G

3106

C

oil,

plat

e:2.

3-50

x160

0~35

20x6

000-

2400

0 1.

5

1.5

7 E

ngin

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g an

d m

achi

nery

ste

el

StE

690,

A73

6 A

STM

C

oil,

plat

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x160

0~35

20x6

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1800

0 8.

0 8.

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8 A

utom

obile

be

am

plat

e 09

SiV

L G

B32

73

Coi

l, pl

ate:

2.3-

12x1

600~

3520

x600

0-18

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1.0

1.0

9 C

arbo

n st

ruct

ural

st

eel

Q19

5~Q

275

SS

400,

SS

490

GB

700

JIS

, G31

01

Coi

l, pl

ate:

2.3-

50x1

600~

3520

x600

0-18

000

10.0

10

.0

To

tal

1 00

1

00


Table 2:

Product variety and specification No. Product variety Percentage

(％) Specification

1

Hot-rolled steel plate

～75

Thickness: 4.8-50mm Width: 1600~3520mm Length: 6000-24000mm

2

Hot-rolled steel coil

～25

Thickness: 2.3-20mm Width: 1600~2800mm Unit weight of coil: 20.5kg／mm Coil weight: ~45t(max)

10


Chapter 2 Main pollution source, pollutant and control measures

2.1 Main pollution source and main pollutant

Primary fume containing dust and CO is generated during converter

melting process

SS contained waste water is produced during wet-gas cleaning

process of converter

Sludge collected from waste water coming from converter-gas

scrubbing system

Noise produced by pump, motor, etc. during operation.

2.2 Pollution control measures and results

2.2.1 Fume-emission control

Passing through furnace mouth and fume hood, the primary fume

generated in converter smelting will enter into evaporated cooling

duct. After cooled and cleaned by two-stage Venturi tube as well as

de-watered by dehydrator, it will be discharged via 47m stack. The

dust content is lower than 120mg/Nm3, which is in compliance with

the criteria of category 3 (criteria of emission:150 mg/Nm3) specified

in Criteria for Air Pollutant Emitted from Industrial Furnace/Kiln .

During emission, in case that CO content in fume is high, the ignition

device on top of stack will be ignited automatically to make CO in

fume into CO2 through combustion.

2.2.2 Treatment of waste water

The total water consumption is 629m3/h and the make up water is

80m3/h.The reusing rate of water is 80%. The method of “using

indirect cooling water to make up direct cooling water” and series

arrangement will be adopted in production process.

11


The indirect cooling water is mainly used for 2-stage Venturi tube

jacket and fan, with only a water temperature rise and no

contamination. The water will be recirculated and cooled through

cooling tower and reused in direct cooling system and other system. A

little amount of ~32 m3/h non-pressure waste water will be discharged.

The discharged waste water is in accordance with criteria of category

1 (SS content=70 mg/L) specified in Criteria for Waste Water

Discharge in Steel Industry.

The direct cooling water system mainly contains the water from gas

scrubbing system. The waste water will be reused after thickened in

vertical sediment basin, cooled in cooling tower and pressurization,

and has no water to be discharged. The slurry discharged from the

bottom of sediment basin will under through dehydration treatment in

board-frame filer press.

12


2.2.3 Solid waste treatment and overall utilization

The slurry produced from wet purification system of converter fume is

pressed into slurry cake with the board-frame filter press. The main

composition is ferro- oxide which will be used for material proportion

in sintering plant.

2.2.4 Noise control

The fan is installed in an separate room for sound proof. Flexible

connection will be adopted at the inlet and outlet of fan and in

between the pipes.

Hydraulic pump will be installed in a separate room sound isolation.

After adopted the above-mentioned measure of sound insulation,

noise reduction and distance attenuation, the noise level at the plant

boundary can be maintained as before.

The main pollution source and main pollutant for this project are

shown in table 3.

Table 3 Main Pollution Source and Main Pollutant

No. Pollutant Control measure Emission/discharge/level 1

Dust-laden fume

Emitted through high stack afterdedusting by 2-stage Venturitube

emission amount:23.1t/a Emission intensity: ≤120 mg/Nm3

2

Waste water

SS


2.3 Environment monitoring & the management organization of environmental protection

The environmental management department will take the

responsibility for the work of environment control and monitoring in

this project.

