STEELMAKING THROUGH EAF ROUTE AND ITS EFFECT ON ENVIRONMENT BY DURBA TALUKDAR & SOMNATH GUPTA

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES”

23rd -24th MARCH 2012M.N. Dastur & Company (P) Ltd

STEELMAKING THROUGH EAF ROUTE AND ITS EFFECT ON ENVIRONMENT

BYDURBA TALUKDAR & SOMNATH GUPTA

M.N.DASTUR & COMPANY (P) LTD,KOLKATA



CO2 EMISSIONS BY GLOBAL STEEL INDUSTRY

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ENERGY INTENSITY OF STEEL INDUSTRY

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SPECIFIC ENERGY CONSUMPTION (Unit : GCal/TCS)

Plant 2007-08 2008-09 2009-10 2010-11(Apr – Dec 2010)

SAIL 6.95 6.74 6.72 6.82

BSP 6.72 6.5 6.56 6.66

DSP 6.94 6.5 6.55 6.78

RSP 7.39 7.09 6.97 6.89

BSL 6.89 6.83 6.74 6.88

ISP 8.14 8.18 8.18 8.23

RINL (GCal/TLS)

6.21 6.54 6.09 6.18

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SPECIFIC ENERGY CONSUMPTION(Unit : GCal/TCS)(Continued)

Source: 1. Sail News – February – June 20102. Annual report 2010-11, Ministry of Steel, Govt. of India

Note: **BF and Sinter Plant were under capital repair for approx 6 months.

Plant 2007-08 2008-09 2009-10 2010-11(Apr – Dec 2012)

TaTa Steel 6.555 6.587 6.173 (Apr-Dec 2009)

NA

JSW Steel 6.847 6.704 6.495 6.31

JSPL 7.68 7.25 7.14 6.98

Essar Steel 5.99 5.81 NA NA

IIL 5.73 5.42** 5.46 (Apr-Sept 2009)

Merged with JSW

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STEEL PRODUCTION THROUGH ELECTRIC FURNACES IN INDIA

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Total CrudeSteel Production(Million tons)

27.291 28.814 31.779 32.626 45.780 49.450 53.468 57.791 63.527 68.321

ProductionOf CrudeSteel in Electric Furnaces(Million tons)

9.980 10.850 12.680 14.300 24.780 27.650 31.300 34.800 36.200 41.300

% of SteelProduction in Electric Furnaces

36.5 37.7 39.9 43.8 54.1 55.9 58.5 60.2 57.0 60.4

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MAJOR WASTE GENERATED FROM EAF

• Solid waste Slag Dust Sludge Refractory debris Skull

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MAJOR WASTE GENERATED FROM EAF ( Continued)

• Gaseous waste Carbon-monoxide Carbon-dioxide Sulphur-dioxide Oxides of Nitrogen Particulate matter

• Liquid waste Polluted water

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EAF SLAG

• COMPOSITION Main constituent – Calcium Oxide and Iron Other minor constituents - Magnesium, Manganese, Silicon, Aluminium

• APPLICATION Land Filling Road Construction Aggregate for concrete Clinker Kilns as a replacement for mined limestone Reuse in internal processes Soil conditioner Making prefabricated shapes for sewerage

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EAF DUST

• COMPOSITION Main constituent – Iron Other constituents – Zinc in the form of oxide/sulphide/chloride

Lead as oxide, Cadmium, other metals, halides and fluxes

• Treatment Recycling back into the furnace High temperature metal recovery processes Hydrometallurgical and pyro-metallurgical processes

• APPLICATION Reuse in EAF Landfilling Extraction of Zinc Use in rotary hearth furnace

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GASEOUS EMISSIONS

• Harmful SubstancesOxides of carbon Oxides of nitrogen Oxides of sulphur Cyanides Fluorides

• Measures adopted Improved Fume extraction system and control

technologies Furnace off gas analysis system

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DEVELOPMENTS IN EAF PROCESS ROUTE

• Development of Shaft Furnace, Consteel Process and other processes

• The processes developed lead to : Lower noise level Lower dust content in off gases Reduced off-gas volume Full heat incineration of carbon-monoxide

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TECHNOLOGICAL DEVELOPMENTS IN EAF

Period Technological Development

Tap-to-Tap Time

Electricity Consumption

(kWh/t)

Electrode Consumption

(kg/t)1965-70 Oxygen lancing 180 630 6.5

1970-80 -Water cooled panels-High power operation (UHP)

105 490 3.5

1980-85 - Ladle furnace- Foamy slag- Eccentric bottom tapping - Scrap pre-heating

80 450 2.5

1985-95 -Oxygen carbon injecton ( lance manipulator)- Pneumatic bath stirring

60 410 2.0

1995-2005 -Oxygen carbon/oxyfuel side wall injection-Use of hot metal as charge material

55 250-300 1.6

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TECHNOLOGICAL DEVELOPMENTS IN EAF (Continued)

• The technological developments lead to : Reduced energy consumption Resource savings Reduction of carbon footprints Cost savings

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23rd -24th MARCH 2012M.N. Dastur & Company (P) Ltd 15

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STEELMAKING THROUGH EAF ROUTE AND ITS EFFECT ON ENVIRONMENT BY DURBA TALUKDAR & SOMNATH GUPTA