international convention on clean, green & sustainable

International Convention onCLEAN, GREEN & SUSTAINABLE TECHNOLOGIES

in Iron & Steel Making

15th-17th July, 2009

Venue:Hotel Swosti Plaza,

Bhubaneswar, Orissa, India

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International Convention on Clean, Green & Sustainable Technologies in Iron & Steel Making

Published by

Multi Disciplinary Centre on Safety, Health & EnvironmentBhubaneswar

(A Govt. of Orissa sponsored Autonomous Institute)

C-38, Unit - VIII, Bhubaneswar-751 003, Orissa, IndiaTel.: 0674-2563339 / 2560156, Fax: 0674-2563339

IDCO Plot No.: 04, Chandaka Industrial EstateBhubaneswar - 751 024, Orissa, India

Tel.: 0674-2743768 / 2741652, Fax: 0674-2741651

E-mail: [email protected]

The Organisers do not take the responsibility on the opinion expressed by the Authors of the technical papers published in the Souvenir.

Printed at

VIBGYOR PRINTERSPh.: 09337103016, 09337124034

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S.N. SahuDirector

MESSAGE

I am happy to know that Orissa Mining Corporation and Multi DisciplinaryCentre on Safety, Health & Environment, Bhubaneswar are jointly organisingan International Convention on "Clean, Green & Sustainable Technologies inIron and Steel Making" from 15-17 July, 2009.

Steel is the essential ingredient for spreading industrialisation, buildinginfrastructure and accelerating modernization of our nation. The volume of steelused by a country is indicative of its progress and development. India has ahuge potential to grow and register impressive success in all spheres. To achieveit we need more steel. While augmenting our ability to produce more steel, weneed to be mindful of the appropriate technology which are supportive of greaterproduction capacity and protection of our environment. The theme of theInternational Convention is very appropriate for addressing this challenge. ThePrime Minister hopes that the deliberations in the Convention will be fruitful andresult oriented.

The Prime Minister extends his greeting and good wishes to the organizersand participants for the success of the Convention.

(S.N. Sahu)

July 14, 2009

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Murlidhar C. BhandareGOVERNOR, ORISSA July 13, 2009

MESSAGE

I am happy to know that Orissa Mining Corporation (OMC) and MultiDiscipl inary Centre on Safety, Health & Environment (MDC on SHE),Bhubaneswar are jointly organizing an International Convention on “Clean,Green and Sustainable Technologies in Iron and Steel Making” on July 15-17,2009 at Bhubaneswar. A souvenir is also being brought out commemorating theoccasion.

Industrial pollution is one of the major causes of environmental degradationat the global level. Iron and steel industries are no exception to this as theyconsume substantial quantities of natural resources. It is essential that the steelmanufacturers give priority to lessen adverse impacts on environment by adoptinginnovative manufacturing technologies and management practices.

Though, the steel production in the world has witnessed a fall except inIndia and China, the demand both globally and within the country is expected toimprove in near future. In this context, the steel manufacturers should preparethemselves to make best use of this opportunity. India is in a better position toseize the advantage and contribute immensely to the country’s growth andeconomy. Orissa being a mineral rich region and presently witnessing fastindustrialization in iron and steel sector, it is the ideal place to hold such animportant convention. I am sure, the participants at the convention woulddeliberate on various aspects of iron and steel making to address new challengeswith best practices of clean, green and sustainable technologies.

I wish the convention and publication all success.

(Murlidhar C. Bhandare)

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Naveen PatnaikCHIEF MINISTER, ORISSA Dated 13/7/09

MESSAGE

I am glad to know that the Orissa Mining Corporation and Multi Disciplinary Centreon Safety, Health and Environment are jointly hosting an International Convention on"Clean, Green and Sustainable Technologies in Iron and Steel Making" at Bhubaneswarfrom 15th to 17th July, 2009.

Over the last few years Orissa has been experiencing an industrial revolutioncatalyzed by rich minerals and other natural resources available in the State. Iron andSteel sector has taken the initial lead. As many as 49 MoUs have been signed by theGovernment to produce an envisaged steel output of 90 mtpa. I am also happy that alarge number of these MoUs have already been translated into operating projects. Manyother projects are at different stages of execution.

However, it is the Government's conviction that any economic activity, be it inagricultural or industrial sector, should serve the cause of people of our State and therefore,our State Policies are designed to address issues relating to people and sustainability. Iam aware that mining and steel production impact the people and environment directly. Itis, therefore, important that these activities including steel sector adopt appropriatetechnologies that will promote efficient use of natural resources, minimize adverse influenceon environment and ecology and cause least displacement of people. The industry shouldpreferably adopt best practices in the arena of both technology and management thatpromote sustainable development of an economic activity and improve the quality of life ofour people.

I am, therefore, happy that an International Convention with focus on clean, greenand sustainable technologies is being organized at Bhubaneswar. I hope that participantsfrom within and outside the country representing different stakeholders will have aninformed deliberation on various issues and come up with a package of recommendationsthat are feasible for adoption.

I wish the convention a great success.

(Naveen Patnaik)

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VIRBHADRA SINGH MINISTER OF STEELGOVERNMENT OF INDIA

NEW DELHI

MESSAGE

I am happy to know that Orissa Mining Corporation Limited (OMC) and Multi Disciplinary Centre onSafety, Health & Environment (MDC on SHE) Bhubaneswar are jointly organizing an InternationalConvention on “Clean, Green & Sustainable Technologies in Iron & Steel Making” at Bhubaneswaron 15-17th July 2009.

The mineral rich State, like Orissa will be the prime contributors to the nation’s vision of creatingmore than 250 MTPA of steel output capacity by the year 2020.

I am happy that this Convention will be focusing on clean, green and sustainable technologies. Suchtechnologies are paramount need of the hour, considering that the steel industry is a huge consumerof energy and natural resources and therefore, it has to play a huge role in conserving energy andreducing air & water pollution.

I hope that the delegates at the Convention will share their knowledge and experiences, in thearena of both technology and management, with one another with an open mind set, and arrive atsolutions to meet the new challenges of resource constraints, global warming, high capital cost andincreasingly sophisticated market demands.

I wish the Convention a great success.

(Virbhadra Singh)

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JAIRAM RAMESH MINISTER OF STATE (INDEPENDENT CHARGE)ENVIRONMENT & FORESTS

GOVERNMENT OF INDIANEW DELHI-110 003

11th July, 2009

MESSAGE

I am glad to know that Orissa Mining Corporation Limited (OMC) and Multi Disciplinary Centre on Safety,Health & Environment (MDC on SHE) Bhubaneswar are organizing an International Convention on“Clean, Green & Sustainable Technologies in Iron and Steel Making” at Bhubaneswar on July 15-17,2009.

The Steel industry can strengthen India’s infrastructure and facilitate higher growth rates for our economy.As India targets to create around 250 million tons of annual steel capacity by 2020, it is Orissa and fewother mineral rich states, who would be making significant contribution to this. As we move ahead, itshould be remembered that iron and steel making consumes substantive raw materials and energy,while simultaneously impacting the environment and ecology adversely.

This calls for adoption of pollution prevention and control measures, besides adopting suitable technologyin iron and steel manufacturing, so as to minimize generation of wastes. It is important, that the manufacturersaims at achieving the load targets per unit of production of steel as per the global norms and strive tobetter them on consistent basis. Water is a critical input with competitive demands. Hence, treatment andrecycling of water upto a minimum level of 90% should be the target. Similarly, the solid waste generationshould be contained to achieve the standard norms of 80 k.g. per ton and further solid waste containingheavy metals should chemically neutralized for disposal.

While improvements will take place in DRI (Direct Reduction Iron) and Electric Arc Furnace technology,Blast Furnace will continue to be the key process for iron making. This warrants an evolving technologythat will minimize the use of coke, as the later generates pollutants during production.

I am happy that an international convention on clean, green and sustainable technology is being organizedand I hope that the participants would bring to bear upon the deliberation their expertise and experiencesand conduct them with an open mind, so as to identify appropriate technologies and best practices thatwould help to face the current and future challenges.

I wish the Convention all success.

(Jairam Ramesh)

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SHRI RAGHUNATH MOHANTY MINISTERIndustries, Steel & Mines and

Parliamentary AffairsOrissa

MESSAGE

I am extremely happy that Orissa Mining Corporation Ltd (OMC) and Multi DisciplinaryCentre on Safety, Health and Environment (MDC on SHE) are co-hosting an internationalconvention on clean, green & sustainable technologies.

The convention is being held at Bhubaneswar, the capital of Orissa, which is set to utilize itswealth of natural resources including minerals for value addition, primarily within the State andgenerate revenue and employment for its people. With 49 Memoranda of Understanding (MoUs)in the steel sector and 30 Memoranda of Understanding (MoUs) in other sectors includingAluminium and Cement, Orissa is going through historic times industrially.

But it should be remembered that steel consumes substantive quantities of mineral resourcesand also impacts adversely the environment.

The State is interested in sustainable development and would not like to compromise withecology and people related issues. I am, therefore, happy that the convention will be focusing onclean, green and sustainable technologies. I will be personally looking forward to the outcome ofthe deliberations so as to use the package of recommendations in policy formulation and projectexecution for the State of Orissa.

I wish the convention all success.

(Raghunath Mohanty)

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AJIT KUMAR TRIPATHYChief Secretary & Chief Development Commissioner,

Govt. of Orissa, Bhubaneswar &Chairman, Organizing Committee

Orissa has taken a welcome initiative of organizing an international convention on clean,green and sustainable technologies at a time, when, the world economy is going through a period ofrecession triggered by a financial crisis in the world’s largest economy – the U.S. of America. It iscommon knowledge that there exists a strong correlation between an economy’s growth rate andmarket demand for steel. Influenced by a negative growth rate, the global steel market has taken abeating over the last one year. The global output of steel that stood at 1197 million tonnes in April2008 dipped by 23% bringing down the total output to 840 million tonnes by April 2009. It is,however, heartening that the global recession has begun to mellow down and it is projected that itwill begin to make a turnaround sometime in the year 2010 leading to financial stabilization by theyear 2013. We can, therefore, be optimistic that global steel output will pick up in due course.Simultaneously, there already exists an optimistic mood in the steel output in India and China, theonly countries that have been able to buck the negative global trend as seen from the output for thefirst quarter of the year 2009. Another factor that is likely to catalyze the continued growth of steelover a long period is the expected increase in per capita consumption of steel in densely populatedcountries, namely, India and China. Today both these countries consume relatively less steel thanthe global average per capita consumption.

Steel-a guzzler of non-renewable resources:

Global warming has become a matter of real concern. The people all over the world arefocusing on innovative green technologies in different sectors. Iron & Steel making is critical from theperspective of green house gases. Iron & Steel making is among the largest energy consumer in themanufacturing sector, since it involves many energy intensive processes that consume raw and re-cycled materials in large quantities. Raw materials with intensive carbon contents which are theprimary resources for steel production influence climate changes materially. About half of the steelindustry’s energy is derived from coal and a large portion of this is consumed during the reductionof iron ore to pig iron. The Carnegie Mellon University’s Study commissioned by Sloan SteelIndustry identifies four main technology drivers for the steel industry. These include (i) high capitalcost (ii) raw materials shortages (iii) environmental concerns and (iv) customer demand.

Research and development will, therefore have to focus on these four factors for evolving asustainable framework.

FOREWORD

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Sustainability of Steel Industry:

The International Iron and Steel Institute (IISI) published its first report on sustainable development of steel industries inJanuary 2005. According to this Report, sustainable development means development aimed at improving the quality of life for everyone now and for generations to come. For the global steel industry, it means valuing the interdependence of environmental, socialand economic aspects in all decision making processes. The indicators enable the steel industries to measure their economic,environmental and social performance and these can be used to track the industry’s progress towards a sustainable development.

i. The environmental performance are measured by indictors like:

� Green house Gas Emission

� Energy intensity

� Steel Recycling

� Environmental Management Systems

ii. Steel Industry’s economic performance is measured by indicators like:

� Investment in Processes and Products.

� Operating Margin

� Return on Capital Employed

� Value Added

� Material efficiency

iii. Social performance is measured by:

� Employee Training

� Lost Time Injury Frequency Rate

IISI also highlights that the steel industry needs a systematic method to measure and report their performance with regard toorganized sustainable development indicators.

Cleaner Technology Options:

Since conventional steel making processes are highly polluting, a search for some less polluting technology options is necessary.It is believed that coke making, D.R.I. production, steel making and hot rolling areas hold vast scope for minimizing pollution levelsleading to a cleaner and greener environment.

Coke oven by-product plants with complete gas tight collector headers in the by-product recovery plant leads to a higher eco-friendly process. Another eco-friendly option in this area is to develop new coking process that reduces emissions at the source. Theaim should be to approach zero pollution level.

The COREX iron-making technology could be truly a zero waste approach if the excess fuel gas generated can be usefullyharnessed. A DRI technology that uses iron ore fines is a zero pollution complement to the existing coal based DRI technologieswidely used. One option which produces a true zero pollution process is a combination of COREX and DRI technologies.

Opportunities for pollution minimization include the reduction of slag volume through better control of lime input to the furnaceand improved control of silicon and sulphur in blast furnace hot metal.

Zero pollution approach in Basic Oxygen Furnace (BOF) will involve two strategies; (i) minimization of the amount of dustdischarged in the off-gas and (ii) recycling the dust back into upstream processes. Scrap management ensures that the zinc oxidecontent of dust and sludge remains low. New EAF dust treatment processes seek to recover both zinc and iron and are designed toproduce minimal by-products, making them virtually zero pollution processes.

Optimized Mining and Beneficiation System:

Fines, discarded as pollution are becoming a valuable commodity considering the scope for sintering and pelletisation. Modernbeneficiation processes allow for effective and low cost upgrading of lump, fines and ultra fines. Since mining is pre-requisite to ironand steel making, professional and scientific mining with concern for resource conservation and environment & ecology is another

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dimension of a sustainable approach. In order to conserve the mineral resources, beneficiation, calibration, sintering and pelletisationwill have to be adopted so that low-grade ores which are now being discarded will come to be used.

Conclusion:

Steel companies have both challenges and opportunities to improve their management practices and respond effectively to theneeds of environment protection. Many leaders in the steel industry, as well as in other sectors, are beginning to practice newtechnologies and adopt management principles that reduce greenhouse gas emissions and minimize overall climate impact. Theyhave, for example, launched voluntary emission reduction programmes and are participating in emissions trading markets. With theushering in the Kyoto Protocol, the industry will be expected to calculate and manage actual reductions in green house gasemissions, as opposed to improvements in emission intensity levels that occur normally over time. Purchasing and producingrenewable energy, investing in low-carbon technologies, working to improve energy efficiency and offering new products andservices aimed at reducing emissions are all meaningful strategies for the steel industry to undertake. They must monitor thesustainability indicators for their mining as also iron & steel making so that both current and future generations will stand to deriveeconomic advantages.

While highlighting the importance of technological and environmental factors, the prime concern for the people cannot beoveremphasized. It is the people who need to be taken care of at both project execution and project management stages. The projectaffected people, in particular, have to be given their due entitlements and enabled to acquire the desired skill set, managerial &enterprise – ability and become partners in the process of growth.

I am happy to note that, the organizers have received well researched and relevant papers on all the areas of concern. Thiswill enable a wholesome and comprehensive deliberation at the convention. The propose of this convention will be well served if,feasible and practical package of recommendations are arrived at and followed later by all the stake holders in the industry and thetrade. I am thankful to MDC on SHE for providing me with necessary technical data and information on the above subject from theirlibrary.

Bhubaneswar AJIT KUMAR TRIPATHY

Orissa, India

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ASHOK DALWAISecretary, Department of Steel & Mines,

Govt. of Orissa, Bhubaneswar &Co-Chairman, Organizing Committee

PREFACE

Steel was discovered by the Chinese under the reign of Han dynasty (202 BC to 220AD). Prior to steel, Iron was a very popular metal and was used over a wide region of theglobe, its use originating in India and China around 2000BC. Thanks to multiple uses of iron byman in his everyday life, the time period of around two thousand years Before Christ is termedas Iron age. More than 3000 years after this early beginning of the Iron Age, the modernsteelmakers continued to use the same carbo-thermic process discovered by early iron makers.But with the change in technology, people were able to find an even stronger and hardermaterial in this form of Steel. From China, the process of making steel from iron spread to itssouth and reached India. High quality of steel was being produced in southern India evenBefore Christ. Most of the steel then was exported from Asia only. Around 9th century AD, thesmiths in the Middle East developed techniques to produce sharp & flexible steel blades. In the17th Century, Smiths in Europe came to know about a new process of cementation to producesteel. The first Blast Furnace is about 600 years old but both incremental & radical change inIron and Steel making technologies has occurred over the last 200 years.

The Iron and Steel making process intensively uses minerals and energy besides thecapital cost. Steel making is one of the most intensive consumers of energy in the manufacturingsector. The steel makers need to be sensitive to customer demands in terms of product properties,quality, prices & delivery due to highly competitive market, guided by rapid technologicalchange and accelerating market globalization. It also faces severe environmental concernsarising out of high global steel output of 1200 million tons per annum and the last 30 years haveshown that the technology of steel making has & can change rapidly on a global scale. Theenvironment friendly & greener technologies along with minimum cost and highest quality shallonly sustain in time to come. The Grey shall be produced by the Green and the blue sky shallcontinue to remain blue.

There are four technology drivers influencing the steel sector and these are: High capitalcost, Raw material shortage, Environmental issues and Customer demand. The biggest challengeis to evolve appropriate technology as a roadmap through research and development forsubsequent transfer to users.

Improvisations in established routes of Iron & Steel making:

Direct Reduced Iron (DRI) & Blast Furnace for Iron making and Basic Oxygen Furnace& Electric Furnace (Electric Arc & Induction) are by far the most established processes usedworld wide. Blast Furnace in various forms has remained the backbone of Iron production formore than 200 years to yield carbon saturated hot metal for subsequent processing by steelmakers. However, the modern blast furnace has undergone basic process & technological

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changes vis-à-vis its earlier ancestors. Injection of pulverized coal, natural gas, oil and in some cases recycled plastic is used as asubstitute for a portion of metallurgical coke as a primary reductant and source of chemical energy represents an important developmentin this direction. Coke making is extremely problematic from an environmental perspective as many of the hydrocarbons driven offduring the coking process are hazardous. Also not all types of coal are suitable for the production of coke. Improvement in processcontrol and reduced refractory wear has increased blast furnace campaign life significantly, which is critical to the economics of theprocess. The current expected lifetime of newly rebuilt furnaces is 20 years or greater.

There has been a rapid increase in the production of Iron via DRI process over last 10 years. Further, the basic open-hearthprocess has been almost completely replaced worldwide by various top, bottom or combination blown Basic Oxygen Steel makingprocesses over the last 40 years. This has improved productivity and efficiency of Oxygen Steel making vessels. The abandonmentof Open Hearth steelmaking practices for steel making was also accompanied by a parallel widespread departure from Ingot castingto the Continuous casting of steel. This has had a dramatic effect on the steel industry worldwide. Between 1960’s and now,continuously cast steel as a percentage of total steel production has risen from essentially 0% to more than 90% in most countries.

With lower capital cost than an integrated mill, Mini mills based on Electric Arc Furnace melting (EAF) of scrap were able toestablish a cost advantage in the production of certain steel products. The development of ultra high powered Electric Arc Furnaceand reliable billet and bloom continuous casting machines provided a low cost route for the production of lower quality steel LongProducts, such as reinforce bar and structural steels. As a result, Integrated Steel producers have been completely displaced fromthis low-end segments of the steel market in developed countries and has allowed them to focus on the production of high qualityplate and thin gauge flat products. Though global DRI capacity via existing gas based technology is likely to increase further in orderto support expansion of EAF steel making to new high quality products, the Blast furnace is expected to remain the mainstay of globalIron production for several decades. Hence, further improvements in blast furnace technology are warranted.

Further improvements expected in the process of Iron Making:

It is noteworthy that a great opportunity exists to develop an entirely new process that better fits the needs of contemporary andfuture steelmakers as the supply of coke gets more & more constrained, causing closure of smaller Blast Furnaces but the need foradditional Hot Metal capacity continues to rise. The characteristic of a new and ideal process for increased iron unit productionshould include the following:

� Very high efficiency with respect to energy and materials usage

� Greater flexibility in feed materials

� Reduced capital costs

� Operational flexibility

� Capacity of producing steel or low carbon Iron directly

Latest processes for iron making like Corex, Hismelt and Finex technologies are slowly finding commercial operations. Thesetechnologies need to be improved & evolved based on problems at the application level.

Pollution Prevention and Control:

In addition to upgrading Iron and Steel making technologies, adoption of various pollution prevention and control measures areinevitable.

It is possible to re-use over 90% of the wastewater generated after proper treatment. Discharged waste waters should in allcases be targeted less than 5 m3/t of steel manufacturing and efforts should be made to bring it less than 1 m3/t. As regards solidwaste, the Blast Furnace slag should normally be generated at a rate of less than 320 kg/t of iron, with target of 180 kg/t. Acute focuson energy recovery in various processes of Iron & Steel Making is absolutely necessary. The technologies related to waste heatrecovery like Waste heat recovery boilers (WHRB), Organic Rankine Cycle (ORC), Phase change materials need to establish andmature themselves on war footing. Using photo cells for energy recovery from huge radiation losses during various processes andharvesting wind energy for steel making also should be given high priority by researchers & technology suppliers.

The greenest technologies & operating plants shall subsequently survive. The wake up call is already there in the form ofglobal warming and for those who do not wake up, the darkness is never going to end. This one issue for sure is going to rule theIron & Steel scenario for a very long time and the technology suppliers & steel producers who focus on this issue from today will bethe winners of tomorrow.

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Technologies for various treatments:

Appropriate treatment technologies for air emission, waste water and solid wastes are integral to good manufacturing practices.Air emission control technologies for removal of particulate matter include Scrubbers, Bag houses and Electrostatic Precipitators(ESPs). Wastewater treatment systems typically include sedimentation to remove suspended solids, precipitation of heavy metalsthrough physical or chemical treatment and filtration. Solid waste treatment involves stabilization of heavy metals using chemicalagents before disposal.

Compliance with Emission Guidelines:

The key production and control practices which will lead to compliance with emissions guidelines are summarized as under:

� Prefer the direct steel manufacturing process wherever technically and economically feasible.

� Use pelletized feed instead of Lump feed wherever appropriate.

� Replace a portion of the coke used in the blast furnace by injecting pulverized coal or by using natural gas or oil.

� Achieve high-energy efficiency by using blast furnace and basic oxygen furnace off-gas as fuels.

� Implement measures (such as encapsulation) to reduce the formation of dust, including iron oxide dust & whereverpossible recycle the collected dust to a sintering plant.

� Treat and re-circulate waste waters.

� Use slag in construction materials to the maximum extent possible.

Future and growth of Mining & Steel:

Based on cumulative output of 66 countries who report their data to World Steel Association, world crude steel production inApril, 2008 stood at 1170.23 million tonnes. By April, 2009 the output reduced to 894.52 million tones, registering a decline of23.56%. The major decline was registered in European Union, North America, Japan and South America. China, the main producerof steel registered a marginal decline by 3.94%, while India bypassed the trend and registered a positive growth of 8.07% over thesame period. This worldwide decline was on account of global recession amidst the year 2008. For most parts of the world, this trendcontinued into the first quarter of 2009. China and India have alone been an exception to this trend. Improvements in steel consumptionin the 2nd half of 2009 will depend upon stimulus packages of various Governments and stabilization of global financial system.However, steel being a vital component in the global economy’s production chain, steel industry is expected to adjust to the changedmarket condition. The Economists expect that global recession will mellow down by the year end and begin to recover in 2010 andstabilize sooner than the year 2013.

There is a strong correlation between growth rates of economy and demand for steel. The optimistic growth rates in theemerging economies of China, India, Russia and Brazil are expected to generate demand for steel and support the global steelindustry. The world’s average per capita consumption of steel is 160 Kgs. The consumption is high in developed countries and is atnear saturation level. India’s per capita consumption stands as low as 37 Kgs, while China consumes 100 Kgs per capita. These twocountries, which are expected to see increased per capita consumption will drive the demand. Hence, over the long run, the globaldemand for steel can be projected to be higher than current levels.

The growing steel industry will come to face wide ranging environmental concerns that are fundamentally related to consumptionof raw materials with intrinsic carbon contents, high quantity of energy requirement and the by-products associated with quantum ofsteel production. The challenge, therefore, is to improve upon the technologies that will bring about reduced consumption of energy,reduced consumption of raw materials and reduced levels of emissions besides being cost effective. Steel being one of the majorenergy consumers in the manufacturing sector, major intervention will be required in this aspect. A roadmap for achieving energyefficiency and energy conservation will be required. Technology driven solutions can be expected to yield results in case of Indiaand other countries operating at low end of technology. In the short-term, however, quick results can be achieved by implementationof small projects relating to waste heat utilization and process optimization. Also, deployment of various technologies and practices inmining, ore beneficiation & pelletization will lead to use of low grade ores now being discarded and ease the resource constraints.

The Triangle of Sustainability - People at the base :

Any sustainable approach to development is based on the principle of transferring of developmental benefits to the presentgeneration as also ensuring scope for it in favour of generations to come. In the context of mining and steel making, sustainability willbe defined by an interplay of three factors, namely, environmental, social and economic. People’s issues are as critical as those

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under the economic and environmental domains. Ultimately it is the people who facilitate an economic activity and also stand to benefitor suffer from the consequences of an economic activity. Hence, a facilitative environment that co-opts people as partners is integralto sustainability in mining and steel making. The issues become sharper particularly in developing countries where the population islargely agriculture dependent. When the society is asked to shift from an agricultural to an industrial economy, it entertains apprehensionsthat arise from their social and economic insecurities. Therefore, a liberal and comprehensive Resettlement and Rehabilitation (R&R)package has to be offered by both Government and Private Sector investors. This would mean not only financial entitlements but alsoenabling acquisition of required skills, managerial ability and entrepreneurship that would help them transit from a simple agriculturaleconomy to a more complex industry and service led economy.

This Souvenir being published for the “International Convention on Clean, Green & Sustainable Technologies” has receivedwell researched, well analyzed and logically presented papers on various areas of concerns related to mining, energy efficiency &waste heat recovery in Iron and Steel making. Due to overwhelming response, it has been difficult for the organizing committee toprovide time for presentation and space for all the papers. Therefore, the Committee has been constrained to publish abstracts ofsome papers which are as valuable as those published in full. We hope that this Souvenir containing valuable papers will serve asa reference book and will continue to keep the interest of the delegates alive in Clean, Green & Sustainable Technologies in Iron &Steel making.

Bhubaneswar ASHOK DALWAIOrissa, India

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CLEAN, GREEN AND SUSTAINABLE TECHNOLOGY

B.K. PandaManaging Director, NINL

Working Chairman ‘CGST’

Introduction

The 21st Century will go down in history as the make or break century for life and existence on this planet as we know it. If wetackle climate change and the carbon challenge, at scale and with vigour, we stand a chance, just a chance, that our grandchildrenand their families will enter the 22nd century in better shape to deal with the climate change legacies which will surely lie ahead.Cutting emissions of greenhouse gases like carbon dioxide (CO

2) by 70 percent during the 21st century could help nations worldwide

avoid the most dangerous potential consequences of climate change, according to a new study by scientists at the U.S. NationalCenter for Atmospheric Research (NCAR) in Colorado. The planet already is committed to some changes in surface temperature,rainfall and sea level for hundreds of years or more into the future, scientists say, but if CO2 concentrations in the atmosphere can beheld to 450 parts per million, the climate system would stabilize by about 2100 instead of continuing to warm, Warren Washington,NCAR scientist and lead study author, told America.gov. Today, according to the National Oceanic and Atmospheric Administration,the average global concentration of atmospheric CO2 is 383.9 parts per million by volume of air. If nothing is done to decreasegreenhouse gas emissions, CO2 concentrations could reach 750 parts per million by 2010. To create clean, green, sustainableeconomies requires a common sense of purpose, global leadership, a massive shift from high to clean, green investment and asignificant change in behaviours. To inform and underpin the actions we all need to take, the principal stakeholders – Governments,business and consumers – need a robust and comprehensive fact base on carbon emissions, carbon footprints, etc. This is wherenecessity of clean, green & sustainable technology can help on climate change mitigation measures. Governments need carboncounting to keep track of progress and become better informed about the efficacy of policy instruments. Businesses need data oncarbon reduction performance to demonstrate, or verify, what progress they are making. And consumers need the results ofindependent carbon counting analysis to be sure they can trust the green claims of both business and Government. Clean, GreenTechnology implemented to an agreed, single standard, brings confidence to the stakeholder partnerships which are essential tosustain the shift to a clean, green economy.

Few worrying facts that make clean and green technology important

Harm to the ozone layer from vehicles, factories, landfills, industrial solvents and so on, can cause health hazards such asimpaired lung function and inflammation. It is the most injurious pollutant to plant life. Carbon-mono-oxide from motor vehicles andother kinds of engine affects the cardio-vascular and nervous systems. Nitrogen-di-oxide from burning fuels in utilities, industrialboilers and trucks is one of the major pollutants that causes smog and acid rain.

Particulate matter, which is solid or liquid droplets from smoke, dust, fly ash and condensing vapours come from industrialprocesses, smelters, vehicles, industrial fuels and wood-smoke, can adversely affect breathing and respiratory health causingincreased respiratory diseases and lung damage. Lead from fuels and coal combustion, smelters and car battery plants canadversely affect mental development, kidney function and the blood composition; children are most at risk. Toxic air pollutants suchas arsenic, asbestos and benzenes are suspected to cause cancer, respiratory and reproductory diseases and birth defects.Greenhouse gases such as carbon-di-oxide, methane and nitrous oxide can increase global temperature, lead to an increasedseverity and frequency of storms and other weather extremes, melting of the polar ice cap and the EI Nino effect.

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Important statistics that we mostly don’t know.

The energy saved by recycling one aluminium can equals the amount of energy it takes to run a TV set for four hours. Thisis the energy equivalent of 1.9 litres of gasoline. It takes nearly 4,086 kg of aluminium ore and 463 kg of fuel to manufacture onetonne of aluminium, which means that using recycled aluminium to produce aluminium reduces raw material requirements by 95 percent and energy requirements by 90 per cent. A paper mill uses 40 per cent less energy to make paper from recycled paper thanit does to make paper from fresh lumber. All this just point out to the fact that the saving and generating of energy from natural sourcesthat do not harm the environment is the prime need to the hour. It only goes on to say that we have lesser time to take firm actions tosave this world that we have.

Clean and green Transformation

The transition to a clean, green world will transform our whole economy. Lord Stern of UK’s landmark Review in 2006 set outthe economic case for action on climate change and for investment in a clean, green economy. Recognising that economic necessity,developing nations have through the latest Climate Change Acts become first few nations in the world to adopt a legally binding targetto reduce carbon emissions – by at least 26% by 2020 and by 80% by 2050.

Achieving this means that by that date, every unit of output in Britain will need to be produced using on average just one tenthof the carbon used today as an example.

This transition will transform our whole economy. It will change our industrial landscape, our supply chain, and the way inwhich we all work and consume. For as well as being an environmental and economic imperative, the shift to a clean, green economyis also an economic opportunity. Businesses and consumers can benefit from significant savings through energy and resourceefficiency measures. And supplying the demands of the clean, green economy offers a significant potential contribution to economicgrowth and job creation in India, not only as part of the short term economic recovery, but also through sustainable growth over thedecades to come.

The global market for clean, green goods and services is already worth over several crores of Rupees and growing rapidly.For India, which is already putting emphasis in many clean, green and resource efficient services, technologies and processes, thisis a huge potential opportunity.

The challenge for business and government is to make that India benefits economically and industrially from the move to clean,green technology – ensuring that the jobs and growth that it could bring support our recovery from the downturn and our long termindustrial future.

The transition to a clean, green economy is necessary for two reasons. Primarily it is to stabilize greenhouse gas concentrationsin the atmosphere. Secondly, the clean, green path is seen as a viable stimulus for a tipping economy. But it is also important toacknowledge that the ‘limits to growth’ thesis has been confirmed after decades of poor criticism. The way forward to a sustainablefuture is to master and widely deploy clean engineering technologies.

Opportunity from change : new industrial activism

A clean and green industrial strategy must seize the opportunities that will come with change: a new industrial activism for a newgreen industrial revolution.

We already have in place the key targets and regulatory drivers for carbon reductions in the areas of households, transportand power generation. The framework Government has put in place aims to give industry the confidence to invest in bringing clean,green products and services to the market.

But we must also think about how we best equip Indian businesses and workers to compete for these opportunities. In anincreasingly competitive global market it is vital we create the conditions that make India the best country in the world to grow a clean,green business. We need a new industrial activism that brings together different strands of government policy to ensure clean, greencompanies based here have access to the infrastructure, skilled workers, research and development and investment opportunitiesthey need. We need to make sure that we drive the green industrial revolution from the regions as well as nationally, building ondistinct regional and local advantages across India, and market Indian strengths in a competitive global market place.

For businesses, the transition to clean, green offers both commercial opportunities and the chance to save money and releaseproductive resources through greater energy efficiency. At the heart of the Clean, green Industrial Strategy are drivers of fundamentalchange in four key areas :

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· Energy efficiency to save businesses, consumers and the public services money

· Putting in place the energy infrastructure for India’s clean, green future – in renewables, nuclear, Carbon Capture andStorage and a ‘smart’ grid

· Making India a global leader in the development and production of clean, green vehicles.

· Ensuring our skills, infrastructure, procurement, research and development, demonstration and deployment policiesmade India the best place to locate and develop a clean, green business and make sure international business recognisesthat.

The global shift to a clean, green economy could help to drive renewed growth that will lift us out of the economic downturn. Itwill be key to India’s long term industrial future.

Set out here are the areas in which the Government believes we can build on existing work to create a comprehensive andambitious step change that ensures India’s businesses can benefit fully from global moves to a clean, green economy. In closeconsultation with businesses, unions, environmental experts and other stakeholders we will now develop our approach for ensuringIndian businesses can benefit from the transformative change to a clean, green economy.

Saving through energy and resource efficiency

More efficient use of energy and other resources could save businesses and consumers in India millions of Rupees everyyear. Much of this can be achieved from simple and cheap actions. The savings made could be quickly channelled into newinvestment.

Greater resource efficiency has a fundamental role to play in increasing the productivity and competitiveness of Indian businessand it is also increasingly becoming a selling point for both India and international customers. A national shift to greater resourceefficiency would also support the creation of tens of thousands of jobs for businesses in this sector.

Despite the clear economic case for undertaking energy efficiency measures, lack of information and lack of finance – especiallyin the current economic climate – can prevent businesses from taking them up.

The public sector has to demonstrate leadership in the move to a clean, green economy. The public sector could save asignificant proportion of the several crores it spends on energy each year through energy efficiency measures. The public sectorcould also boost demand for innovative clean, green products and services as part of the substantial amount it spends annually onproviding public services.

We have two objectives on energy efficiency for our Clean, green Industrial Strategy : to facilitate a comprehensive stepchange in the number of businesses and public sector operations making the shift to greater energy efficiency, and to make sure thatan active industrial policy means Indian firms have the skills to advise and carry out this work, and to bring new energy efficiencytechnologies to market.

There are only two ways you can improve energy efficiency, change the consumer’s attitude or invest in better technology.Much research is showing that consumer change is not so easy or assured for the longer term. So, we are left with technology whichrequires finance. Unfortunately in local government a financial incentive, understanding or interest in delivering a clean, greeneconomy is severely lacking. Unless local government is mandated, penalised for non compliance and resourced, the lighter shadeof very pale green will continue.

Energy for the future

Energy is the engine of our society and our economy. Since the industrial revolution, the world has been dependent on highcarbon fossil fuels for its energy needs. That will change dramatically in a clean, green economy. In the years ahead we will betransforming our electricity generation and energy grid to deliver power more efficiently and to adapt to new forms of powergeneration.

By 2020 we will need to increase energy from renewable sources by nearly 10-fold to meet our renewable energy targets,saving 20 million tonnes of CO2 each year. Alongside our civil nuclear sector and a shift to clean coal through Carbon Capture andStorage, these new technologies will vastly reduce the carbon released in generating our electricity supply and heating our homes.The shift to renewable energy sources could also help to reduce India’s dependence on imported oil and gas, helping to reduce thevulnerability of Indian businesses to shifting energy prices.

But it is not enough to increase our use of clean, green energy generation sources. We must also transform the electricity grid

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itself, ensuring that it is equipped for the rapid connection of new forms of energy, able to adapt to the move to clean, green vehiclesand increasingly efficient in the way it transmits and distributes electricity. Improving our grid architecture will be essential as wesupport more small-scale generation through the advent of our new Feed-in Tariffs. Crores of investment in the grid is alreadyplanned for the next five years, and we have set an aim of having smart meters installed in every home by 2020. We could alsoachieve carbon savings by generating heating centrally and distributing it to local homes and businesses through district heatingnetworks.

India’s clean & green Industrial Strategy will develop further our approach for delivering maximum economic benefits fromIndia’s shift to greater use of renewables, civil nuclear power and Carbon Capture and Storage. It will wet out our strategy for makingIndia’s energy grid more efficient and ‘smarter’. Details of a proposed approach for improving heat generation, creating opportunitiesfor Indian businesses are set out in the Government’s Heat and Energy Strategy for consultation very shortly, and we will need tocontinue to explore other opportunities such as Combined Heat and Power.

Sustainability of World Steel Industries

Sustainable development is an emerging concept which has been brought in realization of the importance of environmentalissues linked with development objectives and policies. A project activity can cause impacts on the environment either positively ornegatively throughout its lifetime depending on the type of its activity.

Steel Industry is among the largest energy consumers in manufacturing sector. The production of steel involves many energyintensive processes that consumes raw materials such as iron ore, lime stone, dolomite, recycled materials like scrap, slag etc.

The International Iron and Steel Institute identified eleven (11) (1) sustainable indicators in January, 2005 based on the informationfrom 42 steel companies representing over 33% of world crude steel production. The eleven sustainable indicators are :

1) Green House Gas Emission 7) Return on Capital Employed (ROCE)

2) Energy Intensity 8) Value Added

3) Steel Recycling 9) Material Efficiency

4) Environmental Management System (EMS) 10) Employee Training

5) Investment in Processes and Products 11) Lost Time Injury Frequency Rate

6) Operating Margin

The industries environmental performance measured by the indicators from Sl. No. 1 to 4, the economic performance ismeasured by the indicators from Sl. No. 5 to 9 and the social performance is measured by two indicators i.e. Sl. No. 10 & 11.

On sustainable development, it is essential the steel industry needs a systematic method to measure and report how theindustries performing with regard to the above 11 indicators.

Around 1.7 ton of carbon dioxide is emitted per ton of steel produced. Considering the global steel output as around 1.3 billiontons / year, it is essential for steel industries to improve the efficiency in operation for minimizing the green house gas emission.Considering the conventional steel making process, a search for some technology options which will help reducing GHG emissionsare discussed below.

Coke making (2) has been traditionally a major culprit for polluting the environment. Production of coke in eco-friendly manner is notonly reduce environmental pollution but also improve the efficiency of the process by way of increasing the yield of the products.

Japan Iron and Steel Federation (JISF) and Centre for Coal Utilization, Japan (CCUJ) has conducted 10 years researchprogramme (1993-2003) for development of innovative coke making process SCOPE-21 (Super Coke Oven for productivity andenvironmental enhancement towards the 21st Century). Pilot plant tests are being carried out to scale up the data for designing acommercial plant.

Some of the steps adopted for achieving zero emissions from CO batteries are water sealed stand pipe / ascension pipe caps,HPLA for on main charging, goose neck with rear window design, screw feeder for charging car, PLC controlled hydraulic drivenpusher machine, luting of lids, sealing of doors with improved door design. The coke dry quenching technology is one of the vitaloptions to achieve energy conservation, improved coke quality with quantifiable environmental benefits.

The non-recovery coke making process has very distinct environmental advantage from the point of view of very low emissionsto no hazardous waste generation. It is strongly believed that heat recovery / non-recovery coke making will be the most attractivealternate coke making technology for the 21st century.

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For Iron and Steel manufacturing process the carbon emission value depends on the company’s mix of production route. ForIndian conditions following process routes are popular depending on the capacity and location of the plant.

- BF-BOF-CC routes for high capacity plant.- Natural gas based DR & BF-EAF-CC route for high capacity plant.- Coal based DR-BF-EAF-CC route for low to medium capacity plant.

The COREX iron-making technology could be truly a zero waste approach if the excess fuel gas generated can be usefullyharnessed. A DRI technology that uses iron ore fines is a zero pollution complement to the two DRI technologies widely used. Oneoption which produces a true zero pollution process is a combination COREX and DRI plant.

Opportunities for pollution minimization include the reduction of slag volume through better control of lime input to the furnaceand improved control of silicon and sulphur in blast furnace hot metal.

Zero pollution approach in BOF steel making has two elements ; minimization of the amount of dust discharged in the off-gas andrecycling the dust back into upstream processes. Scrap management, the use of alternative sources of iron units or black scrapensures that the zinc oxide content of dust and sludge remains low. New EAF dust treatment processes seek to recover both zinc andiron, and are designed to produce minimal by-products, making them virtually zero pollution.

A lot of mining and beneficiation activities are carried out for raising coal & iron ore required for steel plants. This scenario ischanging dramatically and demands new approaches. Fines, disregarded as pollution, are becoming a valuable product consideringthe upcoming sintering and pelletization capacities. Modern beneficiation processes allow for effective and low cost upgrading oflump, fines and ultrafines.

There are methods that processes the non-pelletized fine particles (various types of dust generated in iron and steel making)in the molten slag bath. Such techniques include Romelt, (3) the latest developments in HI smelt and processes AISI-DOE, developedby AISI. The Romelt process is a single stage continuous iron making technique from the unprepared iron bearing raw materials inslag baths using steam coal.

Today steel makers are under Increasing pressure to minimize net energy consumption and reduce CO2 emission. The someof the emerging steel making process viz. CONSTEEL Process, FASTEELTM Process, FASTOXTM Process, KWIKSTEELTM Processetc. are capable of accomplishing the above goals. The calculated energy consumption and CO

2 emission for several steel making

process are compared below. (4)

Process Energy Consumption Carbon Emissions(GJ/t liquid steel) (kg CO2 / t liquid steel)

BF / BOF 16.8 1959

30% cold DRI/70% Scrap 10.4 702

80% cold Dri/20% Scrap 18.2 1163

30% IT mk3/70% Scrap 11.9 876

FASTEELTM 10.2 895

FASTOxTM 16.4 1467

Material efficiency is a measure of how well a company optimizes the raw materials it uses to produce products while minimizingwaste. The table below gives the input and output ratio of liquid steel to cold rolled sheets in various countries.

Input / Output Ratios from Liquid Steel to CR Coil / Sheet

Sl. No. Country I/O Ratio (LS/CRS)

1. CIS 1.208

2. China 1.225

3. South Korea 1.145

4. Brazil 1.179

5. Taiwan 1.168

6. Australia 1.174

7. Mexico 1.179

8. UK 1.152

9. India 1.236

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10. France 1.168

11. Germany 1.152

12. Canada 1.163

13. Japan 1.135

14. USA 1.154

It is observed that the input and output ratio is highest in India. This indicates that Indian steel Industries had lot of opportunities toimprove the above ratio in fully utilizing raw materials and producing minimum waste. Further improvements in material efficiencymight be realized through improved recycling of byproduct materials from the steel production process.

The figure below indicates the 100% use and recycling solid waste arising out of iron and steel industries. (4)

In the areas of finished steel production, the technologies mainly Thin Slab Casing, Endless Strip Production (ESP), Direct StripCasting (DSP), near net shape beam blank casting, continuous casting director rolling (CCDR) are some of the technology whichincreases the input output ratio to a considerable extent.

Natural gas (3) is emerging as an important factor for the world’s total primary energy consumption. The use of natural gas in steelindustries will reduce the consumption of energy derived from Fossil Fuel and thereby the contribution towards GHG emission will besignificant as per commitment towards a clean, green and sustainable society. Use of waste heat from coke oven flue gas forgenerating power through gas turbo generators and heat recovery steam generators will also contribute in reducing green housegas significantly besides contributing towards generation of additional electric energy. “In the areas of reheating, NKK” and NIPPONfurnace Kogyo have jointly developed and commercialized eco-friendly regenerative burners heating system where it is claimed thatthere is around 30% of energy saving and reduction of over 50% of NOx gas generation. This system will provide an effectivecountermeasure for the global greenhouse effect and the acid rain.

Society Oriented Steel Plant (5)

Waste treatment has become an important issue to prevent global warming by reducing CO2 emission. Enormous amount of wasteare being discharged in course of mass production, consumption economic activities. By effectively utilizing the synergic effects ofIron & Steel making technology and engineering technology it could be possible to build a recycling-oriented society.

In accordance with the container and packaging recycling law of Japan Kobe Steel accepts waste plastic collected not only inthe works but also from outside as a substitute of coke in their Blast Furnace. For recycling electric household appliances, Japan hasinvested in an appliance recycling business located in its steel work.

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The primary objectives of recycling business is to achieve the best use of the advantages of a steel work located in the urbanarea where huge amounts of industrial and municipal wastes are generated, thus providing the urban steel works with a new socialvalue. The highly skilled personnel available in a steel works with outstanding qualification in high temperature processing can beutilized to take up the challenges of the 21st Century to make steel making a really a green enterprise, but at the same time profitableone to benefit the whole community. The concept of synergic cooperation among the producer and user industries as depicted asfigure below will go a long way for building a recycling oriented society.

Glass sandSoda ash

Conclusion

The world must restrict its carbon emissions to 190 giga tonnes by 2050 if it is to have a chance of escaping the consequencesof global warming.

These are the latest findings published in Nature that put aside all earlier calculations and warned that the planet could takeeven less of the greenhouse gases than imagined before. The warning has never been simpler for all to understand.

Latest studies show there is 75% chance the world can hope to escape the danger of global average temperatures rising bymore than 2 degrees Celsius above the pre-industrial era only if it can keep its carbon emissions below 190 giga tonnes over thenext 41 years.

Put simply, 190 giga tonnes is our carbon budget for the period upto 2050. But unlike a financial budget, there is no room forexceeding it. A 75% chance is, in scientific terms, reasonable, nothing to be ecstatic about. But enough to give hope. If we think 190giga tonnes is a huge amount of carbon to throw up in the air, read this : last year alone, the world emitted over 9 giga tonnes ofcarbon by burning fossil fuels.

And the rate at which we emit carbon is rising 3% every year. If humanity continues to burn fossil fuels and gases at this rate,we shall have consumed the entire carbon budget available to us – 190 giga tonnes – by 2029.

Every single tonne of carbon after that shall progressively reduce our chances of not letting temperatures rise above 2 degreeCelsius over the pre-industrial era and consequently cause havoc. For instance, if carbon emissions touch 310 giga tonnes betweennow and 2050, the chances of averting catastrophic climate change fall below 50%.

Thus the need for clean and green technology, because it is threatening human civilisation on this planet and there isn’t anotherplanet to go to. It’s quite important, but we are not doing it already. Some people in industry are, but overall we are only starting tothink about doing it. Like other types of pollution, we don’t really pay attention to the damage of Co2 emissions are causing.

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In a nutshell the latest clean technologies which we need to go for are Bio-energy fuels, Renewables, Photovoltaics, Wind andexothermal, green buildings and construction, smart grid, transmission, fuel cell & hydrogen technologies, green chemistry,transportation and storage technology, water clean technology, environmental & sensor technology.

Issues such as recycling, global warming and clean energy are also being addressed at a massive level. Now there is evenan Earth Day Network. It promotes environmental citizenship and year-round progressive action all over the world. Activistsconnect change in local, national and global policies. Today, the network has reached over 17,000 organisations in 174 countries.More than a billion people participate in Earth Day Network campaigns every year.

Here, a big responsibility also lies on the shoulders of the corporate world. It should and has, indeed, gone beyond maintainingparks and gardens in the city. Under one such initiative, several companies are shifting towards environment-friendly and energysaving techniques for constructing commercial buildings. Several companies are also organising marches and walk-to-office days.Hotels and restaurants are coming to realise that it also has a positive impact on their bottom line.

At the same time, one cannot ignore the importance of locking in and making use of the biggest source of energy – the solarenergy. From lanterns, heaters, street lights, home lights and pumps to power packs, solar energy is one source of energy that isnon-depleting and comes with a no-hazard guarantee to the environment. The fact that it is reasonable may just be the answer to thecountry’s and even the world’s needs for energy and power.

Punch line

This is the only planet we have and it is our home. Everyone needs to wake up to the fact that we are misusing this planet andhurting its environment beyond repair. Since steel industry is the 2nd largest GHG producer ment to cement, it is the utmost necessityfor the steel industries to select the right technology to combat the effect of warming of the planet and to sustain the steel industries byutilizing the resources deligently and intelligently. It is, therefore, the corporates are required to invest in R&D to control / innovatethe process to use less energy and other resources in the industries, thus cutting CO2 emission. Since there are a good number ofsteel industries in project stage and in operation in Orissa, India, they must match their performance with the sustainable indicesdrawn by IISI in 2003 and improve upon that.

Reference

1) World steel industry sustainability report published by IISI

2 ) Coking Coals & Coke Making : Challenges & Opportunities, R&D Centre for Iron & Steel, SAIL.

3 ) Business Publications : Processing industrial wastes with liquid-phase reduction Romelt process, JOM, Aug.’99

4) A guide for entrepreneurs in the Iron & Steel Industries, Ministry of Steel.

5 ) Communication from Kitakyushu International Techno-cooperative Association (KITA).

6 ) JPC Bulletin on Iron & Steel, December, 2007.

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Program ScheduleJuly 15 (Wednesday)-July 17(Friday)-2009

at Hotel Swosti Plaza, Bhubaneshwar, Orissa, India

July 15th 08:00-09:45 Registration

09:45-10:00 Assemble at the Convention Venue “Chanakya Hall”

July 15th Lighting of the Lamp by the Chief GuestInaugural Ceremony Mr. Naveen Patnaik(10:00-11:30) Hon’ble Chief Minister, Orissa

Welcome AddressDr. Ashok Dalwai,Commissioner-cum-Secretary, Steel & Mines, Govt of Orissa &

Chairman, Orissa Mining Corporation Limited

Keynote AddressMr. P.K. RastogiSecretary, Ministry of Steel, Govt of India

Release of Souvenir & Inaugural Address byChief Guest Mr. Naveen PatnaikHon’ble Chief Minister, Orissa

Presidential AddressMr. Ajit Kumar TripathyChief Secretary & Chief Development Commissioner,Govt. of Orissa &Chairman Organising Committee “CGST”

Vote of ThanksMr. G.D. RathConvenor “CGST” & Secretary, MDC on SHE

11:30-13:00 Chief GuestInauguration of Exhibition & Visit Mr. P.K. Rastogi

Secretary, Ministry of Steel, Govt. of India, New Delhi

13:00-14:30 Lunch

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Technical Session-IENVIRONMENT

Chairperson U.N. Behera, Commissioner-cum-Secretary, Department of Envt. & Forests, Orissa

Co-Chairperson Dr. C.R. Mohapatra, Member Appellate Authority on Air Act & Water Act, Orissa

15.07.09 14:30-14:50 Towards Energy-Efficient Iron & Steel Making-The GreenhouseGas Carbon Abatement Process (G-CAP)Michiel Freislich, Steve Gale/Peter Duncan(New South Wales,2500 Australia,)Sunil Kumar(Sheridan Science & Technology Park,Mississauga), HATCH, Austral ia

14:50-15:10 Energy Efficiency in Steel Making and Clean Development Mechanism”K. K. Singhal, ED & K. M. Khare, AGM,Environment Management Division,, SAIL, Kolkata

15:10-15:30 Regulatory Mechanism Adopted to Control Pollution inDRI Steel Plants of Orissa for Protection of EnvironmentSiddhant Das & Dr. Akhila Kumar Swar, State Pollution Control Board, Orissa

15:30-15:50 Carbon Trading in Steel IndustrySashank Jain, Tata Energy Research Institute,(TERI) New Delhi

15:50-16:10 Energy Conservation & Environmental Protection TechnologyNavin Mishra, Mishra Ispat (P) Ltd. &Yuanchang Sheng, Jiamgsu Zhongxian Group Co. Ltd., China

16:10-16:30 Coffee Break

Technical Session - IIMINERAL PROCESSING

Chairperson B.K.Singh, Vice President, Tata Steel, Orissa Projects

Co-Chairperson Dr.G.K.Pandey, Adviser,Ministry of Environment & Forests, Govt. of India

15.07.09 16:30-16:50 “Reclamation & Rehabilitation” in Goa Iron Ore minesA.B. Panigrahi / Dr. AN Murthy, Indian Bureau of Mines

16:50-17:10 Utilization of lean grade material like Jhama to enhance mine lifeat Jharia Division of Tata SteelMayank Shekhar / Priya Ranjan Roy / Parveen K. Dhall /Dr. T. Venugopalan / C.H. Divakera, Tata Steel, Jamshedpur, India

17:10-17:30 Iron Ore Recovery from Waste Dump fines in SAIL MinesV. Dayal, S.K. Pan, S.K. Mukherjee, M.P. Srivastava, S.K. Sinha,RDCIS, SAIL , Ranchi

17.30-17.50 Utilisation of Low Grade Iron Ore in Steel Making withState of Art Beneficiation & Transport - A Case Study for MeetingChallenges in Orissa StateG. S. Khuntia,Director, OMC Ltd., Mining Advisor, MSL (Ex-ED SAIL & Director, NMDC)

17:50-18:10 Questions/Answers

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Plenary SessionWORLD ECONOMY & GROWTH OF STEEL INDUSTRY

16.07.09 09:00-11:00 PANEL MEMBERSV. Shyamsundar, MD, Durgapur Steel Plant, SAIL

H. M. Nerurkar, ED (India & South East Asia), Tata Steel Limited

P. K. Bishnoi, CMD, RINL

Dr. S. M. Jamdar, MD, Karnataka Power Corporation, Bangaluru (R & R Expert).

Dr. K. P. Nyati, Chief Executive Officer, Indian Mining Initiative(Ex-Chairman, CPCB)

Chairman :Dr. Ashok Dalwai,Commissioner-cum-Secretary, Steel & Mines, Govt. of Orissa & CMD, OMC Ltd.

11:00 onwards Sight Seeing, Lunch & Dinner

Technical Session IIIIRON MAKING

Chairperson B.K. Panda, MD, Neelachal Ispat Nigam Limited

Co-Chairperson N. P. Jaiswal, ED I/C, Jindal Stainless Ltd

17.07.09 09:00-09:20 Corex / FinexK. Wieder / C. Bohm / U. Schmidt / W.Grill, Siemens VAI, Austria

09:20-09:40 HismeltPeter Burke, Rio Tinto

09:40-10:00 Charge Intelligent Sinter into your Blast FurnaceStefan Hotzinger/Johann Reidetschlager/ Hans Stiasny/Edmund Fehringer/Christoph Aichinger /Andre Fulgencio, Siemens VAI, Austria

10:00-10:20 Blast Furnace Modernization and New technologiesIan Craig, Siemens VAI, Austria

10:20-10:40 Midrex Technologies, Inc.Henry Gaines, Director & Mr. Markus Leu, Manager, Midrex

10:40-11:00 Energy efficient and eco friendly Iron Making operations atTata Steel’s ‘H’ Blast furnaceA. S. Reddy / Goutham Raout / Ashok Kumar, Tata Steel, India


11:20-11:40 Coffee Break

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Technical Session IVSTEEL MAKING & SYNGAS USAGE

Chairperson Prof. Omkar Nath MohantyCo-Chairperson Vice Chancellor, Bi ju Patnaik University of Technology, Orissa

17.07.09 11:40-12:00 2nd Generation of dry type ESP and Hydro-Hybrid Filtertechnology-New Technology for BOF primary gas cleaningJan Adams / Thilo Wubbels, SMS Elex, Switzerland

Helmuth Ester / Klaus Schmale, SMS Siemag, Germany

12:00-12:20 Process improvement and emission reduction through minimalfootprint approach towards environmentally sustainable steel making.S. Mitramazumdar / S. Bhattacharya / S.K. Sinha, SAIL-R&D Centre, Ranchi

12:20-12:40 Energy recovery at the EAF by using the off gas heatfor steam ProductionCristian Frohling / Helmut Ester / Wolf Shieke, SMS Siemag, Germany

12:40-13:00 Reduction gas from Coal- Ideal, Economic & Environmental Solutionfor Integrated Steel Plants.Amitava Banerjee / Dr. Horst Kalfa, Lurgi India Company Pvt Ltd andAdrian Reeve, MD-Lurgi Clean Coal

13:00-13:20 Coal Gasification & Syngas based DRIRajesh Jha, Jindal Steel & Power Limited, India

13:20-13:40 PHE’s in the Basic Metals IndustryHenrik Johansson, Tranter, Texas, USA


14:00-15:00 Lunch

Technical Session VRESETTLEMENT & REHABILITATION

Chairperson G. Ojha, Director-Personnel & Raw Materials, SAIL

17.07.09 15:00-15:20 Broad Issues related to CSR and R&RIbrahim Hafeezur Rehman,Director, Social transformation Division,Tata Energy Research Insti tute(TERI), New Delhi

15:20-15:40 Development Projects, Displacement & Rehabilitation- An Overview on OrissaDr. A. B. Ota, Director-Tribal Research Institute,(TRI) Orissa

15:40-16:00 Resettlement & Rehabilitation- The way forwardDr. S. M. Jamdar, National Consultant, UNDP, Orissa Projects.