（1） 3x20t existing converter steel-making process flow chart and

sewage production points

14


Scrap Hot Metal Bulk Material, Ferroalloy

Exhaust stack

Bag Filter

Secondary Waste Refractory 3X20t Converter fume

Filtered dust

Primary fume Liquid steel SlagReturn to sinter for

burdening (Burnt to emission)

Exhaust stack

fume fume BOF-gas fan house

OG System Waste w

ater after treatment

Waste

water

Slurry Treating in vertical settling tank

Waste w

ater

Thickener

De-watered mud cake

Cooling tower OG slurry de-water

then to sinter plant for

burdening

OG system includes：(Treatment in vertical settling tank)

Converter fume from evaporation cooling duct→Stage-1 overflow

Venturi→Stage-1 impact-type gravity dewaterer→Stage-2 Venturi with annular

gap adjustable throat→Stage-2 900 elbow dewaterer→ cyclone dewaterer

Fig 1 Process flow chart of 30t BOF and pollutant source

15


Table-4 Pollutant Generated by 3*20t BOF without Gas Recovery System and Emission Criteria

Pollutant Pollutant Emission criteria Dust content at emission Emission

rate

Fume dust 150mg/Nm3 100mg/Nm3 18.1kg/h

SO2 2000 mg/Nm3 Very small amount Primary BOF

off gas (totally

bleeding) CO2 －

Content in off gas： CO2≥90%.（BOF gas totally burnt and bleed out without recovery. Most of CO in gas will be burnt out to CO2. Small amount of CO will be contained in the gas in case of not fully combusted.

Fume dust 150mg/Nm3

SO2 2000mg/Nm3 Secondary

BOF off gas

CO2 －

The treatment will be completed in

May,2005

Fume dust emitted to outside < 50

mg/Nm3

slag

311423t/a scrap will be selected through slag tightly covering under high temperature, crushing and magnetic screening. After that slag block will be used for road paving and pit filling. Fine slag can be recycled

Solid waste

BOF dust &

slurry

－

47629t/a （return to sintering plant and used for burdening

(2) pollution control measure

16


Chapter 3 Introduction of the new 120t converter

(1) Process flow chart and pollution-generation sector

Scrap Hot Metal Bulk Material, Ferroalloy

Exhaust stack

Bag Filter

Secondary fume120t Converter Waste Refractory

Filtered dust

Primary fume (gas)

Liquid steel SlagReturn to sinter Exhaust stack for burdening

gas gas BOF-gas fan house

OG Gas W

aste water

gas Waster water treatm

ent

dust E-precipitator slurry Thickenin

g in gas

Waste w

ater

Return to

sinter for burdening

thickener To wire-rod Mill shop, etc.

De-watered mud cake

Cooling tower OG slurry de-water then to sinter plant for burdening

OG system include:

Stage-1 overflow Venturi→stage-1 impact-type gravity dewaterer→stage-2 Venturi

with annular gap adjustable throat→stage-2 900 elbow dewaterer→cylone dewaterer

Fig 2 Process Flow Chart of 120t BOF and Pollutant Source

17


18

Table-1 Pollutant Generated by 120t BOF without Gas Recovery System and Emission Criteria

Pollutant Pollutant Emission criteria Dust content at emission Emission

rate

Fume dust 150mg/Nm3 100mg/Nm3 18.1kg/h

SO2 2000 mg/Nm3 Very small amount Primary BOF

off gas (totally

bleeding) CO2 －

Content in off gas：（CO2＋CO）≥90%.（BOF gas totally burnt and bleed out without recovery. Most of CO in gas will be burnt out to CO2. Small amount of CO will be contained in the gas in case of not fully combusted.

Fume dust 150mg/Nm3 11.5mg/Nm3 11.1 kg/h

SO2 2000mg/Nm3 Very small amount Secondary

BOF off gas

CO2 － small amount

slag

160000t/a scrap will be selected through slag tightly covering under high temperature, crushing and magnetic screening. After that slag block will be used for road paving and pit filling. Fine slag can be recycled

Solid waste

BOF dust &

slurry

－

16225t/a （return to sintering plant and used for burdening

N

ISC

O

19

Tabl

e 2

A

mou

nt o

f Pol

luta

nt a

nd D

isch

arge

Crit

eria

for 1

20t B

OF

in N

ISC

O (w

ith g

as re

cove

ry u

nit)

ToR

on

OG

Sys

tem

Des

crip

tion

P

ollu

tant

E

mis

sion

/dis

char

ge c

riter

ia

Con

tent

at e

mis

sion

E

mis

sion

rate

Fum

e du

st

150m

g/N

m3

< 10

0mg/N

m3

7.2k

g/h

SO

2 20

00 m

g/N

m3

Em

itted

CO

2 －

whi

le C

O≤3

5% i

n pr

imar

y ga

s, i

t w

ill be

bu

rnt w

ith ig

nito

r and

ble

ed th

roug

h st

ack.

