Effective Waste Management in Steel Manufacturing

Career summary Possess +20 years of experience in the field of Environmental and IH Engineering Educational Masters in Environmental & Water Resources from KFUPM, Dhahran, KSA Dip in Business Administration – Bangalore University Professional Certification Qualified Environmental Professional ( QEP) from Pittsburg – USA Radiation Safety Officer from KACARE - KSA, 2011 SHUAIB SALMAN Senior Environment Engineer Saudi Iron and Steel Co. (Hadeed)

Table of content  Introduction  Overview of Steel Process  Mission and Vision  Challenges  Onsite Storage  Waste Classification  Type of By Products / Waste (DR Plant, Steel Plant & RM)  Disposable Wastes  Key to Success  Acknowledgement

Waste Management is a global problem - each year millions of hectares are lost … Consequently, effective waste management is a crucial part within the operations of all organization's Introduction Industrial operations generate waste, must find proper reuse / recycling options, Exercise control during storage / disposal and must opt for Environmental friendly options

Overview of Steel Process Steel Industries generate large quantity of by-products/wastes. Generation of byproducts/waste during industrial activity is inevitable. However with efforts and innovative ideas potential reuse/recycle options can be explored to conserve the natural resources.

Saudi Iron and Steel Co (HADEED) Affiliate of SABIC is the only steel making subsidiary of SABIC. Its an integrated steel making company that comprises of  Direct Reduction (DR) Plant  Steel Plant (SP) (Long Product & Flat Product Facility)  Rolling Mill (Hot Strip Mill & Cold Rolling Mill)

Mission : To be provider of competitive steel products through employees empowerment with Safe and environmentally sounds practices Vision : To be the leading producer and marketer of steel products in the middle East & North Africa Mission & Vision

Challenges As a commitment to the protection of natural resources, company made efforts in carrying out research to find potential reuse option that is sustainable and environmental friendly.

Waste Classification During the steel making the following : Municipal Waste: Includes refuse, food waste, paper, carton, etc. from offices and cafeteria. Inert Waste : Ex., Construction materials, wood, paper etc. Industrial waste: Generated from production process.

Types of Byproducts/wastes PlantType of byproducts / Waste DROxides Fines DRSlurry SPEAF Dust SPSlag RM/SPMill Scale CMCFerric/Red Oxide MaintenanceMixed Miscellaneous Waste

Byproducts /Waste from DR Plant Oxide Fines (<6 mm) Iron Ore Slurry DR Plant (+6 mm)

Oxide Fines ( < 6mm) Iron Ore is screened, +6mm containing (96%-97% Fe2O3) is used for Production. Less than 6mm is the byproducts which is called as Oxide fines

Oxide Fines are used in cement industries as a raw material to manufacture cement. Oxide Fines are also used in making briquettes and used back in the furnace. Current Use: Oxide Fines ( < 6mm) Management

Slurry Process and Thermal fragmentation in the reduction process generate fines within the furnace. The fines are diverted to clarifier where it is sedimented as sludge. Slurry is predominantly similar to Ore fines but finer and laden with moisture.

Slurry Management Slurry is used in cement industries as a raw material to manufacture cement. Also used in Making Iron Pellets by pelletizing plants

Byproducts /Waste from Steel Plant Mill Scale EAF Dust Slag

SLAG Slag is a major byproduct generated steel production from EAF & LF. Until potential option were found the generated quantity of slag was being stored within the premises.

Solution:  R&D work was carried in Research labs such as Ministry of transport Riyadh, KFUPM and German Slag Research Institute.  Based on studies and field trials, it was found Slag is excellent feed/additive for the following: Road Asphalt Pavement Road sub base Concrete for Nuclear Radiation Shielding Production of Silico Manganese & Ferro Silica Used as Filter bed Media SLAG Management

It is successfully used in the following projects/areas: Ministry of Roads and Transport - Dammam Airport Road Dammam Kuwait Road Municipality of Dammam, Khobar, Jubail Roads. Gazlan Power Plant Sabic Industries SLAG Management

EAF Dust Melting operation in Electric Arc Furnace (EAF) generates fumes with dust. Dust is filtered off from flue gas/fumes via bag filters and stored onsite for recycling. Hadeed together with Sabic conducted research at king Saud University to find the reuse options.

Continued… The research studies concluded the material has advantages when used as additive with cement.  can be used as an effective set retardant for concrete and can substitute the chemical retardants used presently PropertyEffect Setting time of concrete Increased Compressive strength Increased ( %) Flexural and Bond Strength Improved Concrete Corrosion Potential Reduced

Uses as a set Retarder Uses as a set Retarder (Austria, Germany,France, Italy and UK) Use of Electric Arc Furnace By-products in concrete 1. US Patent for use of EAF Dust 2. European Patent for use of EAF Dust

Site Studies

Mill Scale Mill scale is byproduct generated during casting and rolling operation of steel billets and slabs. Mill Scale

Current Uses: Utilized by cement manufacturing companies Mill scale is recycled back into the furnace for steelmaking Used for the manufacturing of ceramics. Mill Scale Management

Red Oxide Red Oxide is generated from pickling (Cold Rolling Mills) Generation is about 2500 t/year. It is packed in jumbo bags and sold to Paint, Construction and Brick manufacturing companies.

Summary

Waste generated from production & maintenance are stored in designated areas and sent to disposal companies. Oily Sludge Fluorescent Tubes Liquid Waste Chemical Expired Paints & Chemicals Oil Absorbent Clinic Waste, etc.. Disposable Waste <1 % of total byproducts/waste are sent as waste to disposal companies for landfill, incineration etc..

Key to Success Compliance with Regulations. Adherence to company EHSS Policy Commitment towards continual improvement of our environment Non value added byproduct/waste to value added commodity. PREVENT/REDUCE REUSE RECYCLE TREAT DISPOSE Today we are proud 96% of generated byproducts/waste are sold to other industries.

Would like to thank HADEED Management for their commitment and support in achieving this success. Thanks to RC for their encouragement and support in promoting waste reduction programs and giving us the opportunity. Acknowledgement

Every Gift to the Environment makes a difference Thank you