INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd STEELMAKING THROUGH EAF ROUTE AND ITS EFFECT ON ENVIRONMENT BY DURBA TALUKDAR & SOMNATH GUPTA M.N.DASTUR & COMPANY (P) LTD, KOLKATA

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd CO 2 EMISSIONS BY GLOBAL STEEL INDUSTRY 2

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd ENERGY INTENSITY OF STEEL INDUSTRY 3

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd SPECIFIC ENERGY CONSUMPTION (Unit : GCal/TCS) Plant (Apr – Dec 2010) SAIL BSP DSP RSP BSL ISP RINL (GCal/TLS)

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd SPECIFIC ENERGY CONSUMPTION(Unit : GCal/TCS) (Continued ) Source: 1. Sail News – February – June Annual report , Ministry of Steel, Govt. of India Note: **BF and Sinter Plant were under capital repair for approx 6 months. Plant (Apr – Dec 2012) TaTa Steel (Apr-Dec 2009) NA JSW Steel JSPL Essar Steel NA IIL **5.46 (Apr-Sept 2009) Merged with JSW 5

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd STEEL PRODUCTION THROUGH ELECTRIC FURNACES IN INDIA Total Crude Steel Production (Million tons) Production Of Crude Steel in Electric Furnaces (Million tons) % of Steel Production in Electric Furnaces

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd MAJOR WASTE GENERATED FROM EAF Solid waste  Slag  Dust  Sludge  Refractory debris  Skull 7

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd MAJOR WASTE GENERATED FROM EAF ( Continued) Gaseous waste  Carbon-monoxide  Carbon-dioxide  Sulphur-dioxide  Oxides of Nitrogen  Particulate matter Liquid waste  Polluted water 8

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd 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 9

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd 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 10

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd GASEOUS EMISSIONS Harmful Substances  Oxides of carbon  Oxides of nitrogen  Oxides of sulphur  Cyanides  Fluorides Measures adopted  Improved Fume extraction system and control technologies  Furnace off gas analysis system 11

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd 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 12

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd TECHNOLOGICAL DEVELOPMENTS IN EAF PeriodTechnological Development Tap-to-Tap Time Electricity Consumption (kWh/t) Electrode Consumption (kg/t) Oxygen lancing Water cooled panels -High power operation (UHP) Ladle furnace - Foamy slag - Eccentric bottom tapping - Scrap pre-heating Oxygen carbon injecton ( lance manipulator) - Pneumatic bath stirring Oxygen carbon/oxyfuel side wall injection -Use of hot metal as charge material

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd TECHNOLOGICAL DEVELOPMENTS IN EAF (Continued) The technological developments lead to :  Reduced energy consumption  Resource savings  Reduction of carbon footprints  Cost savings 14

INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd 15 THANK YOU