16:00-16:20 Reshaping Life : Our Experiment and Learning onAccount of R & R EffortsR. K. Singh, Head R & R, Tata Steel


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Concluding Session

17.07.09 16.40… Welcome AddressMr. B. K. Panda, Managing Director, Neelahal Ispat Nigam Ltd.

Convention ReportMr. N. N. Sachidananda, Communication Consultant, Bangalore

Convention RecommendationDr. Ashok Dalwai,Commissioner-cum-Secretary Steel & Mines, Govt. of Orissa & CMD, OMC Ltd.

Address by Guest of HonourMr. Raghunath Mohanty,Hon’ble Minister, Steel & Mines, Industries & Parliamentary Affairs, Orissa

Address by Chief GuestMr. Pyari Mohan Mohapatra, Hon’ble Member of Parliament (RS)

Presidential AddressMr. Ajit Kumar TripathyChief Secretary & Chief Development Commissioner, Govt. of Orissa &

Chairman Organising Committee “CGST”

Vote of ThanksMr. G. S. Khuntia, Vice Chairman “CGST” & Vice President, MDC on SHE

High Tea

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I am glad to be at this International Convention on "Clean, Green and SustainableTechnologies in Iron and Steel Making". This convention has relevance to the easternregion of our country and to Orissa in particular.

India and China along with Brazil and Russia are expected to lead global economyin the next few decades. Global recession became visible around October 2008,negatively impacting the demand for steel. The global steel output began to register adownward trend from 2007 itself. The global crude steel output was one thousand onehundred ninety seven million tones in April 2008 and declined by 23% by April 2009.Only India and China have been able to stem this declining trend. India managed toproduce around 14 million tones in the first four months of 2009 and registered amarginal increase in its growth over the previous year's corresponding period. It isheartening to know that the growth within India came from contribution from EasternIndia, which has generally been thought to lag behind in industrial growth. Orissa hasbeen able to attract impressive investments on the strength of its rich mineral wealth.Our State has signed about 49 MoUs in the steel sector envisaging an output of 90mtpa when all the plants will be commissioned fully. Many of these MoUs have alreadybeen grounded and as many as 28 plants have gone into partial or full production.Today, Orissa produces 10 million tones of steel of different grades a year, which is asubstantial jump from 2 mtpa a few years back. This has generated jobs for thesemiskilled, skilled and also degree holders. This has also triggered service sectorsincluding transport, hotels etc. Steps have been taken for setting up downstreamindustrial parks, which will generate many more jobs for our young people.

An important factor, which has ushered in this industrial revolution in the State isthe strong policy framework introduced by the Government of Orissa over the last fewyears. The Orissa Industries Facilitation Act, 2004 has simplified the procedure forfiling of applications and has brought about objectivity and transparency in projectapproval. The State Government considers people as the most important stakeholdersin the process of change. Our R & R Policy also has been held as the most progressiveand liberal one in the country in terms of entitlements that it creates for the displacedand affected families. The objective of our Policy is to promote inclusive growth so thatthe affected people also benefit from Projects.

There are many other pol ic ies that def ine the posi t ive f ramework forindustrialization in particular, and governance in general. I am happy to share with youthat the latest report of the World Bank on 'Doing Business in India' has ranked

Inaugural Address ofShri Naveen Patnaik

Hon’ble Chief Minister, Orissa

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Bhubaneswar at No.3 in the entire country beating many well-known cities includingDelhi, Mumbai, Bangalore, Hyderabad, Chennai and Ahmadabad. Since we believein continuous improvement, we shall continue to effect reforms to reach the top.

When an economy which is predominantly agrarian witnesses a spate ofindustrialization it is imperative that the people have to be equipped with technicalskills, managerial ability and entrepreneurship to take advantage of emergingopportunities. In this context, my Government has recognized the role of professionaleducation. Supported by a facilitative policy, technical training institutes, diploma anddegree colleges in engineering, nursing and medical colleges, management collegesand a number of other professional institutions besides colleges in social and physicalsciences are coming up in the State. Today, Orissa's educational infrastructure iscapable of producing over one lakh trained and educated young people per year.

As Orissa, and the entire eastern region are poised to produce more steel, wewill all need to keep in mind that iron and steel making is extremely material and energyintensive. Steel is among the largest energy consumers in the manufacturing sector.Raw material with intensive carbon contents that forms the primary resource in steelproduction makes material impact on the climate. Both mining, which is a prerequisite toiron and steel making and the latter produce negative impact on the quality of air, waterand soils. It is, therefore, important that suitable pollution prevention and controlmeasures along with appropriate technology are adopted to ensure minimal adverseimpact on the environment and ecology. The finite natural resources need to beconserved for a sustained production. Increased use of clean and green technologywill help us to reduce the carbon emissions and address the concerns of global warming.

I am sure that the delegates at this international convention representing academia,research institutes, mining houses, iron and steel makers, technocrats and professionals,equipments suppliers and policy makers will put their minds together in deliberatingupon the new challenges and evolve a package of practices that will support a holisticdevelopment of our people.

I wish all the delegates coming from various parts of the globe and India have avery pleasant stay at Bhubaneswar. I wish the Convention all success.

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It is indeed a great pleasure for me to address this august gathering on the occasion of "International Conference on Clean,Green & Sustainable Technologies in Iron and Steel Making" organized by the Govt. of Orissa, in association with several otherreputed organizations. Orissa has always been in the forefront of Steel industry revolution in the country, since the establishment ofthe 3rd integrated steel plant in the country, in the year 1961 at Rourkela. It is the grand vision and able leadership of Hon'ble ShriBiju Patnaik that had led the first phase of Steel revolution in the country, during his several tenures as Union Minister of Steel &Mines during the 70's & 80's. Therefore, it is no surprise that, Orissa is again leading the second phase of steel revolution in thecountry, with nearly 49 steel MoUs, intending to create 76 million tone per annum capacity.

2. The State of Orissa is a treasure trove of minerals and natural resources in the country. It has plenty of water, forest &agricultural resources under its command. The State boasts of nearly 20% of the total mineral wealth of the country with vastreserves of Iron ore, Chromite, Bauxite, Manganese and Coal. All these resources along with its geographical position and availabilityof skilled manpower makes Orissa the ideal place to become a steel hub of the nation.

3. Steel is fundamental to our modern way of life and also very essential to the economic growth of the world. Keeping pace withthe growing demand, world steel production has increased rapidly. During 1950s. The world steel production was around 200 milliontones (MT). This has increased many folds since then and during 2007, the world steel production crossed 1350 MT. We havefurther noted that during the last 4-5 years, the world steel industry, led by China has witnessed spectacular growth. However, dueto global economic down turn during the last quarter of 2008, production of steel during the year reduced marginally, substantivelyduring the year 2008. However, India bypassed the trend and registered a growth of about 8 %.

4. India's growth in Steel demand has been increasing in consonance with the nation's appreciable growth of its GDP. The Steeloutput too has been registering positive growth rates. Between 2003 & 2008, India's Steel output grow by 10% annually. During theyear of global recession, India has moved up from being a fifth largest producer to 3rd largest steel producer in the world. While thenational steel policy has set a target of 110 mtpa by the year 2020. The projected capacity based on current level of increments is ashigh as 250 mtpa. By 2012, we expect to move up from current output level of 65 mtpa to 120 mtpa by the end of 2012. This increasewill come from expansion of Greenfield projects. A number of Greenfield projects too are under plan & some are at execution stage,which too will contribute to the nations steel output.

a. To have these massive expansions - we have to have policies which will help industries to grow.

- Most important to make iron ore available to the industry for value addition

- Discourage export of Iron ore

- Coal allotment to Steel industries

5. This growth in production & consumption has been sustainable.

6. Unfortunately, iron & steel making is essentially an energy intensive and also material intensive process. These processesincluding mining, sintering & coke making etc are beset with severe environmental ramifications in terms of air pollution, waterpollution, noise pollution and emission of Green House Gases like carbon dioxide (CO2), methane, sulphour oxide (SOx), andnitrogen oxide (NOx). Besides, there are associated problems for disposal of waste. The green house gas of highest relevance tothe steel industry is CO2 which is the root cause of global warming and hence the biggest challenge in containing environmentalpollution.

7. According to International Energy Agency (IEA), the aggregate amount of CO2 emitted from the global steel industry has reachedroughly two billion tons per annum. This accounts for nearly 5% of global man-made CO2 emissions. Over 90% of CO2 generation

Speech ofShri P.K.Rastogi, IAS

Secretary, Ministry of Steel, Govt. of India

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in the steel industry comes from iron production in 9 countries / regions namely, Brazil, Chiana, the EU, India, Japan, Korea, Russia,Ukraine and the US. If per capita consumption of steel in developing countries becomes comparable to other developed countries,the GHG emissions from the steel industry would be more than double the present level. Such a situation will be alarming andwarrants urgent attention and ameliorative measures on the part of both policy makers & steel manufacturers.

8. The Indian Steel industry in general suffers from technologies obsolescence as well as raw material quality constraints. These twofactors result in lower productivity, higher energy consumption and higher environmental emissions including higher carbon dioxideand solid waste generation in a significant manner. It is true that the old steel plants of SAIL and Tata Steel have been modernized andtechnologically upgraded over the years. Despite this, we are far behind the world benchmarks and hence require fresh thoughts toimprove our performance. This could be possible only through adoption of clean & green technologies that could sustain the growthand development of the steel industry in the future.

9. The august gathering would agree with me that, notwithstanding the inherent problems, we cannot wish away our steel productioncapacities. Steel has become a way of our life and we have to increase our steel production substantially to improve the quality of lifeof our fellow citizens. Our per capita C02 emission is very low at around l/4th of the world average and with improvement of qualityof life, this may increase in aggregate terms. But we must ensure that we minimize the overall energy consumption in the productionprocesses in all the sectors of economy including iron & steel. We have to gradually phase out all inefficient production units in favorof clean, green, energy efficient and environment friendly processes at the earliest. There are relevant technologies all over theworld and many plants are operating at the minimum level of energy consumption and hence with minimum CO2 emission. We haveto adopt similar technologies and strategies in all our existing steel plants - integrated or otherwise. These should include adoptionof state-of-the-art, sustainable technologies that take care of the economic and social concerns of the society as a whole. In otherwords, the steel industry must focus its attention on sustainable and inclusive growth. Hence, I want to underline the need forutilization of India's low grade iron ore and slimes.

10. Side by side we need to engage ourselves in developing alternate iron / steel making technologies by extensive R& D activitiesto suit to our iron ore and non coking coal deposits. In this regard, I must make a mention of what are called Smelting Reductiontechnologies or alternate Iron making processes like the COREX, FINEX, HI-SMELT which have distinct advantages in terms of useof non coking coal, iron ore fines and reduced Green House Gases (GHGs). What is more relevant is to develop such technologiesto suit to Indian raw materials like iron ore fines and non coking coal.

11. Yet another promising technology being considered for implementation in India by some of the entrepreneurs is the Coalgasification process and to utilize the gas thereof to produce sponge iron and recovering entire heat values of outgoing gases.

12.1 understand, the World Steel Association has already created a platform called "C02 Breakthrough Programme "for exchangeof information on long term Research & Development for such futuristic technologies. This may cover production of iron / steel usinghydrogen or biomass and identify ways & means of capturing & strong Co2 produced during iron/steel making process. These areno doubt very difficult and challenging tasks and steel industry must join hands together to address the problem.

13. The Ministry of Steel through various schemes & regulations of the Govt. is facilitating improvement in energy efficiency andreduction in environment emissions in steel plants:

“We in the Ministry of Steel encourage R & D by extending financial support from SDF & Govt.Budgetary support that will result in innovative technologies for beneficiation/agglomeration ofIndian lean ores and for developing alternate iron making technologies using Indian iron ore andnon coking coal. I call upon the industry and research laboratories to avail of these opportunitiesfor the benefit of the Indian Steel industry.”

We have other projects known as UNDP- GET Steel project to achieve energy efficiency in re-roling mills and NEDO model projectassisted by Govt. of Japan. We are signatory to Asia Pacific partnership on clean development meet on climate.

14. The Convention has been organized at an appropriate time. The theme of Clean, Green & Sustainable technologies is extremelyrelevant & timely. Evolution & adoption of these technologies will help us to strike a balance between economic necessities &environmental concerns. I am sure that the distinguished delegates will have fruitful deliberations and arrive at meaningfulrecommendations that Government at both national and state level can adopt in policy formulations and iron & steel manufacturerscan adopt suitable technologies in their manufacturing processes. Thus, the convention would become both locally relevant andinternationally relevant in terms of our commitment to Kyoto protocol

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Recommendations

The current output of steel in India is at a level of 55 mtpa and the expected achievement by 2020 is around 250 mtpa. Orissa hastaken a major lead in terms of steel capacity enhancement of the country by signing 49 Memoranda of Understanding with variousprivate and public sector companies envisaging an output of about 90 mtpa.

In order to facilitate the projected pace of industrialization, the Orissa Mining Corporation (OMC ) along with Multi DisciplinaryCommittee on Safety, Health & Environment (MDC on SHE) realized the need for various interventions that would ameliorate illeffects of industrialization in terms of Energy usage, Carbon footprints & other environmental issues. One of the ways to deal with theforeseen situation was to bring eminent Environmentalists, Academicians, Technology Suppliers, Policy makers & various promoterson one platform and discuss the concerns of the state & the country to identify pro active measures that should guide the industrializationprocess and take care of the future environmental threats related to Iron & Steel making. The Orissa government feels, understands& recognizes that global warming, emission of green house gases and unhindered use of the resources within the state and thecountry is a matter of critical concern. Orissa Mining Corporation & MDC also realized the need of having a meaningful & effectivesustainable platform to discuss these issues along with the need of continuous follow up in order to adopt a result oriented approach.

An organizing committee was constituted comprising Orissa Administration, OMC, MDC on SHE, IPICOL, SPCB, Public andPrivate sector companies to give birth to "International Convention on Clean, Green & Sustainable technologies in Iron & SteelMaking". This convention was held at Hotel Swosti Plaza in Bhubaneswar between 15th to 17th July 2009 with delegates comprisingIron & Steel Producers, Mining Companies, research institutes, universities, equipment manufacturers & policy makers from withinand outside the country. The organizers chose appropriate themes for the convention which included environment, energyconservation, mineral conservation, energy efficiency in Iron and Steel making and issues related to resettlement & rehabilitation.The success of the convention could be judged from the overwhelming response from India and overseas participation & full houseparticipation till the last minute of the convention. This was particularly quite encouraging as it demonstrated the global concernsabout environment & resource utilization and we as organizers are proud to initiate and trigger the much nobler second stage of theindustrialization process.

At the very outset of organizing this convention, the Organizers under the leadership of the Chairman (Shri Ajit Kumar Tripathy,Chief Secretary, Government of Orissa) & Co-Chairman (Dr. Ashok Dalwai, Commissioner-cum-Secretary, Steel & Mines Departmentand CMD-OMC) intended to bring out the recommendations of the convention and share the outcome of the convention with state &the centre. We sincerely hope that these recommendations would be of great help in formulating present and future policies forsustainable growth in Iron and Steel Industry and help creating a better environment for generations to come. The conventionshared International best practices on the chosen themes and enlisted critical & prioritized area of concerns. The package ofrecommendations aims to help the government in firming up policy formulation & execution guidelines for various upcoming andexisting Iron & Steel plants in India.

The package recommendations have been broadly classified into three categories mentioned below:

A. Technology Recommendations

B. CSR, R&R & PD (Peripheral Development) recommendations

C. Policy guideline recommendations

These are further broken down in terms of short and long term recommendations. The short term recommendations are basedon the technologies and practices that are readily available and can be implemented in a short period of time whereas long termrecommendations are based on the upcoming environment friendly technologies and their promotion by the state and the centre. Thelong term recommendation also focus on the size and the technology mix for sustainable Iron & Steel growth in the country. The

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recommendation also focuses on famous Pareto's principle of concentrating on 20% activities that can give 80% results. Theconvention recommendation focuses on creating awareness among different levels like:

a. Policy makers- State & Central government.

b. Facilitators- IPICOL in case of Orissa.

c. Users- Public & Private organizations promoting Iron & steel Industry.

d. Financial organizations.

A. TECHNOLOGY RECOMMENDATION:

1. The technology recommendations are based on short & long term approaches focusing on Coke making, Iron oxide reduction,Energy Consumption & CO2 emission. The focus should be to promote technologies based on the carbon footprint and energyrequirement. The benchmarks and methodology for measuring the energy consumption & carbon footprints should be followedas per IISI standards.

a. Short term:

● Generation of power using top gas pressure in blast furnaces to be made mandatory.

● Insist on hot stove waste heat recovery in Blast furnaces.

● Promote Sinter cooler waste heat recovery.

● Insist on use of Ultra high power transformers.

● Insist on use of variable speed drives.

● Insist on use of SVC.

● Iron ore and coal beneficiation.

b. Long term:

● Promoting investments based on cleaner and environment friendly technologies like Corex, Finex, Coal Gasification& Gas based DRI. A reward & penal mechanism for polluting steel Industries to be developed linked to quantifiableparameters.

● Promote CDQ & PCI maximisation.

● Promote cogeneration-Incentive schemes for producing and selling the green power to be developed by competentauthorities. There should be a supportive mechanism to enable full capacity utilization of waste heat recovery. Thesupport mechanism should include open access to sell green power to various other users.

● Promote EAF & BOF gas sensible heat recovery.

● Promote Reheating furnace waste heat recovery in rolling mills.

● The state and the centre should also encourage technology suppliers who are into waste heat recovery relatedtechnologies and equipments as a proactive measure to promote greener technology. This would allow easy andcheap access to the various iron & steel making industries that are being set up in state and the country at the doorstep.

● Promote possibility of using biomass based fuels, generating electricity based on renewable energy sources (wind,solar, etc).

2. All future investment proposals in Iron and Steel should be subject to cumulative carrying capacity - in terms of environment,water & land.

❖ Promote lease of land for a requisite period rather than ownership.

a. The convention discussed on the issue of leasing the land in preference to outright purchase and the variousrecommendations are as follows:

- The land owner can exercise the option of asking for a lump sum for the share of his land and transferring theright, title & interest to the industries or lease his share of the land at an agreed rate of annual rent. Further,

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such right can be recognized as a 'trading right' which enables him to sell it to anyone at a fair market valueeven during the life of the industry and the purchaser shall then be entitled to annual rent.

- The lease rental shall be similar to trading in the stock market and the rental shall be divided equally amongthe people in a family holding the lease certificates.

- The rental for the displaced families needs to be developed by R & R experts and the rights shall be dividedas the family divides.

b. This kind of system may ease the land acquisition problems faced by the organizations and also provide a continuousincome to the displaced families.

c. Under no circumstance can the land owner demand his land back after being leased to the company. The policyonce again needs to be properly formulated by experts.

❖ Encourage using river bed as raw water reservoir.

- The convention recommends for a study to be undertaken by a competent professional agency as the conceptsaves a lot of land used for making large reservoirs and also avoids wastage of water by reducing the no. ofhandlings.

- The other advantage is low cost involved in pumping due to reduced no. of handlings.

❖ Encourage ash backfilling in the mines.

3. Energy audit and Environmental audit by certified and competent agencies to define as is and to be. (Norms to be prescribedbased on global best practices and definite time schedule).

'To constitute an empowered committee of technocrats and policy makers (IPICOL, Orissa Admin., SPCB,MDC on SHE, Energy Department & Water Resources Department) to recommend benchmark range forspecific energy consumption & CO2 emissions.'

4. Define the critical size of the plants for different types of process route and encourage plants above the critical size/capacity.

a. To constitute an empowered committee (TERI, New Delhi RDCIS, Ranchi, NEERI, Nagpur, Steel & Mines Organizationsand Bureau of Energy Efficiency etc) to study the optimum size/technology matrix and policy adopted by differentcountries in this regard.

b. Energy audit should be conducted and reward system (like Chief Minister's trophy etc) to be started for organizationsmaximizing waste heat recovery and using minimal energy for their processes. A penal mechanism based on energyaudits should also be recommended for Organizations not adhering to basic norms of energy efficiency and perpetualdefaulters.

5. Mining:

a. Promotion of coal beneficiation & coal gasification.

b. Promotion of Iron ore beneficiation.

c. Detailed exploration of steel grade raw materials like Iron ore, Coal, Manganese, Limestone and Dolomite.

d. Selective mining to be discouraged and mine utilization plan to be worked out keeping in mind the entire life span of themine.

e. Mine closure plan as prescribed by the Indian Bureau of Mines (IBM) should be strictly adhered to and audit of miningactivity should be done on a regular basis especially prior to final mine closure.

B. CSR, R&R & PD RECOMMENDATION:

1. Focus on R&R and peripheral development policy implementation. (Organizational infrastructure for effective implementation)

2. Measure and upgrade the living standard of the PDAs by a minimum factor of 2 between pre & post rehabilitation.

a. A social audit by a responsible body to be conducted prior to and post execution of an industry/mining activity.

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b. In order to measure the changes in the living standard a scale-"Living Standard Index" (LSI) may be developed byassigning weightage to both individual oriented & common infrastructure indicators that determine an individual's livelihood.Individual oriented indicators include employment, income yielding assets, education, health etc. Common infrastructureindicators include both social (health, education, water etc) & physical infrastructure (road, electricity, grazing land etc).

3. Focus on opening of technical institutes by the promoters for producing sufficient skilled work force for a sustainable rehabilitationprocess.

C. POLICY GUIDELINE RECOMMENDATION :

1. Create an advisory body comprising of Steel & Mines Department, OMC, MDC on SHE, Coal Ministry, IDCO, IPICOL, PollutionControl Board, Representatives of public & private sector steel companies etc to formulate policy framework which will incentivizethe clean, green & sustainable technologies. This body shall facilitate identifying proper technology selection by investmentbodies with a special focus on SMEs in Iron & Steel.

The department of Steel & Mines, Government of Orissa will take the bottom line responsibility of creating & promoting such abody besides monitoring the steel sector in Orissa along the recommendations made herein.

a. Create awareness on the relevant Acts/Rules/Regulations on environmental protection and pollution control by arrangingworkshops by MDC on SHE.

b. Develop a self regulatory mechanism for fool proof pollution control. A protocol needs to be developed with SPCB.

2. Institutionalize the annual meet of academia, technology suppliers and investors by Department of Steel & Mines (January 4thweek-platform for knowledge sharing).

a. Provide a platform for the industries for experience sharing and learning from the experts about the latest state-of-the-arttechnologies & pollution control devices.

* * * *

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Convention ReportN. N. Sachitanand*

* Communication Consultant, Banglore

Consequent to India's ambitious economic growth plans for the next decade, the country's steel industry is poised for explosiveexpansion, with capacity likely to double to 120 million tones by 2020. Orissa alone, being rich in the mineral resources needed forsteel making, has project proposals for adding 90 million tones per year of steel production capacity in the next ten years , thoughhow many of these will actually come to fruition is still a matter of conjecture.

Making steel is inherently a polluting activity, because of the huge amounts of raw materials and energy involved. The industryis a large contributor to greenhouse gases, particularly Carbon dioxide. It is also land hungry and, in a densely populated countrylike India, this necessitates considerable displacement of people. With increasingly stringent anti-pollution as well as rehabilitationregulations in place and India's commitment to controlling greenhouse gas emissions, the country's steel industry has to adopt clean,green and sustainable systems of production as well as implement extensive R & R practices. The problem is much more acute in astate like Orissa, which is going to witness a sudden transition from an agrarian to an industrial economy because of the huge surgein steel making, and where most of the mineral resources are in tribal areas .

Therefore, this international convention on clean, green and sustainable technologies in iron and steel making, organized bythe Orissa Government and Multi Disciplinary Centre on Safety, Health & Environment (MDC on SHE) backed by the steel industry,is appropriate and timely.

The first day's proceedings highlighted the fact that the Indian steel industry has a long way to go to meet global emissionstandards, with Carbon dioxide output averaging 2 to 3 tonnes per ton of crude steel against global best practices of only 1.2 to 1.8tonnes. Our energy efficiency is also poor with specific energy consumption averaging 7 Giga-calories per ton of crude steelcompared to 4 to 4.5 Gal/tcs in the industrialized countries.

The basic problem with our steel industry is that a large part of it is stuck with the technology of the Sixties. Up gradation of theseplants with more energy efficient technologies like Coke Dry Quenching, Waste Heat Recovery, Thin slab casting, Coal dust injection,Hot slab charging in rolling and many others is feasible but needs considerable capex. There is also the problem of finding space toaccommodate the new systems in existing plants. However, as Tata Steel has shown in its expansion and modernization of itscongested, century old Jamshedpur plant to a highly energy-efficient and low polluting works , where there is a will there is a way.

Making mass and energy flow charts for the entire process is a good starting point to get to know the points of major weaknessand plan the most cost-effective measures to improve overall energy efficiency.

The other aspect of sustainable systems that came to the fore during the first day's deliberations was the need to conservenatural resources by utilizing materials that are at present discarded for being sub-standard. For example, SAIL'S R & D has comeup with beneficiation technology that permits recovery of a large part of the fines in its iron ore mines which has been dumped in thepast as waste.

Similarly, Tata Steel has come up with a washing technology to upgrade the low volatile matter Jhama coal in its Jhariacollieries. This coal cannot be coked but has been found useful in sinter charge , after washing it to below 17 % ash.

The importance of statutory regulation in controlling pollution from industries cannot be overemphasized. Take the case ofsponge iron plants in Orissa. There are some 244 of them, ranging in size from 25 to 500 TPD. Being coal-based, these plants couldbe a major source of pollution considering that almost 17 tons of dust is emitted from each 100 TPD rotary kiln. By mandating use ofbag filters and ESPs and setting a maximum emission norm of 100 mg/NM3 at the stack, the Orissa State Pollution Control Board hasbeen able to curb the dust menace from these plants. However, in the long run, the State Government's new steel policy, now under

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formulation, is expected to discourage the setting up of stand alone sponge iron units.

Open cast mining is usually the practice adopted in extracting iron ore from deposits. This causes tremendous physical damage to theland. But it is possible, by comprehensive mine planning and rehabilitation exercises to restore the mined land to some semblance ofnormalcy. Some of the Goan iron ore mines have achieved this and not just re-grreened the abandoned mines but also made the landsuitable for horticulture, parks, stadia etc.

The second day's panel discussion turned out to be very lively because it focused on one aspect that has been upsetting allplans of Greenfield expansion of the steel industry. And that is, land acquisition. Land is at a premium in India. It has only 2.4 % ofglolbal land area and supports 18 % of the population. Back in the Fifties and Sixties, when the population was one-third of what itit is today and there was very little understanding of land rights , it was easy for the government to acquire vast tracts of land forindustrial purposes. Today it is not the case and acquisition of every square inch of land is being bitterly contested by the originalinhabitants as well as the NGOs and political elements who support them . Moreover, the Government, because of the politicalsensitiveness of the issue, is backing away from acquiring land for industries. In fact, a legislation is under way at the Centre thatmandates that any company wanting land should acquire 70 % of it need on its own, with 30 % being acquired by the localgovernment, if necessary.

The other significant change in policy is very extensive , mandatory R & R for the displaced. This R & R may be required tobe first completed before work can begin on the land. This has become necessary to make the original inhabitant feel that they arereal beneficiaries of the industry coming up on their land. Although this was not discussed , it is inevitable that because of thedifficulties in fresh land acquisition, steel companies should maximize use of land that is already in their control. For example, TataSteel is expanding its Jamshedpur plant to 10 million tones capacity where once it was thought that it could not grow beyond 7 milliontones. Similarly, RINL is planning to double its capacity to 6 million tones and can even think of expanding to 16 million tones withoutfeeling the pinch. It has so much land.

The first session of the final day of the conference was devoted to cutting edge technologies which promise to enhanceproductivity, increase energy efficiencies, permit use of low grade and waste materials and reduce pollutant loads in the steel making.All the three new iron making technologies presented - Finex, Hismelt and Coal Gassification based Midrex - address the peculiarproblems faced by Indian steel makers , that is shortage of coking coal, abundance of high non-coking coal, paucity of land,generation of a large percentage of fines during iron ore mining etc. These new technologies do offer out-of-the-box solutions but arestill in the experimental stage. A lot of investigations have to be done still , particularly on the suitability of Indian raw materials, beforeany one of them can be taken up for commercial operations in India. For example, the suitability of being able to produce an adequatesyngas from high ash Indian non-coking coals for using in Midrex vertical shaft reducers has to be verified extensively. I recall, whenJindal Steel chose to use the Corex process for iron making at its Karnataka plant , it thought it could easily use India's vast reservesof non-coking coal. However, it soon discovered that it had to import its non-coking coal requirement from Africa , since Indian coalwas not particularly suited for the Corex process. In fact, they had to ultimately add a blast furnace in order to ramp up productionof hot metal for steel making.

On the other hand , the presentation by Siemens VAI on making the blast furnace and sinter making operations more energyefficient and with lower effluent outputs by gradually introducing more modern sub-systems seems to be the way to go for the present.Tata Steel seems to have the correct answer in that it has , through incremental and gradual improvement , reduced its Carbonddioxide emission per tone of crude steel produced from over 3 tonnes in 1996/97 to 2 tonnes in 2007/08 and is working towardsfurther reducing the figure to 1.5 tonnes by 2012.

The second half of the third day's proceedings was devoted to a very sensitive and contentious issue - R& R for the displacedfrom land acquired for steel projects. The consensus of opinion among the experts who made presentations was that R & R has to gomuch beyond mere compensation. It has to be holistic, comprehensive and enable the displaced to a better quality of life than whatthey faced in their original habitations. The importance of imparting skills training to enable them to take up occupations in the newindustrialized environment, very different from their old rural milieu, cannot be overemphasized. The sum total of the opinions wasthat inclusive growth for the displaced should be part and parcel of the project.

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Convener ReportG. D. Rath*

* Secretary,Multi Disciplinary Centre on Safety, Health & EnvironmentConvener, Organising Committee'CGST'

We all know that the production of steel involves many energy intensive processes that consume raw or recycled materials , suchas iron ore and scrap material. The steel industry is also a major consumer of electricity.

Realizing the effects of industrialization in terms of energy usage, carbon footprints and other environmental issues, the StateGovernment, Orissa Mining Corporation (OMC), Multi Disciplinary Centre on Safety, health and Environment (MDC on SHE) thoughtof creating a meaningful and effective platform to discuss and address these issues.

An organizing committee headed by the state Chief Secretary and with the active involvement of MDC on SHE, Governmentdepartments, OMC, Public and Private sector companies, regulators and academicians was constituted to define the goal, formulatestrategy to address these issues and also draw an appropriate action plan. The organizing committee in a series of meetings andinteractions decided to hold an 'International Convention on Clean, Green and Sustainable Technologies in Iron and Steel Making,on 15th, 16th & 17th July, 2009 at Bhubaneswar, Orissa.

Invitations were sent to steel producers, raw material suppliers, equipment manufacturers, research and technical institutions,professional bodies, central and state governments and regulating agencies for their participation and presentation of state-of-artpapers on contemporary relevant issues.

There was overwhelming response from within and outside the country. Major overseas technology suppliers like HATCH,Australia, Jiamgsu Zhongxian Group Company and Beijing OKLS New Technology, China, Siemens VAI, Austria, COREX/FINEX,Rio Tinto (Hismelt), Australia, MIDREX (Midrex Technology Inc), SMS Siemag, Germany, LURGI, TRANTER, Taxes, USA, and inhouse steel majors like SAIL, TATA Steel, RINL, NINL, OMC and regulators including Indian Bureau of Mines, Pollution ControlBoards presented excellent technical papers, shared their rich experience and expertise with the delegates. The themes included(i) Environment (ii) Mineral Processing (iii ) Plenary session on 'World Economy and Growth of Steel Industry' (iv) Iron Making (v)Steel Making & Syngas usage and (vi) Resettlement & Rehabilitation. As many as 25 technical papers were presented in thesesessions.

The large number of delegates were from major steel producers and equipment manufacturer of Austria, Australia, China,Japan, Korea, USA, Germany and in house steel and mines majors, refractory manufacturers, equipment manufactures, technicalinstitutions, regulatory bodies, industrial associations namely, SAIL (Rourkela Steel Plant, Bokaro Steel Plant, Bhilai Steel Plant,Durgapur Steel Plant, Environment Management Division, Raw Materials Division, R&D Centre) TATA Steel, RINL, NINL, JSPL,OMC, MCL, NMDC, JSL, Bhushan Steel & Power Ltd., VISA Steel, Monnet Power & Ispat Co Ltd., Maithan Ispat, POSCO India,Arceler Mittal, Arati Steels, Tata Sponge Iron Ltd., OMDC, Terruzzi / Vulcan, Areva T&D India, Geo Ecoflex India Ltd., IPICOL,Grewal Associates , Misra Ispat Pvt. Ltd., Nava Bharat Ventures, MECON, Prowess International Pvt. Ltd., Tafcon Projects, RohitFerro Tech. Tata Refractory Ltd., OCL India Ltd., Vanashree Minerals & Industries Pvt. Ltd., Vedanta Alumina Ltd., MN Dastur & Co,Mysore Minerals Ltd., NALCO, Hari Machines, Narvheram Power & Steel Pvt. Ltd., Dr. Sarojini Pradhan Steel & Power, 3M India,Tafcon Projects (India) Ltd., State Pollution Control Boards, Orissa, Andhra Pradesh Pollution Control Board, Vikram Pvt. Ltd.,Vanashree Minerals & Industries Pvt. Ltd., Joint Plant Committee, Ministry of Steel, Govt. of India, Essar Steels, Emergent VenturesIndia, FIMI and others.

The participation of the Ministries of Steel, Mines, Coal and Environment & Forests, Government of India demonstrated the totalsupport of the Union Government to the convention.

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Hon'ble Chief Minister, Orissa Shri Naveen Patnaik inaugurated the convention and Shri P. K. Rastogi,IAS, Secretary, Ministryof Steel, Government of India delivered Plenary address and inaugurated the Equipment Exhibition organized on the occasion on15th July, 2009. The Concluding session on 17th July, 2009 was graced by Shri Pyari Mohan Mohapatra, Hon'ble Member ofParliament as the Chief Guest and Shri Raghu Nath Mohanty, Hon'ble Minister, Steel & Mines, Industry and Parliamentary Affairs,Orissa as Guest of Honour.

The much awaited open house discussion (plenary session) on 'World Economy and Growth of Steel Industry' with theparticipation of MD, Durgapur Steel Plant, SAIL,Shri P.K.Rastogi, CMD, RINL, Visakhapathnam, Shri H.M.Nerurkar,ED (India &South East Asia), TATA Steel, Dr.S.M.Jamdar,IAS, MD, Karnataka Power Development Corporation & CEO, Indian Mines Initiatives,and Chaired by Dr.Ashok Dalwai,IAS, Secretary, Steel & Mines Department was an intensive exercise and proved to be a successfulevent. The speakers focused on international and national steel scenario in the contest of current and future trends of global economyand the participants had also the opportunity of clarifying some of the issues of contemporary relevance like R&R policy on the 2ndday.

The 2nd attraction of the 2nd day programme was sight seeing at Konark and Puri. Participants had full satisfaction of their visitto Sun Temple at Konark, afternoon Tea at sea shore and cultural evening at Puri.

In course of three days deliberations, the Convention evolved number of 'Recommendations', which were presented at theconcluding session by Dr. Ashok Dalwai,IAS, Co-chairman 'CGST' and the same were adopted.

The convention, which was first of its kind in the state turned out to be an all round success. This was largely due to able anddynamic leadership of the state chief secretary Shri Ajit Kumar Tripathy and equally supported and carried forward by the secretary,steel and mines department Dr. Ashok Dalwai. Shri B. K. Panda, MD, NINL, Shri G. S. Khuntia, Director, OMC, Shri Rajesh Jha, ED,Shri Ajay Pal Singh, GM & Shri Sanjeev Kothari,GM, JSPL provided the technical guidance including mobilization of technicalpapers & delegates. Shri B. K. Singh, Vice President, Orissa Projects, TATA Steel provided the leadership in finance managementand Shri Siddhant Das, Member Secretary & Dr. A. K. Swar, Sr. Env. Engineer, State Pollution Control Board, Orissa, Shri S. K.Mishra, Director of Factories & Boilers and Shri A. K. Pani, GM, OMC were instrumental for the excellent hospitality management.The equipment exhibition was meticulously supervised by Shri B. N. Palai, GM, IPICOL and Shri Rajesh Chintak, CRE, TATA Steel.The media management by Shri Mohit Das deserves special commendation. The first aid team of OMC Ltd. led by Dr. Kamalini Das,Sr. Medical Officer, help desk of MODDUS and registration counter management led by Shri Ramesh Kumar Behera, Asst. Directorof Factories & Boilers, Cuttack zone deserves special thanks. Of-course, there are many more who worked silently & sincerely tomake the event a success and all their names cannot be listed for want of space.

The whole hearted support of the members of the MDC on SHE, officials of the steel & mines department, OMC and membersof the organizing committee in particular made every arrangement smooth.

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List of Invitee / Guests

1. Naveen PatnaikHon'ble Chief Minister, Orissa

2. Pyari Mohan MohapatraHon'ble MP, Rajya Sabha

3. Raghunath MohantyHon'ble Minister, Steel & Mines, Industries &Parl iamentary Affairs, Orissa

4. Ajit Kumar Tripathy, IAS

Chief Secretary &Chief Development Commissioner, Orissa &President, MDC on SHE

5. P. K. Rastogi, IAS

Secretary,Ministry of Steel, Govt. of India

6. Dr. Ashok Dalwai, IAS

Commiss ioner-cum-Secretary,Steel & Mines Dept, Orissa& Chairman, OMC Ltd.

7. P. K. BishnoiCMD, RINL, Visakhapatnam

8. V. ShyamsundarManaging Director, Durgapur Steel Plant, SAIL

9. H. M. NerurkarExecutive Director (India and South East Asia),TATA Steel Ltd.

10. Dr. S. M. Jamdar, IAS

Managing Director,Karnataka Power Corporation Ltd., Bangalore

11. Dr. K. P. NyatiCEO, Indian Mining Init iative, New Delhi

12. U. N. Behera, IAS

Commiss ioner-cum-Secretary,Environment & Forest Dept., Orissa

13. Dr. C. R. Mohapatra, IFS (Rtd.)

Member Appellate Authority on Air Act, Orissa(Ex-Chairman, SPC Board, Orissa)

14. Dr. G. K. PandeyAdviser, Ministry of Environment & Forests,Govt. of India, New Delhi

15. I. Srinivasan, IAS

Principal Secretary, Excise Dept., Orissa

16. P. K. Jena, IAS

Commiss ioner-cum-Secretary,Energy Dept., Orissa

17. Suresh Chandra Mohapatra, IAS

Commiss ioner-cum-Secretary,Water Resource Dept., Orissa

18. Ashok Meena, IAS

Revenue Div is ional Commissioner,Central Division, Orissa, Cuttack

19. Aurobindo Behera, IAS

Commissioner-cum-Secretaryto Govt. of Orissa

20. Jagar Singh, IAS

Commiss ioner-cum-Secretary,Labour & Employment Dept., Orissa

21. Saurabh Garg, IAS

Commiss ioner-cum-Secretary,Industries Dept., Orissa

22. Saswata Mishra, IAS

Managing Director, OMC Ltd., Bhubaneswar

23. Dr. A. B. Ota, IAS

Director, Tribal Research Institute, Orissa

24. Sahadeva Sahoo, IAS (Rtd.)

Ex-Chief Secretary, Orissa & Member, MDC on SHE

25. M. K. Purkait, IAS (Rtd.)

Ex-Chairman, OMC Ltd.

26. C. R. PradhanChairman-cum-Managing Director,NALCO, Bhubaneswar

27. Satyajit Mohanty, IPS

Director, Training & IG of Police, Orissa Police

28. Siddhanta Das, IFS

Member Secretary, State Pollution Control Board, Orissa

29. B. K. PandaManaging Director, Neelachal Ispat Nigam Ltd.,Duburi, Jajpur, Orissa

SL. NAME OF INVITEE / GUESTS(S/SHRI)


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30. N. P. JaiswalED I/C, Jindal Stainless Ltd., Jajpur

31. B. K. SinghVice President, Orissa Projects,TATA Steel Ltd., Bhubaneswar

32. Prof. (Dr.) Omkar Nath MohantyVice Chairman,Bi ju Patnaik University of Technology (BPUT),Bhubaneswar

33. G. OjhaDirector (P & RM) SAIL, New Delhi

34. B. K. SharmaSecretary General, Federation of India Mining Initiative(FIMI), New Delhi

35. Dr. D. K. BeheraSr. Environmental Scientist,State Pollution Control Board, Orissa

36. S. K. MishraDirector of Factories & Boilers, Orissa

37. Dr. A. K. SwarSr. Env. Engineer, State Pollution Control Board, Orissa

38. G. S. KhuntiaDirector, OMC Ltd. (Ex-ED, SAIL) andVice President, MDC on SHE

39. I. Hafeezur RehmanDirector, Social Transformation Division,TERI, New Delhi

40. Sashank JainTERI, New Delhi

41. R. K. SinghHead, R & R, TATA Steel Ltd.

42. N. N. SachidanandaCommunication Consultant, Bangalore

43. S. N. PadhiEx-DGMS, Govt. of India, Bhubaneswar

44. P. D. BagriConsultant, (I, S, H & E), Bhubaneswar

45. G. UpadhyayaEx-CMD, NALCO & Ex-Director I/C (Pl.) SAIL

46. Sanjay PatnaikHead - Raw Materials,TATA Steel Ltd., Jamshedpur

47. Rajesh ChintakChief Resident Execut ive,TATA Steel Ltd., Bhubaneswar

48. Asim Kumar ChatterjeeChief-Electrical Maintenance, TATA Steel Ltd.

49. P. K. MishraConsultant, Mine, (Ex-DGM, SAIL) Bhubaneswar

50. S. K. BhuyanEx-DGM, Rourkela Steel Plant, Bhubaneswar

51. Dr. S. N. NayakJt. Secretary-cum-Treasurer, MDC on SHE

52. R. K. BeheraAsst. Director of Factories & Boilers,Orissa, Cuttack

53. Prof. (Dr.) P. K. DasDirector of Medical Education & Training, Orissa

54. G. D. RathSecretary, MDC on SHE & Convener, 'CGST'



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List of Participants

SL. NAME & DESIGNATION OF PARTICIPANT ORGANISATION(S/SHRI)

1. B. Sadual, AGM(BF) SAIL, RSP, Rourkela2. C. Tirkey, AGM(SMS) SAIL, RSP, Rourkela3. S. C. Sahoo, AGM(Env.) SAIL, RSP, Rourkela4. K. K. Singhal, ED EMD, SAIL, Kolkata5. K. M. Khare, AGM EMD, SAIL, Kolkata6. S. Gangopadhyay, DGM (Env.) SAIL, Bhilai Steel Plant7. N. P. Srivastava, Sr. Manager (Env) SAIL, Bokaro Steel Plant8. S. Mitra Mazumdar, Sr. Manager SAIL (RDCIS), Ranchi9. Viaks Dayal , Manager (Mining) SAIL (RDCIS), Ranchi10. A. Das, DGM SAIL (RDCIS), Ranchi11. Dr. S. K. Pan, AGM SAIL (RDCIS), Ranchi12. A. K. Mishra SAIL (RDCIS), Ranchi13. R. C. Behera SAIL (RDCIS), Ranchi14. S. C. Mishra, IFS, ED (F & E) Govt. of Orissa15. A. K. Pani, OAS (SAG), GM (P & A) Govt. of Orissa16. M. Ahmed, IAFS, GM (Finance) Govt. of Orissa17. J. B. Das, Company Secretary Govt. of Orissa18. P. K. Bhatacharya, Addl. G.M.(Mining) Govt. of Orissa19. J. Mishra, GM (S & M) I/C Govt. of Orissa20. N. C. Sahoo, DGM(Mining), Project Govt. of Orissa21. P. C. Mohapatra, DGM (F & E) Govt. of Orissa22. P. S. Kanungo, Sr. Manager (LW) Govt. of Orissa23. P. K. Bose, Sr. Manager (Geology) Govt. of Orissa24. Rudranil Dutta TATA Steel Ltd.25. Niraj R. Kumar TATA Steel Ltd.26. S. Mishra TATA Steel Ltd.27. S. Chatterjee TATA Steel Ltd.28. R. Agarwal TATA Steel Ltd.29. A. Agarwal TATA Steel Ltd.30. Priya Ranjan Ray TATA Steel Ltd.31. A. S. Reddy TATA Steel Ltd.32. R. K. Singh TATA Steel Ltd.33. S. Barik TATA Steel Ltd.

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34. Ajya Pal Singh, GM Jindal Steel & Power Ltd.35. R. K. Sabat, Sr. GM Jindal Steel & Power Ltd.36. N. K. Tripathy Jindal Steel & Power Ltd.37. Miss. Priyanka Upadhyaya Jindal Steel & Power Ltd.38. Deepak Das Jindal Steel & Power Ltd.39. Rajesh Jha, ED Jindal Steel & Power Ltd.40. Shakun Sirohi Jindal Steel & Power Ltd.41. Pranjala Mishra Jindal Steel & Power Ltd.42. Dharma Singh Jindal Steel & Power Ltd.43. Amit Upadhyaya Jindal Steel & Power Ltd.44. Anju Choudhury Jindal Steel & Power Ltd.45. R. P. Goyal, Director Bhushan Power & Steel Ltd., Sambalpur46. P. K. Mishra, Vice President Bhushan Power & Steel Ltd., Sambalpur47. R. K. Ghosh, AGM(Env) Bhushan Power & Steel Ltd., Sambalpur48. Dr. M. Brahman, Advisor Bhushan Power & Steel Ltd., Sambalpur49. B. S. Satyendra Rashtriya Ispat Nigam Ltd. (Visakhapatnam Steel Plant)50. Ajay Sen Rashtriya Ispat Nigam Ltd. (Visakhapatnam Steel Plant)51. A. P. Panda Rashtriya Ispat Nigam Ltd. (Visakhapatnam Steel Plant)52. A. K. Baral Rashtriya Ispat Nigam Ltd. (Visakhapatnam Steel Plant)53. P. C. Panda Rashtriya Ispat Nigam Ltd. (Visakhapatnam Steel Plant)54. Siddharth Jain, GM (Iron Ore) Rio Tinto, New Delhi55. Peter Burke Rio Tinto, Australia56. Ms. Jaspreet Gulati Rio Tinto, New Delhi57. L. K. Sarangi Rio Tinto, Bhubaneswar58. Ms. Archana Sehgal,Advisor-External Relations Rio Tinto, New Delhi59. Sanjay Pratap Arati Steels Ltd., Athagarh60. LTP Narayan, President Arati Steels Ltd., Athagarh61. P. K. Jain Arati Steels Ltd., Athagarh62. P. K. Mohanty Arati Steels Ltd., Athagarh63. Rakesh Singh Areva T & D India Ltd.64. Gour Saha Areva T & D India Ltd.65. S. Palchaadhuri Areva T & D India Ltd.66. N. K. Chelvaranga Areva T & D India Ltd.67. Nanda Kumar C. D., National Manager (Mines & Metals),Chennai68. Ms. Liang Xing Zheng Beijing OKLS New Tech. Co. Ltd., China69. Janey Liang Beijing OKLS New Tech. Co. Ltd., China70. P. Gopakumar Beijing OKLS New Tech. Co. Ltd., China71. Nitin Sawant GEA Ecoflex India Ltd, Mumbai72. Debdeep Halder GEA Ecoflex India Ltd, Mumbai73. Milan Maity GEA Ecoflex India Ltd, Mumbai74. Kartikeswar Patra, Chief Executive Officer Global Coal and Mining Ltd., Talcher75. A. K. Bandopadhyaya, CGM (Mining) Global Coal and Mining Ltd., Talcher76. B. S. Das, GM (Marketing) Global Coal and Mining Ltd., Talcher


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77. Dr. Sunil Kumar, Consultant HATCH, Australia78. Naresh Kumar Sharma (Rolling Mill), HATCH, Gurgaon79. Michiel Freislich, Director (Energy & Env., Iron & Steel) HATCH, Australia80. A. B. Panigrahi, Regional Controller of mines IBM, Goa81. S. Tiu, Regional Control of Mines IBM, Bhubaneswar82. G. C. Sethi, Asst. Controller of Mines IBM, Bhubaneswar83. Hemanta Sharma, IAS, MD IPICOL, Bhubaneswar84. R. P. Panda IPICOL, Bhubaneswar85. S. Deo IPICOL, Bhubaneswar86. S. B. Satpathi IPICOL, Bhubaneswar87. B. N. Palai, General Manager IPICOL, Bhubaneswar88. J. K. Mohanty, Adviser Grewal Associate Pvt. Ltd., Barbil89. S. K. Kanungo Hari Machines, Rajgangpur90. H. Gaurang INTUC-Orissa91. Rajeshwar Mishra, Chairman Mishra Ispat Pvt. Ltd., China/India92. Navin Mishra, President Mishra Ispat Pvt. Ltd., China/India93. Nirmal Chandra Kulshrestha, Director Gen. Mishra Ispat Pvt. Ltd., China/India94. Tanmoy Roy, Engineer Mishra Ispat Pvt. Ltd., China/India, Kolkata95. Pravin Kumar Pranav Mishra Ispat Pvt. Ltd., China/India96. Chandrasekhar, AGM (EQ) Mysore Minerals Ltd., Bangalore97. Y.M.R. Murthy Mysore Minerals Ltd., Bangalore98. Jiban Mohapatra, Chief Manager (Env) NALCO, Bhubaneswar99. B. Rout Narvheram Power & Steel Pvt. Ltd.100. A. K. Parida Nava Bharat Ventures101. A. K. Roy Nava Bharat Ventures102. S. P. Padhi, ED (P & A) Neelachal Ispat Nigam Ltd., Duburi, Jajpur103. N. G. Banerjee, ED(Works) Neelachal Ispat Nigam Ltd., Duburi, Jajpur104. P. C. Sahoo, Jt. MD Neelachal Ispat Nigam Ltd., Duburi, Jajpur105. R. K. Sethy, Sr. Manager NMDC, Hyderabad106. S. B. Koise, Sr. Manager NMDC, Hyderabad107. S. K. Behera, Manager (Mech) NMDC, Hyderabad108. P. C. Sahoo NMDC, Hyderabad109. Dr. N. Sahoo OCL India Ltd., Rajgangpur110. A. Sen OCL India Ltd., Rajgangpur111. Aditya Mahapatra OCL Iron & Steel Ltd.112. K. K. Mohanty MECON Ltd.113. R. S. Chakravarty MECON Ltd.114. B. B. Mazumdar MECON Ltd.115. P. K. Das MECON Ltd.116. K. Ranjan MECON Ltd.117. H. K. Nagwani MECON Ltd.118. J. Das MECON Ltd.119. Ataria Mitra, Sr. Manager Vinar Systems Pvt. Ltd.


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120. D. K. Trivedi Vinar Systems Pvt. Ltd.121. Andre Fulgencio Siemens VAI, Italy122. Dave Osborine Siemens VAI, Australia123. W. Grill Siemens VAI, USA124. Ian Craig Siemens VAI, Australia125. Christoph Avchinger, Vice President Siemens VAI, Australia126. Jan Addms SMS Siemag (SMS) Group (Germany), Switzerland127. Saumabha Bagchi, GM (Sales & Marketing) SMS Siemag (SMS) Group (Germany), Gurgaon, India128. Ayya SMS Siemag (SMS) Group, Germany129. Helmat Ester SMS Siemag (SMS) Group, Germany130. Satyajit Pradhan, Partner Dr. Sarojinin Pradhan Steel & Power131. B. K. Mohanty Dr. Sarojinin Pradhan Steel & Power132. Murari Sharan, GM (Business Development) Monnet Power & Ispat Co. Ltd., Bhubaneswar133. Ardesh Kumar Monnet Power & Ispat Co. Ltd., Bhubaneswar134. P. C. Pal Monnet Power & Ispat Co. Ltd., Bhubaneswar135. Amit Kumar Tripathy Monnet Power & Ispat Co. Ltd., Bhubaneswar136. Navin Mishra, President Metallon Holidings Ltd., Central Hong Kong137. M. S. Shivarama, GM (H & E) Jindal Stainless Ltd., Jajpur138. A. K. Singh Jindal Stainless Ltd., Jajpur139. Manoranjan Mohanty Jindal Stainless Ltd., Jajpur140. Kanhu Charan Barik Jindal Stainless Ltd., Jajpur141. Rajesh Kumar Singh Jindal Stainless Ltd., Jajpur142. S. Prasad Jindal Stainless Ltd., Jajpur143. I. P. Wadhwa, Dy. MD (Operations) TAFCON Projects (India) Pvt. Ltd., New Delhi144. Sailendra Kumar TAFCON Projects (India) Pvt. Ltd., New Delhi145. P. Mohanty Surendra Mining Industries Pvt. Ltd., Banai, Sundargarh146. Prabhakar Panda, Director (P &A) Hi-Tech Medical College & Hospital, Bhubaneswar147. U. Chatterjee Tata Sponge Iron Ltd., Joda, Keonjhar148. G. Pathali Tata Sponge Iron Ltd., Joda, Keonjhar149. B. R. Rao Andra Pradesh Pollution Control Board150. Gajan Chawla 3M India151. L. C. Mahapatra Arcelor Mittal, Bhubaneswar152. B. B. K Sahu Arcelor Mittal, Bhubaneswar153. D. S. Arora Arcelor Mittal, Bhubaneswar154. Rohit Bhale POSCO India ltd., Bhubaneswar155. T. C. Hota, Vice President POSCO India ltd., Bhubaneswar156. N. M. Swain POSCO India ltd., Bhubaneswar157. C. Banerjee OMDC Ltd.158. K. Mahanta OMDC Ltd.159. Prakas Kumar Prowess International Pvt. Ltd.160. P. Nayak Puran Alloy & Steel Pvt. Ltd., Bhubaneswar161. S. S. Pattanayak Rohit Ferro Tech162. A. K. Pattanayak Rohit Ferro Tech


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163. B. Mallic Kumar, GM - Sales & Marketing Terruzzi / Vulcan164. Mandar Golatgaon Kar, Engineer-Sales & Marketing Terruzzi / Vulcan165. P. Barik TRANTER, USA166. Ulf Westergreen TRANTER, USA167. Pravin Nilawar TRANTER, USA168. S. Banerjee TRANTER, USA169. A. N. Prasant TRANTER, USA170. D. Raipure MOIL (Manganese Ores India Ltd.)171. R. S. Tiple MOIL (Manganese Ores India Ltd.)172. Henry Gaines MIDREX173. Markus Leu MIDREX174. Dibyendu Parul TATA Refractories, Belpahar175. Dr. Arup Kumar Samanta TATA Refractories, Belpahar176. D. Behera, GM TATA Refractories, Belpahar177. S. K. Mishra Vikaram Pvt. Ltd.178. A. Dash VISA Steels Ltd., Jajpur179. Y. S. Thakur Vanashree Minerals & Industries Pvt. Ltd.180. Jayram Mishra Vedanta Aluminium Ltd.181. S. Banerjee Joint Plant Committee, Ministry of Steel, Govt. of India, Kolkata182. K. K. Das Joint Plant Committee, Ministry of Steel, Govt. of India, Kolkata183. P. K. Pal Joint Plant Committee, Ministry of Steel, Govt. of India, Kolkata184. D. P. Panda (BPNSI) Joint Plant Committee, Ministry of Steel, Govt. of India, Puri185. Adrian Reeve LURGI, CTL186. Amitav Banerjee LURGI, CTL187. Dr. Horst Kolta LURGI, CTL188. Samaresh Chakraborty M. N. Dastur & Co., Kolkata189. Bikash Chandra Roy M. N. Dastur & Co., Kolkata190. Ms. Madhumita Mukherjee M. N. Dastur & Co., Kolkata191. C. Jayadev Mahanadi Coal Fields Ltd., Burla192. J. Biswal Mahanadi Coal Fields Ltd., Burla193. A. K. Sethy Maithan Ispat Ltd.194. Xabier Etxeberria Saralee Equipment India Pvt. Ltd., South Africa195. J. P. Panda Essar Steels, Bhubaneswar196. Ajit Gautam Emergent Ventures India197. N. Subramanyam Govt. of Andhra Pradesh, Hyderabad198. A. Sriniwas Rao Govt. of Andhra Pradesh, Hyderabad199. R. K. Day Kirloskar Brothers200. S. Kulkarni Kirloskar Brothers201. K. L. Khadoi Kalinga Nagar Industrial Association, Jajpur202. S. N. Mishra Kalinga Nagar Industrial Association, Jajpur203. Ashok Pattnayak Kalinga Nagar Industrial Association, Jajpur204. S. S. Pattnayak Kalinga Nagar Industrial Association, Jajpur


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Media Clippings of the Convention

13, 14 & 15 July, 2009

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16 July, 2009

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17 July, 2009

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18 July, 2009

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Content

Abstracts A1-A23

List of Exhibitors

Technical Papers | Part-ITowards Sustainable Iron and Steelmaking – the Greenhouse Gas Carbon Abatement Process (G-CAP)Michiel Freislich, Sunil Kumar, Steve Gale and Peter Duncan ................................................................................................... 1

Energy Efficiency in Steel Making and Clean Development MechanismK. K. Singhal, K. M. Khare ............................................................................................................................................................ 16

Regulatory Mechanism Adopted to Control Pollution in DRI Steel Plants of Orissafor Protection of EnvironmentAkhila Kumar Swar, Siddhanta Das ............................................................................................................................................... 25

Reclamation, Rehabilitation Practices in Goan Iron Ore MinesA.B.Panigrahi, Dr. A.N.Murthy ...................................................................................................................................................... 37

Utilization of lean grade material like Jhama to enhance mine life at Jharia Division of TATA STEELMayank Shekhar, C H Divakera, Dr T Venugoalan, Parveen K Dhall, Priya Ranjan Roy .................................................. 45

Iron Ore Recovery from Waste Dump Fines in SAIL MinesV Dayal, S K Pan, S K Mukherjee, M P Srivastava, S K Sinha ............................................................................................ 50

Utilisation of Low Grade Iron Ore in Steel making with State of ArtBeneficiation & Transport - A Case Study for Meeting Challenges in Orissa StateSri G.S. Khuntia ............................................................................................................................................................................... 57

COREX® / FINEX® - Prepared for present and future iron making challengesK. Wieder, C. Böhm, U. Schmidt, W. Grill .................................................................................................................................. 66

Hismelt Plant Ramp-upNeil Goodman, Rod Dry .................................................................................................................................................................. 73

Charge Intelligent Sinter into your Blast FurnaceAchieve Real Cost Efficiency with Siemens VAI Sinter TechnologiesStefan Hötzinger, Johann Reidetschläger, Hans Stiasny,Edmund Fehringer, Christoph Aichinger, André Fulgencio ......................................................................................................... 78

Blast Furnace Modernization and New technologiesIan Craig ............................................................................................................................................................................................ 85

Coal Gasification & Syngas based DRIRajesh Jha ......................................................................................................................................................................................... 99

Plate Heat Exchangers for a greener tomorrow ................................................................................................................... 108

New technologies for BOF primary gas cleaningJan Adams ........................................................................................................................................................................................ 117

Energy Conservation & Environmental Protection TechnologyNavin Mishra, Yuanchang Sheng ................................................................................................................................................. 122

Energy efficient and eco-friendly iron making operations at Tata SteelA.Srinivasa Reddy, Goutam Raut, S.A. Khan, G.S.R. Murthy, S.K. Roy & Ashok Kumar ............................................ 129

Carbon Trading in Iron & Steel sectorShashank Jain ................................................................................................................................................................................. 136

Coal-Based DRI Solution for Indian IronmakingHenry Gaines, PE ......................................................................................................................................................................... 145

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An Overview of Development Projects, Displacement and Rehabilitation in OrissaProf.A.B.Ota .................................................................................................................................................................................... 150

Energy recovery technology for EAFsImproving over-all energy efficiency of the EAF process by generation and usage of steamHelmuth Ester ................................................................................................................................................................................. 154

Process improvement and emission reduction through ‘minimal footprint’ approach towardsenvironmentally sustainable steel makingS.Mitra Mazumder, S.Bhattacharya, S.K.Sinha ........................................................................................................................ 162

Reduction Gas from Coal : The Economic & Pro- Environmental Solution forIron making in Mini-Integrated Steel Plant Concept in IndiaDr. Horst Kalfa, Mr. Amitava Banerjee, Mr.Adrian Reeva ....................................................................................................... 172

Administrative Perspectives on Displacement, Resettlement, Rehabilitation ........................................................... 196

Broad issues related to CSR and R & RIbrahim Hafeezur Rehman ............................................................................................................................................................. 201

Technical Papers | Part-IITechnology for utilization Iron ore fines of Noamundi depositSunil Kumar Tripathy, C.Raghu Kumar, and T.Venugopalan ........................................................................................................ 1

Measures taken by A.P. Pollution Control Board in ControllingAir Pollution from Sponge Iron IndustriesB. Raghavendra Rao .......................................................................................................................................................................... 8

Advanced Power Generation Technology in Steel IndustryNeelachal Ispat Nigam Limited – A Case StudySri N G Banarjee, Sri A.Lahiri, Sri Kalyan Mohanty ................................................................................................................. 15

Eco-Friendly Refractories for Iron & Steel IndustriesAnupal Sen, B Prasad, Dr N Sahoo & JN Tiwari ....................................................................................................................... 22

Heat Recovery Cokemaking - Environmental friendly Technology by choiceB.Biswas, Anil Kumar, Sanjoy Paul, Prosenjit Sarkar & Ashok Kumar ................................................................................. 25

An Overview of Eco-Friendly Technology in Iron & Steel IndustriesS.K. Naskar, Kumud Ranjan, P.K. Paul, K.K. Mehrotra ........................................................................................................... 29

SVC for Industrial application- Improving the Power Quality and Productivity in Metal IndustryRakesh Singh .................................................................................................................................................................................... 36

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Organising Committee i-iii

Multi Disciplinary Centre on Safety, Health & Environment - A Birds Eye View iv-v i


Abstracts

A-1


Towards Sustainable Iron and Steelmaking – the Greenhouse Gas CarbonAbatement Process (G-CAP)

Michiel Freislich1, Sunil Kumar2, Steve Gale1 and Peter Duncan1

ABSTRACT

The iron and steel industry uses enormous quantities of resources including iron ore, coal, water, energy in the form ofelectrical power and fuels, as well as chemical additives such as fluxes, alloys etc. Efforts are being made by the steel companies toreduce the resource consumptions, minimize emissions and thus, make their operations eco-friendly and sustainable. Amongst thenumerous options being considered by the steel industry, a major thrust area is the reduction of CO2 gas or Green-House Gas (GHG)emissions, since this has a strong bearing on climate change and sustainability.

