& THE NEXT STEPS ASAD ULLAH KHAN, A.M.(Materials) UEC No.-D2758 1

It is believed that in 2500–2000 BC iron was not produced deliberately but was obtained from natural resources, e.g. meteorites Deliberate production of iron began in about 1300 BC with the use of charcoal as fuel and reducer, in small furnaces that made use of cold air The temperature that could be achieved in above furnaces was probably below the melting point of iron. The product had to be hammered for it to be freed from slag and to make wrought iron. 2

 Steel is a basic commodity of all activities  steel is very important for development of any economy  steel is considered as the backbone of the human civilization  Quantum of steels consumption is indicating the index of prosperity of the country. 3

 Stuckoven (13 th century) – Pig iron  Puddling (1785) – Semi-fluid steel  Crucible (18th century) – Wrought Iron  Bessemer (1860) - oxidation of carbon & impurities  Thomas process (1878) - low-phosphorus steel  Open hearth furnace (1864) - Re- generative furnace  Electric arc furnace (EAF)(1900)- Low carbon steel  Basic oxygen furnace (1952) – Pig Iron  Linz Donawitdz (LD) Converter- Low Carbon Steel  Oxygen bottom UHP-EAF (1970) – Low Carbon Steel  Blowing (1967) DC-EAF (1985)- Low Carbon Steel 4

 Bessemer converter  Crucible  Electric Arc Furnace  Basic oxygen steelmaking (BOF) (main processes involved in the making of pig iron, which is reduced iron ore that still contains impurities, mainly carbon. Then we deal with the main processes used to improve the quality by removing impurities) 5

RRaw materials handling yard CCoke oven complex & by-product plants SSinter plant LLime and dolomite calcinations plant BBlast furnace complex SSteel making and secondary steel refining SSlab, billet and bloom casters OOxygen plant PPower plant UUtility services i.e. civil, electric, fuel oil and gas, water supply, QC,R&D, compressed air etc. 6

 Iron ore  Lime stone  Coking coal  Dolomite  Quartzite  Bauxite  Fe-Mn,Fe-Si, Si-Mn, Zn, Cr, Cu, Ni, and Mo  Aluminium  Fluorspar 7

 BOF process need raw materials like iron ore, coking coal, agglomerates, etc. for its efficient operation.  EAF process need raw materials like solid charge of DRI/HBI 8

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 Raw materials handling & transportation (wagon tippler, stackers re-claimers, ball mill ) i.e. iron ore, coal, limestone, dolomite, etc  Blast Furnace complex  Coke Ovens complex  Basic Oxygen Converter (SMS) complex  Casting (slab, bloom, billet) complex  Mills (for flat or long products)  Oxygen plant  By product plant complex(Ammonium Sulphate (Fertilizer)Tar and tar products, (Pitch, Naphthalene, Creosote Oil Road Tar, Anthracene oil, Dephenolised oil, PCM etc.), Benzol & its products (NG Benzene, Toluene, Xylene, Solvent oil, By. Benzol etc.)  Power plant (waste heat recovery) 10

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15 IRON CARBON DIAGRAM IRON CARBON DIAGRAM

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 3CO + Fe 2 O 3 2 Fe + 3CO 2 (gas) + Heat  4CO + Fe 3 O 4 3Fe + 4CO 2 (gas) + Heat  The iron and steel industry is the largest energy-consuming manufacturing industry in the world. (The average specific energy consumption for steel making is estimated to be 24 GJ/tonne ) 17

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19 NEXT STEPS

Techniques for the reduction of the specific energy consumption for iron and steel making are identified and characterized to assess the potential for future energy-efficiency improvement and research and development priorities like ULCOS (mitigating CO 2 emissions), ISARNA (melting reduction) etc. Lowering the Worldwide average specific energy consumption for steel making up to below 10 GJ/tonne. Achieve the most energy-efficient process 5 GJ/tonne for primary steel and 3 GJ/tonne for secondary steel 20