M

ost

of

CO

w

ill be

ch

ange

d to

C

O2

thro

ugh

com

bust

ion.

Fum

e du

st

300m

g/N

m3

（B

OF

gas

mai

nly

supp

lied

to re

heat

ing

furn

ace

in m

ill sh

op, e

mis

sion

crit

eria

in

furn

ace:

300

mg/N

m3 ）


(2) Pollution control measures

①Waste-gas pollution control measures

As shown in Fig. 2, the pollution source in converter melting process is mainly the

primary and secondary fume. During production a lot of primary fume is generated,

which contains a high proportion of CO, and is a kind of good secondary energy

source. In the meanwhile, this off-gas contains a lot of dust. So it cannot be used

directory without any treatment. Direct emission of the off-gas will bring serious

pollution to the atmosphere. The secondary fume is mainly generated during the

procedures of hot-metal charging, tapping and slag disposal.

BOF gas primary fume control measures (OG system):

Converter gas from evaporated cooling flue→step-1 overflow Venturi tube→step-1

impingement-type gravity dehydrator → step-2 circular-seam throat-opening

adjustable Venturi tube→two-step 90°elbow dehydrator →cyclone dehydrator

BOF gas secondary fume control measures:

The converter secondary fume dedusting system adopts negative-pressure

dry-dedusting process. The dust-laden fume is purified by impulsive bag filter, and

then emitted to the atmosphere through fans and chimneys. The designed dust

content for emission is smaller than 100mg/Nm3. And the actual value taken by the

environment monitoring and inspection center in Jiangsu province in Oct 16th-19th

2004 was 11.5 mg/Nm3.

②Waste-water pollution control measures

As shown in Fig.1, the wastewater pollution source is mainly the waste water

20


generated from gas scrubbing system (OG system) during the wet cleaning for the

primary gas of the converter.

This water is polluted by the fume dust. First it flows into the thickening pool through

an elevated groove. Water after thickening is pressurized by the pump before being

sent to cooling tower. The cooled-down water is recycled in the dedusting equipment.

③solid-waste treatment

As shown in Fig.1, the main solid waste from converter process is steel slag,

converter sludge and refractory waste.

After keeping at high temperature, crashing and magnetic dressing, the scrap is

taken away from slag. The slag lump is used to pave roads and fill pits, while the slag

powder can be recycled.

The slurry from gas scrubbing system will first enter the slurry pool. And then it is

pumped with pressure to slurry clarifier. After that the slurry in the bottom is sent to

plate and frame filter to be dewatered. The left is converter sludge. Generally the

converter sludge will be sent back to sintering plant and be reused in burdening.

The refractory waste mainly arises from the abandoned refractory material when the

converter is relined or repaired, the main component of which is silicon oxide and

aluminum oxide. The agglomerated and castable refractory waste can be used as

normal construction material, or after pulverization, be used to produce refractory

bricks. The smashes and crushes can be used to pave roads and fill pits.

According to the provisions about solid waste category in Guideline for Solid Waste

21


Declaring Registration made by State Environmental Protection Administration,

converter slag belongs to normal industrial solid waste. And converter sludge and

refractory waste belong to other waste. Converter melting process does not generate

poisonous waste.

The quantity of pollutant and discharging criteria is shown in the table below.

Table1 Quantity of Pollutant and Discharge Criteria Actual discharge quantity or

generating quantity

Pollutant Pollution Emission/

discharge rate

If use 3rd generation

OG cleaning system

Actual value from 120t converter in

Nanjing Steel using 4th generation OG cleaning system

Part discharged Dust 150mg/Nm3 100∼150 mg/Nm3 ？mg/Nm3

BOF primary fume

Supplied to user

(after electro-dedusting)

Dust 350mg/Nm3


①waste gas

The converter gas, which is not purified by the OG system, will have a dust content

up to 100～150g/Nm3. This gas will bring serious pollution to the atmosphere through

direct emission. However, the one that is purified by the OG system will have dust

content lower than 100 mg/Nm3.