Legislators around the world are also responding to climate change by limiting the energy consumption and placing a price onthe CO2 emissions. The financial consequences of this vary depending upon the energy intensity and ability of the industrial sectorto “pass on” any increased production costs to their customers. The iron and steel sector is particularly vulnerable due to the close-coupling of production to energy consumption (and the CO2 emissions) and significant global trade in the commodity from regionswithout CO2 pricing.

Legislators recognise this and are providing temporary concessions to the steel industry and the other so-called EnergyIntense Trade Exposed Industries (EITEI). Top-down economic modelling has been adopted as a primary tool to assess andestablish the expected economic impacts of enacting energy reduction legislation or pricing CO2. This methodology is appropriate forsectors such as electrical power, where international trade is limited, the supply chain is simple and production processes are largelystandard. On the other hand, in the case of EITEI sectors, this economic modelling methodology does not do proper justice in termsof adequately defining the impacts of CO2 pricing.

To overcome this impasse, Hatch designed a novel Greenhouse Gas Carbon Abatement Process (G-CAP) that incorporates asound technical element to the modelling. In contrast to the previous models, the methodology is bottom-up, and is applied in muchmore detail to the specific operations of the iron and steel industry. The core of the G-CAP methodology relies heavily on the skilledtechnical specialists to benchmark the different operational units (for example, Coke Ovens, Sinter Plant, and Blast Furnace etc.)within a steel business. The gaps between the current operations, best-in-class practice and the theoretical limits, are carefullyassessed, and the Abatement Activities (AA) that can bridge the gaps are then established on the basis of the identified gaps. Theactivities can range from behavioural changes right through to operational improvements as well as strategic changes, and capitalprojects.

The next stage involves application of risk-filtering to eliminate those activities that are unacceptable on legislative, occupationalhealth and safety (OH&S) as well as technical grounds. The acceptable activities are modelled into different scenarios to identifywhere the activities might compete (for example, two activities might be competing with each other for same limited indigenous gassupply). The resulting AA list is then processed to develop order of magnitude operating and capital costs as well as the likely CO

2

abatement. Finally, the NPV of each AA is determined and reported in dollars per tonne of CO2 abated.

By ranking the activities from the highest return (most significant negative dollar cost) to the most costly, a Marginal AbatementCost Curve (MACC) is formulated. The MACC is essentially a summary picture of how much abatement is economically achievablefor any particular energy saving (or CO2 price). With the help of the MACC, it is possible to identify the “transfer point”; the point atwhich it becomes cheaper to purchase the abatement permits rather than implement the abatement activities. In addition to the

HATCH1. 25 Atchison Street, Wollongong, New South Wales 2500 Australia2. Sheridan Science & Technology Park, 2800 Speakman Drive, Mississauga, Ontario, Canada L5K 2R7

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assessment of the cost impacts, each AA is also programmed into a “project” schedule that identifies how long it would take toimplement the activity. The schedule is then employed to create a “target pathway”, over a time period, for emissions reduction thatis based on real projects within the business.

Policy makers want to ensure that industry continues to support the national economies whilst reducing emissions in a sustainablemanner. Doing this requires that the policies do not erode the competitive advantage of the industry in a region or within a nation.Industries that can demonstrate visible progress towards global best practices would be highly influential. The Hatch G-CAP offersthe EITEI’s a robust techno-economical platform that helps demonstrate that.

The G-CAP has been successfully applied to generate the Marginal Abatement Cost Curves (MACC) at three steel plantsnamely, New Zealand Steel, BlueScope Steel and OneSteel. Currently, the G-CAP is being employed to develop the MACC for theAustralian Steel Sector, as a whole.

The paper describes the novel Hatch G-CAP that has been developed with the main objective of quantifying and qualifying thepotential energy savings and CO2 abatement within the iron and steel industry.

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Energy Efficiency in Steel Making and Clean Development MechanismK. K. Singhal1, K. M. Khare2

ABSTRACT

Iron and steel industry is the largest energy consuming manufacturing industry. In the last 30 years crude steel production inIndia has increased more than 5 times. Enhancement of production in such an industry is always a social imperative and also anenvironmental concern because of its high energy and pollution potential. Consumption of energy, the main performance indicator ofan industry like steel, is directly linked with GHG emissions and inter-alia its economic performance. Considering these, the Iron andSteel Industry has taken actions to implement modern and energy efficient technologies during their expansion and modernizationprograms. However the specific energy consumption in Integrated Iron and Steel plants in India is still higher than the world’saverage. Demand for steel in India is fast increasing to meet the domestic and global demand. At this juncture, improvement in theenergy efficiency is the only option to counteract the associated maladies.

This paper outlines the energy efficient technologies available for integrated iron and steel making vis-à-vis, policy frameworkof Government of India for energy conservation with particular emphasis on the mechanism for carbon trading under Kyoto Protocolfor developing countries like India

Key Words: Specific Energy Consumption (SEC), Green House Gases (GHG), Clean Development Mechanism (CDM),National Mission for Enhanced Energy Efficiency (NMEEE), Emission Trading (ET), Certified Emission Reduction (CER)

1 . Executive Director, Environment Management Division, SAIL2 . AGM, Environment Management Division, SAIL

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Regulatory Mechanism Adopted to Control Pollution in DRI Steel Plants of Orissafor Protection of Environment

Akhila Kumar Swar1, Siddhanta Das2

ABSTRACT

In the wake of rapid industrialization and development there is rapid depletion of natural resources with consequent generationof waste and pollutants all over the world. This has serious consequences on the human health and the environment. Thetremendous demand for steel and shortage of steel scrap in the world market boost the efforts to develop alternative steel makingprocess than the conventional Blast Furnace (BF) – Basic Oxygen Furnace (BOF) route giving birth to Directly Reduced Iron (DRI/Sponge iron) process during eighties. DRI has been proved to be the prime feed stock to replace scrap in Electric Arc furnace /induction furnaces and even in blast furnaces for manufacturing of steel. Due to boom in steel market, during the last 8 years therehas been rapid growth of coal based sponge iron plants and integrated steel plants (DRI route) in iron and coal rich states like Orissa, Jharkhand, Chhatisgarh, West Bengal and Andhra Pradesh of India. A large number of iron ore crushers, ingot plants, Ferro alloyplants and coal washeries have been established and mining activities have been intensified. The sudden boom in the industrialscenario has increased environmental burden and it is required to combat pollution problems in proper manner. This paper dealswith the various pollution problems encountered, control measures and enforcement mechanism adopted in DRI Steel/ Sponge ironplants of Orissa for protection of environment.

Key words:DRI, Sponge iron, steel, pollution, standards, Particulate Matter, pollution control measures, enforcement, economicinstruments and clean technology.

1 . Senior Environmental Engineer2 . Member Secretary, State Pollution Control Board, Orissa, India

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Utilization of lean grade material like Jhama to enhance mine life at Jharia Divisionof TATA STEEL

Mayank Shekhar, C H Divakera, Dr T Venugoalan, Parveen K Dhall, Priya Ranjan Roy

ABSTRACT

Raw materials constitute about 75% of the total cost of hot metal1 and 53% of steel making costs for Tata Steel. Thesepercentages are significantly higher for steel companies who do not have captive sources of key raw materials. Captive rawmaterials, therefore, provide significant cost advantage to steel makers at the hot metal and saleable steel stage. Coal and iron oreaccount for 37% of the total steel making cost2 in Tata Steel. Tata Steel has its own iron ore mines (in Noamundi and Joda) andcollieries (at West Bokaro and Jharia). 100% of our iron ore and 60-70% of our coking coal requirements for iron making aresourced from captive mines3. Landed costs of Iron ore and Coal from captive sources are 25% of current market prices. The balance30-40% of coking coal is procured. Apart from these mineable reserves, there is a substantial deposit of inferior minerals, such as‘Jhama’ in Jharia Collieries The high cost of converting these naturally found minerals into suitable inputs to the iron making process,currently make them unsuitable for use.. Furthermore, raw material prices are increasing rapidly. These inferior minerals arebecoming relevant for the steel industry even though they can be used in iron making processes by incurring additional beneficiationand processing costs..

Key Words. Jhama, natural Coke, Washability, Sinter making, Washery

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Iron Ore Recovery from Waste Dump Fines in SAIL Mines* V Dayal, S K Pan, S K Mukherjee, M P Srivastava, S K Sinha

ABSTRACT

Stringent demand on quality of iron ore by integrated steel plants coupled with limited beneficiation facilities available at mineshas forced the Fe cut-off in run-of-mine ore to be raised to as high as 58% in our country. This has resulted in generation of moreover-burden than ore in our mines and has led to huge accumulation of dumped rejects over the years. The accumulated stockpilesof so-called waste dumps are consuming lot of space and creating pollution hazard. In SAIL, Gua iron ore mines has about 40 milliontonnes of such ore and Dalli mines about 12 million tonnes.

These so called waste-dumps are no wastes but contain high amount of valuable iron. Compared to our 58% cut-off, the ironore rejects in advanced countries employing efficient beneficiation techniques contain hardly 35-40% Fe. It is therefore imperativeto find ways and means to recover valuable iron from these dumps and thereby conserve our this very natural resource and reducethe pollution hazard.

With above in view, beneficiation amenability studies were conducted on Dalli and Gua iron ore dump fines in the MineralEngineering laboratories of RDCIS, SAIL. Physical, chemical and mineralogical attributes of these ore were analyzed and based onthat the beneficiation circuit comprising spiral classifier, mineral jig, hydro cyclone and Wet High Intensity Magnetic Separator wasemployed to develop the beneficiation process flow sheets for both these mines.

Ore fines of Dalli mines assaying 53.64% Fe, 7.27% SiO2 and 4.94% Al2O3 could be upgraded to 61.82% Fe 3.87% SiO2 and2.72% Al2O3 with 78% yield which corresponds to salvaging almost 9 million tones of the accumulated dump fines. Dumped ore finesof Gua mines assaying 59.75% Fe, 2.65% SiO2 and 4.08% Al2O3 could be upgraded to 63.53% Fe 2.05% SiO2 and 1.90% Al2O3

with 62% yield which corresponds to utilization of almost 25 million tones of accumulated dump fines.

* RESEARCH AND DEVELOPMENT CENTER FOR IRON AND STEEL, STEEL AUTHORITY OF INDIA LIMITED, RANCHI

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COREX® / FINEX® - Prepared for present and future iron making challengesK. Wieder1, C. Böhm2, U. Schmidt3, W. Grill4

ABSTRACT

Steel work operators face a plenty of challenges in a dynamic market, where even short and mid term fluctuations show theirimpact in a dramatic way. Hence unfortunately, long term considerations seem to be neglected, although especially in the raw materialsector radical changes are inevitable. Resource depletion is not leading to a price increase only; non renewable raw materials alongwith a rising demand create a supply bottleneck. This is expected for coking coal, as well as for natural gas, where the industry isforced to give off more of its shares for public demands like power generation, fertilizer production and/or heating purposes.

On the other hand, environmental care, which is by far not only the reduction of greenhouse gas emissions, becomes animportant economical driving factor as well. More enforced environmental restrictions by law causes operators to revise theirproduction routes to sort out processes which are not complying with these regulations.

Answers to these scenarios give the established COREX technology and the new COREX “Low Coal” and the COREX/FINEX“(L)ow (R)educed (I)ron” concepts.

Both concepts lead to fuel savings for hot metal production, either by direct savings in the COREX process or indirectly bysupporting the traditional blast furnace route.

By fulfilling the criteria, utilization of low cost / high available raw materials, overall fuel savings even for the blast furnace andthe impressive ecological advantages, once again the COREX/FINEX technology approves itself as a recommendable alternative tothe blast furnace and/or a reasonable expansion/substitution of existing production routes.

Focus of this presentation is laid on latest operation results of the operating plants in China, South Africa, India and Korea, newtechnological developments like the “Low Coal” and “LRI” concepts and a Life Cycle Assessment of the COREX/FINEX processes.

1 . Head of the Technology Department Smelting and Direct Reduction2 . Head of the Sales Department Smelting and Direct Reduction3 . Life Cycle Assessment Special ist4 . Product Manager Smelting Reduction

SIEMENS VAI Metals Technologies GmbH & Co., Turmstrasse 44, Linz/Austria

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HISMELT PLANT RAMP-UPNeil Goodman1, Rod Dry2

ABSTRACT

The HIsmelt® process represents one of the main hopes for a future practical alternative to the blast furnace. It is based ondirect injection of iron ore and coal into a metal/slag bath, with smelting in the lower region and post-combustion (using oxygen-enriched hot blast) in the upper region. At the heart of the process is splash-driven heat transfer between the upper (high oxygenpotential) combustion zone and the lower (low oxygen potential) smelting zone.

The first commercial 0.8 Mt/a HIsmelt® plant is in Kwinana, Western Australia. It was hot-commissioned between April andOctober 2005, and has come a long way since then. The core smelting process has been demonstrated at a production rate of 75-80% of name-plate capacity, with coal rates (as-injected basis) of around 800 kg/thm. The hot ore injection system can be furtheroptimised, and in 2010 (if market conditions improve) a revised configuration will be implemented which, together with coupling of theiron ore preheater to offgas from the smelter, is expected to bring production rates close to 100% of name-plate capacity (with coalrates around 700 kg/thm).

Plant availability has fallen short of expectations for a variety of reasons. Frequent starts and stops from low availability haveresulted in low refractory campaign life. To assist in extending refractory life, a set of water-cooled copper slag-line coolers wasinstalled in 2008. These coolers dramatically increased campaign life and contributed substantially to improving overall plantperformance.

Worldwide potential for the HIsmelt process is enormous. Several customers have already acquired user licenses, and arelooking to build as soon as performance in Kwinana achieves certain benchmarks. The smelter is the key, and many of theavailability-limiting issues in other areas of the Kwinana plant are considered irrelevant (by potential customers) because they canbe designed out.

In Kwinana there is hard work ahead. Strategies are in place to address performance-limiting issues, but delivery is still awork-in-progress. HIsmelt very much appreciates the level of support and understanding it receives from the steel industry, and isstrongly committed to delivering the desired result.

1 . General Manager, Operations and Technology2 . Manager, Technology Development

Hismelt Corporation Pty. Limited

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Charge Intelligent Sinter into your Blast FurnaceAchieve Real Cost Efficiency with Siemens VAI Sinter Technologies

Stefan Hötzinger1, Johann Reidetschläger2, Hans Stiasny3,Edmund Fehringer4, Christoph Aichinger5, André Fulgencio6

ABSTRACT

The objective of this paper is to present the latest developments of Siemens VAI Sinter Technologies especially concerning thecost savings potential that can be achieved in existing sinter plants and eventually in the Blast Furnace.

The Siemens VAI Sinter Technologies consists of innovative solutions and design packages which enhance sinter quality andproductivity thus generating ideal blast furnace burden for optimized production.

An advantage of using sinter is that the blast furnace burden can be optimized by adjusting the quality and the ratio of thecharged sinter in accordance with the composition and characteristics, while pellets and lump ore are normally marketed with specificchemical compositions and qualities.

Key Words:

Agglomeration, sinter plant, cost savings, modernization, upgrade, blast furnace burden, sinter efficiency

1 . Head of Technology - Agglomeration Technology2 . Senior Expert – Agglomeration Technology3 . Senior Expert - Agglomeration Technology4 . Senior Expert – Agglomeration Technology5 . Vice President - Agglomeration Technology6 . Marketing Manager - Agglomeration Technology


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Blast Furnace Modernization and New technologiesIan Craig1

ABSTRACT

Siemens VAI are the most comprehensive technology providers for Blast Furnaces, and associated systems. To date SiemensVAI have built over 190 new Blast Furnaces all over the world including India’s newest and largest Blast Furnace. Additionally theseblast furnace experts have carried out 38 rebuilds and provided over 123 Blast Furnace Electrical and Automations systems sincethe 1980’s.

Siemens VAI are introducing new technologies into the market place including the SIMETALCIS Gimbal Top®, cyclone gascleaning, triple external venturi gas scrubber, and a new range of equipment including a mechatronic all hydraulic taphole openerand furnace probes for gas analysis and burden profiling. These new technologies will compliment the tried and tested solutions forblowers, internal and external hot blast stoves, total condensation slag granulation, coal injection and other blast furnace equipment.

Key Words:

Blast Furnace, Gimbal Top, modernizations, upgrade, Gas Cleaning Plant, cost-efficient packages

1 . Head of Technology Blast Furnace TechnologiesSIEMENS VAI Metals Technologies GmbH & Co.

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Process improvement and emission reduction through ‘minimal footprint’approach towards environmentally sustainable steel making

S.Mitra Mazumder1, S.Bhattacharya2, S.K.Sinha3

ABSTRACT

The steel industry provides a classic example of ambiguity and challenge in defining a polluting industry. Over the years it hasbeen termed from most eco-friendly industry to one of the biggest polluting industry. The ambiguity originates from the continualprogression of stringency in defining the relationship between industry and environment. In the late 19th and early 20th century,many integrated steel plants in developed countries provided neighbouring communities with coke oven gas for lighting and heating.By-product coke ovens were also a major source of petrochemicals during this era before modern petroleum refining becameprevalent. Whereas these activities were termed eco-friendly at that point of time today non-recovery ovens are considered mosteco-friendly and in many places older Coke Ovens are being phased out. The Steel industry has to continually meet this dynamicchallenge of meeting the ‘green’ dimension of the day for survival and growth.

Current environmental issues have many facets- from local issues such as air and water pollution, to wider ones such as wasterecycling to global ones such as warming. Therefore the challenge for steel industry is also multi dimensional- it is not only requiredto produce a material that is environmentally benign, but also to produce it through a process that is ecologically sustainable. This isa significant challenge because steel industry handles more raw materials per ton of finished product than any other large-scaleindustry. Only a multidimensional approach can help face this challenge of sustainability. Technology remains at the core of thisapproach since it has a direct linkage with all the components of sustainability, be it process improvements, energy conservation orwaste utilization. The key to achieving this is control over material and energy. Stricter process control and technology upgradationcan also significantly reduce emission level and increase material utilisation efficiency. Since End-of-pipe control and treatment is anactivity which is carried out on a cost minus basis and do not add value to the process, effort need to be made on the part of allstakeholders to reduce the need for the same. The paper discusses this process oriented ‘minimal footprint’ approach. The paperalso elucidates the ‘green’ methodology of water treatment , i.e, reduction in chemical consumption through state-of-the-art monitoringand control through a case study.

1 . Senior Manager, Environment Lab group2 . Deputy General Manager & I/C, Environment Lab Group3 . General Manager (Iron )

Research & Development Centre for Iron & Steel, Steel Authority of India Limited, Ranchi, Jharkhand

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Technology for utilization Iron ore fines of Noamundi depositSunil Kumar Tripathy1, C.Raghu Kumar2, and T.Venugopalan3

ABSTRACT

Due to the depleting of high-grade ore at the mines and increasing loss of mineral values during processing, along with the lackof space to store these rejects it has become an essential to develop efficient and cost-effective methods to recover iron values fromthe ore fines. Conversely, it is not easy to process the slime ores mainly because of the micronized size range typically present in afinely disseminated form. Further, the iron minerals are associated with the clayee minerals, kaolinite and coupled with poor liberation.Hence, the present work assumes importance of sufficient characterization of the ore fines essential for process/equipment selectionto recover the iron values suitable for blast furnace operations. The separation of very fine ferruginous clayee material (less than 45micron size) from the iron ore fines becomes more efficient with the use of Floatex Density Separator. Also further segregation of ironminerals of underflow fraction can be achieved with simple gravitational techniques. This results the number of unit operationsemployed in the circuit would be condensed and hence treating this ore fines becomes more easy and simpler.

Key words: Slime, iron ore fines, Floatex Density Separator

1,2 R&D Tata Steel, Jamshedpur.3. Technology Group Tata Steel, Jamshedpur

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Energy Conservation & Environmental Protection TechnologyNavin Mishra (president), Yuanchang Sheng (Chairman)

ABSTRACT

Iron & steel industry can be termed as the cradle of manufacturing industry needless to say that the finished product has equallyimportant and wide applications, The good done to society since its discovery is endless but it is not late to realize that the side affectslike pollution and energy burden is undesirable and should be the priority to get rid off.

An attempt is being made to focus as to how to minimize pollution and conserve energy. In this paper we have also includedprocess along with success stories.

1. Air & gas double pre-heating of air heating furnace system:

This facility can raise the temperature of gas to 300! through the heat exchanger. The temperature of the hot blast (gas)entering the hot blast stove can be raised by 180-200!.Thus conserving energy to a great extent. This technology can reduce thecoke consumption rate, enhance the coal injected, also the output of product can be improved hence we see that energy andresource can be conserved which in turn minimizes emission and solid wastes.

2. Coal Moisture Control systems:

This technology can remove a certain amount of water from the coal, enhance the product efficiency of Coke-Oven by 7-8%,and reduce the consumption of gas by one third.

3. Power generation by waste heat from sintering system

We design this system combined with the power generation from the waste heat of sintering system/plant in steel industry whichis an advanced technology in the world.

This system is highly energy efficient, does not produce extra waste gas, waste solid, dust and other poisonous gases. It makesthe best use of low temperature waste gas and it’s possible to take control/measures not to pollute the environment the need of theday.

4. Coking desulphurization technology

This technology applies to the process and installation of gas desulphurization by liquid phase catalytic oxidization method. Itcan simplify the process, facilitate the process, reduce the occupation of the facility, economize the investment and cost, reducesecondary pollution and increase efficiency.

Jiangsu Zhongxian Group Co.,Ltd . and Mishra Ispat Private Ltd is reputed with successful t rack record in the area of saving energy &environmental protection as a joint effort specialized in the management of energy-saving and emission reduction.

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Getting clean & green in Iron and steel making- The Tata Steel way…..Vinay V. Mahashabde, Abhijit A. Nanoti, Niraj Ranjan Kumar (Tata Steel Ltd.)

ABSTRACT

India is a developing country with GDP slated to grow at 7-8% post recession. The country is expected to see phenomenalgrowth in the core sectors such as power, transportation, steel and cement. At the same time the entire globe is grappling with greenhouse gas emission and global warming threat. The growth in industrial sector would necessarily lead to increase in the green housegas emission and subsequent global warming. Steel being an industry after power and transportation with a high potential togenerate green house gases, it is imperative for all the steel manufacture to go green in their efforts.

Tata Steel, the Asia first steel plant has always been in the forefront in its efforts to address the concerns of society andcommunity where-in it operates. This paper highlights Tata Steels efforts in improving its steel making operations to reduce the impacton the environment. The study dwells more on where the Tata Steel was in the past, today’s scenario for the company and where theorganization would like to be in 2013 post 10mtpa expansion at its Jamshedpur in view of its cleaner and greener operations. It wouldalso capture the steps the company has taken and would take in its newer projects in achieving its vision of reducing CO2 emission.

Keywords: Iron and steel industry, Green manufacturing, Global warming, Tata Steel.

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An Overview of Eco-Friendly Technology in Iron & Steel IndustriesShri P.K. Paul1, Shri K. Ranjan2, Shri S.K. Naskar3

ABSTRACT

The importance of iron and steel industries in economic development is well-recognized world wide. Iron and steel industriesconsume about 4 % of the world’s total energy. Carbon dioxide (CO2) emission in iron and steel industries mainly comes fromreduction of iron bearing materials by coke (obtained from carburization of metallurgical coal) used as a reducing agent and theenergy source for the blast furnace and decarburization in steelmaking operation. The direct emission of CO2 from steel plant is aboutone tonne per tonne of steel and about 1.5 tonne per tonne of steel taking into account indirect sources like power generation, etc.

Adequate care is to be taken during technology selection for the plant and equipment to bring down energy consumption as wellas CO2 emission. Some of the eco-friendly technologies in iron and steel industries are elaborated in the paper like Coke dryquenching facility in coke oven complex, Heat extraction system from sinter cooler, TRT of BF,etc.

1. DGM I/c (Met. Wing), MECON, Ranchi2. Sr. Manager (Met. Wing), MECON, Ranchi3. Design Engineer (Met. Wing), MECON, Ranchi

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2nd Generation of dry-type ESP and Hydro Hybrid Filter technologyJan Adams1, Thilo Wübbels1, Helmuth Ester2, Klaus Schmale2

ABSTRACT

The compliance with environmental regulations and energy recovery in steelmaking plants have become a major issue withinthe last few years. Thus, clean, green and sustainable technologies for the steel industry have become a major focus.

In BOF plants utilizing converter gas recovery, nowadays gas cleaning is only possible by wet scrubber or round dry-typeelectrostatic precipitators (ESP). As environmental regulations will become more restrictive and wet scrubbers may no longer fulfillthese requirements, dry-type ESP are a suitable alternative.

However, the current generation of ESP for BOF primary off-gas dedusting processes do not comply with the latest availablestate-of-the-art ESP technology. Due to this fact, the two companies SMS Siemag and Elex have founded a joint venture, the newcompany SMS ELEX AG, with the intention to develop a new generation of gas cleaning equipment for converter off-gas from BOFmeltshops.

Consequently, SMS ELEX has designed a 2nd generation of round dry-type ESP, incorporating the latest electric filter know-how.

Moreover, a brand-new process has been developed and patented to upgrade existing gas cleaning systems using wetscrubbers with a round wet-type ESP. The combination of these two technologies is called Hydro Hybrid Filter and enables existingBOF scrubber units to comply with most restrictive environmental regulations, at very low investment cost.

The presentation illustrates the main points of improvement of the 2nd generation dry-type ESP. Secondly, the principle of theHydro Hybrid Filter will be explained, followed by highlighting investment cost and the effects on operating costs.

Keywords

Oxygen steelmaking, gas cleaning, environmental technology, ESP filter

1. SMS ELEX AG, Eschenstrasse 6, 8603 Schwerzenbach, Switzerland2. SMS Siemag AG, Steelmaking and Continuous Casting Technology Division, Eduard-Schloemann-Strasse 4, 40235 Dusseldorf, Germany

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Energy recovery at the electric arc furnace by using the off-gas heat for steamproduction

Christian Fröhling1, Helmut Ester2, Wolf Bernard Schieke3

ABSTRACT

One of the main cost factors within the EAF steelmaking process is energy costs. As this process is very energy-intensive, therecovery of energy is notably important. From the total amount of energy used for the steel melting about 32% are leaving with theoff-gas.

The off-gas waste heat recovery is possible at converter, electric arc furnace and CONARC® systems. For this aim, a part ofthe energy amount is transferred with an evaporation-cooled off-gas duct into steam. Whilst the evaporation cooling system atconverters is state-of-the-art, for the EAF it is an innovative technology.

The hot off-gas behind an EAF can be at least used from 1,250 to 600°C. For a 200 t/h EAF (140 MW average active power)an average of 40 t/h steam (31 MWth) can be produced.

The equipment needed for this comprises as main components: a feed water tank, steam drum, accumulator, feed water andcirculation pumps.

The water coming from the feed water tank is pressurized and pumped into the steam drum. The boiling water is circulated bypumps through the heating surfaces of the off-gas system and partly evaporated. This water/steam mixture again enters the steamdrum and is separated there. The discontinuous amount of steam caused by the EAF batch process is stored in accumulators anddelivered to the consumers. Possible steam applications are e.g. vacuum degassing plants, air separation units, steam turbines orany other process where heat or steam is required. The above mentioned steam amount of e.g. 40 t/h can be used to generate about4.0 MW of electricity, which is equivalent to saving about 32.000 t CO

2 per year. The payback period for this technology depends

highly on the steam usage application and can be less than 4 years.

1,2,3. SMS Siemag AG, Eduard-Schloemann-Strasse 4, 40235 Dusseldorf, Germany

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Waste Minimisation in Iron & Steel MakingMr. Awdhesh Kumar1

1. Chief Executive Officer (Power), MONNET ISPAT & ENERGY LIMITED

SALIENT POINTS TO BE COVERED

1. Conservation of resources like coal and water

2. Energy efficiency

3. End product utilization of the waste producd

4. ISO implementation

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Eco-Friendly Refractories for Iron & Steel Industries* B Prasad, Dr N Sahoo & JN Tiwari

ABSTRACT

Directly or indirectly refractories are used in every industry needing high temperature operation. However, iron & steelIndustries are the biggest consumers of refractories. It takes away about 70-72% of the total production of refractories. Refractory &steel industries are so internally connected that perhaps one may not exist without other. Today development of refractory industryis fully influenced & dependent on the progress of iron & steel industries.

Presently, total refractory production around the world is about 21.0 million ton out of which 14.0 million tons are beingconsumed by the iron & steel industries. This shows that an enormous quantity of refractories are being handled by iron & steelindustries everyday & one can think that if these are not handled properly then how severely it is going to affect our environment.

To take care of the environment, refractory makers along with steel industry have made an immense progress to improveusage, reuse, recycling and waste elimination of refractories in different area of its application. This is considered as the first steptaken by the refractory makers towards supply of eco-friendly (ecologically friendly) refractories.

From 1950 to till date the usage of refractory has declined significantly in all industries, with the steel industry showing thebiggest decrease (80%). As an example, introduction of repair system to improve the life span of converter & ladle has reducedrefractory consumption & as a result the tonnage of refractories available for disposal & recycling is reduced substantially. In 1950,60% of the refractories used ended up in a landfill, while in 2007 that figure was 18%.

Study shows that the steel industry has the highest rate of refractory recycling (55%) compared with 32% by other industries.The iron & steel industry has not only developed the practice of reuse of used-refractories in their process but also collaborated withrefractory makers to recycle the used refractories. For example used slide gate refractories, mag carbon refractories, magnesiterefractories are sent from steel industries to refractory makers for crushing & recycling in many cases. However monolithics/unshaped refractories can not be recycled.

Emission of greenhouse gases like CO, (NO)X etc is a common phenomenon in iron & steel industries especially in the area of

Coke oven. Special types of refractories like high density and high thermal conductivity silica bricks are developed for these typesof critical application which reduces generation of these greenhouse gases. High density silica bricks have high thermal conductivitywhich helps in completion of reaction at comparatively lower temperature which in turn reduces the emission of these greenhousegases. In some cases, the designs of the refractories are suitably modified to reduce the leakage of these gases. Earlier the cokeovens doors were made by lining the silica bricks. Present trend is to use precast doors having almost no joints. Its excellent sealingeffect has reduced the leakage of these harmful gases.

The use of some environment-polluting toxic raw materials & binders are rapidly being replaced by some alternate eco-friendlyraw materials for manufacturing of refractories. For example spinels are being used in place of chrome in refractories to avoid thepollution of water by hexavalent chromium compounds while disposal of used bricks . . Fiber-free insulating coating is alreadydeveloped in place of conventional ceramic fiber to cover the subentry nozzles. This new coating has excellent heat insulation &obviously it is eco-friendly. For the similar reason pitch is being replaced by resin in refractory manufacturing. Although pitchimpregnation is very cost effective binder for refractory manufacturing but as it generates harmful fumes at high temperature, it isslowly being replaced by resins.

This is all about what is already achieved. The refractory industry will continue their R & D efforts to develop materials &systems together with the refractory consuming industries in order to

Minimize refractory wear in the different industrial processes for less specific consumptionMinimize infiltration in refractories in contact with liquid phases to increase the recyclingReduce heat losses in the industrial processes to decrease specific energy consumptionInvent alternate eco-friendly raw materials

Today, in order to cope up with the needs of steel industry, refractory makers have not only made an improvement in itsdurability and reliability but also made a serious effort to develop and cater eco-friendly refractories to the steel industry. Theachievements till date have given a solid base to refractory makers for further progress in this direction.

* OCL India Limited, Rajgangpur, Orissa

A-20


Sustainable Initiatives in Raigarh Steel Works of Jindal Steel & Power Limited

ABSTRACT

The world steel production landscape has been changing dramatically since the 1980s. One notable trend is the shift in steelmaking capability from industrialized countries to developing countries such as China, India and Brazil. Growing production capacityin developing economies, such as India, has been fostering its economic growth and expanding their exports on value-added steelproducts. However, along with this growth, energy shortages and increasing greenhouse gas (GHG) emissions are threateningsustainable growth in these countries and globally. The iron and steel sector accounts for about 19% of global final energy use, abouta quarter of direct CO2 emissions from the industry sector, and roughly 3% of global GHG emissions, mainly CO2 (OECD, IEA,2007).

The efficiency of an iron and steel plant is closely linked to several elements including technology, plant size, quality of rawmaterials and its social acceptance. The success and achievement an organization acquires isn’t measured merely on its balancesheet but on clearly defined indicators encompassing the three main facets of sustainability namely – environmental, social andeconomic. The growth of steel industry and prosperity it brings along to the nation can be real and relished only when the journeyup the ladder is Sustainable. It means valuing the interdependence of environmental, social and economic aspects in all stages ofdecision making.

Jindal Steel Power Limited is Part of the US$10 Billion Jindal Organization with an international presence. Amongst the largeststeel makers in the country today, JSPL is the largest private sector investor in the State of Chhattisgarh with a total investmentcommitment of over US$ 6.25 billion. A 12.5 MTPA steel plant in Orissa and 11 MTPA steel plants in Jharkhand with an investment ofover US$ 9 Billion are amongst the immediate expansion plans of the company.

The presentation outlines the organization’s culture and specific initiatives the company has taken in carrying forward businessthrough sustainable means. The eco-efficiency of our products is optimized through the product life-cycle analysis, including increasedresource and energy efficiency in the production of steel. Business within the organization is operated in an efficient and financiallysustainable way in order to supply steel products and solutions that satisfy our customer’s needs and provide value to our stakeholders.The community at large is engaged through mutual trust by promoting values and initiatives that show respect for the people andcommunities associated with our business. Other stakeholders and independent third parties are involved in constructive dialogue tohelp fulfill our sustainable development commitments. The organization believes in building its knowledge of sustainability andwillingly shares it with others. Our communications will be open to help steel companies and organizations in the supply chain toimplement sustainable practices.

A-21


Energy efficient and eco-friendly iron making operations atTata Steel’s ‘H’ blast furnace

A.S.Reddy, Goutham Raout, Ashok Kumar

ABSTRACT

Blast furnace iron making is quite a mature technology that has reached over the last few decades a high degree of distinction.Tata Steel in its historic journey in iron making has established its ability to adapt to the changing circumstances in terms of rawmaterials, energy resources, hot metal capacities and technology to preserve its competitiveness on the international market.

Tata Steel as part of its expansion program had set up a new ‘H’ blast furnace (Inner volume 3814 m3) along with a 204 m2

sinter plant in year 2008. In its constant strive to improve production and develop products which bring with them environmentalbenefits, realized the current challenges especially with respect to environment and CO2 emissions. The selection of technology andoperational practices including solid waste utilization in sinter production, production of electricity utilizing kinetic energy of the top gasof blast furnace (TRT) and other energy efficient practices were made with an emphasis on improved environment in iron makingoperations. Furnace achieved a highest productivity of 3.0 t/m3/day with a coal injection of 155 kg/thm consistently. The energyrecovery from TRT is about 30% of the energy used for blowing the blast furnace.

This report outlines the achievements of energy efficient and environment friendly iron making operations at Tata Steel’s H blastfurnace.

A-22


Heat Recovery Cokemaking - Environmental friendly Technology by choiceB.Biswas, IMTG

ABSTRACT

With continuous increase in global steel demand, hot metal production through blast furnace route will play a dominant role.Metallurgical coke, therefore, will hold the key to growth in the steel industries. Existing global coke making capacity will fall short ofthe requirement and additional coke making capacity need to be set up to meet the demand. One of the major challenges to cokemakers will be to meet the stringent pollution control norms worldwide, which calls for huge additional investment. Tata steel took upthis challenge by setting up its first Heat Recovery coke making facility at Haldia, to cater to its additional coke demand. Thistechnology is having the unique advantage of being not only cost effective compared to conventional slot ovens, but also has theadded advantage of meeting the stringent pollution control standards, because of its basic design and process of operation . Thispaper describes the major advantage of this technology compared to the conventional slot ovens and how it helps to meet theenvironmental norms with minimum investment along with experience of Haldia plant.

A-23


SVC for Industrial applicationImproving the Power Quality and Productivity in Metal Industry

Rakesh Singh1

ABSTRACT

The Static Var compensator designed for Utility and Industry applications is used for increasing the power quality. Qualitypower has many advantages to end user. As an effect of quality Power SVC increases Productivity by reducing Tap-to-Tap time,Decreases electrode consumption due to more stable arc and reduced losses.

The benefits of an SVC can be seen within a steel plant as a stable power factor in spite of varying loads at the plant andexternally. The disturbances do not effect the supplying grid. In short, the Static Var Compensator affects the following:

● Flicker reduction

● Voltage stabilization

● Reactive power compensation;

● improved power factor

● Increased voltage on the load bus

● Reduction of harmonics

The benefits of reactive power compensation, more constant voltage levels and reduced distortion levels are transferred to theend user as production increases, total power losses are reduced and reactive power penalties are avoided. Static Var Compensatorsincreases the quality of power in many respects.

Energy savings: Compensation and improving the quality of power increases the capacity of active power transmission andreduces energy consumption. Thus, the unnecessary overload of the power network can be avoided. The environment benefits fromthe more efficient use of electricity and saving in the consumption of energy.

Increase in productivity: The SVC system can keep a steel plant bus voltage practically at a constant level. This decreases thesteel processing time and thus increases productivity. The SVC system also reduces production breaks and expensive restartprocedures. The arc furnace, stabilized by the SVC also has a considerable positive effect on the consumption of electrodes, heatlosses and the lifetime of the furnace's inside lining. As the improved quality of power from the network reduces the stress onequipment, its lifespan increases, thus lowering the maintenance and replacement costs. Each plant has its own quality requirementsfor the supply of power, thus the SVC must always be tailor-made. The design of the SVC depends on the fault level and loadparameters. In case of a high fault level the main parameter of the SVC design might be reactive power compensation while flickerand harmonic reduction are major concerns for a low fault level.

1. AREVA T&D India, HVDC & FACTS Group


List of Exhibitors

Adhunik Metalliks LimitedBhushan Power and Steel Limited

Gea Ecoflex India Pvt. Limited

Jindal Steel & Power Limited

JPC, Ministry of SteelJSL Limited

Kirloskar Brothers Limited

Mahanadi Coal Fields Limited

Manishree Refractories & Ceramics Pvt. LimitedMecon

Midrex

Mukand Group

Mysore Minerals LimitedNeelachal Ispat Nigam Limited

OCL India Limited

Orissa Mining CorporationProwess International Pvt. Limited

Ramakrishna Electrical Works

Rastriya Ispat Nigam Limited

SMS SiemagSteel Authority of India Limited

Sun Consultancy Services / CITRAN Consultancy

Tata Refractories Limited

Tata Sponge Iron LimitedTata Steel Limited

Team Orissa

Terruzzi Fercalx / Vulcan

TranterVisiontek Consultancy Services

Wellman Wacoma Limited


Technical papers | Part- I


Part_I | pg-1

Introduction - Climate Change Risks and its Management

Climate change is accepted as presenting new risks to the iron and steel industry in terms of ensuring a sustainable business.

The risks are fundamentally of two types:

1. Climate change can lead to physical changes in the environment, which are addressed through an adaptationstrategy.

2. Climate change is leading to regulatory changes, which impact corporate profitability. This risk is managedthrough proper analysis, negotiating and reasonable target setting by business to ensure industry survival andprosperity.

The main emphasis of this paper is on a novel Greenhouse Gas Carbon Abatement Process (G-CAP) developed by Hatch, foraddressing the second type of risk which deals with the management of the impact of cost on GHG (green-house gases) emissions.Hatch’s G-CAP is a key tool that fits well within the core of an organisation’s GHG management strategy.

The Harvard Business Review established a process for strategically managing climate change risk. The key points of this processare summarized in Table I.

Table I: Key Points of a Process for Strategically Managing Climate Change Risk, as published in the Harvard Business Review

No. Steps Involved Details

1. Quantify Your Carbon “Footprint” Quantify the sources and sinks of CO2 within the business in order tocommence the process of emissions management.

2. Assess your Carbon Related Risks Review the impact or opportunity within the followingand Opportunities risks: regulatory, supply chain, product or technology, Litigation,

Reputation and physical. Understanding the risk is fundamental tomanaging the risk.

3. Adapt your Business Develop and implement activities to reduce energy consumption andcarbon emissions. Identify how to seize new opportunities.

4. Do it Better than Rivals Take the lead in reducing exposure to climate change risk and realizingopportunities. Promote success to the market and legislators.

It is interesting to note that the Hatch’s G-CAP addresses all of the four main steps of the risk management process. Although theoutputs of the G-CAP are mainly focused on Step 3, i.e., creating a strategy and plan to manage CO2 emissions and informingnegotiations with regulators, the core elements of Steps 1 and 2 are also covered during the application of G-CAP. It is noted thatmany businesses in India may have already completed Steps 1 and 2, and so the G-CAP simply builds on this important foundation.

With respect to Step 4 which puts the plan into action and manages GHG emissions into the future, the GCAP provides the basis fordoing this with a robust techno-economic plan. The G-CAP has several key outputs enabling the establishment of abatement and

Towards Sustainable Iron and Steelmaking – the Greenhouse Gas CarbonAbatement Process (G-CAP)

Michiel Freislich1, Sunil Kumar2, Steve Gale1 and Peter Duncan1

HATCH1. 25 Atchison Street, Wollongong, New South Wales 2500 Australia2. Sheridan Science & Technology Park, 2800 Speakman Drive, Mississauga, Ontario, Canada L5K 2R7

Part_I | pg-2


capital targets and trajectories. These are driven by a powerful Marginal Abatement Cost Curve (MACC) that is developed as partof the methodology.

The Marginal Abatement Cost Curve (MACC)

A sample MACC is shown for reference in Figure 1 (including a sample of its use). The MACC allows a business to identify withcertainty as to how much CO2 (or energy consumption) can be abated by a defined point in time and at what cost to the business. TheMACC is a well-developed tool for setting the initial CO2 reduction targets, negotiating the CO2 cap allocation and managing theemission reduction pathway into the future.

Application of MACC to Energy Consumption Reduction and GHG Abatement

Marginal Abatement Curves are equally relevant to the identification of energy reduction initiatives. Figure 2 shows a case example,where the Marginal Energy Efficiency Curve (MEEC) has been developed for a specific geographic region. The calculation of anabatement curve for energy reduction requires an assessment of the plant (or industry’s) basket of energy consumptions.

In this form the MEEC is a powerful instrument for industry and regulators alike. It allows for the analysis of pricing in EnergyEfficiency Certificates, and to assess through scenario analysis, how a company should respond to energy prices


Part_I | pg-3

High Level Management Commitment

In addition to a robust methodology for management for climate change risk, it is worth highlighting the need of a visible high levelmanagement commitment. The business response to Climate Change is expected to be the same as the response to any otherexternal risk- it is to embark on a change process. Implementing any change and deploying G-CAP begins with visible commitmentfrom the senior levels of an organisation.

Change can be imposed on the business by the governmentoutlining a process to impose a charge on CO2 or energyefficiency. The government can enact cap-and-tradeprograms and offer partial or full shelter through NegotiatedGreenhouse Agreements (NGA) for businesses thatdemonstrate best practise performance. In India, thegovernment may regulate improvements for s tee lmanufacturers that exhibit higher energy consumption thanthe norm.

Companies that aim for best practise improvement, suchas some in Australia, recognise that energy and GHGmanagement is now a strategic issue with the furtherdevelopment of the Kyoto agreement and associated GHGAbatement programs developed by governments. Inresponse, these companies are def ining reduct ionprograms (such as G-CAP) to create the abatement plansand engage the operating units in a cultural change towardssuperior energy management and GHG reduction targets.

The most visible leadership commitment is the establishment of policy and mandatory targets for the business units to achieve.Creation of achievable targets requires a bottom- up approach identifying the opportunities that exist within each of the businessunits. The sum of these activities is the final corporate target. Managing, and incentivising, targets from the bottom-up provides unitmanagers with a clear pathway for achieving their objectives.

Overcoming organisational barriers has been a key element of our work in developing a successful methodology for optimising plantefficiency. Figure 3 outlines the major stumbling blocks encountered and steps taken to overcome.

Part_I | pg-4


Overview of Hatch’s G-CAP

The G-CAP package is composed of a number of sub-package elements.

The key elements of G-CAP are outlined below:

1. Create inventory of all emission sources and sinks at site/business boundary level

2. Disaggregate inventory to operating unit level

3. Accuracy audit of disaggregated inventory, implement data quality improvements

4. Establish Energy/Mass balance for each unit

5. Collate operational key performance indicators (KPI’s)

6. Identify Best in Similar Class and Best Practice benchmarks

7. Normalise units to benchmark conditions

8. Identify abatement opportunities to compress the gap with the benchmark

9. Expected Improvement with CO2 Abatement Technologies

10. Risk filter and eliminate unacceptable opportunities

11. Model remaining opportunities and eliminate competing alternatives/suboptimal scenarios

12. Develop operational cash cost (Opex), capital investment requirements (Capex), Abatement and lead time estimates foropportunities and generate MACC

13. Identify CO2 price scenarios

14. Map abatement and capital trajectories from MACC over time

15. Set targets based on abatement cost/permit price differential

When applying the G-CAP package in steel companies, it was noted that different businesses are at different stages of GHGreadiness. While some companies have required all the elements of G-CAP to be addressed, others have been further ahead andhave employed only the relevant elements from the G-CAP package. This flexibility is illustrated in the Table II.


Part_I | pg-5

A key strength of G-CAP is its holistic approach that links the corporate abatement targets to the appropriate units for action. Thisintegrates the existing energy management plans, capital development plans as well as any business plans. The G-CAP successfullyintegrates the pre-existing energy efficiency and GHG management programs, into one common program.

The G-CAP has been successfully applied to generate the Marginal Abatement Cost Curves (MACC) at three steel plants namely,New Zealand Steel, BlueScope Steel and OneSteel. Currently, the G-CAP is being employed to develop the MACC for the AustralianSteel Sector, as a whole.

Details of the different elements of the G-CAP methodology are presented as follows.

(i) Inventory of Emissions and Materials

An inventory of all emission sources and sinks at the site / business boundary level, is created as the first step in the G-CAPmethodology.

(ii) Disaggregating the Emissions Inventory to Unit Level

The next step involves creating boundaries for the steel plant and for disaggregation of the different process units. Figure 4 showsthe disaggregation adopted for New Zealand Steel.

Part_I | pg-6


Various GHG protocols outline methodologies for identifying the business boundaries (e.g. WBCSD GHG Protocol). The steelproducers we have worked with have all had some form of business boundary level energy and emissions reporting structure. Ourrole has been to assist these businesses to “fill the gaps” in their existing inventories. This has required a combination of direct datacollection and statistical analysis to estimate emissions from a multitude of smaller sites.

Reporting at the boundary is inadequate for detailed benchmarking. Disaggregating the business to management units is essential forsuccess. The smallest unit required is that which is capable of being benchmarked and has discreet management.

Most steelworks, have systems in place for tracking energy and raw materials use. However these systems are generally fragmentedand collected for purposes other than GHG reporting.

Data is collected from the units and matched to the site inventory to allow the disaggregation to the unit level. Plant services that areshared are split between processes. Most importantly the mass of raw materials entering the plant (coal and limestone) are allocatedto the correct unit processes. Mass/energy flow between units is identified.

Tracking mass flow identifies opportunities to debottleneck the operations and reduce the circulation of internal scrap.

(iii) Accuracy Audit and Data Quality

It was found that data quality is essential to seeking improvement opportunities. As modern steelworks operate close to best practiceor theoretical limits, practical brownfield improvements are expected to be marginal. In the audits of several iron and steel operations,the range of accuracy was identified as ±3% to ±9%, whereas ±5% is essential to ensure quality decisions can be made.

Figure 5 shows the impact of error on a plant inventory of 12.5MTPA CO2. Assuming $20/t CO2, with the minimum 3% error, theliability is $7M increasing to $22M at 9% error. The data capture, collection and reporting systems were audited in accordance withISO-14064 standard. The audits covered metering of fuels and electricity as well as weighing of solid fuels, reductants and fluxes. Toensure accuracy of the specific KPI’s the weighing of product at each unit were audited. The systems for collecting the data from thefield, transferring it to the reports and storing it were also audited.

As comprehensive emissions management systems are relatively new, we usually find a high degree of nonconformance, whichrequires system improvement. Table III lists examples of key actions recommended for a client for improving the emissions inventoryquality.


Part_I | pg-7

(iv) Energy & Mass Flow

The G-CAP approach is to achieve efficiency in both absolute and specific terms. The methodology recognises that wasted productis wasted energy (and profit). By focussing the process on maximising throughput and minimising emissions we identify significantcost savings.

Figure 6 indicates that in aggregateacross 4 steel businesses we havefound over 1MTPA of profitable CO2sav ings (Pos i t i ve NPV @10%discount rate) from a combinedinventory of 17MTPA CO2. Furtherover 100 ,000TPA o f s labproductivity has been identified.

In o rder to iden t i f y theseimprovements the detailed mass/energy flow was mapped for eachof the disaggregated units.

Part_I | pg-8


Figure 7 shows a typical Sankey diagram of the energy balance for a blast furnace.

The most cost effective efficiency opportunities have usually been found in the de-bottlenecking options, reducing scrap, utilisingwaste heat and improving energy efficiency. By comparing the source of the energy /material and how it is consumed, the comparisoncan be made with calculated best theoretical practice,

Figure 8 and Figure 9. This calculation identifies the total “waste” in the system, focusing attention on those areas with the mostopportunity for improvement.

Although this is based onthe work completed forspec i f i c c l i en t , i tdemonstrates how areas ofinefficiency were readilyidentified by mapping thevar ious losses andinefficiencies.


Part_I | pg-9

(v) Collating Operational KPI’s

G-CAP is a bottom up process that works by identifying the efficiency improvements within each unit. This is done by collecting theoperational KPI’s from each unit e.g. those KPI’s used to monitor and manage the process. An example of important KPIs compiledfor blast furnace are presented in Table IV.

For a typical integrated steelworks, data for over 200 parameters are collected covering a period of 2 years of operations. The 2year period is used to ensure there is an adequate data set to minimise the effects of anomalies or outages and provide enough detailto establish “best 3 month” periods. Data from the best 3 consecutive months and best 3 months is compared to the averageperformance. This demonstrates the stability of operations and the opportunities that exist to improve efficiency through improvedpractices.

The KPI data is formatted to allow ready identification of similar plants and their KPI’s for benchmarking.

(vi) Benchmarking

Benchmarking against a suitable cohort of like for like processes, is the most reliable way to identify how close any plant is to besteconomic practice. The keys to success are demonstrating that the right benchmark has been selected and obtaining the operationalKPI data for the benchmark for comparison.

In summary benchmarking requires the following activities to be completed:

1. Identify the KPI’s for benchmarking

2. Identify the best in class benchmark/s

3. Obtain the operational KPI data set for the benchmark/s

4. Ensure that the boundaries of each benchmark study are the same and adjust where necessary

5. Normalise the benchmarks to accommodate issues that are beyond the control of the plant (e.g. size differences, feedstock,etc)

For businesses that lack detailed benchmark data the G-CAP integrates specialist skills. The specialists are globally regardedindustry experts with access to a variety of detailed benchmark data and significant experience in a wide variety of operations. Thespecialist proposes a range of benchmarks to represent best in similar class and best in class.

The outcome is an agreed benchmark/s to represent the following:

Best in class- Benchmark represents the best efficiency using a similar process at a similar scale with a similar product mix. Thebenchmark performance can be theoretically achieved by a series of plant improvements.

Best Practice- Benchmark represents a most economical scale and also may have a different process or product mix. Thebenchmark performance can only be achieved by premature capital replacement or significant change to product mix.

Part_I | pg-10


Plants at world’s best practice have invested a lot of effort and expense in reducing these inefficiencies and are operating close to theincompressible limits. Any plant approaching the theoretical limits faces an exponential increase in costs to abate emissions.

(vii) Normalisation to Benchmark

Once the benchmark/s have been agreed the unit operation is mathematically normalised to the benchmark. This ensures the unit iscompared on a like for like basis. Each of the KPI’s are adjusted up or down in order to place the unit and its benchmark in the samecontext.

Normalisation accounts for the following:

• Differences that are beyond the control of the business e.g. legislative constraints/imperatives, different market drivers,differing raw materials, etc (as appropriate).

• Minor technological differences between the unit and the benchmark (e.g. comparing a 5 stand and 6 stand Hot Strip Mill).

(viii)Opportunity Identification-Closing the Compressible Gap

Opportunities to compress the gapare identif ied from a variety ofsources. Figure 11 summarises ourexperience across the projectsconducted.