 Australia (Hismelt) & (Ausmelt- process)  Japan (DIOS process)  Russia (Romelt process)  U.S.A. (AISI process) & (Midrex process)  Austria (Corex process)  Finex (Posco & Siemense) 21

 Does not require COKING coal  Eliminating the need for COKING plants  Less waste-water emissions 22

 In corex process a liquid iron is produced in two stage reactor.  As energy source coal, coke breeze and charcoal is used.  Iron ore used in the form of pallet or lump  By product Process gas is used for co- generation of power. 23

 Finex-Iron ore is directly charged in fluidized bed reactor in presence of limestone and dolomite flux.  Hisment- iron ore fines and non coking coal is directly poured into a molten bath of iron. 24

 Substantially reduced specific investment costs and operation costs compared with conventional blast furnace route  Outstanding overall environmental compatibility, as less carbon dioxide is produced  Use of COREX export gas for a wide range of applications  Use of a wide variety of iron ores and coals  Elimination of coking plants  Hot-metal quality suitable for all steel applications.  The gas leaving the reduction shaft is cooled and cleaned and is suitable for a wide range of applications (e.g., power generation, DRI production or use in reheating furnaces)  iron ore can be used without agglomeration  non/weak-coking coals can be used directly without coking;  start up and shut down in operation are much easier than with a BF 25

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 Pre-coated steel does not require painting after processing  lubricated steel requires neither oiling during processing nor degreasing after processing.  fire-resistant steel does not require heat insulation by post-coating  Advanced heat treatment for developed ductility, toughness, fatigue strength, corrosion resistance, hardness, lubricity, soiling resistance, and adhesiveness of steel  Improved strength, abrasion resistance, toughness, formability, and electromagnetic properties by precise control in micrometer to nanometer range of the grain size, texture, and microstructure 29

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 Use of Recycling scrap of various grades of iron resources.  Use of direct-reduced iron.  The direct use of coals as reducing agents.  Use of degrading coals to provide more effective utilization of less expensive resources  Use of better refining and solidification processes  100% utilization of waste heat recovery & waste water treatments.  Use of improved automation and advanced control technology 31

 The framework of steelmaking were driven by cost and productivity in the past. Today, energy, environmental and quality issues are also driving similar changes, enhanced by technological progress in related areas.  Improvement in repair technologies for coke oven refractory's, pulverized coal injection into the BF, and development of the formed coke process.  The present coke-making process has drawbacks such as emissions of particulates and harmful gases, low productivity, entailing high equipment cost, and high energy consumption due to high temperature processing, which discourage the construction of new capacity.  New scrap recycling- Recycling of steel scrap considerably contributes to the reduction of energy consumption and Co 2 evolution  New coke making processes 32

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Profitability pressure Control of Energy intensity and Co 2 emission Environmental protection 34

The reward of energy efficiency Regularity mandate for Co 2 emission Addressing pollution beyond Co 2 reduction 35

Improving the installed base and enhancing operations Upgrading industrial power plants Use of steel making by products Enhancing the quality of input materials & logistics Adapting new technologies and alternative concept of production Improving control of environmental pollution 36

37 Design a sustainability based business strategy Evaluate the relative position.

The role of the government in improving energy efficiency in the iron and steel industry is still limited  Financial support for the development of energy-efficient technologies. All smelting reduction processes are being developed by financial support from the government.  Encouraging iron and steel companies to implement the most efficient techniques  Providing an efficient and effective scrap recycling system  the maximum use of scrap by iron and steel companies;  Encouraging research to further improve energy efficiency, e.g. by developing techniques to recover and apply high- temperature heat and processes to make steel directly from iron ore. continue 38

 Heat recovery of the hot steel at temperatures below800±C is a commercial technology. R&D should be directed at recovering heat at higher temperatures  A concept can be developed to recover heat from hot steel and slag.  long-term energy-efficiency improvement should be directed toward reducing these losses by I. avoiding intermediate heating and cooling steps. II. reducing the temperature required in various process steps. III. recovering the applying heat at high temperatures. 39

40 The Beginning of next steps - Questionnaire