②waste water

The converter steel-making process with OG system will generate the off-gas

scrubbing water as shown in part ② paragraph (2). This water has been

contaminated by the gas dust, so it needs water treatment such as thickening and

cooling. But it still can be recycled after treatment.

③solid waste

The converter steel-making process with OG system will generate sludge during gas

scrubbing, as shown in part ③ paragraph (2). However, generally this part of

converter sludge can be reused in burdening for sinter process.

The pollution affecting operator’s health during converter production is mainly the

breathable particles. According to the results of monitoring and inspection made by

the environment control station of Nanjing Steel in December 2004, since Nangang’s

newly built 120t converter adopts effective control measures to primary and

secondary off-gas, the atmosphere dust content (as 5.6 mg/Nm3) in every post meets

the criteria of harmful factors (8 mg/Nm3) for Job Contact (GBZ2-2002) in working

site.

23


(4) Implementing schedule

The construction of converter OG system started in May 2002. After two - year

construction, it was completed and put into production in June 2004.

(5) Cost evaluation

The total investment of 120t converter OG system is 43.8362 million yuan, including

OG system as 3.9034 million yuan, BOF gas fan room as 11.9789 million yuan and

storage and distribution station as 27.9539 million yuan.

(6) Environment monitoring plan � Criteria for monitoring evaluation - criteria for waste-gas emission

The monitoring will base on the criteria used for project environment assessment and

specified in project basic engineering. In addition, the prevailing general criteria for

emission/discharge issued by the state government and industry shall be observed

according to functional division of the area where the company is located.

The criteria of category-3 specified in Criteria for Pollutant Emitted to the Atmosphere

from Industrial Kiln/Furnace (GB9078-96) will be used for secondary fume of the

converter. See table 6-1 for details of the criteria limit.

Table 2 Waste Gas Emission Criteria

pollution source Pollutant

Chimney Height（m）

Density（mg/m3）

Rate（kg/h） Standard

Sec. BOF Fume

fume dust / 150 /

criteria of category-3 specified in Criteria for Pollutant Emitted to the Atmosphere from Industrial Kiln/Furnace (GB9078-96)

� Monitoring content of waste gas

24


For monitoring spots, items and frequency please see Table 6-2.

Table 3 Monitoring Spots, Items and Frequency

pollution source

Duct Dimension （mm） Monitoring Spot Item Frequency

inlet,

Round（inner diameter 3520）

Q3， Cross tap, 12 spots for each tap, 24 spots in total

Sec. BOF Fume outlet,

rectangle（2300×2600）

Q4， Three taps, 8 spots for each tap, 24 spots in total

Waste gas data, fume dust, emission density and rate, dedusting efficiency

One time per quarter, Every time (take samples according to standard), four times per year

� Monitoring quality guarantee and analysis method

The monitoring will strictly go with the requirement of Quality Manual by Environment

Monitoring Center of Jiangsu Province. Total quality control will be carried out

through out the whole course. 20% of double-samples and 10% standard samples

will be added according to the requirement of quality control. During monitoring

period, we shall be aware of the working condition and ensure that the working

condition meets the requirement. The monitoring spot shall be reasonably arranged

in order to guarantee a scientific and comparable arrangement of the spots.

The monitoring analysis will adopt standard analysis method issued (or

recommended) by state authorities concerned. The monitoring personnel have to

take exams and hold qualification certificate before taking the posts. All the

monitoring instruments have to be verified by measurement-service authorities and

within the valid period. Those field-monitoring instruments have to be calibrated

before being used each time. And we will take three-level checkup towards the

monitoring data.

Table 4 Monitoring and Analysis Method of Waste Gas

No. Item Analysis Method Method Source

1 fume dust Gravity Method GB/T16157-1996

25


26

Note: Both parties agree that the figure with question mark in the table will be provided at the end of March.

Dust content at emission(1)Process flow chart and pollution-generation sector

Dust content at emission(2) Pollution control measures?Waste-gas pollution control measures?Waste-water pollution control measures?solid-waste treatment

(3) The impact of converter OG system on the environment?waste gas?waste water?solid waste

(4) Implementing schedule(5) Cost evaluation(6) Environment monitoring plan

Documents

ToR on OG System NISCO - World Bank...GB700 JIS, G3101 Coil, plate:2.3-50 x16 00~3520x6000-1 8000 10.0 10.0 Total 1 00 1 00 ToR on OG System NISCO Table 2: Product variety and specification