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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
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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
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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
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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) Plant2007-082008-092009-102010-11 (Apr – Dec 2010) SAIL6.956.74 6.726.82 BSP6.726.5 6.566.66 DSP6.946.5 6.556.78 RSP7.397.09 6.976.89 BSL6.896.83 6.746.88 ISP8.148.18 8.23 RINL (GCal/TLS) 6.216.54 6.096.18 4
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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 2010 2. Annual report 2010-11, Ministry of Steel, Govt. of India Note: **BF and Sinter Plant were under capital repair for approx 6 months. Plant2007-082008-092009-102010-11 (Apr – Dec 2012) TaTa Steel 6.5556.5876.173 (Apr-Dec 2009) NA JSW Steel 6.8476.7046.4956.31 JSPL 7.687.257.146.98 Essar Steel 5.995.81NA IIL 5.735.42**5.46 (Apr-Sept 2009) Merged with JSW 5
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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 2001200220032004200520062007200820092010 Total Crude Steel Production (Million tons) 27.29128.81431.77932.62645.78049.45053.46857.79163.52768.321 Production Of Crude Steel in Electric Furnaces (Million tons) 9.98010.85012.68014.30024.78027.65031.30034.80036.20041.300 % of Steel Production in Electric Furnaces 36.537.739.943.854.155.958.560.257.060.4 6
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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
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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
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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
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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
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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
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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
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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) 1965-70Oxygen lancing1806306.5 1970-80-Water cooled panels -High power operation (UHP) 1054903.5 1980-85- Ladle furnace - Foamy slag - Eccentric bottom tapping - Scrap pre-heating 804502.5 1985-95-Oxygen carbon injecton ( lance manipulator) - Pneumatic bath stirring 604102.0 1995-2005-Oxygen carbon/oxyfuel side wall injection -Use of hot metal as charge material 55250-3001.6 13
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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
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INTERNATIONAL CONFERENCE ON INDIAN STEEL INDUSTRY: “CHALLENGES AND OPPORTUNITIES” 23 rd -24 th MARCH 2012 M.N. Dastur & Company (P) Ltd 15 THANK YOU
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