Figure 10 shows the aggregationof the normalisation process toplant level.

The normalisation has reducedbaseline emissions by 0.25MTPAresulting in a reduced gap of3.22MTPA between the businessand Best in Class benchmark.This is the compressible gap inwhich efficiency opportunities arelocated.

The gap between the Best inClass benchmark and Best ofClass is used to demonstrate howclose the chosen benchmark is to“Best Practice”. It is generallyregarded as unobtainable due tothe need for premature capitalreplacement.


Part_I | pg-11

The following points can be noted from the figure:

• 70% of the abatement opportunities (by CO2 Tonnage) are well known and identified in literature such as the APP andIISI best practice lists.

• A further 15% of opportunities are identified by the operations team.

• During the G-CAP process the specialist identifies abatement opportunities providing another 15%.

• On average businesses have identified and systemised 60% of the total abatement opportunities before the G-CAPprocess commences.

G-CAP formalises the process by creating an “Abatement Activity” list for each unit through structured brainstorming and discussionof the plants improvement systems. The abatement Activities (AA) can fall into the following list of classes:

• Brownfield technology upgrade

• End of life technology replacement

• Operational improvements

• Product mix change

• Fuel switching

• Strategy change

(ix) Expected Improvement with CO2 Abatement Technologies

There are a number of CO2 abatement technologies can be considered by the steel plants for the different area of iron andsteelmaking. Table V summarizes the range of expected improvements for key- CO2 abatement activities based on the evaluation ofthe different technological options. These are site specific and depend on constraints encountered.

Part_I | pg-12


(x) Risk Filtering Abatement Activities

The AA’s can usually compress the gap between the unit and Best of Similar Class Benchmark by 70-80%. However, this is a rawfigure and does not take into account the risks associated with each AA.

An initial risk filtering process is used to eliminate AA’s that are unacceptable on the following grounds:

• Not permitted by legislation

• Technically incompatible with the process/raw materials, etc

• Breach company policy e.g. OHS&E

• Require large scale replacement of early/mid life equipment

• De-optimises other parts of the process

(xi) System Modelling to Identify the Optimum Scenario

Each unit is modelled to test the impact of activities within the unit and across the plant. This prevents the implementation of AA’s at oneprocess unit de-optimising outcomes at other process units. The heat and mass data is used to support the integrated models.

Modelling can successfully identify activities that were impractical for the following reasons:

• Exceeded fundamental system constraints

• Competed for a limited resource

• De-optimised other parts of the system resulting in a net deterioration of the plant

(xii) Economic Modelling to Calculate the MACC (Opex, Capex & Abatement Calculations)

The MACC is calculated on the basis of the AA’s discounted cash flow stream. A set of models are used to calculate the project’simpact, capital investment timeline and operational costs. At the same time, the model calculates and verifies the abatement that canbe achieved.

The MACC in Figure 1 shows the position of these activities. (Table VI shows the key raw materials and energy unit-prices for thesteel plant in question, that were employed in the development of MACC).


Part_I | pg-13

In work completed to date, fuel switching (e.g. PCI), waste heat recovery processes and the integration of energy efficiencyupgrades have been found to be the most cost-effective. Further, the MACC indicates that the well known technologies, such as PCIinjection, BOS Off-gas recovery and Coke Dry Quenching (CDQ), are viable under future energy scenarios and should be consideredfor implementation.

It is impossible to use the MACC without adjusting it to the plant circumstances:

• The price indicators and value chain for supplies as well as products (including by-product waste), differs from site to site,

• The installed plant equipment determines the investment requirements on the site.

To improve the usefulness of the MACC as a strategic decision making tool, the activities identified require improved abatement andfinancial data. It has been found that the minimum accuracy is ±50% in aggregate to allow the tool to meaningfully inform decisionmaking.

For all major operations there are a large number of AA’s within the MACC. These are screened to establish a shortlist of activitiesfor further work. The screening criteria are as follows:

• Level of risk previously identified

• Position sensitivity in the MACC ranking

• Impact on decision making (NPV proximity to actual cost of CO2)

• Abatement potential

Activities that fit one or more of these criteria are closely reviewed and the error range established. Those with particularly largeerrors that are significant to the corporate decision making process have further technical work completed to improve the certainty.

The end result is a MACC that decision makers have a reasonable level of confidence in. In all the cases, a significant amount ofabatement that can be considered low hanging fruit and is profitable to implement, was identified. It is worth mentioning that to-datesome 1MTPA CO2 reduction with a cost saving in energy consumption of over $17M per annum has been identified. Our experienceis that after the profitable abatement opportunities have been implemented, the gradient increases significantly – resulting in a cost ofabatement that increases in an almost exponential fashion.

(xiii) Establishing the CO2 Scenarios

The MACC establishes what abatement is achievable at any given price of CO2 (and using the businesses preferred WACC).However, in many markets the price for CO2 is uncertain.

One of the key benefits of the MACC is that it enables decision making on what AA to implement depending on the forecast price ofCO2. Thus the strategic plan is readily updated should the CO2 price behave in a manner that is unexpected.

Our preferred method to establish business targets is to simply establish a forecast range for the CO2 price. This is done through areview of available literature. The lower end is the generally expected cost and the upper end the worst case scenario consideredlikely. Currently in Australia this range is between AUD$10- $50 per tonne CO2.

Abatement activities are then selected from the MACC in accordance with the expected CO2 price in order to identify the amount ofabatement that is economically rational. This is compared to the businesses CO

2 allocation or reduction target, to establish if the

business is in surplus or deficit.

(xiv) Creating Abatement and Capital Trajectories

The G-CAP MACC is used to generate abatement targets in response to carbon price scenarios. Error!

Reference source not found. shows a typical abatement and capex forecast.

The abatement scenarios considered as follows:

• BAU- Business as usual incorporating business plan growth

• “No Regrets” AA’s that require a price of $0/T CO2

• $20/T CO2 price taken as a “realistic” price in this case

• $50/T CO2 price taken as a “high” carbon price

Part_I | pg-14


The solid lines show the % abatement achieved over time against the left hand axis. The dotted lines show the Capex required overtime to implement each trajectory. This data is generated directly from the AA’s within the MACC . Each AA is flagged with the lead timefrom project conception to implementation. This provides the necessary data to plan the capital development pipeline and set theimprovement trajectory.

(xv) Target Setting

In jurisdictions with a CAP or a declining permit trajectory the MACC is used to identify if the abatement can meet the efficiency capor if permits are required.

As can be seen, Figure 1 includes an example of a 10% or 3.2MT reduction target. If slag granulation is excluded from the MACC,it can be seen that 2.75MT can be achieved through abatement leaving a shortfall of 450kT CO2

Role of G-CAP in the Indian Scenario

It has been reported that the Indian government, as part of its National Action Plan on Climate Change, is planning to introduce aregulation that is focused on reducing energy consumptions in the energy-intensive industrial sectors of the country, of which the ironand steel industry is a part. As per this regulation, industrial plants would be expected to attain reduction targets as a percentage ofbaselines developed based on historical data. Clearly, the underperforming plants would be expected to attain a higher percentageof improvements as compared to their better counterparts.

In this emerging scenario, it is apparent that the iron and steel industry would need to adopt a robust technoeconomic platform, suchas the G-CAP methodology, for evaluating the targets assigned and developing improvement plans based on real projects within thebusiness, to achieve the reduction targets.

For the policy makers, the G-CAP methodology is equally important. This would provide a guideline for target-setting such that theycan support the industries in a manner that the emission reductions are planned in a sustainable manner, and that the policies simplydo not erode the competitive advantage of the industry.

Summary and Conclusions

As presented in the paper, it is evident that the G-CAP provides a rigorous, robust and defendable method to build the strategic CO2abatement plan. The methodology is rigorous in the sense that it identifies and quantifies the entire range of abatement alternatives


Part_I | pg-15

available. This is also robust since it is developed from the bottom up, utilizing both the unit’s and Hatch’s industry technical expertise.It is defensible through the systematic approach to decision making, use of globally recognised specialists and transparency ofmethodology.

The following guidelines apply to the successful application of G-CAP.

• The energy and emissions inventory must be determined accurately

• The energy envelope for each process unit must be determined accurately

• The energy and mass balances must be modelled on a detailed KPI level

• Proper benchmarking through normalisation must be completed to enable accurate target setting

• Cost of abatement curves enable target setting through the analysis of the economic evaluation of improvement opportunities

In addition to the focus on GHG, the G-CAP methodology can be applied equally successfully to the field of Energy Efficiency.

With respect to the Indian scenario, the iron and steel industries will need a robust techno-economic platform such as G-CAPmethodology, to prepare for the energy / GHG reduction targets as part of the emerging climate change policies in the country.

References

1. J. Lash & F Wellington, Competitive Advantage on a Warming Planet, Harvard Business Review, March 2007

2. J Reinaud, Emissions trading and its possible impact on investment decisions in the Power Sector, IEA, Information Paper,2007,

3. McKinsey Quarterly (2003), Power producers should pay close attention to European Commission proposal to curbgreenhouse gas emissions. It could have paradoxical effects, Quarterly 2003, number 1, Paris.

4. D Gielen, The Future Role of CO2 Capture and Storage Results of the IEA-ETP Model, November 2003

5. IEA Statistics, Energy Prices and Taxes (Second Quarter 2008)

6. IISI – Training manual and Website , IISI Climate change Initiative, 2008

Part_I | pg-16


Energy Efficiency in Steel Making and Clean Development MechanismK. K. Singhal1, K. M. Khare2

1 . Executive Director, Environment Management Division, SAIL2 . AGM, Environment Management Division, SAIL

1.0 Introduction

Steel in its many forms plays a crucial role in shaping modern industrial society. It is a decisive factor for the economic and socialdevelopment of our global society. However, in this global and highly competitive environment, we have to continue our efforts toproduce steel at less costs, fulfill the stricter quality demands and find solution to the limitations of energy and raw materials as wellas environmental constraints.

Iron & steel industry is the largest consumer of energy in the Indian industrial sector, consuming about 10% of electricity and 27%of coal consumed by the Indian industry. The energy costs constitute nearly 30-35% of this sector’s production costs.

Energy is essential for economic growth. If India is to achieve the targeted growth in GDP, it would need commensurate input ofenergy, in the form of coal, oil, gas and electricity.

In the last 30 years, crude steel production in India has increased from 10 million tons to 55 million tons per annum and the growthis expected to continue. National Steel Policy 2005 envisaged crude steel production of 110 million tons by the year 2020. However,in a recent release, Ministry of Steel has projected that the steel capacity in the country is likely to be 124 MT by 2011-12. In thisscenario, energy consumption in iron & steel industries in India is projected to increase.

Improvement in energy efficiency of steel protection is one option to counteract the increasing demand for energy. The objective ofthis paper is to identify and characterize through a systematic approach, technologies that can contribute to increase in energyefficiency of steel making in integrated iron & steel industries. Reducing energy intensity is therefore not only beneficial in savingscarce resources but also in reducing carbon emissions and thus mitigating global climate change.

Such technological initiatives for curbing Green House Gas (GHG) emission, require substantial capital investment and needs toestablish a national action to achieve real, long term, measurable and cost effective GHG reduction through policy framework in Indiafor climate change and implementation of Clean Development Mechanism (CDM).

2.0 Global and Domestic Steel Production

Global crude steel production during the year, 2007reached to 1343.5 Million Tones, which shows agrowth of 7.5% over the previous year. It is the fifthconsecutive year that world crude steel productiongrew by more than 7%. However, during the year,2008, the world crude steel production was marginallydeclined to 1327 Million tones, due to the recession.China remained the world’s largest crude steelproducer and India occupied the 7th position for thethird consecutive year.

In India, iron and steel production has been increasingover the last 30 years from 9.85 MT in 1980-81 to54.52 MT in 2008-09.


Part_I | pg-17

3.0 Future Demand of Steel in India

Growth in steel demand is highest in developing countries of the world. In India, present per capita crude steel consumption is 50 Kgper annum compared to the world average of 208 Kg. The per capita steel consumption in India is likely to be increased to 150 Kgper annum which shows a growth of 475% in the next 12 years. The reason for increase in demand is due to more urbanization andsubsequent change in life style, development in infrastructure and demand in automobiles and transportation sector.

The National Steel Policy has envisaged steel production of 110 Million Tones by the year 2019-20. However, based on theassessment of the current ongoing projects, both in green-field and brown-field, Ministry of Steel (MOS) has projected that the steelcapacity in the country is likely to be 124 Million Tones by 2011-12. Further, based on the status of MOUs signed by the privateproducers with the various State Governments, it is expected that India’s steel capacity would be nearly 293 Million Tones by theyear, 2020.

4.0 Energy Use

Primary sources of energy utilized in the iron and steel sector encompass coking coal, non-coking coal, liquid hydrocarbons, andelectricity. Out of these, coking coal holds the major share of energy used (65-80%). While coking coal, non-coking coal and liquidhydrocarbons are primarily used in integrated steel production, electricity by far presents the major input for steel making in miniplants using electric arc furnaces or induction furnaces.

Specific Energy Consumption (SEC) in India has reduced considerably in recent years. While in the 1985s energy consumption hadbeen on average 10.7 GCal/tcs, in the early 1995s it had already declined to around 8.4 GCal/tcs and has since further decreasedto an average 6.9 GCal/tcs in 2007-08. However, SEC in India is still considerably higher than in the industrialized world (rangingfrom 4 to 4.5 GCal/tcs).

Besides technology and process related factors, there are several other general factors affecting SEC in steel plants. The productmix, for example, has impact on energy use. The manufacture of more complex and high quality products increases overall energyintensity. In addition, there are factors specific to India that should be taken into account when trying to understand why SEC in Indiansteel plants is higher. They include the quality of raw material that is available to Indian industries, the scale of operation, plant sizesand sizes of coke ovens, plant utilization factors, economic and political incentive structures for adoption of technology updates andmodernization, and the installation of energy saving and recovery systems.

5.0 Energy Saving Potential in India

Figure represents energy saving potentials by comparing specific energy consumption in Indian integrated iron and steel plants withspecific energy consumption in plants using world best technology (best performance)

Production in iron and steel sector has been increasing. Average specific energy consumption for Indian steel industries is 6.9 GCal/tcs compared to the world’s best performance of 4.0 GCal/tcs. With the present production of 54.5 million tons /Year, the Indian steelindustry has potential for energy conservation of about 158 million GCal per year.

With a conservative estimate of about 200 million tons steel production by 2020, the energy conservation potential in Indian steelindustry will be around 484 Million GCal/year (considering same SEC of Indian steel industry and world average).

Therefore Indian steel industry has tremendous potential for energy conservation by adoption of energy efficient technologies.

Part_I | pg-18


6.0 Energy Efficient Techniques

Potentials for energy efficiency improvements build to a large extent on on-going changes in the iron and steel sector. They arisefrom improvement in input factor, from technology conversion and retrofitting as well as from recycling and waste heat recovery, forexample. Currently, over 50% of the energy used in integrated steel plant in India is lost. Loss occurs as exhaust and by-productgases that could be used as fuel or low heat steam production.

Technologies that reduce energy losses, resulting from higher temperature application can be divided into three groups, accordingto the degree to which the need for high temperature is avoided or reduced:

1. Techniques that avoid at least one heating and cooling step e.g. near-net-shape casting, smelting reduction process of coal &iron ore

2. Techniques that reduce the temperature required in different process step e.g. DRI process, Casting & shaping without meltingby powder metallurgy, a process that is already used commercially, for production of some specialty products.

3. Technologies that recover and apply heat at high temperature e.g. Waste Heat Recovery systems in integrated iron & steelplants

7.0 Policy Framework in India for Energy Conservation

7.1 National Action Plan for Climate Change (NAPCC)

Hon’ble Prime Minister of India has released “National Action Plan for Climate Change (NAPCC)” on 30th June’ 08, identifying theroad map for climate change.

In order to achieve sustainable development path, NAPCC has identified 8 National Missions. National Mission for Enhanced EnergyEfficiency (NMEEE) is one of the missions which directly concerns all industry sector (including iron and steel industry), besidesother.

Out of the initiatives which are in place to implement NMEEE, one which concerns iron and steel industry is;

“A market based mechanism to enhance cost effectiveness of energy efficiency improvement in 9 sectors through Perform, Achieveand Trade (PAT)”

A working group has been set up to work out the methodologies for evolving norms for energy consumption, verification process ofenergy consumption, issuance process of energy saving certificates, trading mechanism etc.

7.2 National Environmental Policy (NEP) 2006

National Environmental Policy 2006 highlights the framework of sustainable development in the country, by way of promotion ofenergy efficiency, appropriate mix of fuels and primary energy sources, including nuclear, hydro and renewable sources, energypricing, pollution abatement, afforestation, mass transport, besides differentially higher growth rate of less energy intensive servicessectors as compared to manufacturing.

7.3 Charter on Corporate Responsibility for Environmental Protection (CREP)

The Ministry of Environment & Forests (MoEF) launched the Charter on “Corporate Responsibility for Environmental Protection(CREP)” in 2003 for the steel industry with the purpose to go beyond the compliance of regulatory norms for prevention & control ofpollution through various measures including adoption of clean and energy efficient technologies.

8.0 Some Energy-efficient Technologies in Steel Making (Integrated Iron & Steel Industry)

Units Energy Management Technologies

Coke Ovens § Coke Dry Quenching§ Automatic Combustion Control§ Automatic Ignition for Coke Oven Flare§ Tall batteries and stamp charged batteries

Sintering Plant § Sinter Cooler Waste Heat Recovery§ Multi-slit Burners

Blast Furnace § Top Pressure Recovery Turbine§ Hot Stove Waste Heat Recovery


Part_I | pg-19

§ Coal Dust Injection process§ Bled BF Gas Recovery

Steel Melting Shop § BOF Gas Recovery§ BOF Sensible Heat Recovery§ Continuous Casting replacing Ingot casting

Rolling Mills § Thin Slab Casting / Near-net-strip casting§ Reheating Furnace Waste Heat Recovery

Some of the above examples are explained below:

Energy Conservation in Coke Making

Most of the recovery type coke ovens of integrated steel plants were set up during 1950s to 1970s and subsequently were expandedand modernized. During those days, the pollution control facilities were installed basically aiming at process requirements rather thancontrol of pollution. Energy consumption associated with coke production is best reduced by decreasing the amount of coke used inthe iron melting process. Process modifications in actual coke production are not widely available and are very expensive. However,many energy efficient technologies can be installed with recovery type of coke oven batteries.

Coke Dry Quenching (CDQ)

Coke Dry Quenching (CDQ) is an environment friendly process, alternative to the conventional wet quenching of coke.

In the CDQ process, hot coke is quenched by utilizing nitrogen gas and recovered waste heat, thus achieving energy conservationand controlling the spread of atmospheric pollutants, such as coal dust. Circulating gas (generally nitrogen) is heated to a temperatureof 900 – 9500C by heat exchange with hot coke. This heated circulating gas, after passing through the primary dust removing deviceis conveyed to a boiler to generate steam.

Parameter per Wet Dryton of Coke Quenching Quenching

Environmental Aspects per ton of coke

Water Consumption 0.5-0.6 m3 Nil

Air Emission < 50 gram Nil

Energy Recovery Potential per ton of coke

Steam Nil 500-600 kg

Electricity Nil 40-50 kWh

Other Benefits

§ Cleaner process, offering significant reduction in environmental emissions

§ Produce high pressure steam suitable for steam generation

§ Low energy consumption

§ Improved and more uniform coke quality

§ Marginal moisture content generate energy saving in Blast Furnace

§ Better reliability and lower maintenance need

§ CDM Benefit

SCOPE- 21 Process for Coke Making

This is an innovative Coke Making Technology, developed by Japan, which allows greater use of poor quality coal and providehigher productivity and less polluting coking system. However, application of this technology in India needs further researchdepending upon the quality of Indian coal and quality of coke in demand in the down stream of steel making process.

Part_I | pg-20


SCOPE -21 eliminates the problems of limited choice of coal sources, associated environmental pollution and high energy consumptionin a conventional recovery type Coke Ovens.

Targets for SCOPE-21:

Increase in the use of poor quality of coal

Saving in energy and CO2 reduction

Reduction of NOx and dust

Higher productivity

Energy Conservation in Sinter Making

Sensible heat recovery from the main exhaust gas from the Sinter Machines and the Sinter Coolers have got great potential forenergy conservation in steel plants.

This facility is available in some of the new generation Sinter Plants in India, however, Sinter Plants of first generation (1960- 70s)are unable to recover this sensible heat due to logistics and space problems. A suitable technology /design supplier for retrofitting thesame in the existing layout would definitely yield less pollution and less energy cost for steel production.

Benefits:

Fuel savings in steam and coke of 0.55 GJ/ton of sinterwith power generation of 1.5 kWh/ton of sinter

Reduction in SOx (3-10%), NOx (3-8%) and particulatematter (PM)-30%

CDM Benefits:

CO2 emission reduction-approximately 15 kg/ton ofsinter

Energy Conservation in Iron Making

Direct injection of reducing agents

Direct injection of reducing agents (hydro carbons), in place of coke, in the furnace at the tuyere level, reduces the need for coke,reduce overall pollution and energy demand as well as avoid emissions at the Coke Oven Plant. Hydrocarbons may be in the formof heavy fuel oil, tar, granular or pulverised coal, natural gas or plastic wastes. Since coke acts as a mechanical medium as well,certain amount of coke is still necessary to allow proper Blast Furnace operations.

Benefits:

Replace coke in ration of 1:1Lower consumption of expensive coking coalExtend coke oven life as less coke is required to be producedReduced coke rateReduction of overall emissions from steel plant, particularlyin coke ovenPayback period is short as non-coking coal is utilized

CDM Benefits: Energy saving: 0.77 GJ/IHM

Theoretical maximum rate for coal injection at the tuyere level is @270 kg/THM. For every kg of coal injected, approximately 0.85 -


Part_I | pg-21

0.95 kg of coke production is avoided. At an injection rate of 180 kg/ton of hot metal, energy savings amount to 0.68 GJ/t hot metalor 3.6% of the gross energy consumption of the Blast Furnace. This saving is achieved indirectly due to reduced coke consumption.The use of CDI along with oxygen enrichment, saves coke and increases productivity of Blast Furnace.

Energy recovery from top gas pressure

High top pressure Blast Furnaces provide an ideal opportunity for recovering energy from the large volumes of pressurised top gasgenerated by means of an expansion turbine, which is installed after the top gas cleaning device. The electricity generated isreported to be as much as 15 MW in a modern Blast Furnace with a top gas pressure of 2 - 2.5 Kg / cm2.

Benefits:

Energy conservation, may save up to 0.4 GJ/ton ofhot metal for 15 MW turbine

Generate electicity of approx. 40-60 kWh/ton of hotmetal

CO2 emission reduction

Excellent operational reliability, abrasion resistance

Energy Conservation in Rolling

Walking Beam Furnace

The walking beam furnace can be designed to receive cold product from the slab yard or hot product from the caster. The walkingbeam furnace is designed to efficiently heat the incoming material to rolling temperatures with satisfactory temperature uniformity forfurther processing. The walking beam furnace replaces the energy-intensive pusher type furnace that employs combustion controltechnology resulting in reduction of electricity usage by 25 percent per ton produced and , overall, reduction of fuel consumption by35 percent per ton produced.

Features & Benefits:

Highly energy efficient

Uniform heating

Enhanced quality

9.0 Barriers to Energy Efficiency Improvement

Although most of the measures for energy efficiency improvement are cost effective and provide net benefits within a certain timeperiod, only few measures have been or are currently being implemented in the Indian integrated iron & steel sector. Barriers toenergy efficiency improvement are of both general and process specific:

In capital scare country like India, capital intensive industries generally focus on reducing capital costs rather than beingconcerned about energy inputs.

Furthermore, since most of the more efficient and modern technologies and equipment cannot yet be manufactured in India,acquisition of such technologies is difficult.

Part_I | pg-22


Public sector integrated steel entities are usually old using obsolete technology. Many, particularly more advanced, energyefficiency options do not apply unless a complete conversion or retrofit of these technologies take place.

10.0 Effects on Carbon Dioxide Emissions

Energy is the single largest source of carbon dioxide emissions in the iron and steel sector contributing to global environmentalproblems. Reducing energy intensity is therefore not only beneficial in saving scarce resources and input costs, but also in reducingcarbon emissions and thus mitigating global climate change.

Carbon dioxide emissions range approximately 2 – 3.2 tons of CO2 per ton of crude steel production. Best practice CO2 emissionsamount to only about 1.2 to 1.8 tons of CO

2 per ton of crude steel. They vary from year to year due to structural changes in the sector.

India emits 4.4% of world’s CO2 emission and has grown very rapidly. The per capita CO2 emission is around 1.1 tones. The latestand most comprehensive national GHG inventory for India was prepared under the GOI endorsed the “Asia Least Greenhouse GasAbatement Strategy (ALGAS)” project (ADB 1999), a summary of which is worth mentioning.

CO2 emission accounts for 53% of the total GHG emissions. CH

4 and N

2O contribute 39% and 8% respectively.

The energy sector is the main emitter of CO2, accounting for 87% of the total emission, the rest coming from cement industry(4%) and land conversion (9%).

Biomass burning and agriculture sector are the main sources of CH4 and N2O emissions. A small portion is contributed by thetransport sector.

The industrial sector consumes about 50% of the total commercial energy produced in the country. The most energy intensiveindustries are fertilizer, Iron and Steel, Aluminum, Cement and Paper and Pulp. These industries account for nearly 65% of thetotal industrial energy consumption.

It can be seen from the Table below that by adoption of energy efficient technology, even with increased production of 110 milliontons, the CO2 emissions per year will remain unchanged.

Total Carbon Dioxide Emissions

Year 2007 - 08 2019 - 20

tCO2 / tcs 2.99 (Avg.) 1.5 (NEP-2006 Target)(2.04 to 3.18)

Crude Steel Production in India (MT) 54.52 110 (NSP-2005 Target)

Total CO2 Emissions per annum (MT) 163 165

11.0 Clean development Mechanism (CDM)

Steel sector is highly energy intensive industry. In India SEC in steelmaking is in the range of 6.5 to 8.2 GCal/tcs, vis-à-visinternational value of 4 to 4.5 GCal/tcs. India is the sixth largest producer of green house gases, contributing almost 3% of word’stotal emission. CO

2 emission in steel making stem from the intense consumption of fossil fuels – for thermal energy, coke making,

process requirement and electrical energy, mainly. Reducing energy intensity is therefore not only beneficial in saving scarceresources but also in reducing carbon emission and thus mitigating global climate change. It is need of hour for iron & steel industriesof developing countries like India to take a sustainability approach for utilization of the limited fossil fuel reserves on the earth.However, such technological initiatives for curbing GHG emissions, requires substantial capital investment. The question is at whatcost can this be made possible, how can we negotiate technology transfer deals and how can we make these transfers financiallyviable. The only ray of hope that could be visualized is through the adoption of Clean Development Mechanism (CDM) more so whenIndia became a party to the Kyoto Protocol under the United Nations Framework Convention on Climate Change (UNFCCC).

CDM is one of the three “flexibility mechanisms” identified in the Kyoto Protocol that participating countries can use to meet their GHGreduction targets. The other two are Joint Implementation (JI) between the Annex-I Parties [Article 6] and Emissions Trading (ET)[Article 17].

Kyoto Protocol [Article 12] allows developed countries and countries with economies in transition to meet their greenhouse gas


Part_I | pg-23

reduction commitments by engaging in CDM projects that reduce GHG emissions. Developing, or non-Annex I, countries that haveratified the Kyoto Protocol can benefit from these CDM projects to promote sustainable development. Annex-I countries, in return,receive Certified Emission Reduction (CERs) credits for investing in CDM projects in non-Annex I countries, which can be usedagainst their GHG reduction commitments under the Kyoto Protocol. Those credits (certified emissions reductions, or CERs, in unitsequivalent to one ton of CO2 emission reduction) can be sold, traded, or used towards reducing the investor’s domestic commitmentsto GHG emission reduction.

The Clean Development Mechanism (CDM) has dual goals: to reduce global GHG emissions and to bring about sustainabledevelopment in developing countries. To achieve these goals, CDM promotes investment flows from developed countries to developingcountries in “environmentally clean” technologies or upgrading existing technologies.

CDM project opportunities exist in a number of sectors, including power, oil and gas, renewable energy, energy efficiency,transportation, solid waste management, agriculture or any industry where by implementation clean technologies either directreduction of GHG can be attained or energy conservation can be effected. Afforestation and reforestation project activities are alsoeligible under the CDM and are commonly referred as “sinks” projects or carbon sequestering projects.

The salient Features of the CDM are:

Participation in a CDM project activity is voluntary. Both public and private entities are eligible to participate.

CDM investments are market driven.

CDM activities lead to measurable reductions in emissions, which is transferable to the investor in the form of CERs, uponquantification and certification by a third party.

The reduction in emissions is additional to any that would occur in the absence of the approved project activity.

Contributions to sustainable development in the host country are a primary aim of CDM projects.

11.1 CDM in SAIL

SAIL has achieved significant production cost reductions in the last decade and the thrust on cost reduction is expected to continuein the medium to short run. A large part of the cost reduction is achieved through improved energy efficiency in the productionprocesses. This is reflected in the fact that the major integrated steel plants on an average have achieved reduction in specific energyconsumption to the tune of 12-13% in the last decade. The scope of energy savings and GHG mitigation exists in nearly all theprocess of integrated steel plants. Many such initiatives are planned in the near future also, which are likely to be potentiallyattractive CDM projects such as:

Coke Dry Quenching with new coke oven batteries

Tall coke oven batteries in place of conventional batteries

Waste heat recovery from sinter cooler of Sinter Plant

Multi-slit burners at Sinter Plant

Top recover gas turbine at Blast Furnace

Waste heat recovery from stoves of Blast Furnace

Coal dust injection in Blast Furnace

Use of by-product gas as fuel

Use of surplus gases for power generation

Thin slab caster

Walking beam furnace at Rolling Mill

Part_I | pg-24


SAIL has already identified 71 projects covering 5 integrated steel plants and having potential to attract CDM benefits. These 71projects have been segregated into two groups. The first group (A) comprises 38 projects from Coke Oven, Blast Furnace and SinterPlant, while the second group (B) comprises 33 projects from Basic Oxygen Furnace, Rolling Mills and other units. To facilitate,bundling of similar projects at different plants two separate consultants are planned to be appointed. M/s Asia Carbon EmissionManagement India (P) Ltd. is working on Group A projects.

Estimated carbon reduction from implementation of these projects is likely to be 6.1 million tons of CO2 annually.

12.0 Conclusions

Growth in steel demand is highest in the developing countries and will continue to grow to meet domestic as well as global demandof steel. Further improvement in energy efficiency is the only option to counteract the increased energy demand. However, lack offinancing capabilities as well as lack of incentive and investment programs impede the implementation of such measure. Therefore,sectoral policies should be devoted to the promotion of such investments. An optimal policy strategy would consist of a mix ofregulatory and price based incentives within a set political and economic framework.

References:

1. Report on India’s Iron & Steel Industry: Productivity, Energy Efficiency and Carbon Emission by Katja Schumacher &Jayant Sathaye, US Deptt. of Energy

2. Future Technologies for Energy Efficient Iron & Steel Making by Joroen de Beer, Ernst Worrell and Kornelis Blok

3. National Environmental Policy-2006

4. SAIL Vision-2020

5. National Steel Policy-2005


Part_I | pg-25

Regulatory Mechanism Adopted to Control Pollution in DRI Steel Plants of Orissafor Protection of Environment

Akhila Kumar Swar1, Siddhanta Das2

1 . Senior Environmental Engineer2 . Member Secretary, State Pollution Control Board, Orissa, India

1.0 introduction:

Steel making through Sponge iron route involves the separation of iron from iron ore by reduction in a kiln at appropriate temperatureand pressure. Direct reduction of Iron (DRI) is defined as a process used to make solid metalized iron product named as sponge ironfrom iron ore or pellets using natural gas or a coal-based plant. DRI steel industry in India is growing since introduction use ofsponge iron in 1980 as a substitute for ferrous-scraps in secondary steel production and knows as one of the mineral based industry.In less than a quarter century, Indian sponge iron industry has earned the distinction of being world’s largest producer of spongeiron. India became the major destination for establishment of DRI sponge iron/ integrated steel plants due to its huge mineral reserveof suitable grade of iron ore and non-coking coal. All these new capacities are mostly coal based and are located in iron and coal richstates like Orissa, Chhatisgarh, Jharkhand, West Bengal and Andhra Pradesh.

But due to limited availability of natural gas in India, coal-based DRI steel units have witnessed exponential growth in recent past.The sector is attracting investment mainly due to short gestation period, proven technology and equipment, assured market, quickpay back and growth potential and of course, highly remunerative. Additionally, sponge iron for the blast furnace will continue toreceive attention for high productivity or lower coke rate for an existing blast furnace. In the recent months, some for the majorintegrated steel plants of the country have made trials to use sponge iron in blast furnaces to decrease the costly and scarce coke.

Orissa having huge reserves of iron ore of all grades) and non-coking coal has attracted entrepreneurs to establish coal based DRIsteel/ sponge iron plants. Most of these plants have come up in clusters especially in the areas having coal or iron ore. All these unitsdepend on high grade Iron ore (+65% Fe content) in the form of Hematite available from Keonjhar and Sundargarh districts and coalfrom M/s Mahanadi Coalfields Ltd (MCL, both from Talcher and Ib Valley area) of Orissa. In addition to 50 TPD/ 100 TPD (ton perday) large DRI steel plants through have also come up in the state having multiple kilns of capacity of 300/350/500 TPD. The trendof growth of sponge iron plants in Orissa is given in figure 1. So far 107 DRI steel/ sponge iron plants have been operating in Orissahaving 244 rotary kilns and installed capacity of around 33225 TPD (about 10 million TPA). Government of Orissa in the mean timehave signed Memorandum of Understanding (MOU) with some leading mega industrial houses for establishment of new integratedsteel plants/ capacity expansion of existing plants which are mostly DRI/ Blast furnace based. The integrated steel plants coming upthrough DRI route consists of coal washery, iron ore crushers, DRI kilns, WHRB (Waste heat recovery boiler)/ AFBC (AeratedFluidized bed boiler), Steel melting shops (induction furnaces/ arc furnaces), Re-Rolling mills, blast furnaces, Ferro-Alloy plants,CPP (Captive Power Plant), inside the same premises.

The sponge iron plants are mostly concentrated in nine districts of Orissa. The district wise distribution of sponge iron industriesoperating in Orissa is given in figure 2. It is observed that around 62% of Sponge Iron Plants are located in two mineral rich districtslike Sundargarh and Keonjhar of Orissa.

Part_I | pg-26


Table 1 : Sponge iron plants operating in different districts of Orissa ( Number of kilns and production capacity)

District No. ofSponge Kiln Capacity (TPD)/ No. of PlantsIronPlants 25 TPD 40/50 TPD 100 TPD 300/350 TPD 375/500 TPD

Sundergarh 47 01 40 65 02 0(01) (20) (27) (02)

Keonjhar 20 Nil 15 28 05 04(07) (11) (05) (02)

Sambalpur 10 Nil 02 10 04 05(01) (05) (02) (02)

Jharsuguda 13 Nil 01 22 06 0(01) (08) (04)

Angul 03 Nil 0 03 02 0(02) (02)

Denkanal 04 Nil 0 02 02 06(01) (02) (01)

Jajpur 05 Nil 02 05 02 02(01) (03) (01) (01)

Cuttack 04 Nil 02 04 0 01(02) (01) (01)

Mayurbhanj 01 Nil 0 02 0 0(01)

Total 107 01 62 141 23 18

Kiln Capacity No. of kilns Installed production Capacity (TPD)No. of 25 TPD Kilns - 01 25

No. of 40/50 TPD Kilns - 62 3050

No of 100 TPD Kilns - 141 14100

No. of 300/350 TPD Kilns - 22 7300

No. of 375/500 TPD Kilns - 18 8750

Total - 244 33,225Maximum annual production potentiality of sponge iron (DRI) in Orissa – 10 million TPA (ton per annum)

Figure 1 : Cumula t i vegrowth of sponge iron plantsin Orissa


Part_I | pg-27

2.0 POLLUTION POTENTIAL OF DRI STEEL PLANTS:

2.1 AIR Pollution Potential AND ITS CONTROL IN Sponge Iron Plants:

After direct reduction of iron (hematite) in the rotary kiln the hot flue gas with high temperature at about 1000 OC at a rate of 24,000Nm3 /hr/ 100 TPD kiln containing high concentration of fine dust particles (P.M. – 30 gm/Nm3) is released to the atmosphere throughABC (After Burning Chamber) of stack height 35 meter. The residual carbon or CO is burnt by the excess air made available in ABCbefore the flue gas is taken through heat exchanger/ waste heat recovery boiler/ ESP . Rotary Kiln is the measure source of airpollution in a DRI manufacturing process besides a number of material transfer points where fugitive dust is generated.

Considering the above figures, it is calculated that 17,280 kg of dust would be emitted to the atmosphere per day from each 100 TPDrotary kiln in the absence of air pollution control device. This is the main source of air pollution in the vicinity. In ideal condition withthe operation of adequate pollution control devices like ESP, the emission of Particulate Matter is expected to meet the standard of 100mg/Nm3 and in such condition 57.6 kg/day of dust is emitted from the chimney of ESP/GCP (Gas Cleaning Plant) of a 100 TPD kiln.

The SPCB, Orissa has stipulated stringent emission standard of 100 mg/Nm3 for kiln ESP/ GCP stack and 100 mg/Nm3 for Bag Filterstack. To achieve the prescribed emission norm varieties of air pollution control systems are adopted in Indian sponge iron plants toclean the particulate matter from the flue gas emitted from the sponge iron kilns. These can be broadly classified into wet system anddry stem. Due to the fact that most of the sponge iron plants are located in water scarce area of Orissa, these plants have adopteddry system. It is observed that 100 TPD or larger capacity sponge iron plants generally have installed Heat Exchanger/GasConditioning Tower/ WHRB followed by ESP. Where as 50 TPD plants have mostly installed Gas Cleaning Plants (GCP) consistingof Heat Exchangers followed by Cyclone and Pulse Jet Bag Filters. However, only two 50 TPD plants have adopted Heat Exchangerwith ESP. The kiln flue gas is passed through heat exchanger or WHRB or GCT to bring down temperature from 900 oC to about 180oC as per the design requirement of ESP/ Bag Filter. Then the cooled gas is passed through either ESP/ Pulse Jet Bag Filter.

Lot of fugitive dust is generated during crushing of raw material like iron or coal and at all material transfer points along conveyor line.The sources of fugitive dust generation in the sponge iron plants and the prescribed control measures are given in table 2.

Figure 2: Distr ibut ion ofsponge iron plants in ninedistricts of Orissa

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Table 2: Sources of fugitive dust in DRI steel plants & prescribed control measures

SI. No. Sources of fugitive dust emission Control measures prescribed by SPCB, Orissa

1 Raw material handling & preparation area Automised water spraying system. Work zone to be concreted.

2 Crushing and screening of coal (Coal circuit) Pulse jet Bag Filter & automised water spraying nozzles(Dry fog system)

3 Crushing and screening of iron ore (Iron ore circuit) Pulse jet Bag Filter & automised water spraying nozzles

4 All material transfer points and conveyor belt Enclosures with hood and suction arrangement followedby Pulse jet Bag Filter

5 Material transfer points and vent of Pulse jet Bag FilterRaw material storage bins

6 Raw material feeding point into kiln Pulse jet Bag Filter

7 Coal injection point into kiln Pulse jet Bag Filter with recycling of coal finesback into the coal injection system

8 Leakage from slip rings of the rotary kiln Realignment of the kiln and changing of seal/ packingmaterials during shutdown period

9 Cooler discharge circuit Pulse jet Bag Filter

10 Intermediate bins in between cooler Pulse jet Bag Filterdischarge area and product separation unit

11 Product separation unit Pulse jet Bag Filter

12 Induction Furnaces/ Arc Furnaces Hood and suction arrangement folloed by Pulse jet Bag Filter

13 Blast Furnace Gas conditioning plant (GCP) consisting of scrubber

14 Coal crusher and screen in coal washery Combination of dry fog system and Pulse jet Bag Filter

15 Wind blown dust from solid waste dump yard Provision of boundary wall around the dump yard,covering by earth and automised water spraying onthe dump area by rotating nozzles.

16 Handling of fine dust retained in the Air locking valves, enclosures, pneumatic dust handlinghoppers of the ESP system followed by pug mill for the plants above

200 TPD kiln capacity

17 Handling of fine dust retained in the hoppers Air locking valves, enclosures, pneumatic dustof the Pulse jet Bag Filters handling system followed by pug mill installed in

some of the plants above 300 TPD kiln capacity

18 Internal roads/ Transport roads Construction of Black topped/ concrete internal roadsand approach roads. Installation of rotating type watersprinkling nozzles along the roads. Periodical cleaningby road sweeper, cleaning by water hose or by adedicated team of sweepers.

19 Care during transport of materials/ solid waste Vehicles should be covered

2.1.1 OPERATIONAL AND TECHNOLOGICAL BOTTLENECKS CAUSING AIR POLLUTION:

A. Emission of untreated flue gas through kiln cap by-passing ESP/ GCP of the kiln:

Many sponge iron industries are found to emit untreated flue gas through kiln caps by-passing air pollution controldevices (ESP/GCP). This happens due to the following reasons.

1. Malfunctioning of pollution control devices like ESP, Bag Filters, dust handling systems


Part_I | pg-29

2. Inadequacy of the existing pollution control devices

3. Extreme unstable condition of the rotary kilns

4. Pollution control devices when not operated to save energy

5. Power failure from the grid

6. Technological limitation like opening of cap during start up and shutdown period of the rotary kiln

7. Failure of grid/ failure of WHRB

B. Air pollution caused due to other non-compliances:

Even after installation all pollution control devices in the plant, the ambient air quality with regard to SPM and RPM, do notmeet the standard many times due to generation of dust from the following sources,

1. Bad house keeping,

2. Internal and approach roads not black topped/ concreted, work zone not concreted. Loose dust periodically notremoved from roads, which become airborne.

3. Unloading of raw materials, loading of chars and fines carelessly. Trucks not covered and there is spillage ofmaterials on the road during transportation.

4. Fine loose dust form the work zone and raw material and solid waste dump yards become wind borne during stormyweather.

5. Leakage of flue gas through kiln cap in between power failure and start up of D.G.

6. Inadequate dust suppression

7. ESP/ BF dust handling system not mechanized in smaller capacity plants. Dust collection points under the hoppersproperly not enclosed.

8. If the plant do not have dedicated team for proper house keeping and attending to pollution problems.

9. Non-availability of experienced technical manpower

10. Extra dust load to the system due to bad coal quality in the region

11. Lack of maintaining proper maintenance schedule of the pollution control equipments.

2.2 Sources of Water Pollution and its Control:

Water requirement generally varies in the range of 3-5 m3 per tonne of product, which is used mostly for the purpose of cooling, boilerfeed, scrubbing, coal washery, water sprinkling for dust suppression, domestic purposes and plantation. All efforts should be madeto reuse and re-circulate the water and maintain zero effluent discharge.

2.2.1 STATUS OF WATER POLLUTION CONTROL:

It is observed that water used for cooling of rotary cooler is completely recycled in all the units. The sludge generated at the bottomof the wet scrapper of After Burning Chamber of the kiln is collected in settling tanks and the settled water is so scanty that it getsevaporated and not recycled. Most of the water injected into Gas Conditioning Tower to bring down the flue gas temperature from 900to 180 oC in a few plants get evaporated and the remaining water that is collected in tanks is recycled after settling. Domestic effluentis generally discharged to septic tanks and soak pits. Large plants are adopting STP.

The integrated steel plants (DRI route) have provided neutralization system for DM plant effluent. The boiler blowdown and coolingtower blowdown is used for dust suppression or plantation. In rainy season, the chances of surface runoff & seepage of rain waterthrough solid waste dumps are very high. The water coming from all around the dump area contains high concentration of Totalsuspended solids (TSS). Since this type of plant handles lot of fine dusty materials, the storm water from factory premises during rainsalso contains high TSS. The polluted runoff water when finds its way to the nearby land or stream create water/ land pollutionproblem and invites public complaints. Many of the industries in the meantime have constructed garland drains and settling tanks atthe end of runoff drains to prevent discharge of solids to outside. Now it has been made mandatory to construct settling tanks forsettling of runoff water and prevent the solids to go out of the factory premise. The coal washeries are required to clarify the effluent

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and fully recycle the water in the process.

2.3 Solid Waste Management:

Next to air pollution problem, solid waste disposal has become a major concern in DRI plants. Ideally 154 tones of iron ore (+65 %grade) and 120 tones of coal (B grade) are required for production of 100 Tones sponge, which should generate about 45 tones ofsolid waste including 25 tones of char. But due shortage of good grade of coal and abundance availability of poor quality coal (Fgrade), the raw material requirement increased upto 370 Tones (Approx.) including 160-170 Tones of iron ore and 170- 200 tonesof coal for production of 100 Tones sponge.

The main solid waste is char (50 Tones/day for a 100 TPD plant), which is generated from reduction process of iron ore blended withcoal in sponge iron kilns. After reduction and cooling of iron ore, the char is separated from sponge in the product house by meansof magnetic separators and stored in separate bins for further transportation. The char is blackish in colour and has particle size inthe range of 0.5 mm to 3 mm and density of 0.8 in dry powder form.

The generation of solid waste in the form of fine dust (about 50 Tonnes/day for a 100 TPD plant) is directly proportional to theefficiency of pollution control devices installed (ESP/ GCP/ VS). Thus Air pollution is converted into solid waste disposal problem.Due to use of high ash containing coal (ash > 40 %) higher amount of solid waste is generated and it is estimated that more than 100tons solid waste including char, ESP and Bag Filter dust is generated from the production of 100 Tons of sponge. As per a roughestimation dumping of waste will require minimum of 10 acres of land per 100 TPD sponge iron production considering a life span of10 years.

2.3.1 PRESENT STATUS OF SOLID WASTE MANAGEMENT:

1. At present none of the 50/ 100TPD DRI plant in Orissa is using char for power generation. However few DRI plants (300– 500 TPD Kilns) have started using char mixed with coal as fuel in AFBC boilers for generation captive power and fewhave proposed to do so.

2. The flue dust collected from ESP is utilized for making bricks in some leading sponge iron plants for their internal use.

3. Some entrepreneurs have tried to use char and coal fines for making briquette, used as fuel. It is yet to be popularized,but this practice is not going to solve the problem.

4. In the absence of substantial practical use of such huge quantity of solid waste, there is no alternative but to use it for fillinglow lying area and follow proper dump management practice. Most of the sponge iron and steel industries are simplydumping their solid waste on their own land, earmarked for it or for filling low-lying area inside or nearby the factorypremises. Few industries have their dumping area away from the factory premises and transport of waste some timecreate public nuisance when dumped on the road side.

5. Solid wastes like scrap, slag ,dust, sludge generated from EAF/ IF/ SMS/ Blast Furnaces are reused or dumped on ownland.

6. Many industries have stabilized and reclaimed their solid waste dumps with earth cover and started plantation.

So acquisition of sufficient land is essential during setting up sponge iron plants/ DRI steel plants. Proper dump management plan willfacilitate disposal of larger quantity of solid waste on a fixed area with stable dumps of optimum height. Possibility for utilization ofchars and fines should therefore be explored. Filling of abandoned mine pits should be adopted.

3.0 Enforcement MECHANISM ADOPTED IN ORISSA for control of pollution IN DRI STEEL PLANTS:

The following enforcement mechanism has been adopted by the State Pollution Control Board, Orissa to ensure effective pollutioncontrol in DRI steel/ sponge iron plants.

1. All the plants are required to obtain consent to establish and Consent to operate from SPCB, Orissa under the provisionof Water (Prevention and Control of Pollution) Act, 1974 and Air Prevention and Control of Pollution) Act, 1981 and theamendments made thereafter.

2. Consent to operate is not granted by the SPCB, Orissa and the industry is not allowed to start operation till completion ofinstallation of ESP/ GCP/ Bag Filters and other major pollution control measures in the plant. 3. Monitoringof PM, RPM, SPM and other environmental parameters is conducted at regular interval to assess their status of emissionof pollutant and ambient air quality.


Part_I | pg-31

4. Surveillance inspection and monitoring of the industries are conducted even during night hours.

5. Installation of separate energy meter for ESP/ GCP and Bag filters is mandatory and furnishing energy meter readingsand production figures every month to the State Pollution Control Board (SPCB) to cross check if the pollution controldevices are operated continuously.

6. Watch-dog-committee at the local level (inducting members from the local public) under the supervision of districtadministration has been constituted by the direction of the Board to report operational status of pollution control devicesand other pollution problems pertaining to each sponge iron to the District Collector and SPCB. This has been done toencourage public participation in controlling pollution.

9. Since filing of legal case in the court of law and its disposal is a time taking process, prompt action is achieved to solvethe pollution problems by issuing show cause notice and after giving sufficient opportunity,closure direction is issued tothe defaulting DRI plants under section 31A of Air(Prevention & Control of Pollution) Act, 1981 and 33A of Water (Prevention& Control of Pollution) Act, 1974 to close down the operation of the plant till the pollution control measures are rectified oradopted. In such cases the district Collector and Superintendent of Police (SP) are directed to ensure physical stoppageof the operation of the plants if necessary. The Electric Supply Authorities, Mahanadi Coal Fields. Ltd., Minning Departmentare directed to stop supply of electricity and minerals to implement closure direction. As soon as the defects in pollutioncontrol systems are removed, the industries are allowed to restart their operation. This mechanism has yielded goodresult in correcting the polluting industries.

3.1 Directions issued by SPCB, Orissa to DRI Steel Plants :

Due to technological limitations, coupled with use of inferior grade coal and non-availability of qualified technical manpower, thissector has posed serious problems of air pollution especially in areas where they are located in clusters, in the districts of Sundergarh,Keonjhar, Sambalpur, Jharsuguda, Dhenkanal, Cuttack and Jajpur. The problem had reached alarming proportions and there waslarge scale dissatisfaction among the local people, who were facing the brunt. Through strict enforcement mechanism, installation ofmodern pollution control equipments/ devices, scientific disposal of solid waste, the problem of dust pollution has been contained toa great extent. Solid wastes containing dolochar and fly ash were not being scientifically disposed of, causing public nuisance.Board has geared up its enforcement mechanism in the recent months by making surprise inspections through surveillance team andhas taken strong punitive action against defaulting units, found causing pollution. As many as 37 DRI Plants had been issued withclosure orders during 2008-09. To prevent the situation from further aggravation and to bring down the level of pollution in theproblematic areas, Board has issued the following directions and guidelines to the DRI steel/ sponge iron plants for strict compliance.

Directions:No sponge iron plant shall use coal having ash content more than 35% in the kiln as feed.

Iron ore below 5 mm size shall not be fed into the DRI kiln so as to minimize dust generation in the process;

Frequent shutdown and startup of the kilns shall be avoided and normal campaign period shall be maintained, keepingthe kilns in healthy condition.

DG sets of adequate capacity with Auto Mains Failure System (AMF) shall be installed within 2 months to ensure that allpollution control devices operate continuously.

The coal circuit in full or part thereof shall not be operated during 6 P.M. to 6 A.M., During this operation, air pollutioncontrol devices shall be operated effectively.

The aforesaid direction is reviewed from time to time and significant compliances have been observed. For effective implementationof the pollution control measures in DRI steel/ Sponge Iron Plants, Board has formulated the following guidelines.

Guidelines :1. The industry shall take up preventive maintenance of the existing pollution control devices/measures to ensure their

effective operation. The industry shall maintain a separate register for this purpose and the register shall be open forverification of the inspecting officers of the Board.

2. The operation time of coal crushers of the sponge iron plants shall be restricted to 6.00 A.M. to 6.00 P.M. The crushershall be operated alongwith adequate pollution control measures. Under no circumstance, the coal circuit shall beoperated during 6.00 P.M. to 6.00 A.M.

3. Presently pneumatic dust handling system/ screw conveyor is being installed to handle ESP /GCP dust of the kilns.Henceforth, all the sponge iron units shall also install mechanical dust handling system like screw conveyor with water jets

Part_I | pg-32


at the hopper of each bag filters to control fugitive emission.

4. Accumulated dust from process area shall be removed on daily basis. The solid waste generated from the plant includingchar and fines shall be transported to the dump site by covering the truck/dumper with tarpaulin. The solid waste shall bedumped only in the designated site approved by the Board and shall be leveled with earth cover and compressed fromtime to time. The active portion of the dump shall be wetted periodically through spraying of water mixed with specialchemicals to control propagation of dust from the dumping site.

The inactive portion of dump and the slopes shall be adequately covered with tarpaulin immediately to prevent air bornedust. The slope of the dumps shall be stabilized by putting coir mats and soil followed by plantation of grass or othersuitable plant species. Dry disposal practice of the solid waste in a scientific manner shall be followed by the industry.

5. Utilization of Char and Solid Waste:

The industry shall utilize 20% of the char generated in the 1st year and progressively increase by 20% of chareach year. At the end of 05 years, 100% of char shall be utilized.

It shall be mandatory for the sponge iron plants having kiln capacity of 200TPD or more to install WHRB and AFBCboiler to utilize char as well as to ensure continuous power supply for ESPs and other pollution control devices.

All the sponge iron industries with the capacity of 200 TPD and above will install fly ash brick manufacturing unitwithin a period of 6 months to utilize the fine dust captured by ESP/GCP/bag filters/Boilers.

All sponge iron plants shall install coal brequitting plant and adopt other available methods for effective utilization ofchar and solid wastes.

6. In order to ensure effective operation of the pollution control devices and strengthen environmental management insidethe plant, it shall be mandatory for each sponge iron plant to appoint Graduate Engineers having who will lead adedicated pollution control team independently in the plant and report to the Managing Director/occupier of the plantdirectly.

7. The surveillance team of the Board officials shall visit different areas of the State every month.

8. Further, the Regional officers shall hold interaction meetings within the villagers located around the sponge iron clusterto discuss issues related to environmental issues periodically.

9. Dedicated D.G. sets of adequate capacity shall be installed to ensure sufficient standby power supply to run allpollution control devices of the plant in the event of power failure. D.G. sets should be equipped with A.M.F. (Auto MainsFailure Panel) for auto change over of power supply from grid power to D.G. Power in the event of power failure. TheAMF Panel shall be PLC (Programmable Logic Control) based.

10. All the sponge iron plants operating in Orissa shall use washed coal having ash content, less than 35% to reduce theburden of solid waste disposal around the plants and amount of dust load in the flue gas of kiln. This will also increasecampaign period of kilns and reduce emission due to frequent starting and shutdown of the kilns.

11. Adequate sealing arrangement shall be made at the emergency cap of each rotary kiln to prevent leakage of flue gaswhen cap is closed. Except very emergency situation the cap shall not be opened during operation of the kiln and all kilngas shall be passed through ESP or GCP. The practice of frequent opening of caps shall be stopped and the industryshall train its kiln operators immediately to control kiln pressure by synchronizing the I.D Fan with variable speed driveand heat exchanger/GCT with ESP/GCP system without frequent opening of the kiln caps. The industry shall keep arecord of events of cap leakages in a register and inform to Regional Office immediately by Fax or SMS justifying thecause.

12. Overstretching the campaign period of the kilns increases generation of dust from different points of the kiln and capleakage. The kilns shall not be operated beyond the normal period of campaign and shall take shutdown as soon as thefollowing conditions are noticed.

i) When back flow of raw materials like coal/iron ores starts (whichever is earlier).

ii) When kiln rpm, ID fan rpm and kiln pressure starts exceeding the normal range.

3.2 Achievements made in implementation of pollution control measures in DRI steel/ Sponge IronPlants in Orissa through regulatory action over a period of time:

To achieve the prescribed emission norm, various pollution control systems are adopted in the DRI steel/ sponge iron plants. Thestatus of improvement achieved during 2000-2008 with the continuous guidance and effective enforcement action made by the SPCB,Orissa, is summarised as follows.


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Prior to 2000 : M/s Orissa Sponge Iron Ltd, Palaspanga and M/s IPITATA Sponge Iron Ltd ( presently Tata SpongeIron Ltd.), Bleipada, Keonjhor were operating with Wet Ventury Scrubber as APC device. GasConditioning Tower (GCT) with Electrostatic Precipitator (ESP) were installed in these plants later.

2001-2002: The 50 TPD/ 100 TPD sponge iron plants adopted wet scrubbing system to clean flue gas at the top ofthe stack attached to ABC of the kilns called Jumbo Scrubber. These units were not confident if ESP willwork for these small kilns. After conducting performance evaluation, the Jumbo Scrubbers were foundto be not effective and gradually discarded.

2002-2003: In the matter of OJC No.109/2002, M/s Sivashakti Sponge Iron Ltd., Pandersil, Maurbhanja Vrs OSPCBoard & others, the Board submitted to the Hon’ble High Court, Orissa that the industry must install ESPat its 100 TPD Kiln to control the emission of Particulate matter from the kiln stack. As per the direction ofthe Hon’ble High Court of Orissa, ESP was installed by the industry in a time bound manner and thecase was disposed on 12.08.2002. After successful operation of the ESP in this 100 TPD plant, theBoard directed all other 50 TPD/ 100 TPD sponge iron plants operating at that time to install ESP at theirkilns.

2003-2004: The Ministry of Environment & Forests through a notification in Aug,2003 directed all Sponge IronPlants to complete installation of ESPs at rotary kilns by 31.12.2003. As follow up action to the above,the Board imposed bank guarantee to these industries for installation of ESP in a time bound mannerand closure directions were issued to the defaulting industries.

2004-2005: Due to the fact that most of the sponge iron plants are located in water scarce area of Orissa, theseplants have adopted dry system. 100 TPD sponge iron plants generally have installed Heat Exchanger/WHRB followed by ESP. 50 TPD plants have mostly installed Gas Cleaning Plants (GCP) consisting ofHeat Exchangers followed by Cyclone and Pulse Jet Bag Filters. However the 300/ 350/ 500 TPDsponge iron plants generally have installed waste heat recovery boiler Gas Conditioning Tower (GCT)followed by ESP. The Board has prescribed stricter emission standard of particulate matter i.e 100 mg/Nm3 at the outlet of ESP/ GCP of rotary kiln and bag filters of the sponge iron plants operating in Orissato minimise the pollution level around such plants.

Consequent upon mushrooming growth of DRI plants in cluster form, serious problems of dust pollutionwas witnessed. The board immediately swung into action and conducted a comprehensive study onimpact of sponge iron plants.

2005-2006: Government of Orissa after careful consideration of the study report of the SPC Board, Orissa andpublic resentment, made certain restrictions vide their letter No. 3808, dt. 4.8.2005 for regulating theestablishment of DRI sponge iron plants in the State of Orissa so that serious environmental problemscreated by such units are addressed properly.

2008 - 2009: By this time about 200 ESPs and 43 GCPs have been commissioned and operating in 107 DRI plantsof Orissa. It is observed that few plants have installed common ESP, designed for handling the flue gasof two 50/100 TPD Kilns, but GCP is found to have been connected to individual 50 TPD kiln. Suchhuge number of installation of air pollution control system (ESP/ GCP) could be possible due to effectiveenforcement action and continuous efforts of the Board.

Although the performance of GCPs are effective to comply the norms of 100 mg/ Nm3,but are highlymaintenance prone. On the other hand, ESP has been found to be effective and low maintenance need.The Board has issued direction to the sponge iron plants of capacity 2x50 TPD or more to replace theGCPs with ESP in a time bound manner.

Lot of fugitive dust was found to be emitted during handling of the dust pollutants retained in the hoppersof ESPs and bag filters. Direction has been issued to the sponge iron plants to install pneumatic dusthandling system followed by silo and pug mill at the ESPs and Bag Filters to control fugitive dustemission in the BF and ESP area. Many of the plants have either installed or in the process of installationof such system. By installation of such system dust nuisance in the work zone has been minimised andhouse keeping improved.

The DRI plants have installed separate energy meters for the pollution control devices to cross checkcontinuous operation of the ESP/ BF.

By constant pursuance and enforcement through Bank Guarantee mechanism, the internal roads and

Part_I | pg-34


work zone have been concreted or black topped and provided with water sprinkling system to minimisefugitive dust which is one of the major cause of dust nuisance.

House keeping and proper solid waste management have been given top priority to contain theenvironmental problems to a large extent. The industries which had dumped char and dust unauthorisedlyout side their premises, along roads side and riversides were made to remove the waste materials andrehabilitate to make the area fit for use. Efforts have been made to develop common solid waste dumpingsites for the sponge iron plants located in clusters in Sundergarh and other districts through the help ofdistrict administration and IIDCO.

Performance bank guarantee system has been adopted by the board to ensure that addition, up-gradation and improvement in existing pollution control devices/ measures are completed by the industryin a scheduled time frame. The mechanism has yielded very good result in accomplishing the objective.

Dusty environment due to wind action from the solid waste dump sites has been an eyesore and one ofthe issues of public complaint. All sponge iron plants were asked to cover their solid waste dumps withlayer of earth to control generation of wind borne dust. The compliance rate in this aspect is very highand there has been appreciable improvement. Further the industry has been advised to take upplantation after stabilising the dump with soil cover.

Besides the approach of end-of-the-pipe treatment, the Board has adopted the concept of prevention atsource by asking the DRI producers to use cleaner coal (or washed coal). This shall not only reducethe generation of air emission, but also reduce load on Air Pollution Control equipments, solid wastegeneration and land requirement.

For utilisation of Waste Heat from the flue gas emitted from the kilns, 31 nos. of sponge iron plants haveinstalled Waste Heat Recovery Boilers with a capacity to generate about 380 MW of Captive Power.This also help the industry to get continuous power supply for continuous operation of the pollutioncontrol devices thereby reducing the frequency of direct emission from the kiln and other dust generatingsources. This has attracted CDM benefit while reducing GHG (Green House Gas) emission andconsidered as a clean technology.

It has been observed that in spite all requisite pollution control measures are in places, problems ofemission continued to remain unabated due to under qualified technical manpower handling the job.

The Board has been strict and non-comprising on the point that the process plant and pollution controlequipments must be operated under the supervision of adequately qualified and skilled manpower tocontain the problems of pollution more effectively in a scientific manner.

There is significant improvement in AAQ due to adoption of effective Pollution control measures by thesponge iron plants. Concentration of SPM inside the premises of these plants has come down from alevel of 2000 mg/m3 to down below 500 mg/m3 in most of the plants.

The Board organised a workshop on “Emission Reduction in sponge Iron Plants and Integrated SteelPlants (DRI Route) of Orissa by adoption of clean technology” on 14.09.2008 at Hotel Swosti Plaza,Bhubaneswar which aimed at bring the statutory authorities, industries, technology suppliers, pollutioncontrol device manufactures and technical experts across the country on a common platform to sharetheir knowledge and experience on clean technologies and better operational practice for control ofpollution in sponge iron plants in a more effective manner. The Board is making continuous efforts forfurther improvement of environmental management in DRI steel/ sponge iron plants of Orissa.

Preventive and capital maintenance is now being practiced by the DRI plants with prior intimation toSPCB, Orissa to ensure effective operation of the existing pollution control devices/measures

Many DRI sponge iron plants (operating without WHRB CPP) have installed A.M.F. (Auto Mains FailurePanel) for auto change over of power supply from grid power to D.G. Power in the event of powerfailure.

The Regional Officers of the Board have been delegated with power to issue direction to the industriesto rectify the pollution control problems which can be sorted out in a short time.


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Some DRI Plants have installed fly ash brick manufacturing units inside their plant for effective utilisationof fly ash. Rest of the units have been asked to to use fly ash bricks for their construction work.

Some large DRI plants have installed coal washery and using wash coal. Some industries are in theprocess of installation of their coal washery. But small DRI plant could not install the same due toeconomic reason and there is large demand of washed coal in the state.

SPCB, Orissa is under taking Central Pollution Control Board sponsored project “ Assessment of emissionreduction by adoption of Clean Technology in sponge iron and integrated steel plants of Orissa”.

State Pollution Control Board sponsored a project “Laboratory Investigation on the Characterisation ofDolochar/ Waste Generated in Sponge Iron Industries” which is undertaken at IMMT (formerly RRL),Bhubaneswar to examine the utilization aspects of the solid waste.

SPCB, Orissa has introduced 3rd party Environmental Auditing of DRI steel plant which has now beingconducted for one plant.

All the sponge iron plants have installed Bag Filters at different material transfer/ handling points tocontrol generation of fugitive dust and maintain clean environment. Dust nuisance at other processareas is observed very often indicating inadequacy and defects continue to remain in their bag filtersystem. To address this problem the Board had engaged the IIT, Kharagpur for performance evaluationof all the bag filters of the 104 sponge iron plants of Orissa. The job is completed. Appropriate directionin line of recommendations of the study report is being issued to the respective units for rectification/ up-gradation of their bag filter system in a time bound manner.

Recently the SPCB, Orissa has started conducting participatory training programmes for senior levelexecutives responsible for accomplishment of Pollution Control in various industries with the followingobjectives: (a) Creating awareness on the relevant Acts/ Rules/ Regulations on environmental protectionand pollution control, (b) Provide a platform for the industries for experience sharing and learning formthe experts about the latest state-of-the-art pollution control devices and (c) Develop a self-regulatorymechanism for fail-safe pollution control.

All the above achievements have been made by continuous continuous efforts made by the SPCB, Orissa forfurther improvement of environmental management in DRI steel/ sponge iron plants of Orissa.

4.0 CONCLUSION AND RECOMMENDATIONS:

The steel making and mineral processing is inevitable. However the economic growth vis-à-vis environmental degradation shouldbe balanced and sustenance needs to be maintained with the following emerging concepts.

1. All the steel plants (DRI route)/ sponge iron plants should operate with the best available technologies.

2. Continuous power supply from the grid is essential. Alternatively the industries should install captive power plant alongwith Waste Heat Recovery Boilers to ensure continuous supply of power to the pollution control devices to prevent airpollution. Initiation should be taken to further encourage the potential industries to implement WHRB-CPP system andclean technologies in their plants in Orissa to minimize the GHG emission.

3. Technical solution should be evolved to provide appropriate pollution control device to prevent direct emission of flue gasthrough the chimney of the Kilns during the start up and shut down of the kilns, when the flue gas cannot be taken throughexisting ESP/ GCP.

4. Better technology for proper sealing of ABC cap is essential to control cap leakages from the rotary kilns.

5. Coal based DRI process has been proved to be highly air polluting. Alternative clean process technology like gas basedshould be adopted.

6. Complete recycling of cooling, scrubbing water, settling tank and rainwater harvesting structure will minimize waterconsumption. Wet scrubbing should be replaced with dry system.

7. Process modernisation & reducing water consumption, adopting optimum recirculation for reusing treated effluent andutilising maximum quantity of treated effluent for plantation & agriculture is essential

8. Maximum utilization of solid waste like char, fines, slags for briquitting, brick making, cement making should be emphasized.

Part_I | pg-36


Rest should be filled in mine pits/ low lying area. Prime agricultural land should not be used for dumping of wastes.

9. Management of natural resources vis-a-vis waste utilisation is an important area to think of.

10. Most of the proponents outsource the environmental issues to their consultants. But sufficient awareness and training isrequired for the shop floor people, managers on possible impact of their projects on environment and consequencesthereof. Pollution control and production activities should go side by side. The proponents/ occupier of the industryshould be personally review the pollution control activities and local environmental issues to avoid exploitation by thelitigant publics, penal action and closure direction from statutory authorities and to build up public image and gainconfidence of the financers in order to achieve better production and business promotion.

11. All the sponge iron/steel plants must adopt ISO 14000 international standards for environmental practices to improve theirhouse keeping, environmental management system and productivity.

12. A software controlled interlocking facility should be installed in order to prevent bypassing of untreated flue gas throughemergency cap of the rotary kiln of the DRI Plant and non-operation/malfunctioning of ESP or any other pollution controldevices attached to the kiln. This interlocking system shall ensure automatic stoppage of raw material feed conveyor to thekiln based on the real time data with provision for password, temper proof, keep a log with printing option and online datatransmission of non-compliance reports to the regulator.

13. To develop the mechanism of voluntary compliance at the state level like CREP (Corporate Responsibility for EnvironmentalProtection) guideline adopted at center, to adopt cleaner technology/pollution reduction to meet the stringent norms.

14. To adopt latest technology like open path monitoring/ on line monitoring and display system for monitoring of ambient airquality of polluted areas/ cities. To develop Web-based Database Management System and development of network fordata sharing among industries, Regional Offices and Head Office of the Board and stake holders.

15. To develop a mechanism for public awareness by providing a platform for regular industry–public interface, so that acongenial atmosphere can be created for effective control of pollution and sustainable development in the State.

16. Cleaner production is the final answer in any waste reduction, pollution prevention and it holds the key to sustainableindustrialization.

REFERENCES:

Administrative Staff College of India, Hyderabad and State Pollution Control Board, Orissa, State of Environment, Orissa-2006 report.

Chartterjee, Amit, 2005, A critical appraisal of Sponge iron production Technologies, Proceedings of National Seminar on “ Potentialo f SpongeIron in Indian Steel Industry, held at Ranchi, India.

Central Pollution Control Board, Charter on corporate responsibility for environmental protection (CREP), New Delhi, 2003

Crittenden B and Kolaczkowski S “Waste Minimisation Guide” Institution of Chemical Engineers, UK

Jha, Sudhahar, 2005, Future of Sponge Iron: Prospects and Challenges, Proceedings of National Seminar on “ Potential of Sponge Iron inIndian Steel Industry, held at Ranchi, India.

Mecalf & Eddy, Inc., “Waste water Engineering – Treatment and reuse”, 2003, Tata-McGra-Hill Publishing Co. Ltd., New Delhi.

Patnaik, N. M., 2005, Raw Materials for Sponge Iron Making Under Indian Condition. Proceedings of National Seminar on “ Potential ofSponge Iron in Indian Steel Industry, held at Ranchi, India.

Pradhan P.C, 2003, Handbook of Sponge Iron

Saha, V.P., 2005. Jharkhand Calling , Proceedings of National Seminar on “ Potential of Sponge Iron in Indian Steel Industry, held at Ranchi,India.

Sinha, Rajiv K. and Herat Sunil, 2003. Cleaner industrial production. Indian Journal of Environmental Protection, 24.

Sinha, R.P., 2005, Co-generation from waste gases emanating from Kiln in sponge iron plant – A must, Proceedings of National Seminar on “Potential of Sponge Iron in Indian Steel Industry, held at Ranchi, India.

Swar, A. K. , 2005, “ Pollution control strategies for sponge iron plants” 21st Environmental Engineers Convocation, 2004, BBSR

Swar, A. K. ,2001, Assessment of concentration and physico-chemical characteristics of atmospheric suspended particulate matter at Rourkela,Ph. D. Thesis submitted to Sambalpur University.


Part_I | pg-37

Reclamation, Rehabilitation Practices in Goan Iron Ore MinesA.B.Panigrahi1, Dr. A.N.Murthy2

1 . Regional Controller of Mines2 . Senior Mining Geoligist

Indian Bureau of Mines, Goa

Mineral exploitation (Mining) is second only to agriculture as the World’s oldest and most important industry. It is the ancient methodof winning the hidden treasures of the mother earth for human consumption. Civilization are chronicled as per the minerals mined outduring the period. Stone age, copper age, iron age etc. indicate that mining has contributed in abundance to human comforts andquality of life through the ages. In fact mining paved the way for other technologies to grow. Mineral and mineral based products areintegral parts of the economic and social fabric of modern society. Ultimately mining has become the strong pillar of human civilization.

Mining is a unique industry wherein project site is determined by location of deposit. However, as major minerals are generally foundin ecologically fragile and biologically rich forest areas their exploitation by mining inevitably leads to disturb the balance of natureand leaves a scar on mother earth unless protective measures are taken. Mining disturbs the equilibrium of land, soil, water, flora,fauna as for mining land has to be broken open. Mining does not mean permanent loss of land for other use. On the other hand itholds potential for altered and improved use apart from restoring for agriculture, forestry and irrigation provided planned measuresare taken from pre-mining till post-mining stage. Thus in order to harmonise the imperatives of mineral development with need toprotect the environment, scientific mining with simultaneous reclamation and rehabilitation of degraded area is vital.

The legacy of pollution and environmental degradation associated with mining industry has made the sustainability of the industry abig question mark. It has now become crucial to take drastic measures to develop the image of mining as an industry with a humanface with consideration for sustainable development.

Working Group on Mining & Environment’ constituted by Govt. of India, vide notification in 1979, identified that, out of the 10environmental problems 6 are related to land. These are land degradation, deforestation, problems caused by mine fires, land slidesin hilly regions, disruption of water regime and damage to sites of cultural, historical and scenic importance.

As per National Mineral Policy, 1993 the mining should be permitted only when accompanied by a comprehensive time boundreclamation programme. Further, the Environment Management Plan should cover restoration of mined out areas and for plantation.Reclamation and Afforestation have to proceed tandemly concurrent to mineral extraction. Efforts should also be made to convert olddisused mine sites into forests and other forms of land use.

The Government from time to time has been amending various statutes apart from persuading the mining industry for properreclamation and rehabilitation of mined out areas. Inspite of the best efforts the response from the industry was far below thesatisfaction level.

Under this backdrop the Government of India have made certain drastic amendments in Mineral Concession Rules, 1960 andMineral Conservation and Development Rules, 1988 in 2003 and have introduced the Mine Closure Plan.

Mine closure plan consists of two phases namely progressive mine closure and final mine closure. “Progressive Mine Closure Plan”means a progressive plan, for the purpose of providing protective, reclamation and rehabilitation measures. “Final Mine ClosurePlan” means a plan for the purpose of decommissioning, reclamation and rehabilitation in the mine or part thereof after cessation ofmining and mineral processing operations.

Thus Mine Closure Plan has the basic theme of enforcement of reclamation and rehabilitation measures of mines during the life of themine and to develop the mining areas to be compatible and self sustainable, when there is no mining activities in the area. Thenecessity is the proper planning and implementation of closure plan, specifically reclamation/ rehabilitation of degraded mining areasin a systematic and scientific way.

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The mining activities results in environmental degradation and in case of large scale opencast mining methods practiced, visibleeffects are eye catching.

Surface mining (1) eliminates surface vegetation, (2) can permanently change topography, (3) can permanently and drastically altersoil and subsurface geological structure, and (4) may disrupts surface and subsurface hydrologic regimes. Mining operationsspecifically open cast mining methods generate considerable amount of waste and waste dumping & its management is recurringchallenge for mining industry to make it environment friendly. The lack of proper reclamation / rehabilitation of degraded mined outareas can result in severe environmental consequences. In case of large-scale open cast mining areas, the land degradation in formof development of quarries and dumps is most conspicuous. Thus reclamation and rehabilitation of degraded land forms basic ladderof Mine Closure Plan.

Three terms are usually coined to describe the reclamation / rehabilitation process in general .

Reclamation:

The term Reclamation in simple term means return the mined out land with a useful condition. It implies restoring the land to a form andproductivity that is useful and in conformity with a prior land use and is not derelict. Reclamation always may not be a single-phaseoperation. Proper scientific planning and landscape development onwards is required to achieve the land or waste dump etc. fortheir productive use.

Rehabilitation :

Rehabilitation is to bring back the degraded land to a normal stage by a special treatment.It is process of taking some mitigationmeasures for disturbed environmental condition created through mining activities. This includes monitoring environmental parametersand adopting systems to prevent environmental pollution.

Restoration:

Restoration is the process of returning the mined out land being fit to an acceptable environmental condition. However the generalacceptable meaning of the term is bringing the disturbed land to its original form. Returning the land to its original form involves fillingand covering the disturbed areas. Further restoration is often applied to progressive or short life excavations, when the land can bequickly and obviously returned to its original state. Restoration is often used to indicate that the biological properties of soil are putback to what they were. This is a rare phenomenon.

The process of reclamation includes maintaining water and air quality, minimizing flooding, erosion and damage to wildlife & aquatichabitats caused by surface mining. The final step in this process is often topsoil replacement and revegetation with suitable plantspecies. Reclaiming the minesite and incorporating it into the existing landscape encompasses rehabilitating the mined out pits,tailings disposal, water & waste rock management, and ecosystem reconstruction. The main concern here is to blend the mine siteinto the surrounding landscape while minimizing environmental impacts.

In the present paper the feasibility of reclamation / rehabilitation of degraded land mainly quarry area and dumps which are the mostconspicuous features of iron ore mining in the state of Goa have been discussed. The land damage is the major impact of open castmining method. The land degradation occurs as result of excavations / pits made for winning the minerals, for disposal of waste, stackand topsoil storage etc. The extent of land degradation depends on the scale of operation and nature of topography. However,mining methods and development of mines vary depending on the nature of occurrence of mineral, its quality and techno-economicfeasibility of mining methods.

Mining is bound to cause land degradation for which corrective measures are required to be taken. Rehabilitative plans willenvisage broadly with an unsurpassed clarity of vision and wisdom the impacts, their extent & the mitigatory measures.

Unless a proper management of physical manifestations like dumps, tailing impoundments, open cast exhausted mine pits is carriedout it will become an uneconomic as well as ecological burden, at the end.

Thus the reclamation and rehabilitation measures should be taken up timely, as per the proposals made in the mining plan of whichProgressive Mine Closure Plan is an integral part. At the final stage Final Mine Closure Plan (FMCP) determines the completion ofreclamation.

Though over burden is non-toxic the washoffs to nearby land and consequently to water bodies is one of the critical problem, onaccount of wash offs from some mining areas into the watersheds several water courses, rivers may also get polluted. Iron orewashing is carried out to improve the quality for exports. During this process there is a slime loss of about 20-30 % of Run Of Mine.The slimes are impounded in tailing ponds which result in loss of large useful / fertile lands.


Part_I | pg-39

Goa produced more than 32.70 million tones of Iron ore in 2008-09(Provisional) also generates about 2.5 to 3 times of over burden/waste rock annually. Here, an acute problem of overburden management is being faced. Since the place is of tourist interest mininggenerates a lot of reluctance. Heaps of waste material is seen in almost all the mines. The ideal mining is to exploit the mineral fromone end to the other end of the lease and backfill the area with waste rock, so that the land could be used for various purposes. Butas on date only very small part of the lease area are exhausted and taken up for backfilling. Goa being a small state with about 15Lakh population the area reclaimed and area put to use for mining and allied activities is not matching and gap is increasing year afteryear. The villagers are extremely adverse in allowing further land for mining. This poses problem about the management of land formining industry. Further the complete process of reclamation, rehabilitation and handing over the land to the society is taking a longtime in the present set up.

Yet another problem in Goan Iron ore mining is water. As many of the mines have gone beyond the water table and the habitationare nearby to the mining areas excess pumping of mine water results in drying of water sources for the nearby habitation unlessproper watershed development is planned. Regular complaints are received from villagers in this regard. The pumped out water isto be recharged in such a way that there is minimum grievance from the nearby habitation. A study by IBM with BRGM, France in1997 has revealed that Mine water pumping has no Regional Influence on the water Table. In the same study it has been inferredthat piezometric variation and conductivity data also depict that pit water has no influence on sea water intrusion. However, if exceespumping is made without proper ground water recharge Sea and freshwater interface can not be ruled out as the Arabian Sea is notfar away.

Backfilling vis-a vis leaving the worked out pit as water reservoir is under debate in Goa. Very recently due to ever increasingdemand for water the Water Resource department of Goa is of the opinion to keep the Deep pits as water reservoir as they are thecatchment areas and these could be used as intermediate water supply stations thus reducing the load of the existing water supplyinfrastructure.

Method of Reclamation

Reclamation of land is carried out by landscaping or site preparation, soil amelioration and re-vegetation. A Mining Plan includes thereclamation plan specifying the details of various reclamation activities. It is worthwhile to take up the reclamation activities immediatelyafter the first phase of mining is over.

Landscaping or site Preparation Activities

Landscaping or site preparation covers all the activities used for the removal of soil & overburden, disposal of wastes and themodification of disturbed land, and waste disposal sites for achieving the reclamation of the areas mined. It may include :

(i) Contouring or reshaping the back filled pits or dump of waste rock.

(ii) Installation of an effective drainage and sediment control system

(iii) Covering of toxic wastes, barren waste rocks, tailing or any inhibition to plant with the previously stored top soil (up tomaximum of 30cm)

(iv) Tillage operations

(v) Prevention of erosion and excessive run off by grading and levelling

(vi) Preparation of seed bed, including ploughing, and application of mulches

(vii) Pittings and gouging of land.

Thus the site preparation is carried out with a view to improve the physical condition of the mined land, overburden and wastedisposal area for eventual land use. In most of the cases, the ultimate land use may be in the form of revegetation by agriculture orforestry. However, it may be in the form of housing and industry, stadiums for sports, wild-life habitants, water storage ponds, orpisciculture, etc.

If the old dumps or tips are to be used for revegetation or agriculture, they are first graded to a gentle slope of less than 1:4 or 5. Thegraded surface is then covered with 15-30 cm thick layer of topsoil to ensure proper growth of vegetation. Compacted topsoils of olddumps are not suitable for plantation because of closing of voids due to compact and hard nature of the soil. These compacted soilsare made suitable for plantation by deploying tillage methods i.e. ripping, discing or scarifying.

In cases where the dump height is more and the area is restricted the dumps may be vegetated in the existing position. In such cases,the dumps should be vegetated by grasses followed by plantation of trees. The trees may be planted by giving contour and drains

Part_I | pg-40


all around the dumps and also on the top of the dumps after flattening them. However, in such cases arrangements for watering maybe made in the beginning.

The various aspects of Reclamation & Rehabilitation are high lighted in the table below:

Table

RECLAMATIO STABILIZATION AND REHABILITATION OF ENVIRONMENTAL& REHABILITAION OF BARREN AREA MONITORINGREHABILITATION DUMPS WITHIN LEASE (Core zone & BufferOF MINED OUT (within lease) zone separatelyPIT/ LAND/AREA

(i) Backfilling (i) Terracing (i) Afforestation (i) Ambient Air Quality(green belt building)

(ii) Afforestation on (ii) Pitching (ii) Others (ii) Water Qualitybackfilled area.

(iii) Others e.g. Afforestation (iii) Construction of parapet (iii) Noise Level Surveyon exhausted benches. wall / Retaining wall at toe

of dumps.

(iv) Pisciculture (iv) Construction of Check (iv) Ground VibrationDams along slope of vallies etc.

(v) Converting into (v) Construction of settling ponds, (v) Otherswater reservoir. (garland drain etc.)

(vi) Picnic Spot (vi) Desilting of settling ponds,channels.

(vii) Afforestation on dumps.

(viii) Others

Reclamation Techniques

Reclamation in mining can be best achieved only when full knowledge of the deposit is available. To have this information a detailedexploration of the area by core drilling in suitable grid interval is required to be made. Thereafter ore body modelling by computergenerated software will determine the mineability of the ore and the sequence of reclamation. In the absence of this information, thereclamation can never be very scientific. In Goan iron ore mining, the ore body is complex in Nature as it is dipping, and is folded& faulted. The footwall and hang-wall are extremely weak with rocks like phyllyte, manganiferous clay etc. Further ore winningplaces where the mining presently is going on in the large mine are below water table. This is because the Goan iron ore mining isstarted in the 40s and is continuing. The weak footwall and hangwall rocks demands greater bench widths for stability of the slopes.Therefore, depth-ward mining is prone to collapses particularly in the rainy season.

In some of the Goan deposits of South Goa, the ore body consists of a few synclines where the mining consists of opening a numberof quarries depending on the position of the synclinal deposits.

It is a matter of satisfaction that most of the large mines of Goa have a permanent exploration division/department to undertakeextensive exploration of their deposit in 50m x 50m grid to delineate the deposit. Even sometimes 25m grid is also adopteddepending on the insitu formations.

The extensive exploration conduced by the lessees has helped in determining the commencement of reclamation in various leasesof Goa. Due to higher ore waste ratio of approximate 1:3 tonne to tonne many a time land is not available for waste dumping insidethe mining lease areas. This has created a situation where waste has been dumped outside the lease areas in many cases.

Reclamation by backfilling is being undertaken by many of the lessees in their worked out pits. The backfilling in the deep pits aredone stage-wise like dumping in terraces. This is followed for years together as the pits are large. During the course of time rainsalso help in filling the pores and during the dry season it gets compacted by the movement of machines on them. After the backfillingis complete, the area is planted by suitable species. In the olden days for fast growth of greenery Acacia and Eucalyptus had beenplanted. With the passage of time, knowledge and availability of species now the locally growing species are being planted. Goa has


Part_I | pg-41

been endowed with GOD’s gift in the form of heavy rainfall to the tune of 3500 mm to 4000mm annually. The seeds germinate fast andgrow equally faster.

The dumps have been rehabilitated by thick afforestation by using soil ameliorative techniques. In case of very fragile waste rockswith more soft and clayey material jutemat/coir mats have been rolled on the terraces of the dump and afforestation have been carriedout for its stabilization. The growth of plants on these jute-mats/ coir mats is exceptionally good compared to other places in thecountry. The reason may be the heavy rainfall and extended rainy season.

Many of the large mines have developed their own nurseries with appointment of Horticulturists and environmentalists to devote fulltime on environmental management. Some of them have developed techniques like environmental friendly root trainer concept whichhelps the sapling for better growth and survival. In this method the sapling is put inside the truncated plastic conical structure andonce the sapling grows it is transferred to the place of plantation with full transfer of the roots which helps in faster growth andincreases the survival rate . Many of the mines have developed a system of vermiculture which also helps in growth of the saplingsin places where nutritional value of the waste rocks are less. It is important to note that one of the mine in Goa has very successfullyreclaimed a major part of the mine and is having a football ground on the reclaimed area, a beautiful garden called Nakshtra gardenbased on Charaka Sahitya, a football academy after reclamation in that area from which even first division league players are comingout. Further, an ITI has been set up in that mine. Apart from this pisciculture also has been successfully experimented. Over andabove this biodiversity created on the reclaimed ground is unique.

The case study of a mine in North Goa

The mining lease area was about 200 Ha. and the mining operation commenced in 1960 and the mine was nearly exhausted in 1988where 125 Ha of area Reclamation and Rehabilitation is taken up.

A detail and scientific land reclamation strategy was planned. The clay was covered on lateritic terrace and check dams and settlingponds were constructed followed by plantation of Acacia and Cashew.

Pot culture experiment was conducted with the objective to identify plant species that can tolerate inhospitable condition of mine sitesand grow without artificial aid such as fertilizers and irrigation. In the pot culture, an earthen pot was buried adjacent to the plant andfilled at regular interval of time. Through seepage the plant could get regular supply of water. After six months 90% survival wasobserved indicating moisture was the main inhibiting factor for plant growth. The results revealed that local flora can grow on minerejects if the soil is supplemented with organic matter in the form of neem cake etc.

These findings were used for introduction of local flora to improve the bio diversity of the reclaimed area. Success was recorded bysurvey and that in all total of 164 species belonging to 138 genera distributed among 55 families consisting of grasses, legumes,climbers, shrubs and trees. More than 5 lakh saplings have been grown over the reclaimed area.

To utilize the rejects for more productive use the hybrid horticulture approach was adopted on experimental basis. Initially Acaciawas planted at close spacing. The dumps have become richer with hummus due to foliage of Acacia which resulted in soil microbialactivity. Legumes and creepers were used as a cover crop and rubber plantation was also introduced. The creepers apart fromfixing, nitrogen also acted as a mulch for water conservation, prevention of soil erosion and encouraging microbial activity.

The entire area got stabilized in four years. Horticulture crop like cashew, jack fruit, coconut, banana were introduced. Irrigationwas provided from the exhausted pit water. In the recent years spice plantation and even the most difficult vanilla plantation has beensuccessful. The view of this agri-horticultural approach is a spectacular site and is one of the best bio-diversity ever created on thereclaimed area.

One of the worked out pits in the mine has been converted for pisciculture with the collaboration of National Institute of Oceanography,Donapaula in 1990. The pit is 150 x 30m with an average depth of 6m of water. To make the pit suitable for pisciculture steps takenwere to reduce acidity, maintain important nutrient contents of water, monitoring of temperature on daily basis at 1m depth foradjustment of feed etc. The finger limbs of Rahu, Mrugal and Carp around 15,000 were released in the pit and were fed @ 5% ofbody weight with soaked groundnut cakes. The pisciculture has also been very successful.

Since in the olden days Acacia had been planted and now after the scientific evidences, it is being discouraged. The Company hastaken the permission from the necessary authorities to cut down the Acacia plantation on phased manner and replace them with localgrowing species.

The football ground, the football academy and the ITI are another example of converting the mined out sites to a better use than theoriginal one which are outstanding examples of reclamation. This can be sited as an example for a spot of eco tourism. The relevantphotographs/video presentation are enclosed as Annexure.

Part_I | pg-42


Data & Analysis:

There is a great awareness in minimizing land degradation and conserving ecological balance. Presently thrust on plantation onOutside Mining Lease i.e. road side, colony, barren land is also being given apart form planation in the mined out areas and dumps.In Goa, out of 83 working mines(112 leases)in 29 iron ore open cast mines(i.e about 35%) the part abandonment backfilling is beingcarried out. Of them 15 mines are in \North goa district and 14 mines in Souh Goa District. So far about 333.52 Ha. area has beenbackfilled in North Goa, and 58.83. Ha in South Goa . Besdides Rehabilitation on mine dumps etc on 249.27 ha. in Goa in the miningareas have been carried out. Details are furnished in the annexure. Further a number of waste dumps outside lease areas have alsobeen rehabilitated.

As on 1-4-2009 it may be inferred that about 1208 Ha. area is afforested with about 9 million saplings within the lease and about 6million saplings in Outside the Mining Lease over an area714 Ha in Goa . It may be mentioned every year about 5 lakh saplingsinside the lease area and 2 lakh saplings out side the lease area are afforested .

It is seen that the data maintained and furnished by lessees are inconsistent. Therefore all the individual mines in future have toprepare and maintain a separate data base in this regard along with environmental data.

Conclusion:

A great improvement is noticed in the reclamation of mined out area and rehabilitation work in the mines in the recent days in Goa.A considerable emphasis is laid on the need for backfilling of the worked out areas in opencast mines after inception of ProgressiveMine Closure Plan. Therefore it is felt that waste so generated may be used for reclaiming the worked out pits and the land may berestored to its original level or for more beneficial purpose in the form of agricultural use, or conversion to a recreational area likefootball ground, parks, botanical garden, wild life or human habitat area, Pisciculture, Educational institutions etc. This should beplanned in the pre-mine stage itself. Integrated Bio-Technological Approach, is an effective solution for Mine Land Reclamation.However depending on the local conditions worked out pit can be used as water reservoir subject to a intensive hydrological study.

A study by IBM with BRGM, France in 1997 has revealed that Mine water pumping has no regional influence on the water Table inGoa. Further, it is concluded that still a large gap exists between the area degraded by mining and that reclaimed so far. If all theMine Managements adhere to strictly the proposals made in Approved Mining Plan /Approved Mining Scheme it may be possible thatthe entire area be reclaimed by the end of the conceptual period of the mine.

Acknowledgement:

The authors are thankful to the Controller General, Indian Bureau of Mines, Nagpur for giving an opportunity and encouragementto present the paper. The views expressed in this paper are exclusively of the author’s and not necessarily of the Department.

References:

1. Bulletin on Reclamation / Restoration Techniques for Mined out areas, IBM Publication, Bulletin No.37,August 2000.

2. Bulletin on Environmental aspects of Mining areas(Revised Edition)IBM Publication, Bulletin No.27,February 2005

3. Development of Application Techniques in relation to Environmental management of Mines and waste recoveries,RegionalEnvironmental Assessment(REA) of the North Goa iron ore Mines(India), IBM-BRGM report, November 1999.

4. Reclamation/Rehabilitation of Mining areas of orissa with particular reference to Progressive Mine Closure Plan by ShriA.B.Panigrahi and Shri D.Dass, Paper published in seminar organized by SGAT,Bhubaneswar,2005-06.

5. Training material on Reclamation/Rehabilitation of Mined out Areas of Shri Mahesh Patil, General Manager, Sesa Goa,2005

* * * * *


Part_I | pg-43

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Part_I | pg-44


Reclaimed & rehabilitated pit in an Iron ore mine inNorth Goa Water filled pit converted as a pisciculture pond in anIron ore mine in North Goa

Root trainer Nursery

Reclaimed pit of a mine in North Goa Reclaimed mine pit is converted into a Foot ball Stadium,North Goa


Part_I | pg-45

Utilization of lean grade material like Jhama to enhance mine life at Jharia Divisionof TATA STEEL

Mayank Shekhar, C H Divakera, Dr T Venugoalan, Parveen K Dhall, Priya Ranjan Roy

Introduction

Jharia Coal field is the best resource for good quality of coking coals available in India. But unfortunately a large quantity of coalreserve was badly affected due to geological igneous intrusion in the past, resulting into transformed natural coke4,5 known as“Jhama”. Normally, the coal is transformed to natural coke, Jhama along its contact zone with the intrusion. The carbonization effectslowly and decreasing away from the contact igneous intrusive such as dykes and sills. The coal that was affected, depends onnature of intrusive, their thickness and geological characteristics of the affected strata

A huge quantity of Jhama type coal is available in Tata Steel leasehold area, mainly at Digwadih Collieries, Jamadoba colliery. Whichremains unused due to its stringent quality properties for coke making. In this study an attempt was made to find out avenues frrational utilization of Jhama by suitable beneficiation techniques

Further its usage has been explored in areas other than coke making such as sinter making. Accordingly a study was undertaken,which showed that the Jhama has inherent VM in the range of 6-8 % with ash content of 20-35%. The fixed carbon was 65% andsulfur was very low at 0.4%

The chemical analysis of Jhama is summarized in Table 1

Table 1 Jhama coal chemical analysis

Quanlity H2O Ash VM C N O S SiO2 P Al2O3 MgO MnO

Value 3.2 27.6 5.2 64.1 1.3 1.9 0.5 8.5 .1 4.8 .4 .01

Reduction of ash to make it suitable for steel plant use

The Jhama coal samples were collected from the face using Groove/ Channel sampling method. Representative samples of 15 Kgeach lot were collected from the groove made in the running face vertically. They were tested in the lab for their washability,Proximate and ultimate analysis.

Washability Test

The Jhama coal was analyzed for its washability at our laboratory. The sink float test results were tabulated in table 2. It is observedfrom the table that at 1.8 sp gravity the ash is 16.6% with 52.5% yield. It was concluded that it can be washed in the washery if gravityis maintained very high. In order to improve the washability different sizes were also tried for analysis and the results were tabulatedin table 3. Form the table it is evident that maximum yield was achieved at –10mm size with 16.5% ash content. With this washablitydata the samples were tried at the plant.

Part_I | pg-46


Table:2 Washability Analysis at –15mm + 0.5 mm

Cu Wt% Cu Ash%F-1.40 0.80 12.04

F-1.45 0.82 12.06

F-1.50 7.51 14.71

F-1.55 11.38 15.29

F-1.60 18.11 15.72

F-1.65 28.01 16.08

F-1.70 37.28 16.31

F-1.75 47.16 16.49

F-1.80 52.54 16.60

S-1.80 100.00 28.99

Table 3 Size wise distributional and analysis.

Original Sample -15mm -10 mm -6mm -3 mm

Size Wt% Wt% Wt% Wt% Wt%

+15 71.68

+10 6.96 41.35

+6 8.31 25.24 59.46

+3 4.06 12.22 11.22 49.89

+1 4.10 10.61 14.59 25.69 66.58

+0.5 1.91 3.50 4.96 7.01 13.22

-0.5 2.97 7.09 9.77 17.41 20.20

Total 100.00 100.00 100.00 100.00 100.00

Theoretical yields at the size fraction

W/Coal 40.08 48.82 40.39 41.48

Reject 56.52 46.59 52.75 42.10

Midlings 3.40 4.59 6.86 16.41

Plant trail at Jamadoba Washery

Based on the lab trial Jhama was treated at Jamadoba Washery ( figure 1). The lab trial suggested that the best yield will come at 10mm and below size range. But due to crushing plant design the Jhama was crushed to 15mm and below size range. The plant settingswere changed, Specific gravity were increased form 1.3 to 1.65, at that density the required ash levels with reasonable yields wereachieved. In initial trials the yields were only 41% against 52% theoretical. On analysis it was found that the increase in Sp Gravitycould not be achieved and sustained. This resulted in the misplacement and yield loss.

To overcome the misplacement better and in order to overcome this problem in the next trial, the heavy media circuit was closelymonitored and the density level were maintained for higher gravity built up in the plant. The subsequent trials improved the yields upto 50%

The Jhama clean coal was sent to Sinter plant for the trial as replacement for RPC.

The Jhama clean coal was analyzed size wise for VM analysis and tabulated in table 4. Furthermore it was found that the VM of finesin the plant trial were very high (19.6%). It was attributed to ultra fine. So Plant operation were again modified for cleaning ofthickener before and after Jhama washing operation. The Plant VM improved drastically from 14.4 % to 8.2 during trial and up to 7.3during commercial processing (Graph 1).

Flotation Cell Lab Result -0.5 mm

Yield% Y%-R/C Ash% Reagent Doases

43.61 0.00 16.43 Nalco— 30

56.39 0.00 37.64 Disel— 200

100.00 0.00 28.39


Part_I | pg-47

Use of Jhama in sinter plant of Tata Steel

The Jhama, after reducing ash at 16.5% at Jharia through washing process was tried at R&D for Pot sinter test for establishing itsusage in sinter making. The sample was taken from washing plant at regular interval of 30 minutes and mixed The sample of washedJhama is –15 mm size, which was reduced to –3mm at R&D for Pot sinter trial. The Pot sinter test was conducted in the laboratory Potsinter apparatus.

Experimental condition

The pot sinter test conditions were tabulated in table 5. The pot sinter were made with 8-10% cao with bed height 55-750 mm andsuction 1400 WC. Jhama coal has been varied at 0- 30% of the base mix. It contained average ash 15-18%%

Table 4 Size wise VM Distribution

SIZE VM

-15 X0.5 6.87

-0.5X00 6.54

-10 X0.5 5.65

-0.5X00 6.42

-6 X0.5 5.24

-0.5X00 6.41

-3 X0.5 4.87

-0.5X00 6.05

Graph 1: Plant trial for establishing washing at Jamadoba

Figure 1 Schematic diagram of Jhama Washing at Jamadoba Washery

Part_I | pg-48


Table 5 : Pot Sinter test conditions

Parameters

Bed height, mm 550-750

Suction, mm WC 1400

(Coal+Coke) in green mix,% 5-8%

Moisture,% 6-8%

CaO% ( aimed) 8-11%

Experimental results

Chemical analysis of sinter is given in Table 6. FeO in sinter is indicative of thermal level during sintering. Though the variation inJhama coal did not effect in the sinter FeO but it shows the marginal variation in TI, RDI, mean size and Cun+10 mm of pot sinter.However, an improvement of 6% in RDI has been observed.

The waste gas analysis is tabulated in table 7. From the table it was observed that at 10% and 30% Jhama coal in base mix, CO andCO2 showed a maximum value of 5.9% & 4.9% and 18% & 9.6% respectively. The second sample collected after 10 minutes ofignition showed 9.2% CO, 0.2% CO

2 at 30% Jhama coal in base mix, 4.9% CO, 0.1% CO

2 at 0.6% Jhama coal base mix as

compared to 2.4% CO and 0.04% CO2 in base condition. Hydrogen content was negligible in all the tests except at 30% Jhama coal,where it was 0.1%, still very very low.

Table 6: Chemical property of Sinter

Tests Fe(T) FeO CaO MgO Al2O3 SiO2 P TiO2

% % % % % % % %

Base 57.7 11.2 9.3 1.5 2.1 4.2 0.1 0.2

10% Jhama 59 10.3 8.7 1.6 2.0 4.1 0.1 0.2

30% Jhama 59.4 10.8 8.8 1.4 2.1 3.9 0.1 0.2

Table 7: Waste Gas analysis

Test Waste gas analysis

Sample 1 Sample 2

CO,% CO2,% H2,% CO,% CO2,% H2,%

Base 3.1 0.1 0 2.4 0.04 0

10% Jhama 5.9 0.1 0 4.9 0.1 0

30% Jhama 18 9.6 0.1 9.2 0.2 0

Plant Trials

Plant trials were conducted based on the lab pot sinter experiment with 10-30% Jhama coal in the base mix, base condition having10-20% RPC in the base mix. The chemical and physical properties are tabulated in table 8 and 9 respectively. It was checked andcompared with the base condition The sinter property does not showed any significant change or any adverse effect. The qualityparameters remain within acceptable limit.

Table 8: Chemical analysis of Sinter

AL2O3 CAO FE FEO K2O MGO MNO SIO 2 PBase 2.24 9.28 57.31 9.55 0.03 1.63 0.03 4.39 0.11

10% Jhama 2.21 9.44 57.24 10.33 0.04 1.59 0.04 4.37 0.10

20% Jhama 2.18 9.25 57.65 9.82 0.04 1.54 0.04 4.06 0.11


Part_I | pg-49

Table 9 : Physical property of Sinter

MEAN_SIZE TI Cum + 10mm RDI R I

Base 18.60 77.57 66.93 27.83 69.51

10% Jhama 18.44 77.89 66.72 26.92 68.08

20% Jhama 18.26 77.62 66.09 29.19 68.80

Conclusion

From the above study it is evident that the Jhama has the potential utility in steel making industry. The washed Jhama having VM andash less than 8% and 17% respectively, which is suitable for sinter making as replacement of Refined Petroleum Coke andanthracite, which are a costly fuel. The washed Jhama is used in sinter helped in not only self-reliance in the fuel availability but alsoincreased mine life from existing 14 years to 32 years.

Acknowledgement

The author is grateful to Mr. A M Misra for giving us opportunity to explore the possibility of usage of Jhama. He is also very thankfulto Mr. B K Das, Chief Sinter plant and Mr M M Kumar head RMBB for in giving permission and extending their help to conduct trialat Sinter Plant 3.

Reference

1. An overview of world iron ore resource and beneficiation practices in leading Iron ore producing country By SatishKumar Rai, Tata Search, 2008

2. An overview of reserves, production, demand and life of sponge grade iron ore in Orissa by 2010 and beyond, D. Dashand A. B. Panigrahi, The Indian Mining & Engineering Journal, October 2004: Special number on raw material for steelindustry, p.24-31

3. Formation temperatures of natural coke in the lower Silesian coal basin, Poland. Evidence from pyrite and clays by SEM-EDX by KWIECINSKA B. K. ; HAMBURG G. ; VLEESKENS J. M.

4. Year Mineral book 2004/Report, Indian Bureau of Mines (IBM), Nagpur, India.

5. SME handbook of Mineral processing

6. Hand Book of Chemical engineers by E J Prior

7. Mineral Processing Technology By B A Wills sixth edition.

8. Ore Deposits of India by Rao and Gokhle.

Part_I | pg-50


Iron Ore Recovery from Waste Dump Fines in SAIL Mines* V Dayal, S K Pan, S K Mukherjee, M P Srivastava, S K Sinha

* RESEARCH AND DEVELOPMENT CENTER FOR IRON AND STEEL, STEEL AUTHORITY OF INDIA LIMITED, RANCHI

1.0 INTRODUCTION

Mineralogical characterization and beneficiation studies were carried out on the samples from dump fines of Dalli Mines and GuaMines, in order to improve the Fe content to the desired level and bring down the gangue content. The said dump fines, stacked instockpiles at the mines, were collected from different benches as well as locations of mines. The total quantity of these fines is about12 million tonnes at Dalli Mines with average analysis of about 56.0% Fe and 13.0% of silica and alumina combined and about 40million tonnes at Gua Mines with average analysis of about 58.0% Fe and 7.0% of silica and alumina combined. It is not economicallyviable to use these fines for sinter making, unless beneficiated to at least 62% Fe.

2. 0 EXPERIMENTAL

2.1 DALLI MINES

The sample of dump iron ore fines from Dalli Mines was thoroughly mixed for homogenization and a representative sample drawn.Screen analysis of the sample by wet method on 10, 8, 6, 3, 1, 0.5 and 0.25 mm screens and chemical analysis of individual fractionwere carried out and is shown in Table 1 (a).

The ‘as received’ dump fines assayed 53.64% Fe, 7.27% SiO2 and 4.94% Al2O3. Wet screen analysis of the sample showed that thetotal +3mm fraction was 29.5% by weight and analyzed 62.28% Fe, 3.12% SiO

2 and 2.1% Al

2O

3. Quality of this fraction was good

enough to warrant any further treatment and can directly be mixed with sinter fines, where as the –3mm fraction (70.5% by weight)had only 51.79% Fe and needed beneficiation. The consolidated results are shown in Table 1 (b).

The -3mm fraction was beneficiated through spiral classifier followed by jigging of classifier sand for enriching the same to therequired level. The jig concentrate assayed 60.9 %Fe, 4.95 %SiO2 and 3.37 %Al2O3 with yield of 34.1%. The overflow from spiralclassifier was treated in hydro-cyclone followed by WHIMS, which produced concentrate of 63.05% Fe, 2.86% SiO

2, 2.63% Al

2O

3

with yield of 14.4%. The final concentrate analyzed 62.0% Fe, 3.9% SiO2 and 2.7% Al2O3 with an overall yield of 78%. Flow sheetdeveloped for beneficiation of the dump fines comprises processing by wet screening, spiral classifier, jigging, hydro-cyclone andWHIMS.

Based on the preliminary characterization tests indicated above, experimental plan was frozen. Since the +3mm fraction was foundto be of acceptable quality (62.28% Fe, 3.12% SiO2 and 2.14 % Al2O3), no treatment was carried out on the same. The -3mm fractionwas treated in a spiral classifier. Sample size processed in the spiral classifier unit was 70 Kg. Chemical analysis of classifier sandand overflow was done and is shown in Table 2. Since the classifier sand was not of desired quality (58.65% Fe), it was furthertreated in a mineral jig to achieve the required quality. Sample size, water rate and duration for jigging was 3 Kg, 2 lit/min and 5 minrespectively. Table 3 shows percentage of different layers after jigging and their chemical analysis.

Overflow from the classifier was processed in a hydro-cyclone with the following experimental parameters:

Percent solid in feed : 15.0

Feed pressure : 10.0 psi

Vortex size : 25 mm

Apex size : 15 mm

Chemical analysis of hydro-cyclone feed, overflow and underflow and their granulometric analysis are shown in Table 4 and Table5 respectively.


Part_I | pg-51

The underflow from hydro-cyclone (concentrate) was not of required quality (53.15% Fe) and was further processed through a WetHigh Intensity Magnetic Separator (WHIMS), at different intensities of magnetic field (2, 4, 5 & 6 Amp). Sample weight for each testwas 50 gms. Yield achieved at different magnetic fields (amps) and corresponding chemical analysis is shown in Table 6. Theconcentrate obtained at magnetic field corresponding to 6 amps analyzed 63.05% Fe with yield of 74.0% of feed.

Thus the final product consisted of (i) +3 mm fraction from wet screening (ii) concentrate (-3+0.2 mm) from spiral classifier and jigsand (iii) -0.2 mm from hydro-cyclone and WHIMS. Table 7 shows the yield and chemical analysis of different products, final productand tails.

2.2 GUA MINESThe ‘as received’ dump fines from Gua Mines assayed 59.75% Fe, 2.65% SiO2 and 4.08% Al2O3. This was ground to 0.5mm andthen beneficiated through conventional hydro-cyclone. The underflow from conventional hydro-cyclone assayed 61.52 %Fe, 2.22%SiO2 and 3.40 %Al2O3 with yield of 79.07% The underflow from the conventional hydro-cyclone was not of desirable quality andhence it was further beneficiated in stub hydro-cyclone. The underflow from the stub hydro-cyclone assayed 63.53 %Fe, 2.05%SiO

2 and 1.90 %Al

2O

3 with yield of 78.51%. The results are shown in Table -9.

Flow sheet developed for beneficiation of the dump fines comprises processing by conventional hydro-cyclone and stub hydro-cyclone.

3.0 RESULTS & DISCUSSION

3.1 DALLI MINESThe sample of dumped iron ore fines received contained 29.5% of total +3mm fraction with Fe 62.28%, SiO

2 3.12% and Al

2O

3 2.14%,

which was of acceptable quality as sinter fines and hence can directly be used without any further treatment (Table 1). Beneficiationwas needed only in the case of –3 m fraction only to up grade its quality.

XRD analysis of the sample showed that the +3mm fraction had higher percentage of iron bearing minerals (45.9 %hematite & 31.5%magnetite) than -3mm fraction (40.6% hematite & 28.2% magnetite). The +3mm fraction did not contain significant quantity of gangueminerals and hence can be considered as product (Product 1).

The combined hutch and the bottom most layer obtained through jigging had 60.9% Fe, 4.95% SiO2 and 3.37% Al

2O

3 with yield

84.2% (34.1% of original sample), and was taken as product (Product 2, Table-3). About 15.8% of feed to the jig was rejected as jigtails which assayed 42.9% Fe only.

The concentrate obtained through WHIMS corresponding to a magnetic field of 6 amp was of required quality with 63.05% Fe, 2.86%SiO2 and 2.31% Al2O3 and yield 77.84 % (14.4% of original sample). This was taken as product 3. The results obtained are shownin Table 6.

XRD analysis of classifier overflow revealed that it contained 31.1% sillimanite as major gangue mineral. The total iron bearingminerals namely, hematite and magnetite were much less (31.3% and 17.7% magnetite respectively). Cyclone underflow contained18.9% sillimanite as main gangue mineral, as per XRD analysis . XRD analysis of concentrate from WHIMS showed that it contained63% iron bearing minerals (44.6% hematite + 21.1% magnetite) and only 9.9% sillimanite as gangue mineral.

Table 7 shows chemical analysis and yield at different stages of processing. Quality of the final product obtained was Fe 61.89%,SiO2 3.88% and Al2O3 2.72% with yield 77.84%. Final tails had Fe 42.2%, SiO2 22.01% and Al2O3 25.10% with yield 22.16% ofROM. Chemical analysis and yield of products and tails at different stages of beneficiation and that of final product and tails is givenin Table 8.

3.2 GUA MINESThe sample of dumped iron ore fines received from Gua was not of desirable quality to be used in sinter making. It was beneficiatedin conventional and stub hydro-cyclone to attain the concentrate assaying 63.53 %Fe, 2.05 %SiO

2 and 1.90 %Al

2O

3 with yield of

62.07% which can be use directly for sinter making. Final tails had Fe 53.60%, SiO2 3.55% and Al 2O3 7.79% wi th y ie ld37.93% of ROM. Chemical analysis and yield of products and tails at different stages of beneficiation and that of final product and tailsis given in Table 9.

4.0 CONCLUSIONSBased on the beneficiation studies carried out in RDCIS laboratory, the following conclusions can be drawn:

4.1 DALLI MINESi ) The “as received” sample of dump fines of Dalli mines does not have requisite quality and hence it cannot be directly used

in sinter fines. The main iron-bearing mineral in it is hematite.

Part_I | pg-52


ii) The +3 mm size fraction is of acceptable quality (Fe 62.28%, SiO2 3.12% and Al2O3 2.14% with yield 29.5% and does notcontain significant amount of gangue. No beneficiation is thus required for this fraction and it can directly be used in sintermix.

iii) The -3 mm size fraction was beneficiated to the desired quality by processing through spiral classifier, jig, hydro-cycloneand WHIMS.

iv) The size fraction of -0.25 mm, obtained from ‘as received’ sample contain very less percent of iron content and very highgangue content.

v ) The concentrate obtained by treating -3 mm fraction through classifier and jig assayed 60.9% Fe, 4.95% SiO2 and 3.37%Al2O3 with yield 34.1% of ROM.

vi) The concentrate obtained by treating the classifier overflow through hydro-cyclone followed by WHIMS assayed 63.05%Fe, 2.86% SiO

2 and 2.31% Al

2O

3 with yield 14.4% Al

2O

3 of ROM.

vii) Chemical analysis of the final product obtained by processing through wet screening, spiral classifier, hydro-cyclone andmagnetic separation assayed 61.89% Fe, 3.88% SiO2 and 2.72% Al2O3, with over all yield of 78.84% and is acceptableas sinter grade fines.

4.2 GUA MINES

i ) The “as received” sample of dump fines of Gua mines does not have requisite quality and hence it cannot be directly usedin sinter fines. The main iron-bearing mineral in it is hematite.

ii) The concentrate obtained by treating 0.5mm grounded ore through conventional hydro-cyclone assayed 61.52 %Fe,2.22 %SiO2 and 3.40 %Al2O3 with yield of 79.07% of ROM, which is not of desirable quality.

iii) The concentrate obtained by treating the conventional hydro-cyclone underflow through stub hydro-cyclone assayed63.53 %Fe, 2.05 %SiO2 and 1.90 %Al2O3 with yield of 78.51% of the first concentrate.

iv) Chemical analysis of the final product obtained by processing through conventional and stub hydro-cyclone assayed63.53 %Fe, 2.05 %SiO2 and 1.90 %Al2O3 with yield of 62.07% which can be used directly for sinter making.

5.0 RECOMMENDATIONS

For recovery from Dalli dump fines the flow sheet shown in Fig. 1 may be followed for beneficiation. The dumped fines may first bewet screened at 3 mm screen. The +3mm fraction does not need any further treatment and may used directly as sinter grade fines.The -3 mm fraction may be treated in a spiral classifier, sand from which is processed in jigs. Classifier over flow may be treated inconventional hydro-cyclone and it’s under flow processed in WHIMS. The two concentrates obtained from jigging and WHIMS maymixed with the +3mm fraction obtained after wet-screening and used as sinter grade fines.

For recovery from Gua dump fines the flow sheet shown in Fig. 2 may be followed for beneficiation. The dumped fines may first beground to 0.5mm. The entire grounded material may be first beneficiated through conventional hydro-cyclone. The concentrateobtained may be further beneficiated through stub hydro-cyclone. The concentrate obtained through can be used as sinter gradefines.

Table 1 (a): Granulometry vs chemical analysis of “as received” dump fines sample from Dalli mines.

Size fraction, mm (%) Chemical composition, %Fe SiO2 Al2O3

+10 8.30 61.22 2.97 2.18

-10+8 5.30 62.79 2.85 1.72

-8+6 3.60 62.36 2.88 1.78

-6 +3 12.30 61.58 3.11 2.24

-3 +1 21.20 58.63 4.35 2.56

-1+0.5 9.00 56.08 5.82 2.32

-0.5+0.25 8.30 56.02 5.91 2.31

- 0.25 32.00 41.38 13.87 10.55

Total 100.00 53.64 7.27 4.94


Part_I | pg-53

Table 1 (b): Granulomtric and chemical composition of +3mm and –3mm fraction of dump fines sample from Dalli mines.

Size fraction, mm Weight, % Fe, % SiO2, % Al2O3, %

+3 29.5 62.28 3.12 2.14

-3 70.5 51.79 8.12 5.54

Table 2 : Results of beneficiation process in spiral classifier (- 3mm fraction.) Dalli Mines

Size fraction, mm Weight, % Fe, % SiO2, % Al2O3, %

-3.0 +0.25 (sand) 57.5 58.65 7.61 5.4

-0.25 (overflow) 42.5 48.39 15.44 22.28

Spiral feed 100.0 54.27 10.94 12.57

Table 3: Results of jigging of classifier sand- Dalli Mines.

Particulars Weight, % Fe, % Si O2, % Al2O3, %

Feed 100.0 58.62 7.61 5.40

Layer 1 from top (tail) 7.7 38.27 25.60 26.45



Bottom layer (concentrate) 38.2 60.47 5.07 3.68

Hutch 46.0 61.17 4.86 3.12

Jig product (bottom layer + hutch) 84.2 60.9 4.95 3.37

Jig tails (layers 1,2 & 3) 15.8 43.0 21.16 19.71

Table 4: Results of processing of spiral classifier overflow in hydro-cyclone Dalli mines.

Particulars Weight, %) Fe, % SiO2, % Al2O3, %

Feed to Cyclone 100.0 48.39 15.44 22.28

Under-flow 64.55 53.15 10.79 10.81

Over-flow 35.45 42.92 17.90 28.40

Table 5: Granulometric analysis of hydro-cyclone feed, over-flow and under-flow Dalli Mines

Size in mesh Weight, (%)

Feed Cyclone CycloneUnderflow Overflow

+30 0 0 0

+65 5.5 6.5 0

+100 6.0 8.0 0

+200 15.5 30.0 3.5

+325 16.5 24.5 2.0

+400 6.0 5.5 2.0

-400 50.5 25.5 92.5

Part_I | pg-54


Table 6: Results of processing through WHIMS- Dalli Mines

Current Particulars Weight, % Fe (%) SiO2 (%) Al2O3 (%)2 amp Magnetic 24.0 60.19 7.44 4.30

Non- magnetic 76.0 50.87 13.24 12.86

3 amp Magnetic 42.0 62.00 5.41 3.25

Non- magnetic 58.0 46.81 14.17 16.23

4 amp Magnetic 66.0 63.15 3.22 3.01

Non- magnetic 34.0 33.73 24.85 25.90

5 amp Magnetic 66.0 62.57 3.55 2.52

Non- magnetic 34.0 34.75 24.80 26.83

6 amp Magnetic 74.0 63.05 2.86 2.36Non- magnetic 26.0 24.66 31.77 35.01

Feed to WHIMS 100.0 53.15 10.79 10.81

Table 7: Yield and chemical analysis of different products and tails Dalli Mines

Process Yield (%) Fe (%) SiO2 (%) Al2O3 (%) ProductYield, %

Granulometry (+3mm) (Product 1) 29.5 62.28 3.12 2.14 29.5Granulometry (-3mm) 70.5 54.27 10.94 12.57

spiral classifier(sand) 57.5 58.65 7.61 5.4

spiral classifier(o/f) 42.5 48.39 15.44 22.28

Jigging(Product 2) 84.2% of 57.5 = 34.1 60.9 4.95 3.37 34.1Jigging (tails) 15.8% of 57.5 43.0 21.16 19.71

Hydro-cyclone (U/F) 64.55% of 42.5 = 27.43 53.15 10.79 10.81Hydro-cyclone (O/F) 35.45% of 42.5 42.92 17.90 28.40

WHIMS (mag) 6 amp(Product 3) 74% of 27.43 = 14.4 63.05 2.86 2.36 14.4WHIMS(non mag) 6 amp 26% of 27.43 39.66 31.77 25.01

Final product (Products 1 + 2 +3) 78.00 61.89 3.88 2.72 78.00Final tails 22.16 42.00 15.52 17.70 22.16

Table 8: Chemical analysis and yield of products and tails at different stages of processing and that of final productand tail-Dalli Mines

Particulars Weight, % Fe, % SiO2, % Al2O3, %Product -1 (+3mm fraction) 29.5 62.28 3.12 2.14

Product - 2 (Jig concentrate) 34.1 60.90 4.95 3.37

Product - 3 (WHIMS concentrate at 6 amp) 14.4 63.05 2.86 2.36

Final product 78.0 61.89 3.88 2.72

Tails -1 (Jig reject) 6.4 43.0 21.16 19.71

Tails -2 (Hydro-cyclone overflow) 10.6 42.92 17.9 28.4

Tails -3 (WHIMS non mag. ) 5.0 39.66 31.79 25.01

Final tails 22.0 42.20 22.01 25.10


Part_I | pg-55

Table 9: Chemical analysis and yield of products and tails at different stages of processing and that of final productand tail-Gua Mines

Particulars Wt, % Fe,% SiO2,% Al2O3,%

Feed 100 59.75 2.65 4.08

Hydro cyclone U/F stage-1 (conventional) 79.07 61.52 2.22 3.40

Hydro cyclone U/F stage-2 (stub) 78.51 63.53 2.05 1.90

Final concentrate 62.07 63.53 2.05 1.90

Hydro cyclone O/F stage-1 (conventional) 20.93 53.01 4.27 6.65

Hydro cyclone O/F stage-2 (stub) 21.49 54.19 2.84 8.90

Final Reject O/F 37.93 53.60 3.55 7.79

Part_I | pg-56


ACKNOWLEDGEMENT

The authors would like to thank the Management of RDCIS for kind permission to publish this paper. The authors express theirsincere thanks to the management of Dalli mines and Gua mines for their support to carry out the work.

REFERENCES

1) B.A. Wills, Mineral Processing Technology, Pergamon Press.

2) Beneficiation Amenability study of iron ore of Chiria and Gua mines (Project No.120538, RDCIS).


Part_I | pg-57

Utilisation of Low Grade Iron Ore in Steel making with State of Art Beneficiation &Transport - A Case Study for Meeting Challenges in Orissa State

Sri GS Khuntia1

1 . Former Director, NMDC /Executive Director (Operation) SAILCurrently Mining Advisor, MSL ,& Director, OMC Ltd

The abundant resources in Orissa state

The abundant resources of Iron ore, Manganese ore, Bauxite, Limestone, Dolomite, Chromites, Coal, Gemstones andDecorative Stones (Granites)

-Due to boom in metal industries/Steel, this has prompted planning of development of large scale mining and establishmentof mineral based industries in the State.

Basing on the large resources of Metallurgical grade Iron ore and bauxite, it has been planned to set up a number of ironand steel plants, aluminum complexes, Power plants.

-The resources of coal have also invited many industrial houses to set up Thermal Power Projects to cater to the need ofelectricity for industrial projects/Steel industries.

-The lucrative occurrences of Diamond have created global eagerness to participate in scientific exploration and exploitationof this valuable mineral and to encourage the investors of International repute

Steel grade & other mineral resources in Orissa state

§ With >5000 MT of iron ore reserves, with a host of accompanying advantages

§ 1. Orissa has substantial reserves of other minerals, which go into steel making, like coal – 61,999 MT (24.37 per centof the national deposit), dolomite – 1734 MT, limestone – 1737 MT & Mn-152 MT.

§ Other mineral deposits are:

§ Chromites——209 MT

§ Bauxites—1808 MT

§ We shall cover on IRON ORE for Steel Industries

National Steel Policy

§ We can not think of Iron ore without touching Steel

§ STEEL is universal intermediate in building up materials base of economy, especially for industrialization & constructionof physical infrastructure

§ Need to boost per capita steel consumption in rural areas to improve quality of life

– Target 110 MT annual steel consumption by 2020 AD & 70 MT BY 2012 AD, corrected now to 150 MT ,principallythrough domestic steel production

– Appropriate steps must be taken to ensure adequate & timely supply of basic raw materials & processed inputs fromdomestic & oversee sources

Part_I | pg-58


Steel Production Scenario

Global Scenario

In 2007 the World Crude Steel output reached 1343.5 million metric tons and showed a growth of 7.5% over the previous year.It is the fifth consecutive year that world crude steel production grew by more than 7%. (Source: IISI)

China remained the world’s largest Crude Steel producer in 2007 also (489.00 million metric tons) followed by Japan (112.47million metric tons) and USA (97.20 million metric tons). India occupied the 5 th position (53.10 million metric tons) for the secondconsecutive year. (Source: IISI)

The International Iron & Steel Institute (IISI) in its forecast for 2008 has predicted that 2008 will be another strong year for thesteel industry with apparent steel use rising from 1,202 million metric tonnes in 2007 to 1,282 million metric tonnes in 2008 i.e. by6.7%. Further, the BRIC (Brazil, Russia, India and China) countries will continue to lead the growth with an expected increase inproduction by over 11% compared to 2007.

Domestic Scenario

The Indian steel industry have entered into a new development stage from 2005-06, riding high on the resurgent economy andrising demand for steel. Rapid rise in production has resulted in India becoming the 5 th largest producer of steel.

It has been estimated by certain major investment houses, such as Credit Suisse that, India’s steel consumption will continue togrow at nearly 16% rate annually, till 2012, fuelled by demand for construction projects worth US$ 1 trillion. The scope for raising thetotal consumption of steel is huge, given that per capita steel consumption is only 40 kg – compared to 150 kg across the world and250 kg in China.

The National Steel Policy has envisaged steel production to reach 110 million tonnes by 2019-20. However, based on theassessment of the current ongoing projects, both in Greenfield and Brownfield, Ministry of Steel has projected that the steelcapacity in the county is likely to be 124.06 million tonnes by 2011-12. Further, based on the status of MOUs signed bythe private producers with the various State Governments, it is expected that India’s steel capacity would be nearly293 million tonne by 2020.

Production

Steel industry was delicensed and decontrolled in 1991 & 1992 respectively. Today, India is the 5th largest crude steelproducer of steel in the world. The share of Main Producers (i.e. SAIL, RINL and TSL) and secondary producers in the totalproduction of Finished (Carbon) steel was 33% and 67% respectively during the period 2007-08.

Demand - Availability Projection

Demand – Availability of iron and steel in the country is projected by Ministry of Steel annually.

Gaps in Availability are met mostly through imports. Interface with consumers by way of a Steel Consumer Council exists, whichis conducted on regular basis. Interface helps in redressing availability problems, complaints related to quality.

Rise in raw material prices, strong demand in the international and domestic market and up-trend in the global steel prices havebeen some of the reasons cited by the industry for increase in the steel prices in the domestic market. The mismatch in demand andsupply is considered to be the main reason on the demand side for the rise in steel prices. Honourable Steel Minister has helddiscussion with all major steel investors including Arcellor-Mittal, POSCO, Tata Steel, Essar, Ispat and also SAIL, RINL to explore thepossibility of expediting the ongoing as well as envisaged steel projects. The Government also took various fiscal and othermeasures for stabilizing the steel prices like exempting pig iron, non alloy steel and steel making inputs like zinc, Ferro-alloys and metcoke from customs duty; withdrawing DEPB benefits on export of various categories of steel products and bringing back railwayfreight on iron ore ,all these helped during FINANCIAL MELT DOWN

STATUS OF MOU:

§ Very strong upturn in consumption

– World crude steel Prod Growth of 7.5 % during 2001-07 from 752/1995 to 1343 MT/2007

– India growth rate is 7.3% during 2001/07 from 27.3/2001 to 53.1/2007

– Medium term projection of 7.3% for next 2-3 years


Part_I | pg-59

– China & India to lead consumption centers

§ India 5th largest Steel producer in the world now at 54 MT/annum

§ Per capita steel consumton-40 kgs

§ India largest Sponge Iron producer in World with 15 MT in 2006(25% of world production)

§ ORISSA STATE: 49 & odd MoU signed (upto 12/2008) by Orissa to establish steel plants in Orissa.

§ Many more plants in Chatisgarh, Jharkhand & Karnataka being planned

§ Aggregate Steel capacity > 75 MT (in Orissa)

§ Total Iron Ore resources in Orissa as per UNFC = About 4760(IBM),Orissa Govt. puts at 5400 MT Approx

§ Directorate of Geology/Orissa Govt. is working on exact useable Iron ore resources (lean grade being accounted)

§ With existing RESERVE of Iron ore adequate for above Steel Plants/Sponge Iron Plants in Orissa ( about > 50 years at @ 50MT steel /year

§ In Orissa ,POSCO is planning a 12 MT Plant (in 3 stages) with Rs. 52,000 crores investment in Paradip-Company-Posco IndiaLtd)

a. Iron ore allocation-600 MT (2-3 mines )

b. 10 years time-Full capacity

c. Expected Royalty to Orissa state>-Rs.500-600/yr,besides Sales tax, Excise tax’s etc

§ -12 MT Steel capacity by M/s Arcellor Mittal,Essar-6 MT,Tata Steel-6 MT,JINDAL-6 MT & others

Steel Production & Consumption

Steel Production: - Apparent steel consumption for each year upto 2011-12 forecasted at 7.3% annual average rate of growth,similar to growth of GDP.

Finished Steel Production: Consumption (MT)

2006-07 50 MT 43.471

2007-08 54 MT —

With this, total finished steel- expected to reach (as per NSP-2005)

- 54.00 MT by 2007-08

- 70.00 MT by 2011-12

- 110 MT by 2018-20 (Import-6 MT,Export-26 MT,Consumption—90 MT) being revised to 150 MTPY

§ Per capita steel consumption in India =40 Kg/head against Singapore = 500-700 Kg.,world average-173 Kgs/head

New Opportunities in India for Steel, Aluminium, Coal

§ New Golden age emerged in Orissa besides Jharkhand, Chattisgarh & Karnataka for Steel /Aluminium Industry, Powerplants

§ This requires optimal utilization of our natural resources in Orissa/Jharkhand/Chatisgarh /Karnataka.

§ This also requires fast track clearances of Mining lease /Forestry /EMP/other statutory clearances for quick establishmentof Iron ore mines for steel plants ,as it takes >8 years to develop a mechansed mine (mines Constrn,Power lines,Rlysiding,Residences,Prodn Stabilsation )-

§ help of state/center reqd here for fast clearances without compromising MC Rules-60/MMRD-56/Forest conservationActs-78

§ Aggregate Investment in India in Steel sector for Total MOU(>250 MT) > Rs.500,000 Cr

§ Orissa Investment (upto 2008 MOU ) > Rs 200,000 Cr ( 75.0 MT)

Part_I | pg-60


Iron ore prodn/despatch from orissa /Iron ore Reserve-Orissa

• Year Prodn in MT

• 2003/4 34.89

• 2004/5 46.05

• 2005/6 55.50

• 2006/7 65.00

• 2007/08 74.50 ( 22% growth rate)

• Iron ore Reserve in Orissa

• District Reserve(MT)

• Keonjhar 3574.00

• Sundergarh 1605.00

• Mayurbhanj 35

• Jaipur-Keonjhar 82

• Jaipur 10

• Total 5306.00

Source:Director of Geology,Orissa

Iron ore Reserve in Leaseholds mines & freeholds

• District Reserve Reserve in

• in leasehold(MT) Freehold(MT)

• Keonjhar 2316 1258

• Sundergarh 574 1031

• Mayurbhanj 28 07

• Jajpur-Keonjhar 82 —

• Jajpur — 10

• Total 3000 2306

Source:Director of Mines,Orissa

Summary of Iron ore Availability in Orissa

• Resources Reserve(MT)

• Total Resources 5306

• Resources in leaseholds 3000

• Resources granted,

But not executed 428

Resources Reserved

(For SAIL+OMC) 517

Resources allotted 3945

Balance Available 1361

Source:Director of Mines,Orissa


Part_I | pg-61

Strategy for Iron ore to meet Steel demand in orissa

• 1. Iron ore in many areas are not fully explored. Detailed exploration by geological mapping, close spaced drilling &sampling may augment extra IRON ORE RESOURCES

• 2.Directorate of Geology in last 2 years had identified 8 blocks in Keonjhar & 3 blocks in sundergarh

• 3.Small/scattered deposites must be assessed

• 4.Gap area between ML areas should be explored

• 5.Systematicexploration be done in all working mines/ML Holders with close drilling say 50x50 m drilling & RESOURCEScalculated at 45% Fe cut off, most of Mines have adopted 56% Fe cut offs/Private mines with no BENEFICIATIONPLANTS have cut offs at say 60-62% Fe

• 6.Entire ML area be explored with 50x50m close drilling with 45% Fe cut offs

• 7 Every mine be asked to drill at least 25 m/MT Iron ore Reserve in next 2years time(Private mines) to assess RESERVE

• (particularly private mines)

• 8.Subgrade dumps /Iron ore fines dumps be beneficiated by HIGH TECH BENEFICITION RECHNIQUES(cyclone/grinding/HGMS/WHIMS ) for upgrading to 65% Fe from 45/50% Fe

• 9 Exploration within BHJ & BHQ bands be done, known to contain Iron ore. Also formation below BHJ/BHQ be examinedfor IRON ORE Availability by DRILLING

Iron ore requirement in Orissa state-MOUs

• Formation below BHJ/BHQ to be drilled to ascertain Iron ore

• Total Mou-49 Nos, Aggregate tonnage of STEEL—75 MT

• Iron ore reqd/Tonne of Steel—1600 kgs processed ore or 1840 kgs of raw ore

• 75Mt steel needs—138 MT ore/year

• With present Reserve—will suffice for 40 years for 75 MTsteel prodn/year

• With 45% Fe as cut off (present cut off in Mining-56% Fe),life will increase at least 25%,ie Reserve will increase by 25%

• Low grade ore i.e. +45% Fe will be beneficiated by cyclone/HGMS /WHIMS to produce ‘CONCENTRATE of +65% Fewith +70% recovery

• Irone ore Slime/processing waste with 40% Fe shall be filtered, so that 30% slime shall yield additional 15% by Volumeof extra IRON ORE CONCENTRATE of 65% Fe i.e. RECOVERY shall be about 85%

Present scenario of Iron ore mining in India (Iron ore production in India)

-Essar Steel Orissa Ltd is planning to beneficiate 10 MT Iron ore fines of 58-59% Fe ,use grinding cyclones /HGMS/Filtrationroute, upgrade to 64-65% Fe ,recover 75% ,also recover Fe values from SLIMES by Filtration (nearly 50% ) i.e. ultimately85%recovery .Concentrate(iron ore fines of +65% Fe shall be transported by Pipe lines of 260 kms by NH side at 20% of Railwayscost -By using low grade fines (58% Fe average i.e. from 56% to 60% Fe ),Essar plans to produce steel by TECHNOLOGY ROUTEboth in beneficiation /transportation /Pelletisation.This will improve ‘RESERVE OF IRON ORE IN ORISSA,as low grade ore is notaccounted in State Reserve -SAIL mines/Tatas/OMC have planned their Mnes operation with Cut off at 56% Fe,A committeecovering Rep of Directorate of Geology/Mines /GSI/RRL /Industries Experts from SAIL/Tatas/OMC/Other big operators mines inOrissa,can update Reserve immediately within 6-12months

What Orissa state should do now for updating present Iron ore Reserve in Orissa (Iron ore productionin Orissa /India?)

§ All sub grade(54 to 58 or 60% Fe) use-can be blended with rich materials to get 63%average grade

§ Geostatical quality control to be adopted in mines>1 Mt/year

§ Ore bedding/blending facilities in mines/plant>1 MT/year

Part_I | pg-62


§ Slime reprocessing by Filtration/HGMS

§ Sinter ability studies with 20% of Fines recovered from slime addition (80% Fines+20% recovered fines from Slime),15% extra RESERVE

§ More emphasis be placed on Mine Lease holders for adopting all above steps-mandatory for RESERVE Conservation

New Mines in Iron ore required to be added in Orissa (MT) by 2020(12 years from now)

POSCO = 22

ESSAR = 12

LN Mittal = 22

TATA Steel = 12

Jindal = 12

Others = 10

Total = 90

New Mines in Iron ore required to be added in Orissa (MT)

Since 90 MT Iron ore capacity is to be stepped up in Orissa by 2018, we need quick Mining Lease, EMP, EIA, and ForestryClearance within 2-3 years

Mines Construction, Prodn stabilization will take 4 yrs+3 years=7 years

Domestic Demand Projections

• For Crude Steel Production of say 110 (MT) as per plan

• -Iron ore requirement—1600kgs/tonne i.e. 1840 kg of raw ore

• 110 MT steel production needs 211 MT of raw ore/year

• With 25,000 MT Iron ore Reserve, it will suffice—25000/211 =211 years

• This presumes NO EXPORT from India (presently 50% of Prodn is exported i.e.>100 MT/year)

• By EXPORT ,India gives opportunities for INVESTMENT in foreign countries

• Of course we need Dollars/Foreign trade, therefore EXPORT is to be controlled /WTO

Minerals Resources development & Regulation-Hoda committee recommendations

(a) Covering changes in MCR & MMDR Act 1948 for grant of RP, PL & ML etc

-Regarding sustainable development of land oustees

-Regarding fast track approval of environment & forest clearance etc

-Regarding infrastructure development in mining areas

-Regarding states asking for value addition as pre-condition to grant ML

-Regarding ban on export of iron ore

§ help of state/center reqd here for fast clearances without compromising MC Rules-60/MMRD-56/Forest conservation Acts-78.Amenment in these central Legislation is required immediately in PARLIAMENT(taking into consideration of opinion ofMineral rich states like Orissa /CG /Jharkhand/Bihar/MP/Rajasthan )

UTILISATION OF LOW GRADE IRON ORE IN ORISSA STATE:

Purpose-Area of concern to day is –Best practices in clean & green Mining & Beneficiation Techiniques

While Essar steel orissa Ltd had signed a MOU with Orissa Govt for putting up a Steel Plant at Para dip of 4 MTPY atan estimated expenditure of Rs.10,000 & odds crores which is now planned for setting up a 6 MTPY steel plant at anestimated expenditure of about Rs.15,000 crores .applied for a no of iron ore Mining leses,particularly for virgin deposits like


Part_I | pg-63

Mankadnacha,Badamgarh,Balia Parbat,Khandadhar,thakurani,Malangtoli Iron ore deposits & few of ML application complete inevery respect has already reached Orissa govt. level for consideration for M L grant ,it is learnt hat subject to ESOL spending >25%capital outlay of Project cost ,the state govt may consider the ML application at least for allocation of ‘Iron ore Reserve for 25 yearssteel production on basis of 1600 kgs of processed Iron ore /tonne of steel making capacity

However, s ince i t takes 8-10 years for any mechanized I ron ore mine (say 5 MTPA) instal lat ion, development ofmines,crushing,screening,Beneficiation plant, mechanized loading. siding development, Tailing dam installation including detailedexploration of deposit for mine planning purpose, EMP, EIA, forestry clearance prior to Mining lease grant, therefore Essar SteelOrissa without waiting for Mine allocation, planned for a beneficiation plant installation/operation by procurement of low grade Ironore fines of 58 % Fe,Beneficiate the same by a state of art beneficiation using grinding ,cyclones,HGMS route to up grade to +64.5%Fe with about +70% recovery. For this 5-6 no of representative Iron ore low grade fines samples (5 tonne each) were collected froma no of iron ore mines of Barbil area, tested in RRL, Bhubaneswar for various beneficiation tests. Different beneficiationprocess routes combination were considered considering highest recovery & lowest cost of production & final processroute is as under

Rom Quality-60.17% Fe,ROM volume-11 MTPA

Size—+100 mesh upto 10 MM

Beneficiation route adopted—Roll crusher-Screw classifier-Hydro cyclone-Rougher spiral-cleaner spiral-Magnetic separation(HGMS)-final products

-Final product of Iron ore fines—Fe-66.07%

Recovery—70.16 %

Tailings analysis- Fe-44.42%, Recovery—29.84%

Tailings can be filtered further at Tailing dam,& about 50% Fe values can be recovered with +64.5% Fe.thus total recovery becomesabout 70+15=85% with products of + 64.5-65% Fe

Part_I | pg-64


IRON ORE SLURRY/CONCENTRATE TRANSPORT:

To further control cost ,Essar has planned about 8 MT concentrate transport by pipe lines from their Beneficiation plant at Dubna toParadip through 20 inch Dia MS pipe lines over 263 kms by side of NH/state high way to Paradip for use in Pellet plant .The detailsof slurry transport is as under

Pipe transport of Iron ore slurry

Length——253 Kms

Route-Dubna/Pallasponga /Narayanpur /Dubri /Chandikhol /Partadip

-Pipe dia—20 inch (OD), thickness-13.4 mm minim & 20 mm-max, Alloy steel pipes /carbon steel pipes

- Some understanding has been developed for purchase of low grade Iron ore Fines from adjacent mines to supply at least11-12 MTPA Fines

- Pipe design-by PSI, USA, and Length of each pipe line-12m/piece

- By side of State high way /National highway.10-20 meters from edge of road

- Pipe joining-by welding, life of pipe—30 years, Pressure—144 Atmosphere

- Water: solid (iron ore fines) ratio=66:34

- Time for laying pipes—12 months

- Cost of laying pipes ——1.2 Cores INR /km

- Capacity of pipe range—12 MTPA

- Water source—Baitarini River,7 kms from Dubna

- Pumping—12 cusec for Beneficiation plant of 12 MTPY & Slurry pipe lines

- Pipe laying has started & has put in ——Kms## pipes & expected to complete by 10/2010

- 11 MT Iron ore fines transportation by Rlys would have been a mammoth affairs, wagon availability, loading in time ,fastercycle time, fast transfer of loads& empty at exchange yard ,development of exchange yard for Rlys at Paradip,all theseproblems are skiped off

- About 80 kms of pipe lines is already laid ,both Pellet plant at Paradip & Beneficiation plant at Dubna are expected to becommissioned by ESSAR by 8 /2010

- Cost of Transport is expected to be only 20% of Rlys transport cost say at Rs.70.00 /tonne against Rly cost of > Rs.300/tonne.

- Iron ore processing & transport is being planned in a very eco-friendly manner

Conclusion:

1. The need of the hour is to develop such low grade deposits with large scale mechanised Iron ore production >10 MTPAwith multi stage crushing,screening,beneficiation in wet circuit along with HGMS/WHIMS with filtration facilities for furtherrecovery of Iron values from slime, recover nearly 85% of low grade Iron ore of 58-60% Fe

2. this will conserve our Iron ore drastically ,our Iron ore Reserve may be increased by 20-30%

3. Leading Iron ore producers in the world have increased their production capabilities to become more competitive throughin-house rationalization & consolidation through mergers & acquisitions.

4. Quick ML Sanction by Orissa / Jharkhand Govt., within 2 years ,EMP,EIA, Forestry clearance in 2 years and speedymine development by 3-4 years and build capacity by 2012./Bigger (.5 MT) mines development be encouraged

5. Due to Gas find in Paradip, Electric process of Steel making I.e. Beneficiate Fines from 58% to 65% Fe/ DR Pellets /BFroute or Electric process of steel making can be solution for cheaper steel production from low grade iron ore. GoodPower plant support by use of captive coal block mining in IB Valley/Orissa is essential

6. India can not remain aloof from the events happening else where in the world


Part_I | pg-65

7. India has to take action by good political will to be globally competitive in quality, quantity & also meet increased domesticdemands. Strong political will is required for speedy ML sanction,EMP,EIA clearance, Mines development

8. Attract investment in infrastructure development in Rlys, Ports, power, and road. Deeper ports development be encouraged

9. Mine owners to develop beneficiation & blending facilities in mines/small existing mines to be amalgamated to a group

10. New technologies like direct reduction/direct smelting process to be encouraged for exploiting low grade ores

11. Economics of marketing should be the deciding factor in Iron ore export/semi products-pig iron, sponge iron ,steel

12. Solution-we have to decide whether we are going to participate in industry consolidation & lead it & define the industry orwhether we are going to watch the industry consolidation around us & be a victim of that consolidation. The same holdsgood for India also.

13. Increasing raw Coking coal availability with 15-17% ash in feed coal & development of new mines. This is possible nowas the economy is opened upto Private Sector, Coal pricing is deregulated.

14. Modification of existing Coking coal Washeries (CIL-20.10 MTPA & Other PSU & private-12.27 MTPA i.e. 32.37MTPA ) to improve capacity utilization as well as quality of washed coal to 17-18% ash

15, increasing raw coal feed to Washeries by supplying low volatile medium coking coals of suitable quality.providing balancing facilities to improve washed coal production at 15-17 % ash

16. Stabilization of newly commissioned washeries of CIL like Madhuban (2.5 MTPA-BCCL) & Kedla (2.6 MTPA CCL).

17. Encouraging for opening up Coking Coal Mines & coal washery installation & operation in private sectors & in Australia/South Africa with 8-9 % ash for suitable blending with Indian Coking coal at <15% ash for coke making

18. With deli censing of Coal Mining in India, the situation in volume of coking coal supply with improvedquality expected to improve by policy measures, like private/foreign companies participation in coal mining,coal washery installation/ operation / smoother process for low ash coal import.

19. CDI coal is to be developed in India, suitable reserve is earmarked & coal mining carried out to supply toIndian Steel Sector.

19. Joint venture by Indian Steel Makers in development and operation of low ash coking coal mine in foreigncountries will contain the cost of imported coal price. To be vigorously persued.Non coking coal washery of70.35 MTPA for Sponge Iron / Cement plant /Power plants in operations are to be stabilized & new washeriesare to be established to reduce ash content from 38-40% to say 25% to improve operational efficiency

Conclusion-It is therefore necessary that with strong political will’ state govt establish a Special Dept with Experts for closemonitoring for land acquisition, grant of ML/PL/Forestry/EMP, EIA, R&R Policy finalisation by Liberalised methods (without compromiseof various laws of land) to make it a SUCCESS STORY.

• Mind sets of people/Govt dept in general needs change in Orissa & vigorous efforts are necessary if above dream plan is to beREAL

Acknowledgement-Author is thankful to Essar steel orissa Ltd & RRL,Bhubaneswar for their works on above project & author’sexperience in Essar Steel orissa Ltd as their Mining advisor for 5 years (upto 3/2009)

Part_I | pg-66


COREX® / FINEX® - Prepared for present and future iron making challengesK. Wieder1, C. Böhm2, U. Schmidt3, W. Grill4

1 . Head of the Technology Department Smelting and Direct Reduction2 . Head of the Sales Department Smelting and Direct Reduction3 . Life Cycle Assessment Special ist4 . Product Manager Smelting Reduction


Introduction

Steel work operators face a plenty of challenges in a dynamic market, where even short and mid term fluctuations show their impactin a dramatic way. Hence unfortunately, long term considerations seem to be neglected, although especially in the raw material sectorradical changes are inevitable. Resource depletion is not leading to a price increase only; non renewable raw materials along witha rising demand create a supply bottleneck. This is expected for coking coal, as well as for natural gas, where the industry is forcedto give off more of its shares for public demands like power generation, fertilizer production and/or heating purposes. On the otherhand, environmental care, which is by far not only the reduction of greenhouse gas emissions, becomes an important economicaldriving factor as well. More enforced environmental restrictions by law causes operators to revise their production routes to sort outprocesses which are not complying with these regulations. Answers to these scenarios give the established COREX technology andthe new COREX “Low Export Gas” and the COREX/FINEX “(L)ow (R)educed (I)ron” concepts. These concepts lead to significantfuel savings for hot metal production, either by direct savings in the COREX/FINEX processes or indirectly by supporting thetraditional blast furnace route. By fulfilling the criteria, utilization of low cost / high available raw materials, overall fuel savings evenfor the blast furnace and the impressive ecological advantages, once again the COREX/FINEX technology approve themselves asrecommendable alternatives to the blast furnace and/or a reasonable expansion/substitution of existing production routes.

Process description

COREX and F INEX arecommercially proven smelting reductionprocesses that allow for cost-efficientand environmental friendly productionof hot metal directly from iron ore andnon-coking coal. The process wasdeveloped to industrial maturity bySIEMENS VAI and i s the on lyalternative to the blast furnace routeconsisting of sinter plant coke oven andblast furnace.

It distinguishes itself from the blastfurnace by:

Direct use of non-cokingcoal and a minimum of cokeas reducing agent andenergy source for meltingpurposes


Part_I | pg-67

Direct use of iron ore in form of lump ore, pellets sinter and, especially for FINEX, fine ore

In the COREX process all metallurgical work is carried out in two separate process reactors – the reduction shaft and the meltergasifier (Figure 1, left). Iron ore (lump ore, pellets, sinter or a mixture thereof) is charged into the reduction shaft where they arereduced to direct reduced iron (DRI) by the reducing gas in counter flow. Discharge screws convey the DRI into the melter gasifier,where final reduction and melting takes place in addition to all other metallurgical reactions. Hot metal and slag tapping are done asin conventional blast furnace practice. For the FINEX technology, the reduction shaft is replaced by a fluidized bed reactor stage(Figure 1, right), where fine ore is directly used. Vieweing the process from the coal route perspective, coal is directly charged intothe melter gasifier. Coal gasification by oxygen injection results in the generation of a highly efficient reducing gas which is blown inthe reduction shaft or the fluidized bed reactor stage as described above.

COREX procces

COREX / FINEX vs. Blast Furnace Route

Figure 2 compares the COREX/FINEX processes with conventionalblast-furnace ironmaking. In the blast-furnace process, blended iron-ore finesare agglomerated at a sinter plant, andcoking coal is processed at coke-ovensin preparat ion for use in the b lastfurnace. The main shortcomings of thisconventional process are high raw-material costs and considerable pollutantemissions f rom the pre-processingplants.

Shanghai Baoshan Iron & SteelCo., Ltd., Medium & Heavy Plate Branch/ China, the largest steel producers inchina is operating a COREX C-3000

plant with an annual outpout of 1.5 million tons hot metal, wich was started up in November 2007. A second plant is already underconstruction and will be put in operation in 2011.

Figure 2. : CORES/FINEX-Blast Furnace process comparison

Current status of operating plants COREX C-3000 BaoSteel / China

Due to the financial crisis, the output of the plant wasdecreased continiously, throughout the month of January meltingrate was restricted to even 100-120 [t/h]. End of March, test runsstarted with a Pulverized Coal Injection system, an importantstep towards fuel savings as it has been proven at the FINEXplant in Korea. With a hopefully increasing future steel demand,the plant will be able to demonstrate its performance.

Figure 3. : COREX C-3000 BaoSteel module 1

Figure 4. : Production figures Baosteel (10 days average)

Part_I | pg-68


COREX C-2000 Jindal / India

At Jindal South West Steel Ltd more than 70% of the plant wastes, such as COREX and BF sludge, limestone/dolomite fines, LDslag, etc. are recycled into the two COREX modules either directly or indirectly through the pellet/sinter plants. The synergy ofCOREX and blast furnace has helped JSW steel to maximize the utilization of solid waste and thereby reduced the cost of hot metal.In addition, COREX export gas is used as back-up in blast furnace stoves, boilers, and in the sinter and pellet plant. Figure 6 showsthe average monthly melting rate of each of the two COREX modules during a 6 months period. Jindal is in the fortunate position tokeep production high due to the ongoing demand for steelproducts in India.

COREX C-2000 ArcelorMittal / South Africa

Figure 5. : 2 x COREX C-2000 Jindal (module 1 / module 2)

Figure 6. : Monthly production figures Jindal (module 1 & 2)

ArcelorMittal South Africa (Saldanha) is operating a COREX C-2000 plant with a downstram DR plant for the production of DRI. Thecapacity of the hot metal production is 650.000 tons and the DRI production 800.000 tons a year.

After relining of the plant in 2008, the financial crisis hit the steelworks. A complete shut down of the plant would have been the worstcase scenario especially for the relined iron making plant. Drastical countermeasures took place to keep the plant in operation: A stopand go operation to keep the output as low as possible started in November 2008. As its shwon in Figure 8, the hot metal productiondropped down to ~25 [t/h], the DRI production was stoped completely. This kind of action is unthinkable for a blast furnace. After someextensive maintenace stops in February, the plant is on the way to its typical performance, the financial situation improved and evenallows the production of DRI.

Figure 8: Production figures Saldanha (10 days average)Figure 7: COREX C-2000 DR combination Saldanha

FINEX 1.5M Posco / Rep. of Korea

A 1.5 million tons per year FINEX commercial plant has been operatingat Posco’s Pohang Works since April 2007. The start-up operation wascarried out smoothly, and improved gradually over time. Recently, thenormal operational performance has been achieved, satisfying target valuesof production rate, coal consumption, plant availability, and hot-metal quality.

Low grade ore with high alumina content resulting in a high Al2O3Figure 9: FINEX 1.5M Posco


Part_I | pg-69

content in the slag which is restricted in the blast furnace, is used. Table 1 outlines the performance data of a FINEX plant and a blastfurnace, operated at the same location at Posco’s Pohang Works.

Pohang BF4 FINEX 1.5M

Production [t/d] 8851 4305

Plant Availability [%] 98 95

Hot metal T [°C] 1514 1530

C [%] 4.5 4.5

Si [%] 0.53 0.85

S [%] 0.027 0.027

Slag B2 1.21 1.21

Al2O3 [%] 15.62 18.03

[kg/t HM] 298 271

Table 1: Posco’s FINEX 1.5M vs. Posco’s BF4

A milestone to reduce investment cost (up to 30%) was reached with a successful 3-reactor test in October 2008. It has been proven,that the same operation results, product qualities and plant availabilities could be reached along with significant reduced operationalcost.

Gas recycling

The conventional Corex process already operates resource preserving. The gas production, which is based on pure oxygen, leadsto a high-quality export gas, best applicable for power generation and other purposes, e.g. heating or further chemical processing.

On the other hand, a valuable second product of this amount is not always an adequate solution. So the focus of process improvementis laid on the technologies intrinsic determination of efficient hot metal production.

COREX “Low Export Gas”

To recycle the export gas – after appropriate conditioning – for metallurgical work in the process, describes in simple words theprinciple of the Corex “Low Export Gas” alternative. Figure 10 shows the flowsheet of a partial export gas recirculation: in anadsorption system1 the recycled gas is liberated from CO2, the CO and H2 enriched gas is reused for iron ore reduction.

Less generator gas from the melter gasifier is necessary to supply a sufficientamount of reducing potential, which is directly reflected in a lower fuel and oxygenconsumption.

Table 2 shows the different consumption figures of the “Low Export Gas” conceptcompared to the standard Corex process:

Standard Recycle

Fuel [kg] 940 770

Iron carrier [kg] 1,500 1,500

Additives [kg] 265 185

Oxygen [m3]STP 520 455

Table 2: Specific consumption figures per ton hot metal

The - in smaller quantities and with lower heating value - resulting export gascan be used as well for power generation. Table 3 compares the produced “by-products” amount and the heating value of the export gas:

Part_I | pg-70


Standard Low coal

Export gas [m3]STP 1,650 1410

Slag [kg] 340 265

Export gas energy [GJ] 13.5 10.2

Table 3: Specific “by-product” figures per ton hot metal

It can be seen, that the slag production goes down bymore then 20% a long w i th the decreased coa lconsumption, which is a further reduction of energy losscaused by the sensible heat of the slag and loweredadditive consumption.

With an implemented recycling circuit, it’s open to theoperator to adjust the system according to its ownrequirements, in the range from minimum coal consumption

to maximised export gas generation, to react accordingly to the steel works demand.

The reduced export gas amount leads to a smaller investment for a downstream power plant as well, in the case, a large amount ofelectrcity is not required for export “over the fence”.

Figure 11: Export gas conversion into electricity

Figure 11 illustrates the thermal and eletrical energy flowsconsidering the power consumptions of the COREX plant andthe air separation unit based on 1 million tons of hot metal ayear. The degree of efficiency of the fed combined cycle powerplant is assumed to be h = 0.46.

The difference in the thermal energy supplied to thesystem by the coal is ~125[MW]

th. Due to the higher efficiency

of the recycle alternative, the difference in the thermal energyleaving the COREX process is reduced to ~105[MW]th. Thehigher energy demand of the recycling circuit is not completelycompensated by energy savings of the reduced oxygenproduction in the air separation unit, but the overall differencein produced electricity is ~57 [MW]

el.

LRI Concepts

“Low Reduced Iron” (LRI) is a pre-reduced material(met. ~50%) generated with the COREX/FINEX technologie inaddition to hot metal. For a best possible incorporation of theCOREX/FINEX technology into existing steel plants it isnecessary to provide advantages for existing blast furnaceroutes. The process development of the COREX/FINEX LRIconcepts aims in that direction.

With the usage of LRI as iron carrier, the coke consumption is reduced and/or melting rate is increased which depends on theoperation of the blast furnace without charging LRI. The specific portion of coke as reducing agent decreases, meanwhile the specificsinter, lump ore and/or pellet portion are also decreased as they are substituted by LRI. The blast furnace gains all advantages fromthe COREX/FINEX technology, which completely gets along without sinter and a minimum of coke. Beside the economical, theecological advantages as well find its way to blast furnace hot metal production by the LRI concepts. For these reasons the COREX/FINEX LRI production is of high interest for brownfield projects, because of its ability to support existing blast furnace routes.

COREX LRI

A recycle gas circuit combined with an additional “LRI” shaft is used for increased gas utilization. Contrary to the well-knownSaldanha concept, where direct reduced iron (DRI) with a metallization of >90% is produced for downstream EAF processing, lowreduced iron is directly used as pre-reduced iron carrier in the blast furnace as substitute for sinter, lump ore, or pellets. Figure 12shows the process flow sheet of the COREX LRI concept.

FINEX LRI

The FINEX process already consists of an recycling circuit, to maintain a sufficient fluidization velocity in the fluidized bedreactors. The expansion for LRI production can be achieved either by an upscaling of the fluidized bed reactors or by the installationof a 2nd reactor stage (see Figure 13), which is operated parallel to the 1st reactor stage. A part of the produced HCI is furtherprocessed in a melter gasifier, the other part is discharged as LRI for blast furnace supply.


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Figure 12: COREX parallel LRI conceptFigure 13: FINEX LRI concept

Blast Furnace Benefit

COREX and FINEX are excellent technologiesfor the production of pre-reduced iron ore for afurther application in the blast furnace. The results ofthe impact of pre-reduced materials show, that asignif icant coal/coke saving or an increase inproductivity is the result of the substitution oftraditional blast furnace iron carrier with HBI/LRI.

Table 4 and Figure 14 show the impact of HBI usage in the blast furnace[1].

Charging of 100 [kg HBI/t HM] Coke savings PCI savings

Coke [kg/t HM] -29.3

Pulverized Coal [kg/t HM] -34.4

Productivity [ %] +6.6 +3.8

Table 4: Effects of HBI charging

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Environmental aspectsLife Cycle AssessmentLife Cycle Assessment, LCA, is getting an internationally acknowledged tool to judgeenvironmental impacts of the steel industry. In close cooperation with three universities– Technical University of Berlin (Germany), University of Mining and Metallurgy (Leoben,Austria) and Technical University of Denmark (Copenhagen) – an LCA study wasconducted in 2007 and 2008 comparing the environmenatl impact of of blast furnaceroute, COREX and FINEX using the environmental software tool “GaBi” for evaluation.Each step in the hot-metal production process, including the mining of iron ore and coal,the transportation to the plant site and the individual production steps were modeled andanalyzed. All by-products and their subsequent utilization were also taken into account.

Five key impact categories were identified in this study which considered most of the interfaces between the environment and theproduction process as a whole. The five categories are Acidification Potential, Abiotic Resource Depletion Potential, Global Warming Potential,Photochemical Ozone Creation Potential and Eutrophication Potential, as shown in Figure 15. The Acidification Potential (AP) provides anoverview of the acidic components that are released to the environment. The Abiotic Resource Depletion Potential (ADP) considers naturalresources. Processes are more sustainable if they are based on the use of coal, which is abundantly available worldwide, instead of non-coking coal, where resources are clearly limited. Global Warming Potential (GWP): One of the most frequently discussed environmental topicstoday is global warming, which most experts believe is caused by an increase of so-called greenhouse gases in the atmosphere. Thesegases, including water vapor, raise the atmospheric temperature by absorbing infrared radiation reflected from the surface of the earth.Photochemical Ozone Creation Potential (POCP) describes the formation of ozone (O3) in the presence of NOx, hydrocarbons and sunlight(summer smog). Another important environmental impact factor is the Eutrophication Potential (EP), which determines the degree of over-fertilization. The relative importance and magnitude of the above-described impact categories were evaluated with the CML normalistionmethod (Centrum voor Milieuwetenschappen Leiden*, NL).

Specific customer-relevant parameters and energy sources, havean influence on the overall picture. Different electricity mixes (country-specific ratio of hydroelectric-, atomic-, wind- or coal-based powergeneration) were also taken into consideration.

F.e. the SO2 – burden of electricity, which is generated from COREX/FINEX Exportgas will be much lower than the SO2 - burden of electricitygenerated by a coal based power plant.

Therefore the credit from the COREX gas leads to an even positiveimpact on the environment, as illustrated in Figure 16.

The results of an independent life-cycle assessment of the hot-metal production processes have shown that the COREX andFINEX processes are environmentally more compatible than the conventional blast furnace production route, especially at siteswhere coal is used as an energy source to generate electricity.

ConclusionTaylor made hot metal production with a special focus on resource saving and an efficient implementation into existing steel works are

the key features of the new COREX/FINEX concepts. The ecological and ecomomical advantages of COREX/FINEX are beneficial forexisting production routes as well as for new ones. During the past years, market conditions and “external” factors have also changed infavour of COREX/FINEX technology, e.g. mandatory environmental legislation, increased costs for metallurgical coal and an increasedenergy price. An answer to these challenges are the COREX “Low Export Gas” and the COREX/FINEX LRI concepts. Developments andoptimization of COREX/FINEX are still underway and major additional economical and technological improvements are yet anticipated.

OutlookWhile fuel consumptions for hot metal production is reaching its lower limits and gas utilization for reduction work is optimized

continiously. Resource preservation and environmental care are one of the “hot potatoes” steel work operators have to handle innear future. The COREX/FINEX technologies already show their high potential on the way to an economical, ecological andresponsible part in the steel making chain.

References[1] Paper of P. Schmöle and HB. Lüngen in Stahl und Eisen 127 (2007)

Figure 16: LCA results


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HISMELT Plant Ramp-upNeil Goodman1, Rod Dry2

1 . General Manager, Operations and Technology2 . Manager, Technology Development

Hismelt Corporation Pty. Limited

Introduction

Direct smelting is a kind of ‘holy grail’ for the ironmaking industry. Technical and environmental limitations of the blast furnaceare well known, and iron-makers would very much appreciate a realistic alternative. However, the blast furnace is technicallyefficient and highly evolved. It has the advantage of a large existing on-ground commitment, and is also evolving further in its ownright. In certain parts of the world (most notably China) it also benefits from a high degree of standardisation in terms of locallyproduced components, effectively reducing capital cost to a significant degree. In an overall sense this makes the blast furnace avery tough competitor for any new smelting technology.

There have been many attempts to develop direct ironmaking processes over the years, and most have fallen short of what isrequired [1]. Reasons are varied, but in general it could be argued that the efficiency (and cost effectiveness) of the blast furnacemakes it difficult to achieve a true “game-breaking” leap to a lower cost solution. This, in conjunction with the inherent risk associatedwith any new technology, has thus far kept direct smelting in check.

Perceived weak links in the blast furnace position include (i) use of a significant percentage of hard coking coal in the feed mix,(ii) environmental emissions associated with coke ovens and sinter plants, (iii) an inability to use ore fines directly, and (iv) aninability to reject phosphorous to slag. These factors can generate considerable debate, with some being discounted in certain partsof the world for quite valid reasons. However, against the background of Chinese and Indian demand growth and its associatedimpact on raw materials, there is really no doubt that coking coal price exposure (into the future) is the key concern for the blastfurnace.

Finex [2] deserves specific mention at this point – Posco have done a remarkable job in bringing their technology to the pointwhere it can be claimed it is now a proven commercial process. It satisfies most of the requirements for direct smelting (ore fines &non-coking coal) and it looks set to play a very significant role on the direct smelting landscape. HIsmelt acknowledges this in the lightof a deep understanding of what is involved.

HIsmelt Background

The HIsmelt process has a relatively long history, having been conceived in the early 1980’s and progressed through twolevels of pilot plant (10,000 and 100,000 t/a respectively) to its first commercial 0.8 Mt/a installation in Kwinana, Western Australia[3,4].

At the core of HIsmelt is the Smelt Reduction Vessel (SRV) which is illustrated in Figure 1. It consists of a water-cooled uppershell and a refractory hearth. The process uses high-velocity injection of coal and ore into the melt via downwardly-angled water-cooled injection lances. Injected coal, after heating and devolatilisation, dissolves to maintain around 4% carbon in metal. Injectedore is then brought into contact with this carbon-rich metal, and smelting occurs. The lower part of the SRV is maintained at lowoxygen potential to allow this reaction to occur, and reduction kinetics balance out at around 5-6% FeO in slag.

Heat supply to maintain the necessary thermal balance comes from combustion of bath gas (mainly CO) in the upper part of thevessel. Oxygen-enriched hot blast (typically 35% total oxygen at 1200 °C) is introduced via a top lance, and combustion occurs inthe relatively oxidizing region in this upper section. The resulting process offgas is typically has a post-combustion degree of 50-60%.

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The key to the HIsmelt process is achieving heat transfer between the upper (oxidizing) region and the lower (reducing) regionin such a way that the oxygen potential gradient is maintained. This is achieved via large amounts of liquid splash moving betweenregions, carrying heat with them as they go. A certain percentage of this heat goes to water panels and lances, and the balance isused for smelting.

Slag is tapped periodically via a water-cooled notch, while hot metal is tapped continuously via a forehearth. The latter isconsidered a key safety feature of the technology, since it is the primary means by which metal level is controlled to ensure there isalways a suitable safety margin between it and the water-cooled lances.

The HIsmelt process configuration has a number of unique features:

1. The method of solids injection, using high-velocity lances, means that capture efficiency in the melt is very high and evenultra-fines can be used directly.

2. The “natural” FeO level in the slag (5-6%), in conjunction with metal carbon at around 4%, creates conditions for strongmigration of phosphorous from metal to slag. Typically, around 80-90% of the phosphorous is rejected to slag.

3. Coal performance has virtually no dependence on particle morphology, since the coal is ground fine for injection.

These features can be exploited to access lower-grade feed materials which would be difficult (or impossible) to use in a blastfurnace.

Figure 1 : HIsmelt SRV

Kwinana HIsmelt Plant Layout

The Kwinana HIsmelt plant operates under a joint venturebetween Rio Tinto (60%), Nucor (25%), Mitsubishi (10%) andShougang (5%). A photograph of the plant is shown in Figure 2, andthe overall process layout is illustrated in Figure 3. Coal is dried andground to -3 mm in an air-swept mill, and is then pneumatically fed bynitrogen to the smelter (with lime flux). Iron ore is preheated in acirculating fluidized bed preheater (Outotec/Lurgi design). Hot oreand calcined dolomite flux are then also pneumatically fed to the SRVusing nitrogen. The coal, lime, ore, dolomite and nitrogen are injectedinto the SRV (Smelt Reduction Vessel) via two opposed water-cooledlances.

Offgas from the SRV is cooled in a hood (similar to that on aBOF) and is then scrubbed before being burned in a boiler as lowcalorific value fuel gas. A special design of gas burner is needed toaccommodate this low CV gas. Flue gas from the boiler is scrubbedfor SO2 removal in a conventional Flue Gas Desulphurisation (FGD)plant before final release.

Figure 2 : Kwinana HIsmelt Plant


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The steam raised by the boiler is used to drive steam turbines for the Hot Air Blast blower, the Oxygen Plant air compressor andan electrical generator. The electrical generator supplies sufficient power for all of the electrical drives on the HIsmelt plant, with 5%excess power sold to the grid.

The ore preheater is designed to operate on SRV offgas (at 1000 °C ex the hood) but, to date; it has been fired on air andnatural gas (decoupled mode) to reduce start-up issues involved with commissioning two new technologies in parallel. The plan isto couple the preheater and start using hot process gas in 2010.

Kwinana Plant Progress

Construction commenced in January 2003 and hot commissioning was initiated in April 2005. The first hot charge (26th April2005) did not go well, and resulted in freezing of metal in the forehearth. The root cause in this case was a steam system failure onthe offgas hood. Since then steady progress has been made. Overall plant availability (averaged since hot commissioning) hasbeen quite disappointing – some of the reasons for this are discussed below.

Iron Ore Preheater

The iron ore preheater was the single most frequent cause of non-availability of the HIsmelt plant during the first 2 years ofoperation. Although the iron ore preheater design had been used previously on the Circored® plant in Trinidad, many painfullessons had to be learned over the first 2 years of operation to obtain satisfactory availability of the preheater. These included thereplacement and redesign of the feed screw conveyors, and replacement of the original vessel refractory lining due to high failurerates associated with sub-optimal installation and material selection.

However, these modifications along with changes in operation have resulted in major improvements in the availability of thepreheater (from <50% in 2006 to >90% in 2008).

Steam System

Due to the independent nature of the HIsmelt plant at Kwinana, it is heavily reliant on the steam generated by the process fordriving steam turbines for the process and oxygen plant air compressors. Any loss of the plant boiler and/or steam system will causethe process to stop, and the oxygen plant to be put on hold.

During the first 12 months of operation, the boiler was the second most frequent cause of non-availability of the HIsmelt plantdue to problems controlling steam pressure and temperature, and flame stability issues due to the low CV SRV offgas.

However, control system modifications along with changes in operation have resulted in major improvements in the availabilityof the boiler (from <70% in 2006 to >90% in 2008).

For future plants it will be recommended that process support equipment and oxygen plant air compressors be electricallydriven. The HIsmelt plant will thus not be as reliant on steam system availability.

Flue Gas Desulphurisation

After a period of initial operation it became clear that the FGD plant was under-sized and that gas rates were limited significantlybelow their design values as a result. For an extended period it was necessary to operate the smelter with a reduced hot blast rate

Part_I | pg-76


in order to stay within the capacity of the FGD plant. The problem was not related to SO2 removal, but rather to demisting of the finalflue gas. With inadequate demisting capacity there was a degree of gypsum carryover (in fine droplets) which was unacceptablefrom an environmental nuisance point of view. This problem was rectified in April 2007 with installation of a supplementary demistingvessel.

Major Operational Lessons

One of the aims of the Kwinana plant is to expose large-plant issues in a controlled and safe manner - this is the only way tomature the technology before it is passed on to others. Key learnings “the hard way” include the following:

1. Freezing of metal in the forehearth (as occurred during first hot charge) was particularly troublesome, since re-openingthe connection between the forehearth and the main vessel was very difficult. It is impossible to operate the plant safelywithout a working forehearth. Appropriate countermeasures have since been developed and there has been no recurrence(none are expected).

2. In March 2007 there was a loss of control over the carbon balance in the SRV. The result was slag foaming (partly as aresult of cold slag and ore over-feed). This condition was sustained (unrecognised) for around 6 hours, by which timethe pig iron inventory had been largely converted into steel. This led to the formation of 200-300mm thick steel accretionson the water panels which, on cooling, exerted enormous stresses on the water piping and led to numerous water leaks.An extended outage was required to remove the steel accretions and to replace a substantial number of water panels.Countermeasures in this case involve a software pattern recognition system, specific operator training and an on-linecarbon-in-dust visual feedback system to show (in real time) if there is a carbon deficit in the smelter.

3. In December 2007 there was a hot metal breakout from the SRV which resulted from loss of the working lining due to acombination of mechanical failure of the lining and wear. The situation was handled safely and professionally, and thecontainment system proved adequate. Failure to properly recognise the status of the refractory and resulting thermalbehaviour of the shell in the critical zone appears to be at the heart of this event. Countermeasures (apart from operatortraining) include selective installation of copper slag-zone coolers (discussed below) and permanent shell surfacetemperature measurements in the critical region.

These (and many other lessons) collectively form the basis for the maturing process that is currently under way. As withvirtually any first-of-a-kind technology, there are a number of issues which must be addressed before the process can move forward.The Kwinana plant is no exception and the result, we believe, is practical know-how generation which will serve as a platform forultimate success.

Hourly Metal Production Rate & Coal Consumption

The plant is rated for (nominally) 100 t/h of metal production in its current decoupled configuration. Figure 4 shows theprogression of maximum hourly metal production rate over time. This is defined as the highest rate sustained for 10 hours or moreto establish steady-state (note that the SRV comes to steady-state much faster than its blast furnace equivalent). From modestbeginnings, hourly production has increased steadily over time to a current maximum of 75-80 t/h.

Figure 4 : Maximum Production Rate

The difference between these rates and full design capacity (100 t/h) is considered to be a function of lance configuration. Itis thought that appropriate changes will substantially close the gap and bring hourly capacity very close to the design target. Partialimplementation thereof has already occurred, with full implementation scheduled for 2010, subject to the pig iron market improving.

In an overall sense, there is a strong feeling that process performance is on track. Figure 5 shows coal consumption per tonneof hot metal. According to this, the HIsmelt process appears to be on target for achieving a coal rate of 700 kg/thm (dried basis),which is equivalent to 750 kg/thm (as-received basis).

Note that higher production rates lead to improved metal quality, not the other way round (which may strike some as being counter-


Part_I | pg-77

intuitive). At the higher rates carbon content is lower (closer to 4.0% as opposedto 4.5% at low rates), as is phosphorous content. Sulphur in the hot metal issignificantly higher than that from a blast furnace, but standard (ladle) hot metaldesulphurisation can be used to reduce the sulphur to acceptable levels forsteelmaking.

Refractory Campaign Life

The original target for a lining was 18 months, but the first campaign lives werecloser to 3 months. The significant contributors to this were the plant availabilityissues described previously. The wear profile is illustrated in Figure 6. There isvirtually no wear at all on the floor, and it was at the side-wall that the bulk of thelining loss occurred. The sloping section is referred to as the “stadium”, and it isthis refractory was consumed over time. If it was allowed to go too far there

eventually was undercutting below the wall coolers. This is what happenedin the breakout scenario described earlier.

The primary wear mechanism appeared to be spalling associated with thermalcycling of the plant. As with the pilot plant, it has been demonstrated (repeatedly)that wear rates are very low when the plant is operated in a steady manner.However, the Kwinana plant was not able to sustain such steady operation fora sufficient length of time to allow this to become the primary mechanismcontrolling refractory wear.

In addition, when several of the stadium bricks were lost, whole sections

Figure 5 : Coal Rate (As-Injected Basis)

Figure 6 : Refractory Wear Profile

of the stadium lining had ‘peeled off’ and been found lying intact at the bottom of the furnace.

To address these issues, HIsmelt installed slag-line coolers which essentially replaced the brick stadium with water-cooled copperelements in 2008. These coolers operated successfully and have drastically reduced refractory wear rates. In future, campaignlives greater than 18 months are predicted.

Care and MaintenanceAlthough the HIsmelt plant set record production rates in December 2008, the severe market downturn led to the HIsmelt JV

participants placing the HIsmelt plant in ‘Care and Maintenance’ until at least April 2010 when market conditions should haverecovered satisfactorily. With the collapse in pig iron prices to below $300/t, the Kwinana plant in its current configuration becameuneconomic to operate. A small core team of operations, maintenance and technology personnel continue to maintain and improvethe plant (where possible) until the global economy recovers.

Summary and ConclusionsThe potential of HIsmelt® technology remains vast, and it offers certain advantages (over other direct smelting options) such as

lower capital cost, natural phosphorous rejection to slag and an ability to treat ultra-fines (e.g. steel plant revert materials) directly.There are a number of customers who have already taken up process licenses and are looking to moving forward as soon as theKwinana plant achieves certain benchmark performance.

There is absolutely no doubt that the core process works. The smelter has already been operated at 75-80% of name-platecapacity with a sub-optimal lance configuration, and changes upon restart currently scheduled for 2010 are expected to bring thisclose to 100%. Informed observers (from outside HIsmelt) who have been exposed to full detail in order to provide arm’s-lengthreviews have consistently re-iterated this point.

The HIsmelt team is well aware of the magnitude and significance of what lies ahead. More hard work is called for – strategiesare in place, but delivery of the improved availability needed remains outstanding. The ongoing level of goodwill HIsmelt receivesfrom a worldwide network of supporters is strong, and is very much appreciated by those “in the trenches” in Kwinana.

List of References1. R J Dry, R J Batterham, C P Bates and D P Price, “Direct Smelting: Why Have So Few Made It?”2. Posco, “The Finex Process – A Revolution in Ironmaking Technology” Powerpoint presentation to German Joint Committee on

Metallurgical Fundamentals, Dusseldorf, 18 Jan 20083. P. Bates and A. Coad, “HIsmelt, The Future in Ironmaking Technology”, 4th European Coke & Ironmaking Conference, Vol. 2, June

2000, pp. 597-602.4. R J Dry, C P Bates and D P Price, HIsmelt - the future in direct ironmaking, Proc 58th Ironmaking Conference, Chicago, 21-24 March 1999, p361

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Charge Intelligent Sinter into your Blast FurnaceAchieve Real Cost Efficiency with Siemens VAI Sinter Technologies

Stefan Hötzinger1, Johann Reidetschläger2, Hans Stiasny3,Edmund Fehringer4, Christoph Aichinger5, André Fulgencio6

1 . Head of Technology - Agglomeration Technology2 . Senior Expert – Agglomeration Technology3 . Senior Expert - Agglomeration Technology4 . Senior Expert – Agglomeration Technology5 . Vice President - Agglomeration Technology6 . Marketing Manager - Agglomeration Technology


INTRODUCTION

Nowadays blast furnace operation at high levels of productivity and high coal-injection rates is only possible using rawmaterials with consistent and uniform properties. As the main component used in the blast furnace burden, the production of high-quality sinter is decisive for assuring high and stable blast-furnace productivity with a simultaneously low consumption of reductants.

The sinter plant no longer can be seen as a separate or stand alone production unit, but must be fully integrated with the blastfurnace to generate the ideal burden for optimized production and cost efficiency.

The performance of a sinter plant, its productivity and energy consumption not only depends on the quality of the raw materials,but also on the design features of the installed equipment and systems, their condition and the integrated process-control systems.

DISCUSSION

What is a High Quality Sinter?

Ideal blast-furnace performance with respect to high productivity, low consumption of reducing agents and constant hot-metal qualitycan only be achieved employing a high-quality sinter with the following characteristics:

§ Optimum grain-size distribution:

o Grain size between approximately 5–50 mm

o Harmonic diameter of >>10 mm

§ High sinter strength:

o Shatter Index (SI) = >92%

§ High reducibility:

o Reduction Index (RI): > 65%

o Reduction Disintegration Index (RDI <3.15 mm): < 20%

§ High porosity

§ Softening temperature above approximately 1250 °C, depending on total burden mixture

§ Narrow cohesive-zone temperature

§ Constant FeO content in the range of 7%

§ Constant basicity B2 and B4 adapted to best suit the overall blast furnace burden


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Investigations have shown that operating a blast furnace with higher content of sinter in the burden mixture can be considerablycheaper then with the similar operation with high usage of pellets or lump ore.

A decisive precondition for the production of high-quality sinter is a homogeneous sinter raw mix of high permeability. Alladditives should be uniformly distributed throughout the mixture. A high and uniform permeability allows the bed height on the sintermachine to be increased, which accordingly lowers the fuel consumption for the sintering process. Excessively high sinteringtemperatures can thus be avoided, positively contributing to the sinter strength, the reducibility of the sinter and indirectly, the FeOcontent, among other benefits. Sinter with a FeO content of less than 7% can only be produced with a sinter-machine-bed height ofapproximately 600 mm. In this context it is important to mention that the proper equipment must be installed to ensure that the fuelconcentration continually decreases from the top to the bottom of the sinter raw mix layer in order to optimize burn through temperatures.

An increased sintering time also has a positive influence on the mean diameter of the sinter product. The sintering time isinfluenced by the permeability of the raw mix and by the suction pressure. Lowering the suction pressure, however, decreases theproductivity of the sinter plant.

High Quality Sinter Demands High Quality Equipment and Innovative Design

In recent years a number of important developments have been made by Siemens VAI in the field of iron-ore sinteringtechnology, which have substantially contributed to increased productivity, improved and uniform product quality, reduced energyconsumption, lower operational costs and particularly, decisive environmental advantages. Furthermore, the production capacity ofsinter plants could be increased by up to 35% in sinter plants.

These benefits were primarily achieved through the application of the following technological developments and optimizationpackages:

§ Proportioning, Mixing and Granulation Technologies for improved raw mix preparation through the implementation of theIntensive Mixing and Granulation System (IMGS)

§ Sinter raw mix charging system to the sinter machine for better segregation

§ New wide-body pallet car design – the Grate-Wings Pallets is an economical solution for new sinter plants and as well forincreasing capacity of existing plants

§ Elongation of sinter plant without change of existing waste gas system

§ Advanced Charging Chute design which efficiently segregates the sinter particles at the sinter cooler reducing energyconsumption

§ Sinter Cooler Design with high cooling efficiency and energy recovery

§ Selective Waste Gas Recirculation System which reduces the sinter off gas volume, CO content and reduces solid fuelconsumption

§ Integrated automation and process optimization systems – Level 2

The key design features and advantages of these solutions as well as examples of application results in addition to modernizationsolutions are discussed below.

Proportioning, Mixing and Granulation Technologies for Sinter Mix

The production of high-quality sinter depends to a high degree on the chemical composition of the raw materials, especially withrespect to the gangue content (SiO2, MgO, Al2O3), interstitial water and the CaO/SiO2 ratio of the sinter raw mix. Particle grain size isparamount in importance. Investigations have shown that fuel consumption at the sinter plant and hence the FeO content of the sinterincreases with an increasing fines content with grain sizes < 0.1 mm and >8 mm.

The maximum grain size of the additives should be limited to approximately 2 mm with consideration to the targeted sinterstrength, reducibility and porosity.

For the proportioning of the raw mix, specially designed raw materials bins are installed. The bins are designed to avoid“bridging” of the raw materials within the bins and to reduce the segregation of coarse and fine particles during charging anddischarging. The segregation in the bins during charging and discharging occurs differently at different filling levels of the bins. Ahigher number of bins allows for simultaneous discharging of a single ore type from at least two bins with different filling levels, thuscompensating the different segregation of the coarse and fine ore particles during charging and discharging.

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The discharge of the raw materials with dosing weigh feeders from the different bins is controlled on the basis of the “real timedosing system”. With this control system, the desired mixture composition will conform to predetermined ratios throughout the entireoperation. Usually a collecting belt conveyor feeds the raw materials to the Intensive Mixing and Granulation System (IMGS).

Coke Preparation System

Coke preparation system uses roll crushers and/or rod mills and Flip-Flop Screens. The system assures defined particle sizerange of the crushed solid fuels.

With solid fuels crushed to the required grain size range according to their reactivity, mainly following improvements areachieved:

§ lower energy consumption

§ high and even sinter quality

§ reduced loads in the sinter waste gas

§ decreased waste gas emissions (e. g NOx)

The Intensive Mixing and Granulation System - IMGS

The IMGS is a highly economical alternative to conventional sinter raw mix preparation systems, especially when raw materialswith a high content of ultra fine materials and high moisture fluctuations have to be treated. Additional benefits are also achieved in thetreatment of raw materials with a standard grain size distribution.

The IMGS is characterized with the combination of a special designed vertical Intensive Mixer (high speed agitating mixer) anda horizontal Intensive Granulator installed downstream to the Intensive Mixer, preferably just before the sinter machine feedingsystem.

With the IMGS 100% of the sinter raw materials are treated. For optimization of the sintering process, an even distribution of theores, additives and fuels within the sinter raw mix is of ultimate importance. With a conventional mixing drum, a homogeneous sinterraw mix can only be achieved to a limited extent.

When comparing the agitating-type Intensive mixer with the conventional mixing drum, the following can be stated:

§ The agitating-type intensive mixer introduces high energy with its mixing tools directly to the raw materials to be mixed,achieving an even distribution of all raw materials within the sinter raw mix and bringing iron ores and fluxes in tightcontact. (micro and macro mixing)

§ The conventional mixing drum can only use gravity forces for distribution and mixing of the raw materials, which verymuch limits the mixing efficiency (only macro mixing)

§ The homogeneity of the produced mixture is therefore substantially higher using the intensive mixer.

With the application of the IMGS mainly the following benefits can be achieved:

§ Reduced space requirement

§ no pre-blending (blending yards) required (only bunker blending system)


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§ completely homogeneous sinter raw mix with high and even permeability

§ high productivity of the sinter plant even when ores and additives with high ultra fine grain size are sintered

§ high and stable sinter quality, resulting in high performance of the blast furnaces

§ low electric energy consumption even when the sinter machine is operated with high bed height

§ low solid fuel consumption, because of best possible fuel distribution

§ Improved performance of the blast furnaces

Charging Concept of Sinter Raw Mix to the Sinter Machine

As modern sinter machines are operated with a bed height of up to 800 mm, the raw mix charging system is of utmostimportance. Controlled charging of the sinter raw mix to the sinter machine leads to the following improvements:

§ High and uniform permeability of the raw-mix layer for the production of high-quality sinter at a low electric energyconsumption rate

§ Controlled segregation of the sinter raw mix during charging to the sinter machine to ensure the desired grain sizedistribution from the top to the bottom of the sinter bed

§ Decreasing concentration of the fuel from the top to the bottom of the sinter bed to allow proper burn through temperature

The sinter machine charging consists of a hearth layer charging system and a system for the granulated sinter raw mixcharging. For achieving the required uniform segregation with consideration to the material grain size and coke content in the sintermachine bed, as well as to maintain a high degree of permeability, the Siemens VAI Twin-Layer Charging System was developed.

The Twin-Layer Charging System

With the Twin-Layer Charging System the coarser fraction is first charged as the bottom layer via a special charging chutesystem, followed by charging of the finer fraction as the top layer via a drum feeding system. The coke content in the sinter raw mixgoes desirable with the finer fraction in the upper layer.

With the application of the Twin-Layer Charging System, mainly the following advantages will be achieved:

§ Increased plant productivity even when the sinter machine is operated with bed height of up to 800 mm

§ Uniform and stable sinter quality

§ Low consumption of coke and electric energy

The advantages achieved with the IMGS will be maintained with the Twin-Layer Charging System. To protect the surroundingareas against dust, the charging system for the hearth layer is covered and connected to the plant de-dusting system.

The Grate-Wings Pallet Cars Design

A modern sinter machine requires pallet cars which have to be designed to minimize false-air intake and therefore should beequipped with rim-zone covers to ensure good sinter quality also along the sidewalls.

The latest sinter machine pallet design featuring grate wings pallet cars was developed by Siemens VAI as a highly economicalsolution for application in new sinter plants as well as for increasing the capacity of existing sinter plants.

The pallet car body forms the upper extension of the wind boxes, allowing a very economical sizing and arrangement of thesuction area. Furthermore, between the suction area and the pallet car side walls, gas-tight rim-zone covers with a width of up toapprox. 300 mm, depending on the bed height of the sinter machine, are installed. This rim-zone cover reduces the false air suckedtrough the gap between side wall and sinter cake, which is formed by shrinking of the sinter. The pallet car bodies are designed inone piece.

With the new generation of sinter machine pallet cars, mainly the following operating benefits can be achieved:

§ Decreased waste gas volumes, as the false air sucked in along the side walls of conventional sinter machines isextensively reduced

§ Increased yield

Part_I | pg-82


§ Improved productivity

§ Lower energy consumption

§ Improved sinter quality

When applied to new sinter machines, the new design has the advantage that the width of the sinter building and of the sinter-machine supporting structure can be kept comparatively narrower. For example, the sinter building width as well as the sintermachine supporting structure for a new sinter machine with a pallet width of 5 m can be the same as required for a conventionallydesigned sinter machine with a pallet width of 4 m. With the application of this new design, the investment costs can therefore be keptlower than in the conventional design.

When existing sinter machines are upgraded with the new pallet car design, the width can be increased. Therefore, aconventional sinter machine with a width of e.g. 4,5 m can now be extended to approximately 5 m, resulting in a capacity increaseof approximately 12%.

New Sinter Cooler Design Combined With Cooler Off-air Recirculation and Energy Recovery

For cooling of the sinter a circular sinter cooler with specially designed cooler trough and pallets is applied


Part_I | pg-83

The trough is designed to minimize the false air by-passing the process of sinter cooling along the side walls. For example, acooler with a pallet width of 4 m is designed with a trough width of 4.6 m.

With the specially designed sealing system the loss of cooling air is minimized.

A special direct charging system assures vertically segregated layers (coarse material positioned in the lower section within thecooler trough), resulting in an additional improvement of the cooling efficiency.

The hot cooler off-air is recirculated to the sinter machine, being used as hot ignition air in the ignition system and as annealingair after ignition.

A main part of the warm cooler off-air is recirculated to the sinter machine where it is mixed in the Selective Sinter Waste GasRecirculation System with the sinter waste gas recirculated to the sinter machine.

With the new designed sinter cooling system mainly the following advantages are achieved:

§ Higher cooling efficiency resulting in decreased specific cooling air volume and in decreased electric energy consumption

§ Substantially decreased off-air volume resulting in minimized environmental loads

§ Lower investment and operation costs

§ The new design can also be applied to increase the capacity of an existing sinter cooler.

This means that the capacity of a conventional circular sinter cooler with a trough width of e.g. 4 m can be increased by approx.15%, without the need to increase the cooling air volume.

The Selective Waste Gas Recirculation System for Sinter Off-Gas

Environmental protection regulations, particularly for sinter plants, require modern and highly efficient waste gas cleaningsystems. The investment and operational costs of a modern gas-cleaning system depend mainly on the waste gas volume.

Therefore, a key target is the minimization of the waste gas volume of a sinter plant. A very efficient and economical solution forthe substantial reduction of the waste gas volume is the application of Siemens VAI’s Selective Waste Gas Recirculation System -SWGR.

Siemens VAI has developed and implemented new technologies which enable environmental emissions in sinter production tobe reduced to previously unattained levels. The Siemens VAI Selective Waste Gas Recirculation System can be installed in existingor in green field plants as 100 % add on or fully integrated.

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This has been achieved with the introduction of a Selective Waste Gas Recirculation System: the waste gas of the second zoneof the sinter machine is mixed with cooler off air and/or ambient air and recirculated to the area above the second zone of the sintermachine.

The selective waste gas recirculation has been developed primarily to keep the off-gas volume the same and increasing thesintering capacity and decreasing the emissions. Specific investment costs are minimized and additional equipment for gas cleaningfacilities shall be optimized in investment and operation costs. Other waste gas recirculation technologies would lead to a higher off-gas amount with all the consequences.

Savings Potential & Benefits:

- Decrease of waste gas volume up to 40%

- Decrease of specific solid fuel consumption up to 10%

- Decreased investment costs for waste gas cleaning plant

- Decreased operational costs for waste gas cleaning plant

- Short shut down times during implementation of the new system

- Reduced dust emissions from sinter cooler

- Increased sinter production per m3 waste gas

- Productivity and sinter quality maintained

- Lower CO2 emissions

- Lower specific emissions of SOx, NOx, PCDD/PCDF and heavy metals

Integrated automation and process optimization systems – Level 2

Combined with Siemens VAI’s sinter technology as described above, the advanced process models and the closed-loop expertare applied:

§ All steps of the sintering process, starting with raw material storage systems and ending with the sinter charged to the blastfurnaces including the sampling system are controlled based on a future-oriented strategy

§ Built-in maintenance diagnostic systems

§ Comprehensive data logging

With the application of Siemens VAI’s integrated automation and process control and optimization systems, the following resultsand advantages can be achieved:

§ High plant productivity at a bed height of up to 800 mm

§ Stable and reproducible sinter process conditions

§ Assured sinter product quality for stable and high-performance blast furnace operation

§ Significantly reduced energy consumption at the sinter plant and the blast furnace

§ Maximized plant availability

§ Easy-to-train and easy-to-handle operating systems

§ Full process transparency

CONCLUSIONS

With these trend-setting developments introduced by Siemens VAI in the field of iron ore agglomeration technology, previouslyunattained levels, especially in respect to plant productivity, sinter quality, energy consumption and environment protection, as wellas in respect to investment and operation costs, are achieved.


Part_I | pg-85

Blast Furnace Modernization and New technologiesIan Craig1

1 . Head of Technology Blast Furnace TechnologiesSIEMENS VAI Metals Technologies GmbH & Co.

Key Challenges

A key challenge for blast furnace operators has always been to assure a continuous and reliable supply of hot metal for thesteel plant at uniform quality and at the lowest possible costs. Any interruption in iron production can lead to potential standstills in thedownstream production and processing facilities, affecting sales, customer loyalty and market position. Downtime must be kept to aminimum while the blast furnace campaign life must be extended for as long as possible. Fluctuations in blast furnace operatingparameters must be avoided for uniform product quality, which is only possible through the application of sophisticated automationand process control solutions.

Figure 1. Jindal Steel Ltd No 3 Blast FurnaceThis is the latest and largest Blast Furnace in India.

An investment in the future

A blast furnace is an investment in the future. New builds and plant modernizations must meet the new demands placed on plantperformance, personnel safety, lower maintenance requirements and environmental compliance.

Success in the harsh and competitive world of iron- and steelmaking is determined by costs, quality and the flexibility to meetthe rapidly changing demands of the market. Advanced technology and proven solutions is the key for long-term sustainable blastfurnace operation.

Part_I | pg-86


Total solution competence

SVAI fully understand the requirements of the blast furnace. With over 190 plants supplied worldwide to date. Siemens VAIoffers a complete portfolio of blast furnace technology, meeting the highest demands of plant performance, operational reliability andenvironmental compatibility. This single source capability, in combination with expert project management and dedication to qualityworkmanship, is the basis for fast project completion and production ramp-up to design capacity.

Optimised furnace charging systems

With the new SIMETALCIS Gimbal Top® charging system, raw materials can be accurately and flexibly charged onto the topsurface of the blast furnace burden, promoting a uniform gas flow and ideal smelting-reduction conditions. In combination with theSIMETALCIS BF VAiron process automation and optimization system, which includes numerous process models and an expert system,lower-cost raw materials can be used and the coke consumption substantially reduced. The result is major savings in blast furnaceoperation.

SIMETALCIS GIMBAL TOP®

An automated blast furnace charging system for infinite flexibility in burden profiles.

Figure 2. SIMETALCIS Gimbal Top®

Flexible burden distribution control is seen as one of the key tools in the iron making process, providing the operator with the meansto control, influence and improve furnace operation.

This means of providing burden distribution is through an innovative design of concentric gimbal rings, through a systemdirectly driven by hydraulic cylinders. This arrangement allows the chute angle and position to be continuously adjusted during thematerial discharge period.

The system provides customers the opportunity to generate any burden profile by directing the charge to any point on thefurnace stock line.

The advantages of using a SIMETALCIS Gimbal Top®

Operational:

High pressure furnace operation

Improved charging flexibility

Improved service life avoiding frequent interventions

Stabilised operation with optimised fuel rates

Increased fuel injection improving productivity

Reduced heat load and extended furnace life


Part_I | pg-87

Engineering:

Simple, robust lever mechanism with external drive cylinders

Even wear, prolonging the life of the distribution chute

Avoids high-precision mechanisms

A closed-circuit water cooling system

Figure 3. SIMETALCIS Gimbal Top® Maximizing Charging Flexibility

Control of the distribution chute is by means of a proprietary control and feedback system, which is fully integrated into the overallfurnace top charging software. The system provides a high level of accuracy and control for the gimbal movements and hence thepositioning of the distribution chute.

GAS-CLEANING PLANTS

Dust removal at its finest

When considering their gas-cleaning requirements, customers must select blast furnace equipment which ideally utilizes rawmaterials, maximizes the gas-energy recovery and meets all environmental regulations.

Siemens VAI has a long and successful history in supplying environmental plants of all types. These include water treatment,dust recycling, energy recovery and clean-gas distribution systems.

Environmental compatibility

Total environmental compliance is achieved with the latest developments in dustcatchers, cyclones and wet scrubbers. Withthese solutions the dust separation efficiency can be flexibly adjusted to maximize dust recycling to the blast furnace and sinter plant– and hence iron recovery – without exceeding permissible concentrations of zinc and other heavy metal components in the burden.At the same time, the quantity of sludge that must be treated and dumped can be efficiently reduced. With the proprietary slag-granulation system of Siemens VAI, a cement-quality product is produced that can be profitably sold on the market.

Projects undertaken range from the supply of new gas-cleaning plants, which maximize the collection of dry dust, to thereplacement and upgrading of existing equipment to state-of-the-art solutions.

Primary-gas cleaning, Solutions are available for dustcatchers, cyclones or a combination of both systems.

Cyclone design

The cyclone optimizes the recycling of blast furnace dusts carried over in the offgas system.

The Siemens VAI Cyclone incorporates key features including:

Classical tangential entry to optimise the number of cyclone spirals

Smooth walls ceramically lined to give reduced erosion and long life

Unimpeded gas flow profile to reduce the potential for condensation build up

Part_I | pg-88


Large entry duct to prevent particle blockages even under slip conditions when large particles of burden (e.g. Coke)could be carried by the dirty gas system

Unique small particle by-pass system which is used to control the efficiency (classic cyclones can be up to 98% efficientbut for Blast Furnace application this needs to be controlled to about 85%)

The by pass system is externally positioned to give maintenance access outside the gas envelope.

Figure 4. SIMETALCIS GCP Cyclone

Secondary gas cleaning

Traditionally secondary gas cleaning typically consisted of two distinct phases. The first stage being a spray tower andcentrifugal separator or venturi washers with a water separator. The second stage of the process would be electrostatic precipitatorswith final pressure control using “septum valves”.

Siemens VAI has developed a range of solutions which combine these two stages in to a single vessel.

The conditioning tower cools the gas to its adiabatic saturation temperature and removes a large percentage of dust particlesremaining after primary cleaning. The scrubber completes the gas-cleaning process to a guaranteed dust content of less than 5 mg/Nm³, while controlling the furnace pressure to within 1.5% of its setpoint.

The gas scrubber has options of one or three annular scrubbing units.

The primary- and secondary-cleaning equipment has been proven over many years on blast furnaces around the world. Thesolutions developed for new gas cleaning plants are also ideally suited for retrofitting into existing facilities.

To accommodate the increased utilization of tuyere injectants, excellent corrosion protection system have been developed forinternal coatings.

The single and multi-venturi scrubbers have been developed. The multi venturi scrubber is available in a internal or externalconfiguration.

SIMETALCIS GCP 3 Cone

The Siemens VAI triple external venturi scrubber has been newly developed and gives the operator unique features which arenot available with other designs.

Key important features include:


Part_I | pg-89

The external venturi scrubbers are mounted on the outside of the vessel allowing maintenance to be carried out withouthaving to enter the gas envelope

The triple external cones are identical and designed on a modular basis and can be quickly changed with replaceablemodular units again outside the gas envelope

The design has built in redundancy where by the furnace can continue to operate with only two scrubber units

The main vessel contains a conditioning tower and a packed bed demister with no moving parts within the main vessel

The packed bed demister can be provided with a back wash system to maximise the demisting efficiency. Flooding watersprays would be operated counter flow when the furnace is down for maintenance. The effectiveness of the demister iseasily assessed by measuring the pressure drop across the packed bed

Figure 5. SIMETALCIS GCP 3 ConeConditioning Tower with Triple-Cone Scrubber

HOT BLAST STOVES

Hot blast stove systems, are available with state-of-the-art designs, internal or external combustion chambers. These featurea high-efficiency ceramic burner, ensuring low CO, SO2 and NOX emissions. A fuel-saving waste-heat recovery system can beprovided.

Internal-combustion-chamber stoves

The modern internal combustion- chamber hot-blast stove is an economical alternative to the more complex external- combustionchamber design. Suitable for a maximum operating dome temperature of 1,450 °C, these stoves will provide a straight-line blasttemperature of up to 1,250 °C.

The stoves incorporate a mushroom dome, which expands independently of the ring walls. A fully ceramic dividing wallconstructed from interlocking panels minimizes gas leakage between the combustion and chequer chambers.

External-combustion-chamber stoves

External-combustion chamber hot-blast stoves are particularly suitable for ultra-high temperature operation at high blastvolumes. These stoves can withstand a maximum dome temperature of 1,550 °C while providing hot-blast temperatures up to 1,350°C.

The up to date design features two domes which are independent and have low interaction stressing and allows independentmovement.

Part_I | pg-90


These features are designed to counteract the onset of inter crystalline stress corrosion cracking. It is well known that this veryserious condition can severely affect the life of the stove even though techniques are available to extend stove life e.g. doubleskinning.

Each dome is independent and basically accommodates internal pressure and refractory expansion pressure forces. Bendingforces and uneven bending stresses are minimised thereby virtually eliminating discontinuity stresses or stress raisers.

Figure 6. SIMETALCIS Stoves, New External and Internal Stoves

BLAST FURNACE EQUIPMENT

Mechatronic tap hole openers

The new range of tap hole openers offer a powerful ‘all hydraulic’ solution to the problem of harder clays and longer tap holesbeing used on modern blast furnaces.

With taphole length measurement and optimized drilling facilities built in, the optimum condition of the taphole is conserved thusallowing smoother flow of the iron stream through the taphole giving the user prolonged life of iron runner linings.

Figure 7. SIMETALCIS Casthouse Drill, Hydraulic Taphole Opener

The latest taphole openers are designed with long service life and low outage time in mind.

Components normally considered vulnerable on hydraulic systems such as rotating hydraulic unions and pipe work areprotected from the harsh working environment by being completely enclosed in the framework whilst still remaining serviceable eitheron the machine or replaceable as cartridge units.

All machines and cartridges are fully workshop assembled, pressure and proof tested during manufacture.

The slew drive is completely enclosed and sited away from the hot metal trough but is still serviceable quickly and safely by useof the exchange cartridge philosophy. To date 30 units have been ordered.

In addition a full suite of casthouse equipment is available including hydraulic Clayguns, Tuyere stocks, tilting iron runners etc.


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SIMETALCIS Furnace Probe

Sub-burden gas analysing probe

The gas analyzing probe is designed to take pressure, temperature and gas samples from the core of the furnace back throughto the side walls at a depth of approximately 5 metres under the burden surface.

The materials used in the construction of the water cooled probe are designed to resist the many eroding elements that arecontained within and surrounding the blast furnace environment.

In particular, resistance to the wearing effect of the descending burden whilst the probe is taking samples inside the furnace thusprolonging service life of the pressure seals that come into contact with the outer sleeve.

Figure 8. SIMETALCIS Casthouse, Tuyere Stocks and Claygun

Figure 9. SIMETALCIS Furnace Probe, Sub-burden Gas Analysing Probe

Also, resistance to cooling water additives at elevated pressure and temperature inside the probe where corrosion defects arenot visible.

In addition to the sub burden gas analysis probe a whole suit of other blast furnace condition equipment is available including:

Above burden microwave profile meter using wave guide technology

Above burden fixed temperature and gas sampling probes

Mechanical stockline measuring devices

Stockline microwave level detectors

AUTOMATION & PROCESS CONTROL

Process control systems

Siemens VAI provides modern process control systems.

Control systems include:

Furnace top control with complex charging patterns and burden distribution

Stockhouse control of sequentially batched materials with ‘in-flight’ weighing and material layering

Gas-cleaning control

Stoves control for cyclic, parallel, lapped parallel and staggered parallel 4-stove operation

Part_I | pg-92


Coal-injection systems

Casthouse operation and control

Slag granulation

SIMETALCIS BF VAIRON OPTIMIZATION

Expert system control

To ensure high-performance blast furnace operation closed-loop optimization system known as SIMETALCIS BF VAiron optimizationhas been developed.

The SIMETALCIS BF VAiron optimization functions on the basis of advanced process models, artificial intelligence, enhancedsoftware applications, graphical user interfaces and operational know-how. Excellent process performance and significantly lowerproduction costs are the proven results.

Process information management

The process information management system collects, prepares and stores all relevant data for subsequent use in, for example,customer site-wide information systems.

Precise control of the blast furnace is achieved on the basis of advanced process models.

Closed-loop expert system

SIMETALCIS BF VAiron optimization is the world’s first expert system where the main parameters of the blast furnace to becontrolled are carried out without the need for operator interaction. For example, control of the coke rate, basicity and the steam-injection rate and even the burden distribution can be simultaneously and automatically executed in a closed-loop mode to ensurestable and consistent process operations at low production costs.


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INTRODUCTION

The challenge for steel industry in the new millennium is no longer to prove its capacity to create growth, but to show that it isa material that is ecologically sustainable. This is because steel industry handles more raw materials per ton of finished productcompared to any other large-scale process industry. One of the key characteristics of sustainability of any industry is that instead ofend-of-pipe pollution control industry should rely more on eco-benign internal processes and technologies that prevents andminimizes negative environmental impact.

CONCEPT OF PREVENTION

Even few decades ago eco-friendliness of a production unit used to be gauged in terms of end-of-pipe control and treatmentmeasures. Although end-of-pipe measure is still an important option, the emphasis has gradually shifted to prevention, reduction orelimination of discharges or emissions to the environment.

The genesis of environmental issues in steel industry , like any other process industry, arise out of thermodynamic inefficienciesassociated with available technology and its reactions under varying conditions of temperature, pressure, flammability, toxicity andsuch physico-process parameters. Technology play a key role in improving the efficiency of operations and thus it has a vital role inreducing pollution. Therefore technology remains at the heart of ‘minimal footprint’ approach toward environmentally sustainablesteel making.

PROCESS IMPROVEMENT AND EMISSION REDUCTION ASPECTS

‘Clean Production’ is a major component of minimal footprint approach. The concept of Cleaner production applies toproduction processes in conserving raw materials and energy, eliminating toxic raw materials and reducing the quantity and toxicityof all emissions and wastes, and having products with reduced negative impacts along the life cycle of a product. This can beachieved through changes in raw materials, improvement in the material efficiency (lower specific consumption) of the manufacturingprocess as well as process optimisation . There is enormous scope of Clean production in almost all processes in steel industry.

In an average pollution prevention efforts have successfully reduced discharges of air and water pollutants by more than 70%in the last 20 years. At the same time, solid waste production at a typical plant has been reduced by more than 60%. Despite thesesignificant achievements, further improvements in pollution prevention technologies are needed to reduce costs, improve profitability,and facilitate compliance with changing regulations. The environmental performance of steel industry should be based on:

The efficient use of natural resources

The use of environmentally sound resources

The optimum use of recycled materials

Regular investigations to identify ways of saving energy

In almost all areas of steel plant like Coke ovens, Sinter plant, BOF etc. technology/material substitution/process integration cansignificantly bring down eco-inefficient operations. Few such areas are :

Part_I | pg-94


IMPROVED MATERIAL USAGE EFFICIENCY

Increase of iron yield in each metallurgical step

Improvement in ferrous burden properties

Improvement of coke properties

Increase of hydrogen in the reducing gas

Increased share of granulated BF slag

Alternatives of TOP gas utilization

PROCESS INTEGRATION AND OPTIMISATION MEASURES

Lowering the content of volatile hydrocarbons in the sinter feed

Lowering the sulphur content in the sinter feed

Heat recovery foe sintering and sinter cooling

Top layer sintering

Emission optimised sintering©

Sectional waste gas recirculation

Deep bed sintering

Improved ignition practices during sintering

COKE OVENS

Coke dry quenching

Use of larger coke oven chambers

Smooth and undisturbed operationof coke ovens

Emission minimized charging

Smokeless charging

Sequential charging

Sealing of ascension pipes and charging holes

BLAST FURNACE

Energy recovery from BF gas

Energy recovery from high toppressure blast furnaces

Energy savings at the hot stoves

Use of tar free runner linings

Oxy coal techniques

Nitrogen free blast combined with top gas recovery

IMPROVING ENERGY EFFICIENCY

Increasing thermal efficiency or reduction in energy consumption is one of the major means of increasing eco-efficiency of asteel plant. The high potential of thermal energy recovery in semi-finished products and by-products available in great quantities andover a wide range of temperatures. the magnitude of the problem can be gauged from the energy consumption flows ( Table 1 ). The saving would be substantial if the waste thermal enegy (43.5%) , in particular if the high-temperature share could berecovered and re-used in the same plant. Reduction in energy consumption is an integral part of clean production since this leads todirect reduction in CO2 emission leading to increase in eco-friendliness of the processes. Table 2 gives the theoretical possibility of


Part_I | pg-95

reduction in energy consumption . Table 3 highlights the improvement opportunities in raw material consumption and emissionreduction.

Few areas in which direct improvement in energy consumption can be envisaged are :

Heat recovery in sinter plants

New ignition furnace technologies for sinter plants

BF waste heat recovery

Top gas pressure recovery turbines

BOF gas recovery

Decrease of heat losses

Table 1 : Energy consumption flows

Energy carrier Percent Utilised % of total Energy Losses for % of Totalcontribution energy for Input

CokingCoal 71.2 Metallurgy 29.0 Thermal properties of solids 13.0

Electric Power 15.4 Rolling and Thermal to cooling water 9.0transportRolled product 16.3 Furnace heat losses

Waste gases 8.5

Oil or Natural Gas 13.4 Thermal energy 11.2 Thermal energy of 8.5gasesOthers 3.0

100.0 56.5 43.5

Table 2 :Comparison of theoretical minimum energy and actual energy requirement for selected processes

Process Energy Gcal,/t of product

Actual Absolute Difference , Practical Difference ,requirements minimum % minimum %

Liquid hot metal, % 3.1-3.35 2.34 25-30 2.49 20-26

Liquid steel (BOF) 2.5-2.75 1.9 25-31 1.96 22.29

Liquid Steel(EAF) 0.5-0.57 0.3 38-46 0.38 24-33

Hot rolling flat 0.48-0.57 0.007 99 0.22 55-63%

Cold rolling flat 0.24-0.33 0.005 98-99 0.005 98-99

Source :IE(I) Journal, MM, Vol 83, Oct 2002

Table 3 : Improvement opportunities in raw material consumption/emission reduction

SL Number Items Unit/ t sinter BAT Range ofparameters parameters in

Indian steel plants

INFLOWS

1 Iron ore fines Tonne 0.68-0.85 0.768-0.814

2 Coke Tonne 0.038-0.055 0.07-0.086

3 Limestone Tonne 0.105-0.19 0.114-0.184

4 Electricity MJ 96-114 100-203

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5 Other recycled materials Kg 42-113 92-198

6 BF gas/CO gas MJ 57-200 190-238

OUTFLOWSANDEMISSIONS

1 CO2 Kg 188-220 288-364

Nox Kg 0.4-0.65 0.23-0.37

Sox Kg 0.83-1.7 0.33-0.51

Particulates Kg 0.16-0.26 0.54-0.92( Dust)

Source : Best Available Technology (BAT) Document, European IPCC Bureau

TREATMENT IMPROVEMENT ASPECTS

Reduction in emission of specific pollutants related to water quality is also possible by adoption proper technological discipline.Few of these are :

WASTEWATER SEGREGATION

One method that can improve wastewater treatment is segregation. Each wastewater source should be sampled and evaluatedfor the parameters of concern. The results will identify the major contaminant origins. At this point, an initial solution may be tosegregate a high-strength, low-flow wastewater that is contaminating the entire wastewater stream and allow it to segregate from theexisting treatment system for separate treatment. Control of high effluent waste streams in this fashion can improve the overallperformance of a wastewater treatment plant.

EFFICIENT EQUALIZATION

Wastewater equalization is employed to smooth out fluctuations in influent characteristics, allowing the wastewater treatmentplant to run more uniformly. However, often this stage is bypassed. Influent wastewater characteristics can be impacted by fluctuationsin temperature and pH, as well as flow surges. Controlling influent wastewater characteristics is crucial so that there is minimalvariance that can be critical to meeting tighter effluent limits. The goal of equalization is to provide adequate dampening of influentconstituents for stable operation of physical/process treatment processes. Many existing wastewater plants may already have anappropriately sized equalization system, but continue to experience wide swings in influent composition. If this condition exists, theproblem may be poor mixing.

PROPER REACTION

Mixing wastewaters to complete process reactions is another area that is often overlooked. Even if a mixer is circulating thewastewater inside a tank in a visibly acceptable manner, that mixing may not be adequate. This calls for expansion to larger reactiontanks with more retention time; larger, more powerful mixers; or new motors to existing mixer shafts to improve mixing performance.These options can be quite expensive. Rather, careful analysis of the existing mixing equipment can often lead to more practicalimprovements.

CONTROLLED CONDITIONS

One of the most common wastewater treatment methods employed for heavy metals removal is the use of primary coagulantssuch as aluminum sulfate (alum), calcium chloride and ferric chloride (iron salt). If these conventional treatment processes are beingused and treatment is not adequate for parameters such as nickel, chrome and zinc, the problem may be the system’s operating pH.Before exploring expensive solutions (such as increasing the dose of coagulants and flocculants), the parameters of concern and theneutralization step pH set point need to be investigated. Depending on the parameter(s) of most concern, selecting and maintainingthe optimum pH set point could be the most effective treatment plant upgrade.

EFFECTIVE TREATMENT

Lower effluent limits may often be difficult to meet, even with optimum pH set points. Once this occurs, A more practical solutionin this is to switch to a metals scavenging polymer that is capable of achieving effluent limits at lower cost and reducing sludge


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production. These processs are specially developed and will typically work with existing process equipment at low feed rates. Theswitch to a polymer-type process treatment program could be very beneficial to an existing wastewater treatment plant, but can onlybe verified through treatability testing.

CLARIFICATION IMPROVEMENT

Wastewater clarification via precipitated solids settling is critical to meeting effluent limits. Most effluent norms limit the amount oftotal suspended solids (TSS) and metals that can be discharged to a receiving stream. Therefore, effective solids settling in theclarifier is an important aspect of the treatment process. In general, clarifier effectiveness can be determined by its wastewateroverflow rate. If wastewater flows exceeding the design of the original clarifier cause the overflow rates to become too high,excessive amounts of TSS may discharge from the system (along with metals), contributing to effluent limit violations. One cost-effective method for improving the performance of an existing clarifier is to install tube settlers. Tube settlers are modules of angledsettling tubes installed in the clarifier just below the water surface, effectively increasing the surface area. Additionally, crosscurrentsand short-circuiting are significantly reduced. In effect, the clarifier will perform better at the higher flow rate without increasing thebasin size. Tube settlers can typically save money and time in improving existing clarifier performance.

EXPERT SYSTEM FOR TREATMENT PLANT OPERATION

Operation of a water treatment plant involves maintaining a balance between the quality of finished water and the minimizationof operating costs. Operators must make judgements based on experience acquired over many years. Gaining this experience canbe difficult because of the time and wide range of knowledge involved. Also the knowledge of the domain is often poorly documented.Plant operation through documentation of this knowledge can improved effficiency of plant operation to a great extent.

REAL TIME WATER TREATMENT PROCESS CONTROL WITH ARTIFICIAL NEURAL NETWORKS

Water treatment consists of a sequence of a number of a complex physical and process processes, currently in water treatmentplants process control is generally accomplished through examining the quality of product water and adjusting the processes throughexperience. This practice is inefficient and slow in control response. With more stringent requirements being placed on watertreatment performance, operators need a reliable tool to optimize the process control in the treatment plant. e.g, The coagulation,flocculation and sedimentation processes involve many complex physical and process phenomena and thus are difficult to model withtraditional methods. Artificial neural network is the tool towards this end.

TOOLS

Various tools can be used to increase eco-efficiency of process industry. Few of these are :

Environmental Burden

Environmental Impact Assessment

Life Cycle Assessment

Environmental Technology Assessment

ENVIRONMENTAL BURDEN (EB)

ICI has developed a new method which is described as the Environmental Burden (EB) approach. It provides a meaningfulpicture of the emissions from operations, help to identify most harmful emissions and reduce them first and give the public a betterunderstanding of the problems and steps taken to reduce them. First a set of recognized global environment impact categories areidentified such as acidity, global warming human health effects, ozone depletion, photoprocess smog, aquatic oxygen demand,ecotoxicity to aquatic life etc on which the emissions and effluents exert an effect . Secondly a factor is assigned to each individualemission which reflects the potential of its possible impact. The next step is to calculate the EB by multiplying the weight of eachsubstance emitted by its potency factor.

EB = (Wa X P Fa) + (Wb X P Fb) + (Wc X P Fc) +…………

where W is the weight in tonnes for each substance of emission (a,b,c,…..) and PF is the specific potency factor based on theknown or estimated environmental risk posed by an individual substance to the specific category under consideration. EB can beused to compare performance with that of the previous years , compare emissions with other similar technologies and processes andset targets for improvement.

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LIFE CYCLE ASSESSMENT

A product’s life cycle starts when raw materials are extracted from the earth, followed by manufacturing, transport and use, andends with waste management including recycling and final disposal. At every stage of the life cycle there are emissions andconsumption of resources. The life cycle assessment makes, through objective and subjective assessment a realistic evaluation of thetotal impact of a product or process.

Life Cycle Assessment (LCA) is a tool for the systematic evaluation of the environmental aspects of a product or service system throughall stages of its life cycle. LCA provides an adequate instrument for environmental decision support. Life cycle assessment has proven to bea valuable tool to document the environmental considerations that need to be part of decision-making towards sustainability.

ENVIRONMENTAL TECHNOLOGY ASSESSMENT (EnTA)

Environmental Technology Assessment (EnTA) is a tool to help decision-makers understand the likely impact of the use of anew or existing technology. The assessment process looks at the costs of the technology, the monetary benefits, and its environmental,social and political impacts. Environmental technology assessments specifically analyse a technology’s implications for human health,natural resources and ecosystems. The goal of EnTA is to assist inmaking informed choices on technologies that are compatible withsound environmental performance; through the use of EnTA moreinformation is gained about technologies, and potential environmentalproblems and costs can be identified and avoided from the outset.

CLEAN PRODUCTION ASSESSMENT

A Cleaner Production assessment is a procedure whichcompanies, consultants etc. can use to identify sources ofenvironmental concern and catalyze corporate effort to achievecontinuous environmental improvement through an on-goingprogramme. It resembles a waste audit in concept but also includesa broader set of steps to search for prevention options. A centralelement of the assessment is analysis of the material and energyflows entering and leaving a process. Cleaner production optionssuch as substitution of raw materials or use of more energy efficientequipment, can be identified using such an analysis. Cost of inputsand outputs are also an important element of such analysis, e.g.costs of raw materials, disposal charges, maintenance charges, etc.By assessing its energy and material use , a company should be able to identify key environmental, health and quality issues.Following the assessment, companies can use a variety of tools such as monitoring and auditing (waste, energy, health and safety)to address these issues and perhaps provide benchmarks for improvement.

CONCLUSION

The objective of increasing eco-efficiency is a continuous process. The optimal combination of material uitilisation , processimprovement and operational efficiency can lead to minimization of environmental footprint in all processes in steel industry.


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Coal Gasification & Syngas based DRIRajesh Jha1

1. Executive Director, Jindal Steel & Power Limited, Orissa, India

INTRODUCTION

Historically, coal based plants have been attractive in India because they require a very small capital investment and can bebrought online in a short period of time. The production volume is low and the quality of DRI is also low when compared to gas-basedDRI; but for small foundries and non-critical steel production, the product has been well received. The lower degree of metallization,very low carbon content combined with higher ash and residuals levels make it an acceptable although not attractive iron source forsteel making In contrast, the 3-4%C and >94% metallization for DRI from the synthesis gas allows steel makers to produce the highestgrades of steel, including flats and special steels. Apart from superior quality of DRI this route also economises the use of coal and hasa lower CO

2 footprint

India has large iron ore reserves which can better be capitalized by processing locally, more added value products such asDRI and HBI. While gas based plants and other alternatives are more expensive, the financial return is greater and the productquality is much higher.

KEYWORDS: coal gasification, coal, DRI, Jindal Steel & Power Limited, syngas

OPTIONS FOR INDIA

With the non availability of natural gas, as well as with limited reserves of coking coal and availability of large reserves of non-coking coal, we see two significant possibilities for Indian steel industry. The first is blast furnace route which requires use of cokingcoal whose reserve is very much limited and as such the dependency on import of coking coal increases. Coking coal is not onlypriced at a high premium but is a very fluctuating and highly volatile commodity. There are many disadvantages of utilizing a blastfurnace like a high specific capital cost, the need to use expensive coke, limited turndown, and the environmental problems associatedwith coke ovens and sinter plants.

The second option left for the Indian steel industry is to go for DRI plant using gas supplied from a coal gasification unit. Theadditional expense of coal gasification would increase the capital expenditure for the plant, however it would be similar to conventionalgas based DRI with external reformer.

For the coal gasification-based DRI plant, economies of scale would operate advantageously for larger plants because of theexpense of the gasifier units. The advantage is that by using abundant and low-cost coal for making syngas, the restrictions of thenatural gas supply would be avoided. Environmentally, the indirect use of coal by gasification provides a cleaner reducing sourcethan that of direct coal reduction for the coal based technologies. Again, the DRI product is of the same high quality as that of anyconventional Natural gas based DRI plant.

Furthermore, since the DRI process is independent of the reducing gas source, the behavior in the reduction zone is the sameas long as the proper balance of the reducing agents (CO and H2) is made available, whether from natural gas, coal gasification orany other source. Table1 shows the input requirements based on both natural gas and syngas for any plant size.

Table:1 Input requirements

Item Unit Natural gas SyngasPlant capacity t/a 2,000,000 2,000,000

Metallization % >94 >94

Carbon (Controlled) % 1.5-3.5 1.5-2.5

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Inputs Specific Consumption

Iron ore t/t 1.42-1.44 1.42-1.44

(Screened-3.2-mm, dry basis)

Natural gas Gcal/t 2.3 -

Syngas* Gcal/t - 2.21

Electricity kwh/t 60-80 70-90

Oxygen Nm3 /t 35-50 -

Water m3 1.5-1.8 1.5—1.8

Steam at 4.5 bar

For Co2 removal in syngas kg/t - 700

For Co2 removal in DRI plant kg/t - 500

Labour man hrs/t 0.11-0.17 0.11-0.17

Maintenance US$ 3.0-3.3 3.0

LOOKING TO THE FUTURE

Looking at the tremendous growth in India, it is clear that change is needed now in order to broaden the country’s industrialbase. In terms of environmental issues, India must begin making progress in lowering its pollution levels. To take better advantageof the abundant iron ore and other resources, the iron processing and steelmaking industries must modernize to compete in the globalmarketplace.

In this respect, Jindal Steel & Power Limited has taken a lead role towards cleaner and greener environment by installing a 6.0MT integrated steel plant at Angul with syngas produced through coal gasification & further using it in reduction of Iron ore in DRIplant.

SUITABILITY OF FEED STOCKS FOR COAL GASIFICATION

A detailed knowledge of coal characteristics is essential to predict gasification behavior when a specific coal source is to begasified. An extensive study of the various variety of coal in the vicinity of Talcher coal mines was carried out to identify the suitabilityof the gasification process for indigenous coal.

Following tests are conducted on Coal sources to determine the suitability for Gasification Purposes:

Proximate Analysis

Ultimate Analysis

Co2 Gasification reactivity

Particle size distribution

Ash melting properties and ash composition

Caking Properties under 30 kg/cm2

Thermal Fragmentation (Atmospheric Pressure)

Mechanical Fragmentation

Fisher Assay

Total Sulphur

Heating Value

Rank of the coal.


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Particle size distribution: Particle size distribution of the coal sample at the outlet of the washery was determined and results aregiven in Table-2. More than 90% of the coal was coarser than 6.7 mm. In order to determine the gasifiability of coal, all analysis wasdone on the +6.7mm fraction.

Table 2: Particle size distribution on sample as received (Mass% -Fraction Retained)

Fraction (mm) Talcher 1 Talcher 2

37.5 9.7 3.0

26.5 39.0 42.5

19 25.4 30.8

13.2 11.8 11.7

9.5 5.9 4.5

6.7 3.4 2.5

4.75 1.5 1.3

3.35 0.9 0.9

2.36 0.6 0.7

1.7 0.3 0.5

-1.7 0.3 1.8

-0.5 1.2 0

Proximity analysis: Moisture, volatile matter, ash content and Co2 reactivity were determined and the same are given in Table-3(air dried basis) and Table-4(dry basis)

Table 3: Proximity analysis (air dried basis-mass %)

Sample Talcher 1 Talcher 2

% Moisture 7.5 6.4

%Volatile matter 26.3 26.2

% Fixed carbon 31.9 31.6

% Ash 34.3 35.8

Co2 reactivity/hr 50% burn off - 5.9

Table 4. Proximity analysis (dry basis-mass %)


%Volatile matter 28.4 27.9

% Fixed carbon 34.5 33.7

% Ash 37.1 38.3

The coal was found to be of higher ash content and thus slightly lower fixed carbon. It is important to note that high ash contentreduces the gasifier efficiency to a certain degree and makes gasifier control slightly more difficult.Co2 reactivity (measured as the50% burn off point under CO2 at 900oC) was determined on the coal samples.

Fischer Assay: The Fischer assay was performed and the results indicating yields of tar, coke, gas and chemical water was givenTable-5.The Fischer assay gives an indication the products, which upon heating the coal, may be formed in the pyrolysis section ofthe gasifier. The Fischer tar yield for Talcher coal is of the order of 6.5%.

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Table 5. Fisher assay (mass %)

Sample Talcher(composite)

% Tar (as received) 6.5

% Tar(dry basis)^A 7.3

% Char*(as received) 77.6

% Water(as received) 10.3

% gas(as received) 5.6

Ash fusion properties and Ash composition: Ash fusion properties and ash composition are given in Table-6 & Table-7. Testsare conducted under oxidizing conditions at a temperature of 1600C.Ash fusion temperature of Talcher coal is significantly high withcoal displaying high ash melting point as a result a low H2:CO ratio gas can naturally be produced. This increases the carbonefficiency by lowering the CO2 content in the product gas.

In Talcher coal SiO2 & Al2O3 contents are on higher side and CaO &Fe2O3 contents are relatively on lower side.

Table 6. Ash fusion properties

Sample Initial Hemispherical Flowdeformation(oC) ( oC) ( oC)

Talcher 1 1530 1590 +1600

Talcher 2 1500 1580 +1600

Table 7. Ash fusion (mass %)


SiO2 66.6 66.7

Al2O3 25.0 25.4

Fe2O3 2.4 1.8

P2O5 1.0 1.0

TiO2 1.4 1.4

CaO 1.8 1.2

MgO 0.9 0.8

K2O 1.7 1.7

Na2O 0.3 0.3

SO3 0.2 0.1

Caking properties: Talcher coal of the size

-19+2.36mm under pressure of inert atmosphere shows no caking tendency.

Thermal & Mechanical Fragmentation: The thermal & mechanical fragmentation tests were conducted on a composite sample.

The thermal degradation of the Talcher at atmospheric pressure is 20%.

The mechanical fragmentation of the Talcher coal was determined as 32.7%.

Ultimate analysis & Heating value: The ultimate analyses of coal (dry ash free) together with higher & lower heating value areshown in table-8.


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Table 8. Ultimate analysis & heating value

Sample Talcher

C Mass % DAF 76.4

H 5.3

N 1.9

S 0.7

O(by difference) 15.7

Lower calorific value(air dried) MJ/kg 17.3

Higher calorific value(Dry basis) MJ/kg 17.5

The ‘Sulphur ’ content in Talcher coal is relatively low. Talcher coal has lower heating value as a result of high ash content.

Inorganic and Organic Sulfur distribution: Different forms of Sulfur: Different forms of Sulphur are listed in Table-9.

Table 9. Forms of Sulpher (mass% as received basis)

Sample Total Mineral OrganicSulphur Sulphur Sulphur

Talcher 1 0.46 0.08 0.38

Talcher 2 0.45 0.11 0.34

Petrographic composition: The rank of the coal is determined by means of reflectance analysis of the vitrinite content in coal. Themean random reflectance value of 0.37 indicates that the coal is of a sub-bituminous rank. Table 10 shows petrographic composition.

Table 10: Petrographic & coal rank

Sample PETROGRAPHIC COMPOSITION MASS %)

Vitrinite Liptinite Total Inertnite Visible minerals

Talcher 49.8 2.2 15.4 32.6

Rank RoV (random)- 0.37

Classification of Coal According To Rank:

———0.25———0.4———--0.6———--—-4.0———-

Lignite Sub-bituminous Bituminous Anthracite

Note: Talcher Coal Rank-0.37

The effect of Coal quality on Gasifier performance is shown in table 11

Table 11. The effect of coal quality on Gasifier performance

S.No Parameter Importance

1 Moisture § Influences gasifier efficiency§ Determines if process must be dry or slurry fed

2 Volatile Matter § Determines the extent & rate of gasification reactions

3 Heating value § Determines plant dimensions§ Influences generation capacity

4 Ash content § Lowers system efficiency§ Increases slag production & disposal cost

5 AFT (flow reduction) § Influences melting ability of discharged slag(must be melted below performance temperature)

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6 Slag viscosity H” 1400oC § Influences smooth slag flow between packedbed particles (viscosity must be sufficiently low)

7 Char reactivity § Influences the extent of carbon conversion

8 Sulfur § May cause corrosion of heat exchanger surfaces

9 Nitrogen § Contributes to NOX emissions.

10 Chlorine § May form HCL which can poison gas cleaningsystem catalysts

§ May form HCL which can cause chloridestress corrosion.

GASIFICATION TECHNOLOGIES AND DRI

There are three different types of gasifiers:

Entrained bed

Fixed bed

Fluidized bed

All the three types can be used to make an acceptable reducing gas for DRI plant. However the entrained bed and fixed bedgasification technologies are by far the most commonly used.

Considering the quality of available coal in Orissa Talcher area JSPL has decided to go for Fixed Bed gasification Technology,as per the Engineering/technology provided by LURGI South Africa.

The SYN Gas produced has the required composition of reducing gases, suitable for use in JSPL Angul 1 .7 MTPA DRI plant.Some important features of different coal gasification process are shown in table 12.

Table 12. Some important features of differentCoal Gasification process

FEATURES Fixed Bed Fluidized Bed Entrained Bed

Lurgi FBDB Winkler Shell Texaco1. a) Pressure , Kg/cm2 10-30 Atm 30-40 40-80

b) Temperature deg C 1200 1100 1600 1600

c) Gas-outlet Temp, deg C 675 ~850 1370 1320

2 Type of Coal and caking coals All ranks except Low rank coal All types All types

3 Feed coal size , mm 6-50 0-9.5 -200 mesh 0-0.5

4 Moisture in feed coal , wt% up to 18 <5 No limit

5 Maximum ash content tried, wt% up to 40 up to 25 up to 25

6 Ash withdrawal Dry Powder Dry Powder Molten Slag Molten Slag

7 Dry gas composition , vol%

CO 18-20 34-36 65-66 55-57

H2 39-41 40-42 30-32 33-35

CH4 10-12 3-4 0.4 <0.1

CO2 28-30 19-20 1-2 10-12

S ‘ Compounds ~0.5 ~0.5 0.4 0.3

N2 and others ~0.5 1 1 0.6

8 H2 / CO ratio in gas 2.1 1.25 0.48 0.65

9 Calorific value of gas , kcal / Nm3 2600-2900 2640 2980 2700

10 Cold Gas efficiency , % >85 80-83 76-77

11 Carbon Conversion , % 93-99 >93 >99


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WHY SASOL-LURGI GASIFICATION

Well demonstrated, Proven Technology, Low risk. 100 Gasifiers in operations.

Suited to wide variety of low grade , high ash content coal up to 40 %

Robust and mature technology, high reliability and on line availability factors. ( 90 to 92 % )

High Carbon efficiency ( i.e. 95 % )High cold gas efficiency = 85 % because of counter current operation.

Oxygen consumption is low ( about 1/3 of entrained bed )

Most suitable for steel industry, as it contains gas H2: CO = 1.6: 1.8 and CH4 of 10 to 12 % which is a requirement of steelindustry.

Ash fusion temp of Indian Coal is high. Hence dry bottom ash is preferred.

No coal drying & grinding. So less energy consumption and not hazardous.

Valuable Co-Products like tar, oil, phenol, ammonia are produced.

SYNGAS CLEANING & CONDITIONING

The syngas produced in the gasifier must be cleaned & conditioned to be used in a DRI plant. Downstream of the gasifier, thehot syngas is cooled & scrubbed, which removes the particulates & most of the water vapor. It also generates a large quantity ofbyproducts that can be sold or used elsewhere in the complex.

The majority of the acid gases (H2S, COS & CO2) are removed from the syngas by a Rectisol type acid gas removal system.The concentrated sulfur gases are further treated to convert them into saleable elemental sulfur. Typically more than 99.5% of sulfurin the gasifier feed stock is collected as elemental sulfur. The concentrated CO2 can be sequestered or injected into oil & natural gasfields. The plants using fixed bed gasifier require additional unit operations to remove the tar, phenol, oil & ammonia from the syngas.The process block diagram is shown in Figure 1.

Figure 1. Coal gasification process block diagram

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DIRECT REDUCTION PROCESS

In the Gas based DRI plant the incoming makeup syngas is first expanded to above 3 bar (g) by a turbo expander. The lowpressure make up syngas is then mixed with recycled top gas to make the required reducing gas. The reducing gas is heated in agas heater to above 800OC.The hot reducing gas enters the shaft furnace where it reacts with iron oxide to produce DRI.

Reduction reactions are as shown below:

Fe2O3 +3H2 2Fe +3H2O

Fe2O

3 + 3CO 2 Fe +3 CO

2

The spent reducing gas (Top gas) exiting the shaft furnace is scrubbed and cooled and then recycled. The Energiron andDanarex process is shown in Figure 2 and Figure 3 respectively.

Figure 2. Energiron process

Figure 3. Danarex process


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INTEGRATION OF GASIFICATION & DRI

The gasifier/MIDREX (SYN Gas based) DRI plant combination is used in JSPL Angul to provide DRI for the integrated steelplant. The integration includes air separation unit, Gasification unit & DRI plant. For this complex the only major raw material is coal& iron ore. The advantages of integrated complex compared to a conventional Blast furnace based integrated steel works include:

Lower specific capital cost

Lower operating cost

Ability to use low cost energy sources (pet coke,lignite,bituminous coal etc)

No coke or coke ovens required

No sinter plant

Reduced air emissions-since the gasifier operates in a reducing atmosphere, there are virtually no SOx or NOx compoundsgenerated.

Ability to capture high purity CO2 for sequestering or injecting into oil & gas fields.

The process route of integrated complex is shown in Figure 4

CONCLUSION

Utilizing a gasifier to generate reducing gases can be technically and commercially viable method for innovative steel makersto produce DRI in areas where low cost natural gas is not available. Even better economics can be derived when the project is foran entire integrated mini-mill complex, including a steel mill & an IGCC power plant.

The gasifier/DRI concept (especially the integrated mini-mill complex) is best suited for the East Asian countries where DRI isneeded but natural gas and power costs are high.

REFERENCES

[1] Thomas Searnati, Tenova HYL, Practical options for advancing the direct reduction industry in India.

[2] B. Madhusudhan, Indian Insitute of Chemical Technology, India, Prospects of moving bed gasification of low grade Indiancoals for fuel gas & syn gas application.

[3] Report on the gasifibility of selected Indian coal in a Sasol Lurgi fixed bed dry bottom gasifier.

Figure 4. Integration of Gasification & DRI

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Plate Heat Exchangers for a greener tomorrowIn today’s scenario, for any industry to survive and grow there is an increasing need to be cost competitive while reducing

energy consumption and also to build and maintain a positive environmental profile.

There is a dire need to look out for ways and means to conserve energy and at the same time look for greener technologies.One product which helps in complementing the above needs is the “Heat Exchanger”

Heat Exchanger, as a product has undergone a series of changes over the years. The objective of the write-up is to introducethe latest technologies in heat transfer and also outline the various applications of heat exchangers in the metal industry.

Conventional Shell and tube Heat exchanger

Shell and tube heat exchangers are the most commonly used heat exchangers in any process industry. Plant personnel aretraditionally so accustomed with this piece of equipment that when it comes to designing this equipment, thumb rules replace allcalculations and designs.

Advantages of shell and tube heat exchanger:

Rugged piece of equipment

Viable heat exchanger for high pressure applications > 27 Bar (400 psi)

Viable heat exchanger for high temperature applications > 190°C (375 °F)

Disadvantages:

Relatively low overall ‘U’ values

Larger exchanger

More expensive exchanger

Exchanger occupying a lot of space

Greater tendency to foul

Not very flexible to process changes


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Better technology – Plate Type Heat Exchanger

How does a PHE work?

Corrugated Plates Induce High Local Velocity

Turbulence is achieved

This Results in Much Higher “U” Values

True Counter Flow— Not Crossflow like S & T

Fouling is Reduced to 1/10 to 1/100 of S & T

Plate Heat Exchangers vs. Shell & Tube HEs

The inherent properties of plate heat exchangers make them a more efficient and compact solution to traditional shell-and-tubeheat exchangers. PHEs make it possible to achieve increased capacity and to recover more heat using fewer heat exchangers.PHEs are also much smaller and can easily be fitted within the footprint of existing installations. The greater energy recoveryresults in savings in fuel consumption as well as reductions in emissions, giving investment payback times that aretypically very attractive.

PHEs also provide faster response to changes in the process, such as at plant startup and shutdown, in addition to longerintervals in between services. The serviceability of a PHE is also far better compared to shell and tube. When service is needed,unrestricted access to the heat transfer surfaces means it is easier to restore full heat-transfer efficiency.

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Better Heat-transfer efficiency

The distinguishing feature differentiating the PHE and the traditional S&T is the use of corrugated plates to form the heatexchanger channels. When these plates are boxed, the many contact points force the fluid to spiral its way through the channels,thereby inducing higher turbulence. This means that for the same flow velocity through the channels, a PHE achieves greaterturbulence than a S&T, thus giving rise to thermal efficiency that is three to five times higher. This greater turbulence leads to a higherwall shear stress, permitting the PHE to operate for longer intervals with no need for maintenance. This is because the wall shearstress has a cleaning effect that reduces any fouling inside the heat exchanger.

Improved Heat-recovery

Another important feature of the PHE is that it can operate with a counter-current flow (ie, the hot fluid enters the heat exchangerat the end where the cold fluid exits). This makes it possible to handle crossing-temperature programs (where the cold fluid is heatedto a temperature that is higher than the outlet temperature of the hot fluid) in a single heat exchanger. This is especially important inheat recovery, where the cold fluid can be heated to temperatures very close to those of the hot fluid, hence recovering as muchenergy as possible. The temperature difference between the hot and the cold fluids (mean temperature difference — MTD) acts asthe driving force for heat transfer. The larger the MTD, the more effortless the heat transfer, and vice versa. The effort needed tocarry out a certain heat transfer duty is often measured in terms of its NTU value (theta [i] value or thermal length).

For single phase service, his parameter is calculated as:

Equation 1: NTU = i = T1 – T2 ————— MTD

T1 = inlet temperature

T2 = outlet temperature

For heat-recovery duties, the temperature program (the difference between the inlet temperature and outlet temperature) isnormally large and/or the temperature difference between the two fluids (MTD) is very small. Equation 1 shows that this results in alarge NTU value. In reality, this means the driving force for the heat recovery duty is low and the two fluids have to remain in contactfor a long time for them to exchange heat. In a S&T, this is tackled by making the tubes longer, arranging the tubes with many passesand/or connecting several tubes in series. This often results in hydraulic problems, because the channel velocity through the largeunits is reduced, thereby lowering the thermal efficiency of the heat exchanger even more (as well as increasing the foulingproblems). In contrast, the high thermal efficiency of the PHE, combined with opportunities for operating with a counter-current flow,allows the PHE to deal with long temperature programs with a small MTD. As a result, in many cases, only a single PHE is neededto tackle the required heat-recovery duties.

A small comparison between PHE and S&T

PHE S&T

Wall shear stress 5-8 1

Heat transfer efficiency 3-5 1

Heat transfer area 1 3-5

Pressure drop 1.2-1.5 1

Service area 1 4-10

Weight empty 1 1.5-4

Weight full 1 2-5

Installation cost 1 1.5-2

Hold-up volume 1 30-40


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Installation requirements

Since the PHE features such a compact basic design, the HTA required for each specific duty can also be assembled in aneffective way. This means a PHE with around 310m2 of HTA needs less than 1.5m2 of floor space for the installation and around 10m2of total floor space, including the service area (with 1m added all around the equipment).

A corresponding S&T heat exchanger with 6m-long tubes would need around 15-16 m2 of floor space for the installation and55-60m2 of floor space including the service area, because room for removing the tube bundle must be taken into consideration. Thecompactness of the PHE design also accounts for a reduced weight, which cuts down on installed cost (investment plus installation),especially when construction and/or foundation work is needed. When estimating the installed cost, a factor of 3.0–3.4 times the initialinvestment cost is often used for S&Ts, while for CPHEs the corresponding factor is normally less than 2.0.

In addition, the reduced hold-up volume means the PHE responds much faster to any changes in the process operatingparameters, such as at startup and shutdown.

Servicing needs

As has already been pointed out, the greater turbulence and the elimination of hydraulic problems extend the operatingintervals between services. Service work is also done more quickly when needed, which saves money on both maintenance costsand production downtime. With the better response to process changes, the plant can be shut down and restarted more quickly. Ifchemical cleaning is used, the lower hold-up volume makes this process faster, with fewer chemicals to dispose of once the cleaningis complete. If mechanical cleaning is needed, simply unbolting the frame provides complete access to the heat-transfer surface forcleaning using a hydro jet of up to 500 bar.

Summary

It is a well-known fact that compact PHEs, with their improved turbulence and counter-current flow, can achieve much higherheat-transfer efficiencies than traditional S&Ts, thereby reducing the heat-transfer area needed. This is especially important in heatrecovery, where the use of PHEs makes it possible to carry out demanding energy-recovery duties that in some cases would noteven be feasible using S&Ts, or would require many large S&Ts connected in series and thus suffer from hydraulic constraints andfouling problems. The increased heat recovery means substantial savings, both in terms of fuel savings and savings on emissionsfrom heaters and boilers. With today’s rocketing energy prices, the Kyoto Protocol and acid rain, these are facts that become evermore important when calculating the payback for a project. Since PHEs provide compact, low weight solutions with minimal installationfootprint and service ground space needs, the installation cost is normally 33–75% lower than for bulky S&Ts. Payback times of lessthan six months, including installation cost, are often feasible when considering heat recovery projects that feature PHEs. Otheradvantages with using PHEs include the reduced heat-transfer area, which makes it possible to utilize materials that are highlycorrosion resistant, and the low hold-up volume, which enables the unit to respond more quickly to any changes in the processoperating parameters, making it easier to start up and shut down the process. From a service point of view, the highly turbulent fl owthrough the heat exchanger channels, measured as wall shear stress, ensures the heat exchanger is kept clean, resulting in longerservice intervals. When cleaning is needed, the unrestricted access to the heat-transfer surface reduces the downtime and maintenanceefforts to a minimum. If chemical cleaning can be carried out, chemical consumption and disposal costs are reduced on account of themuch lower hold-up volume.

PHEs in metal industry:

• Most duties in the steel industry involve straight forward water/water and oil cooling and stainless steel plates can beused

• For corrosive baths, exotic materials are used when applicable

Water cooling:

• Blast furnaces

• Basic oxygen-, rotary- and kaldo furnaces

• Electric arc furnaces

• Induction furnaces

• Vacuum arc remelting and electroslag furnaces

• Extrusion presses

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• Hardening and annealing furnaces

Indirect cooling if the raw water is dirty

• Jacket cooling water must be clean and must therefore be circulated in a closed system

• When cooling tower water is used, it is always advisable to install a PHE. The tower water pH drops continuously due toSO2 and CO2 pickup. Also dust and other pollution pickup can be a problem.

Oil and emulsion cooling

• Heavy section rolling mills (lube oil)

• Cold reduction mills (lube oil or emulsion)

• Extrusion presses (hydraulic oil)

• Finishing operations (grinding/cutting fluids, machine lube oil)

Central Cooling Systems

• Where the outside water is salty or brackish, the use of titanium can be limited to the central coolers. All internal PHE canbe made of S/S.

• Large titanium units are used, often multiple units in parallel.


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1. Introduction

The compliance with environmental regulations and energy recovery in steel plants have become a major issue within the last fewyears. Thus, clean, green and sustainable technologies for the steel industry have become a major focus.

SMS ELEX in cooperation with SMS Siemag offers latest technology and equipment to fulfil or exceed local pollution regulations. Inaddition the SMS ELEX systems and equipments meet the customers increasing demands regarding low maintenance, technical andoperational reliability.

Thus SMS ELEX systems and equipments offer economically sound solutions with low maintenance and operating cost.

2. Evolution of BOF primary dedusting

In BOF plants utilising gas recovery, nowadays dedusting is possible by wet scrubber and round- type ESP. As environmentalregulations will be more restrictive and wet scrubbers may no longer fulfil these requirements, round- dry or wet type ESP's are theonly alternative.

The Dry type round ESP has the following main advantages over the wet scrubber system:

1) Lower clean gas dust content

2) Lower operation cost

3) Lower maintenance

4) No water treatment system required

5) Less water consumption

However, actual generation of ESP in primary BOF dedusting process do not comply with the latest state- of- the- art ESP technology.For this reason SMS ELEX has designed a 2nd generation of dry- type ESP, incorporating the latest ESP know- how. This newgeneration of ESP allows our customers to achieve clean dust content below 10 mg/Nm3 at very low operation cost.

Moreover, a brand new process has been developed and patented to upgrade wet scrubber with a wettype ESP. The combinationof these two technologies is called Hydro Hybrid Filter and enables existing BOF scrubber units to comply with most restrictiveenvironmental regulations, at very low investment cost. As a further advantage this modernisation of existing scrubbers does notrequires long downtime to be connected to the existing system.

3. Second generation ESP system in BOF process

The off gases from the converter are cooled down in the cooling stack. The tube bar tube design of the cooling hood and stackconstruction allows decreasing the gas temperature from 1800°C down to approx. 900 °C. In order to create optimized conditions forthe ESP, the gas temperature has to be cooled in a second step after the cooling stack. Therefore the gas flows through a gasconditioning tower before entering the ESP. The gas temperature at the GCT outlet is approx 200°C and still a "dry" gas as onlypartly saturated. The coarse dust particles are separated and transported to a coarse dust silo via a conveyor system. Based on thisoptimum gas conditions, the ESP is capable to separate the dust with high efficiency, so that the clean gas dust content is lower than10 mg/Nm3 at the outlet of the flare stack. Thus the ESP achieves an efficiency of 99.98%. An internal bottom scraper pushes the dustinto the chain conveyor under the ESP and from there it is transported by a nitrogen flushed mechanical conveyor into the fine dust

1. SMS ELEX AG, Schwerzenbach, Switzerland

New technologies for BOF primary gas cleaningJan Adams1

Part_I | pg-118


silo. Alternatively dust transportation could be realized with a pneumatic system.

The gas flow through the GCT and the ESP is generated by a speed controlled radial fan, located downstream the ESP. The cleangas at the ESP outlet is, depending on its CO content, either directed to the flare stack, or into further gas recovery process. Gas withmore than 25% to 45% CO can be used energetically and is therefore stored in the gasholder. This process requires further coolingof the gas at the outlet of the fan, so that it can be stored in a gas holder. Gas with less than 25 - 45% is routed thru the flare to burnthe remaining CO.

3.1 2nd generation of Gas conditioning tower (GCT)

The GCT has two basic functions to fulfil. First, the gas temperature needs to be decreased to a lower level for further process.Secondary, the gas has to be conditioned in order to allow the ESP working at its best efficiency possible.

The off gas at the end of the cooling stack has a max. temperature between900 and 1000°C. In the GCT of SMS ELEX the entering gas is firstdistributed in order to realize an optimized gas flow over the entire GCTcross section (Illustration 1).

Without gas distribution at the GCT inlet, a back streaming gas flow wouldcause dust caking at the side walls, most likely near the injection. Thesesticking could cause major damage to the dust conveying device by gettingto big and falling down.

However, by utilizing gas distribution at the GCT inlet, the entire systemwill be more reliable with almost zero maintenance during the reliningperiod. Moreover, this attribute ensures a better efficiency of the ESPdownstream the GCT.

In order to decrease the temperature down to 200 °C water is injectedwith spillback nozzles into the hot gas flow below the gas distribution. Thisnozzle type creates water droplets with a max. Diameter of 400 µm. Waterpressure at the nozzle of min. 30 bar (r) is required to maintain the dropletsize. As soon as the water droplets are injected into the hot gas flow, the

Illustration 1: Velocity over cross section in GCT

heat transfer from gas to water starts and the water finally evaporates. Thus the gas temperature decreases continuously down to200°C at the GCT outlet.

A major advantage of using spillback nozzles is that this system requires only one water supply system which keeps the operationcost at a low level. Even with gas distribution the entire GCT creates a max. pressure drop of less then 4,5 mbar. The coarse dust,which is separated in the GCT due to gravity, is discharged with a chain conveyor system or pneumatically into the coarse dust silo.

3.2 Second generation dry type ESP

The function of the dry type ESP is based on electrostatic separation. Electrons are emitted from discharge electrodes which arecharged with a negative high voltage. Due to the potential difference, the electrons migrate to the earthed collecting plates. Duringthis the electrons accumulate on the dust particles in the gas flow. As a result the dust particles become negatively charged and theelectrical field forces them in direction of the collecting plates where the dust is deposited. In the SMS ELEX round type ESP thecollecting electrodes consist of profiled plates.

These form a system of passages through which the exhaust off gas flows. The discharge electrodes are arranged along the axis ofthe 400mm wide passages. Mechanical rapping units clean the collecting plates by means of periodic rapping. Discharge electrodesand collecting plates will be explained more in detail in following chapter.

The ESP is separated in, so called, "fields". Usually an ESP in BOF dedusting has 4 fields, which are separated electrical andmechanical. The mechanical separation means, that each fields has its own rapping unit and its own dust scraper. The electricalseparation is realized by applying 1 High Voltage Unit per field. With this design, dysfunctions in one field do not influence the otherfields.

3.2.1 Discharge Electrodes

The discharge electrodes in electrostatic precipitators are the major parts. Without correct function the ionisation of dust is not possiblein a proper way and as a result the efficiency of the ESP decreases heavily. Furthermore it is most important for the function of an


Part_I | pg-119

ESP, that the discharge electrodes do not break and causeshort circuits of the electrical field. Customers have reportedsuch problems, especially in existing round ESP in BOFprimary dedusting. A reason for this was found in theseparated dust, which is not oxidized during the blowingprocess due to the reducing atmosphere caused by thecarbon monoxide. During the non- blowing period ambientair is routed thru the ESP and the dust in the ESP which aresticking on the internal parts starts to glow on the surface.This effect causes heavy stress for the internal parts due tothermal expansion and crit ical material temperatures.Especially the discharge electrodes in the first field areaffected. As a result electrodes are distorted, break and causeshot down of the field, customer reports say.

Therefore our new design is based on this reports and the75 years of experience from ELEX, SMS ELEX dischargeelectrodes have a special tubular design, highly resistant tostress and with high rigidity (see Illustration 2). In additionthereto the patented discharge electrode suspension systemallows thermal expansion of the electrodes.

Illustration 2: Discharge electrode suspended in fix point

Summarized both advantages of the SMS ELEX design, the tubular electrodes and the optimized suspension, ensure reliableefficiency of the ESP, with low maintenance and operation cost.

3.2.2 Collecting plates

SMS ELEX collecting plates are designed as profiles plates.To allow thermal expansion of each plate, easy rapping andto avoid any mechanical stress SMS Elex designed a newpatented collecting plate system. Furthermore the systemassures an easy assembly The plates are split in the centreof the ESP and dist inguished between "hanging" and"standing" plates. Therefore one passage, as abovementioned, is built out of two plate walls, one plate wall ismade out of one set of hanging plates and one set of standingplates in gas flow direction.

All hanging plates in one wall are connected to one platesupporting profile, located under the ESP roof. The standingplates are as well supported in a plate support profile, whichis located on the ESP bottom. Further, all plates of one wallare guided in the rapping bar in the centre of the ESP. Eachplate pair (one hanging and one standing plate) is touchingone arrester in the rapping bar, thru which the rapping impulseis transferred (See Illustration 3). The rapping bar itself ishold either by two bolts in two upper plates or by a pendulumconstruction outside of the field.

Each individual plate in one field can move independent ofthe other ones as they are not fixed together. As a result the

Illustration 3: Central split collecting plate suspension

new patented suspension design allows thermal dilatation of each plate. Thus, no mechanical stress affects the plates and rapping willno longer damage the collecting plates.

3.2.3 Rapping system

In SMS ELEX dry type ESP discharge electrodes and collecting plates are rapped mechanically. The two rapping units are notconnected to each other and have accordingly separate motors. Each ESP field has one electrode and plate rapping unit. Forged

Part_I | pg-120


hammers are used in both rapping units. The applied systems have been built for 75 years and since then no hammer have broken.This reliability makes the rapping systems unique and keeps operation and maintenance cost at a low level.

In addition to the reliability, the plate rapping unit has an additional advantage. As the plates are not fixed to each other and therapping bar design has been adapted, rapping effects were optimized. One physical rapping with the rapping hammer ensuresacceleration values in the entire plate wall which are in line with the experience from over 75 years and tested and proved at a 1:1model. Today's used systems with interlocked plates need two rapping systems, one from each side, which is in the new design nomore required.

The SMS ELEX rapping system ensures optimized rapping effects to prevent sticking of dust on the plates. In addition the long timeexperience with the system ensures reliability and accordingly low operation and maintenance cost.

4. Hydro Hybrid Filter System

The new and patented Hydro Hybrid Filter System has been developed by SMS ELEX. The system is designed to upgrade existingBOF steel plants, which have a wet scrubber system installed, to comply with most restrictive environmental regulations at very lowinvestment cost.

The upgrade stipulates to connect a wet type round ESPbetween the existing wet scrubber and the existing ID fanstation or between the existing ID Fan and existing Flarestack/changeover station. As the exhaust gas of the scrubberhas a temperature of 70 °C and is totally saturated and alreadya clean dust content between 100 - 500 mg/Nm³. these areoptimal conditions

for a small, maximum 2 field wet ESP as a post or final cleaningunit and accordingly the gas is routed thru it. The dust isseparated by the same principle as in the dry type ESP. Thegas at the ESP outlet is directed into the existing flare stackand/or gas recovery system. (See Illustration 4)

Two main differences in design compared to the dry typesystem have to be mentioned. First, the collecting plates inthe wet type ESP are not split anymore. The plate walls consistout of one set single piece collecting plates, being supported

Illustration 4: Hydro Hybrid Filter System

only in the upper supporting profile. The second difference is the cleaning of the internal parts. Instead of being rapped mechanically,the wet type ESP is simply flushed with water, injected though simple nozzles, located above the passages. In addition to this cleaningsystem, so called "Fog water" is injected at the beginning of each field in order to keep the collecting plates always wet.

This new system has following main advantages:

1) Clean gas dust content of less then 10 mg/Nm3

2) Reduction of power consumption up to 50%, depending on the existing scrubber system

3) Combination with all existing scrubbers

4) Existing water management of the scrubber can be used for the wet type ESP without augmentation

5) Low investment cost

6) Short downtime of existing system during installation

7) Wet type ESP downstream the gasholder is not necessary anymore

4.1 Energy management with the Hydro Hybrid System

The Hydro Hybrid System enables our customer to comply with most restrictive environmental regulations by reducing the energyconsumption of the entire system. shall explain this with two case descriptions.


Part_I | pg-121

Case1 (blue line):The scrubber has a cleangas dust content of 100 mg/Nm3. Therefore thepressure drop over the Scrubber creates in thiscase energy consumption of 2000 KW. duringblowing time. By connecting a 1 field wet typeESP to the scrubber, a clean gas dust content of10 mg/Nm3 can be realized.

The power consumption of the ESP has a minorimpact on the total consumption, as only 75 KWare required for all electrical consumers.

Case 2 (green line):

Compared to case 1, the scrubber clean gas dustcontent is increased to 300 mg/Nm3 by reducingthe pressure drop and accordingly the powerconsumption is reduced heavily by 50%. Thefollowing two field wet type ESP decreases thedust content in the clean gas to 10 mg/Nm3. TheESP power consumption of 120 KW is notsignificant compared to the savings.

With optimized combination of scrubber and wettype ESP the power consumpt ion can bedecreased heavily by complying with mostrestrictive environmental regulations at very lowinvestment cost.

Illustration 5: Energy management for existing BOF Plants

5 Summary

SMS ELEX dry type ESP and wet type ESP enable our customer to be in line with authority regulations regarding dust emissions.Operation and maintenance cost can be reduced due to the reliable systems and by optimizing the actual process with our products.75 years of ESP Know- How guarantee a high professional service during engineering, installation and after sales.

Our second generation dry type ESP is preferable installed in New BOF plants or for modernization of existing BOF plants. TheHydro Hybrid Filter System is most likely to be installed for modernization / upgrade of existing BOF plants.

Part_I | pg-122


I. AIR & GAS DOUBLE PREHEATING OF AIRHEATING SYSTEM FOR BLAST FURNACE.

With the improvement in Iron smelting technology the coke consumption in Blast furnace is decreasing year by year, resulting inlower calorific value of Blast-furnace gas. If only Blast-furnace gas is burnt in air heating furnace, the blast temperature can reachupto 1000 to 1050 ºC, which can not meet the requirement of high blast temperature.

In order to increase the blast temperature, lot of measures have been taken in China, for example, mixed burn of some coke-ovengas of high calorific value, pre-heat the air and gas by flue gas heat in the air heating furnace. Due to general shortage of coke-ovengas with high calorific value in most iron & steel plants and the low temperature of waste gas in flue pipe, where even with a separateheat pipe heat exchanger, the air and gas to be blasted into the hot air furnace can be preheated to 150 to 170 ºC only. Some otherheat source should be developed to pre-heat the air and gas to the required 250 to 450 ºC respectively if we want to realize a hightemperature at 1200 ºC to 1250 ºC with only blast-furnace gas burned in air heating furnace. Under these conditions, thetechnology of double pre-heating device (or sectional type) with additional burning furnace has been developed.

Operating principle

The system is made of additional burning furnace, tube type air pre-heating device, gas pre- heating device (sectional high -temperature air preheater), combustion fan, flue gas induced draft fan etc.

The pre-heating device is of tube-type heat exchanger that induces the flue gas heat in Air heating furnace into the mixing box ofburning furnace by high temperature induced draft fan to mix with the high temperature flue gas in the burning furnace. This helpsto get mixed flue gas at 500 to 600 ºC which further enters into the air and gas pre-heating devices separately. After heat exchange,the air and gases are heated to 250-300ºC.

The sectional pre-heating device is of tube-type heat exchanger that pre-heat the air and gas to 150- 170ºC by flue gas in airheating furnace firstly, then it induces the flue gas heat in air heating furnace into the mixing box of burning furnace by hightemperature induced draft fan to mix with the high temperature flue gas in the burning furnace to get mixed flue gas at 550-700 ºC,and then pre-heat the combustion air which has been pre-heated to 150-170ºC to 450ºC again by such mixed flue gas, and finally,the air and gases are heated to 450ºC and 170ºC respectively.

The pre-heated air and gas further enters into the air heating furnace for burning. Due to the increased physical heat of air and gas,the hot blast temperature can also be increased . It is analyzed according to the result of thermodynamics that the adoption of"double pre-heating systems with additional burning device" can guarantee increase in the hot blast temperature by 180-200 ºC,so as to greatly reduce the Coke Ratio and increase coal injection and output.

Process features:

Increases the Blast temperature to 1200-1250 ºC by burning Blast furnace gas in Air heating Furnace.

Easy & reliable to operate; pre-heating temperature of air and gas can be changed at any time to meet production requirements.

Small floor area and maintenance, thus no additional manpower required.

The equipments are reliable with long service life; over 10 years service life can be guaranteed.

Distinct economic benefit, such as less investment and speedy ROI of about 6 months.

Energy Conservation & Environmental Protection TechnologyNavin Mishra (president), Yuanchang Sheng (Chairman)

Jiangsu Zhongxian Group Co.,Ltd . and Mishra Ispat Private Ltd is reputed with successful t rack record in the area of saving energy &environmental protection as a joint effort specialized in the management of energy-saving and emission reduction.


Part_I | pg-123

Few Success Stories:

● The double pre-heating devices with additional burning furnace were applied on No. 11 Blast furnace (2580 m³) ofAngang Group in Aug, 1998 and have been in stable operation till date.

● In May 2007, this technology was further applied in Bayuquan No. 1 and No. 2 blast furnace (4038 m³) of AngangGroup designed for Blast temperature of 1250 ºC.

● The double pre-heating devices of The Meishan Iron & Steel with additional burning furnace have been put intoservice on No. 2 (294 m³),No. 6 (380 m³). No. 2 Blast furnace occupies 1280 m³ area and is newly built now.

● Due to the benefits, Meishan iron and steel has decided to apply such double pre-heating devices to their No. 1 BlastFurnace (It has also been reported in July 2009 issue of AISTECH).

● In Bayuquan they want to apply system above in 3200m³ Blast Furnace which is again a new one.

In co-operation with Angang Design and Research Institute, we have successfully promoted 19 Double preheating devices withadditional burning furnace and therefore made a great contribution to the energy saving and Emission Reduction of blast furnacefor metallurgical enterprises in China and later carried it Abroad. Based on Experience and Expertise, we integrated the mostadvanced domestic and overseas technologies of course, with great deal of investigations supported by Research, and Developmentand more important with guidance and co-operation from the End users.

II. COAL MOISTURE CONTROL SYSTEM

This technology removes certain amount of moisture from the coal and enhances the product efficiency of coke-oven by 7-8%. Thisalso reduces the consumption of gas by one-third. Decrease of moisture content of coal increase the charging density, which hasa favorable effect on mechanical properties of coke such as - Porosity, Abrasion Resistance, Mechanical strength, Compressivestrength.

Fig.1

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III. POWER GENERATION BY WASTE HEAT FROM SINTERING PLANT.

Energy Conservation:

Energy saving and emission reduction has been attached great importance by governments and industrial fraternity all over theworld to save the Eco-system. Healthy utilization of waste gas, waste heat (generated in industrial production including pollution)are front runners in management.

Iron & steel industry is a large energy consumer amongst manufacturing industries and consumes more than 10% of the total amountin China of the manufacturing segment. It is a key segment to whom new technologies of energy saving & emission reduction needto be promoted. Sintering process generate huge amount of dust and hot waste gas causing waste of secondary energy and seriousenvironment pollution. Since these waste gases are of high temperature and contain lot of dust, advanced recycling technologiesfor sintering waste heat are the necessity but still have not become very popular though it's the necessity for the Industry. Energysaved is more than energy produced.

We have the technologies & experience to arrest dust & utilize heat from the waste gases to produce power.

Fig.3


Part_I | pg-125

Process of standard closed-type sintering waste heat utilization unit

Typical Characteristics of Flue Gas.

● Containing Sox, Nox, dust and other pollutants

● Much dust that is not easy for removal

● Volatile concentration of Sox

● Containing heavy metals and dioxin.

Main processing facilities include Deduster, Waste heat boiler, Circulating fan, Circulating water pump, Feed water pump, Airseparator, Water tank, Different valves and other ancillaries . The Deduster, to Dust collector, waste heat boiler, circulating fan, andcirculator cooler can be installed in series by fixing two exhaust funnels into the sintering circular cooler or the belt cooing machine.

Fig.4

COMPARISONS OF EFFECTS OF TWO WASTE HEAT UTILIZING DEVICES

EXISTING OUR DESIGN

Heat pipe waste heat boiler Standard closed type sinterwaste heat boiler

Steam Grade 0.8 MPa, 180 ºC 1.6MPa,260 ºC

Utilization Rate 30% 85%

Emission Rate 100% Neg. emission

Dust Content > 600mg/Nm3 Neg. emission

Service Life 3-5years 15years

Return on investment 4-5years 3-4years

Iron ore sintering is a large energy consumption process. The latent heat in waste gas emitted with high dust content accounts formore than 50% of total energy consumption rate during the sintering.

Part_I | pg-126


IV. GAS DESULPHURIZATION & DECYANATION

With the developments in Iron & Steel industries, higher and higher standards are set on the quality of coke oven gas.

Generally the coke oven gas contains 3 to 10 gm/m3 Hydrogen Sulphide and 0.5 to 1.5 gm/m3 Hydrogen Cyanide both of whichgenerate oxysulfide and nitrogen oxide respectively and thus pollute the Environment.

While it is used as metallurgical fuel, the harmful substances such as Sulfurated hydrogen seriously affects the steel quality.Therefore, desulphurization and decynation are essential requirements.

In recent years, new single-tower type coke-oven gas and gas desulphurization (desulphurization and regeneration finished in onetower) process designed jointly with Angang Group Design & Research institute has shown excellent performance in desulphurizationand decyanation. This method is wet desulphurization. It substitutes the sodium carbonate with Ammonia (Na2co3) in the gas asalkali source to get rid of the Hydrogen Sulphide and hydrogen cyanide .After three desulphurizations, the Hydrogen Sulphidecontent in the gas can reach the city gas requirements level of 20 mg/m³.

Desulphurization process flow and features

The air blower sends gas at 500C~600C, which is cooled to 300C~320C after the cooling and naphthalene removal made byremaining Ammonia and condensing in the pre-cooling tower, after which the naphthalene content should be less than 300mg/m3.Then it goes to the desulfurization section at the bottom of the primary desulfurization regenerating tower to countercurrent contactthe desulfurization solution sprayed from the top tower; under the reaction of catalyst, the sulfureted hydrogen and hydrogencyanide in the gas get absorbed in the desulfurization solution which is further pumped onto the regeneration section of the towerby the recycle pump through the wet seal in the bottom of the tower to contact with air by self-priming injector for catalytic oxidationregeneration. The regenerated liquid flows into the desulfurization section for rotative spray by means of the liquid level regulator.And then the coke oven-gas after purification in the primary desulfurization system will goes to the second and third classdesulfurization purification system (same class in the process), so that the sulfurated hydrogen content in the gas becomes less than20mg/m3. After the desulfurization, the gas goes to the ammonium sulfate section.

The sulfur foam spills over the regeneration section of desulphurization tower self-flows into the concentrating groove and the sulfurfoam concentrate is sent into the sulfur melting furnace by the sulfur foam pump. Then the molten sulfur after smelting flows into thecooler pan and after natural cooling, we get the product sulphur.

Fig.5


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Technical parameter and technical index

Temperature to enter pre-cooling tower 55ºC - 60ºC

Temperature to go out of pre-cooling tower 30ºC - 32ºC

Gas naphthalene content to enter pre-cooling tower <3000 mg/ m³

Gas naphthalene content to go out of pre-cooling tower < 300 mg/ m³

Sulfured hydrogen content in gas before desulphurization 3000-10000 mg/ m³

Sulfured hydrogen content in gas after desulphurization < 20 mg/ m³

Secondary salt content in desulphurization solution 250g/L

PH value of desulphurization solution 8.0-8.7

Temperature of desulphurization solution 35ºC - 38ºC

Suspended sulfur in desulphurization solution Not more than 1.5g/L

FEW SUCCESS STORIES ON DESULPHURIZATION & DECYNATION :

No Project Name Gas Time to put Operationthroughput into production conditions(m3/h)

1 Third recycling of coke -oven gas in workshopby Angang Group Chemical Corporation 45000 Nov .2001 Satisfactory

2 Phase II of Angang Group Chemical Corporation. 120000 Nov. 2005 Satisfactory

3 Coking Plant coke - oven gas project of Tiantie. 55000 Apr .2007 Satisfactory

4 Phase III Angang Group Chemical Corporation 120000 Sep .2007 Satisfactory

5 Coke-oven gas project of Jiangsu Iron & Steel Co. 90000 Sep .2007 Satisfactory

6 Qingdao Coking & Gas-Making Co.,LtdCoke-oven gas project 27000 Dec .2007 Satisfactory

7 Shanxi Nantie Group Guangda Coking AirSource Co. Ltd. Coke-oven gas project 50000 Under construction

8 Tangshan Dafeng Coking Co. Ltd. coke - oven gas 65000 Under construction

ACCOLADES (Zhongxian Group)

● The ISO 9001:2000 quality control system

● The stainless steel project of Baoshan Steel Company

● The engineering project of Anshan Steel Company

● Brazil Coking Project

● The coking carbon project of Iran Coking Plant

● Having technical cooperation with the North Design institute of the China metallurgical Group waste heat recovery.

● Having technical cooperation with Zhejiang University about power generation

● Having technical cooperation with the Anshan steel design institute Iron making with double preheating and thedesulphurization and de-cyanide by coking.

Part_I | pg-128


WE HAVE EXPERTISE IN:

● Design & supply of energy saving and environment protection equipments.

● Double preheating equipment with additional combustion furnace for Blast Furnace

● Removal of dust from the blast furnace gas.

● Reuse of waste heat of sintering plant.

● Desulfurisation and de-cyanide by the Coke Oven gas in the steel plant

OUR FOREIGN TECHNICAL PARTNERS:

❏ Austrian AE& E Energy &Environment Co. Ltd.

❏ Mitsubishi Heavy Industry, Ltd., Japan

CONCLUSION

To our experience Iron & Steel makers go for a package on energy consumption & pollution thus making these critical areas as apart it is general. These areas need focused and experienced approach and we recommend an attention by addressing them asspecific like Science and technology is being addressed by Nations as focused segment for sustained and one-up growth of a nation.

● We possess the technology of flue gas desulphurization and decyanation, Flue gas desulfurization in sinter plants, Wasteheat recycling in iron and steel industry, Air and Gas pre heating devices to our customers with optimized solutions withour practical experiences of decade and access to continual technological developments for Flue Gas Desulphurizationand Decyanation.

● We warmly welcome domestic and overseas iron & steel enterprises and experts dealing with ore sintering, electric steel-making furnace ,coking and ferrous smelting to join hands in our mission to improve the energy consumption index forreduction of environment pollution with our relentless effort, and R & D. This task is challenging, but rewarding too.


Part_I | pg-129

INTRODUCTION

Tata Steel, the world's 6th largest steel company backed with 100 glorious years of experience in iron making has initiated varioustechnological improvements to reduce CO2 emission and make the process of iron making environment friendly.

Baring this temporary phase of global economic melt-down, demand for iron and steel has been constantly growing, at the same timethe environmental regulations continues to be stringent demanding for conservation of raw material, energy and reduction in CO2emission etc.

Tata Steel with an aspiration to grow both in terms of volume and reasonable global presence with a target to reduce CO2 emissionsto 1.5 t/tls compared to the current 1.8 t/tls, decided to take larger steps to reduce CO2 emission and protect the environment. Thecompany's efforts at continual improvement of its environment are well recognized. Some of the important achievements during theyear in improvement of environment and resource conservation include a reduction in green house gas emissions by 2%, rawmaterial consumption by 5%, water consumption by 4% and increased waste reuse and recycling from 79% in previous year to82%.

It is well known that around 75% of the emissions in integrated steel plants contributed by iron making units including sinter, cokemaking and blast furnace iron making. Tata Steel as part of 2.5 mtpa expansion program had set up a new 'H' blast furnace (Innervolume 3814 m3) along with a 204 m2 sinter strand and a heat recovery coke plant of 1.6 mtpa in year 2007-08.

Energy efficient and eco-friendly iron making operationsat Tata Steel

*A.Srinivasa Reddy, Goutam Raut, S.A. Khan, G.S.R. Murthy, S.K. Roy & Ashok Kumar

* Tata Steel, India

Fig 1. Schematic diagram showing 2.5 mtpa expansion with other support facilities

It is Tata steel's fundamental policy that economic development by increasing the volumes and product mix should be fulfilled alongwith environmental protection. The selection of technology and operational practices including solid waste utilization, production ofelectricity utilizing kinetic energy of the top gas of blast furnace (TRT) and other energy efficient practices were chosen realizing thecurrent challenges especially with respect to environment and CO

2 emissions in iron making operations.

This report presents an analysis of some of the energy efficient and eco-friendly operations of iron making process units that wereset up during 2.5 mt expansion phase of Tata Steel.

Part_I | pg-130


ENERGY SAVING OPERATIONS AT H BLAST FURNACE

Features of H Blast Furnace

The new 'H' blast furnace was successfully commissioned on May 31st 2008 at Jamshedpur works in Jharkhand. With an innervolume of 3,800 cubic meters and a name plate production capacity of 7,200 tons of hot metal per day, this new blast furnace was thebiggest one ever built in India till then. The furnace is equipped with all modern features. Integrating state-of-the-art technology, blastfurnace 'H', which is cooled with copper and cast iron staves, features a new generation bell less top charging system. Two flat casthouses operating four tap holes are fitted with TMT cast house machines. The high-performance hot blast stoves with internalcombustion chamber are equipped with a heat recovery system, recovering the waste heat from the stoves' exhaust so as to saveon the fuel rates. Energy in terms of electrical power is also recovered from the BF gas through a top gas pressure recovery turbine(TRT). It is also provided with a pulverized coal injection system and two slag granulation plants.

Operation at Low Coke Rate and PCI in excess of 150 kg/thm

The operation of 'H' blast furnace at Jamshedpur had been a subject of considerable curiosity - largely because no contemporaryreference could be found for the set of raw materials which were going to be fed to the size of blast furnace as large as 'H'.

The blowing in and stabilization of the blast furnace presented several challenges - which added to the complexity presented by thequality of raw materials. For the sake of simplicity, figure 2 divides the entire journey into four phases (each point represents oneweek's average):


Part_I | pg-131

Energy efficiency and Quality of hot metal at H bf

The fuel rate of the BF, as shown in figure 3, appears high at 540 kg/thm. However after accounting for the higher ash content incoke, the carbon rate (pink line) is at 455-460 kg/thm level - which is no more than about 10 kg/thm higher than blast furnacesoperating with lower gangue raw materials.

Fig 3. Trends of fuel rate and hot metal quality at H blast furnace (Jun '08 -May'09)

The hot metal temperature has a weekly average of 1510 oC after slag; and the average silicon in hot metal is 0.75 %.

The performance at 'H' in terms of production and coke rate achieved in relatively stable run over the last few months was enableddespite high ash coke and with inferior raw material set by the following: a) Coke being supplied to 'H' is unique in strength and size[the M 40 at the BF stock-house is 91; and the mean size is 55 mm: as against M40 of 83 and mean size of 48 mm for the stampcharged coke fed to other BFs]

b) The drainage practice - facilitated by 4 tap-hole design and associated facilities - allows good control on the liquid level in thehearth. With overlapping casts (> 30 hours of casting per day), handling of relatively larger slag amounts has thus far not become abottleneck to production or the internal process dynamics.

With a raw material set - which would considered to be significantly inferior in quality to a 'standard set' of raw materials -theperformance level at 'H' doesn't appear to be commensurately lower. Even more so, if allowance is made for the fact that thisperformance is on the early part of the learning curve for a furnace of this size at the site.

Recovery of top gas energy through Top Gas Recovery Turbine (TRT)

TRT is an energy recovery turbine by which the pressure energy and thermal energy of the gas coming from top of the blast furnaceis converted to mechanical energy so as to drive a generator to recover electricity, which will not only purify the top gas, but alsolower noise pollution.

Part_I | pg-132



Part_I | pg-133

H Blast furnace is equipped with a Top gas recovery turbine of capacity 14 MW. This energy recovery is almost 30% of the energyspent for blowing the furnace. Following fig 5 shows the operating performance of the TRT at H blast furnace.

Solid waste utilization in sinter making

Sinter making at Tata Steel is now over four decades old. At Tata steel there has been a conscious effort over the years to increaseutilization of waste material to reduce the cost of sinter and reduce environmental hazards. Sinter plants provide opportunity to utilizethe solid waste generated in different processes within the plant including fines such as LD sludge, BF flue dust, mill scale, mill sludge,LD Slag etc. The waste materials, depending on their chemistry replaces part of fluxes such as lime stone, pyroxenite, part of orefines and to some extent part of solid fuel too.

Use of waste and reduced consumption of limestone, reduces the consumption of valuable natural resources and reduces the CO2emission from calcinations.

Part_I | pg-134


Heat recovery coke making facility

In heat recovery coke plants, originally referred to as beehive ovens, coal is carbonized in large oven chambers. The carbonizationprocess takes place from the top by radiant heat transfer and from the bottom by conduction of heat through the sole floor. Primaryair for combustion is introduced into the oven chamber through several ports located above the charge level in both pusher and cokeside doors of the oven. Partially combusted gases exit the top chamber through "down comer" passages in the oven wall and enterthe sole flue, thereby heating the sole of the oven. Combusted gases collect in a common tunnel and exit via a stack which createsa natural draft in the oven. Since the by-products are not recovered, the process is called heat recovery coke making. In one case,the waste gas exits into a waste heat recovery boiler which converts the excess heat into steam for power generation; hence, theprocess is called Heat Recovery coke making.

Th is p rocess has l essenv i ronmen ta l impac t as i trequires no by product generation& gas cleaning, operates undernega t i ve p ressu re the re byeliminating leakages from doorsand with no effluent.

Look ing a t t he advan tagesassociated with the heat recoveryas mentioned above, a 1.6mt port-based heat recovery coke makingplant was commissioned at Haldia,a locat ion 400 km away formJamshedpur with an anticipationof catering 2.5 mt expansion atJamshedpur as wel l as othercustomers.


Part_I | pg-135

CONCLUSIONS

Tata Steel with an aspiration to grow both in terms of volume and reasonable global presence with a target to reduce CO2 emissionsto 1.5 t/tls compared to the current 1.8 t/tls decided to take larger steps to reduce CO2 emission. It is Tata steel's fundamental policythat economic development by increasing the volumes and product mix should be fulfilled along with environmental protection. Theselections of technology and operational practices in its 2.5 mtpa expansion phase were considered with a great deal on environmental-friendly and energy efficiency.

Acknowledgement:

The authors express their thanks to H blast furnace team, Mr. B Biswas, Mr. Vipul Mohan koranne, Ms. Adity Ganguly and Mr.Gaurav Saran for their valuable support to complete this study.

References:

1. Lowering energy consumption in iron making -Ashok Kumar and T. mukherjee

2. Coke Rate at 'H' BF, Jamshedpur: the first one year; Tata Steel internal note - Ashok Kumar

3. Waste Management at Tata steel - the Road Ahead - R.P.Sharma, P.C.Sarkar, B.B. Sinha, G.S. Basu and M.D. Maheshwari

4. Resource Conservation: Corporate Responsibility-R.P.Sharma, M.D.Maheshwari, D. sengupta

5. Heat recovery coke oven design & operating principle; Tata Steel internal note -S K Haldar

Part_I | pg-136


Climate Change and its effect

The Greenhouse Effect

* TERI, New Delhi

Carbon Trading in Iron & Steel sectorShashank Jain*

Climate Change – some facts

• Rising concentration of GHGs in the earth’s atmosphere gives rise to greenhouse effect and result in increasing temperatureof the earth’s surface, in turn irreversible climate change

• Scientists worldwide accept that climate change/ Global Warming is a manmade phenomenon due to industrial growth (i.e.increase in GHG concentration)

• Atmospheric temperatures would continue to rise (1.4 to 5.80C by 2100, IPCC-TAR)

• Sea level rise between 10 cm to 90 cm by the year 2100

GHGs and its sources

• Carbon dioxide – combustion of fossil fuels (coal, oil, natural gas)


Part_I | pg-137

• Methane – animal, agriculture & municipal wastes; rice cultivation

• Nitrous oxides – Combustion processes, chemical industry

• Hydro fluorocarbons – refrigerants

• Per fluorocarbons – semiconductors industry

• Sulphur hexafluorides – electrical insulation

• Impacts

– Melting of ice caps and glaciers

– Sea level rise/erosion of costal area

– Precipitation changes

– Severe weather events like droughts, flooding, hurricanes etc.

– Changing crop yields (food security), bio-diversity

– Impact on water resources

– Human and economic dislocations (particularly for developing countries and island nations)

More heavy precipitation and more droughts…

Tide gauge and satellite data on sea level

Part_I | pg-138


Impact of climate change on Gangotri glacier

The Gangotr i Glacier isretreating at a rate of 18 m/yr. It has retreated 2 kmsince 1780

(Thakur et al,

DST 1991)


Part_I | pg-139

Locations of Siberian lakes that have disappeared

Current knowledge about future impacts

Africa

• By 2020, between 75 and 250 million people are projected to be exposed to an increase of water stress.

• Agricultural production, including access to food, in many African countries and regions is projected to be severelycompromised by climate variability and change.

Asia

• Glacier melt in the Himalayas is projected to increase flooding, rock avalanches from destabilised slopes, and affect waterresources within the next two to three decades

• Endemic morbidity and mortality due to diarrhoeal disease primarily associated with floods and droughts are expected torise in East, South and Southeast Asia due to projected changes in hydrological cycle associated with global warming.Increase in coastal water temperature would exacerbate the abundance and/or toxicity of cholera in South Asia.

Worldwide GHG emission and India’s position

CO2eq Emission (1990-2007)

Part_I | pg-140


%age deviation from Kyoto targets

Per Capita CO2 Emissions

Evolution of UNFCCC

• WMO and the UNEP established the IPCC in 1988

– provide the policy makers up-to-date scientific information on climate change

• IPCC First Assessment Report in 1990 confirmed that human induced climate change was indeed a threat and called for globaltreaty to address the problem

• UN General Assembly launched negotiations on a framework convention on climate change

– UNFCCC evolved and was opened for signature at the Earth Summit at Rio

– Came into force in March 1994


Part_I | pg-141

– 186 governments (including the EC) are Party to UNFCCC

The Kyoto Protocol

• Adopted at CoP3 in Kyoto, Japan, in Dec. 1997

• Provides legally binding commitments for Annex-I Countries to bring their GHG emissions to an average of approx. 5.2% percent below their 1990 levels during the 2008-2012

• Target gases – CO2, CH

4, N

2O, HFCs, PFCs, SF

6

What is CDM?

One of the three flexibility mechanisms in the Kyoto Protocol to the UNFCCC

– Joint Implementation

– International Emission Trading

– Clean Development Mechanism

Purpose

■ Assist developed countries in achieving compliance with their QELRCs

■ Contribute to the ultimate objective of the Convention, and

■ Assist developing countries in achieving sustainable development

What is carbon trading?

• Developed countries have targets to reduce GHG emissions under the Kyoto Protocol

• Countries that find it easier to meet their targets can sell surplus emission reductions to others

• Countries that don’t have targets (i.e. developing countries) can sell emission reductions to others after registeringprojects with CDM Executive Board

CDM : - Article 12

About CDM

Eligibility Criteria

For a project to be considered a CDM project it should fulfill following eligibility criteria:

– The project contributes to the sustainable development of the host country

– The project results in real, measurable and long term benefits in terms of climate change mitigation, and

– The reductions must be additional to any that would have occurred without the project.

Part_I | pg-142


CDM Project Cycle

Total Registered Projects

(as on 14th July 2009)

• Regd. Projects - 1724

• CERs issued - 311,743,267

• CERs till 2012 - 1,620,000,000

• Projects in pipeline - >4200

• Expected CERs

till 2012 - 2,900,000,000

• Projects requesting regn. - 52

• Expected CERs from 52

projects (till 2012) - 20,000,000

• Projects from India - 442 (25.64%)


Part_I | pg-143

• CER issued to India - 67, 523, 591

CDM in Indian Iron & Steel Industry

Indian Iron & Steel Industry

• India is 5th largest steel producer in the world

• Crude steel production for 2007-08 is 54 million tonnes

• CO2 emission from this sector is about 100-120 million tonnes

• Specific emission for India is about 2.5 tCO2/ ton of crude steel

• World average specific emission intensity (for all steel making process) is 1.7

Possible CDM projects in Iron & Steel Industry

• Process technology based

• Waste energy recovery

• Fuel switchover

• Demand side management

• Renewable Energy

• Process technology based

– Waste heat recovery from kilns, furnaces, soaking pits, sinter coolers, molten slag, etc and gases in the process

– Use of recovered gas (from coke oven, etc) as fuel for co-gen power plant

– Coke dry quenching

– Top Recovery Turbine

– Coal moisture control

– Regenerative ( re) heating furnaces

– Use of latest technologies (e.g. Castrip, FINEX process, etc)

– Scrap preheating in EAF

– Reducing coke rate by beneficiation of coal and ore

– Coal dust/tar injection in blast furnaces

Part_I | pg-144


• Fuel switchover

– Fuel switch over mainly from existing fossils based to alternate fuels

• Demand Side Management

– Ultra high power transformers

– Variable speed drives

– Other energy saving measures

• Renewable Energy

– Possibility of using biomass based fuels, generating electricity based on renewable energy sources (wind, solar,etc.), etc.

Potential CDM Methodologies for Iron & Steel Industry

AM0066 GHG emission reductions through waste heat utilisation for pre-heating of raw materials in sponge ironmanufacturing process

AM0068 Methodology for improved energy efficiency by modifying ferroalloy production facility

ACM0002 Consolidated methodology for grid-connected electricity generation from renewable sources

ACM0012 Consolidated baseline methodology for GHG emission reductions from waste energy recovery projects

AMS-I.C. Thermal energy production with or without electricity

AMS-I.D. Grid connected renewable electricity generation

AMS-II.C. Demand-side energy efficiency activities for specific technologies

AMS-II.D. Energy efficiency and fuel switching measures for industrial facilities

AMS-III.Q. Waste Energy Recovery (gas/heat/pressure) Projects

AMS-III.V. Decrease of coke consumption in blast furnace by installing dust/sludge recycling system in steel works

CDM project status for Iron & Steel Industry (1st July 2009)

AM00 AM006 ACM ACM AMS AMS AMS AMS66 8/AMS-3.V. 0004 0012 -I .D. - I I .D. - I I I .Q. -IC +I.D.

+ III.Q.

Registered 0 0 44 0 0 1 0 0

Review req. 0 0 0 2 0 0 0 0

Correction req. 0 0 0 1 0 0 0 0

Registration req. 0 0 0 2 0 0 0 0

Rejected 0 0 2 0 1 0 0 0

At validation 1 0 5 32 0 6 10 1

Rejected at validation 0 0 5 3 0 3 2 0

Withdrawn 0 0 1 0 0 0 0 0


Part_I | pg-145

Coal-Based DRI Solution for Indian Ironmaking*Henry Gaines, PE

* Plant Sales - Director, Midrex Technologies Inc.

Figure 1- India Steel and DRI Production

Figure 2- Simplified Lurgi Gasification Plant + MIDREX Plant Flowsheet

Part_I | pg-146


Figure 3 - Lurgi Gasifiers in Secunda, South Africa

TABLE I - Characteristics of the Lurgi Gasification Plant


Part_I | pg-147

Table 2 - Distance between Shaft Furnace and EAF

Distance between

Shaft Furnace and EAF Hot Transport Mode

• 0 – 40 meters HOTLINK®

• 40 – 200 meters Hot Transport Conveyor or HotTransport Vessels

• > 200 meters Hot Transport Vessels

Table 3 - Lurgi Gasification Plant + MIDREX Plant CombinationPredicted Operating Consumptions for Indian Conditions

Basis: MIDREX MEGAMOD® with capacity of 1,8 Mtpy of hot DRI 1

Lurgi Gasifier using typical high ash Indian coal

Input Units Quantity per t hotDRI 2

• Iron Ore t 1.45

• Coal (ash free)3 t 0.46

• Coal (as mined)3 t 0.84

• H.P. steam t 0.7

• L.P. steam t 0.1

• Oxygen t 0.21

• Electricity kW-h 180

• Maintenance & indirect costs $ 10

1 The typical hot DRI product characteristics are:

93% metall ization, 2% carbon, and 700º C discharge temperature.

2 Quantities are for the combined Lurgi Gasification Plant and MIDREX DR Plant.

3 Values assume typical high ash Indian coal.

4 Includes routine maintenance, long-term amortized cost for replacing capital equipment, and indirect costs.

HOTLINK

The HOTLINK Process primarily uses gravity to feed DRI from the MIDREX Shaft Furnace into storage bins located directly abovethe EAF. This hot transport mode requires the bottom of the MIDREX Shaft Furnace to be at a higher elevation than the EAF. TheHOTLINK Process is under construction at ESISCO in Egypt and at Shadeed in Oman.

Hot Transport Vessel

In the hot transport vessel option, the HDRI exiting the MIDREX Shaft Furnace is discharged into refractory-lined containers. Thesecontainers are then transported by truck or rail to the steel mill. At the steel mill, a crane is used to lift the containers above the EAFso that the HDRI can be discharged directly into the EAF. The hot transport vessel approach has been used by Essar Steel since1998 and is operating at the Lion Group plant at Banting, Malaysia.

Part_I | pg-148


Figure 4 - LION HDRI/HBI Plant with Hot Vessel HDRI Transport

Hot Transport Conveyor

The hot transport conveyor option continuously transports HDRI from the discharge of the MIDREX Shaft Furnace via an inclinedbucket conveyor into storage bins located directly above the EAF. For this hot transport mode, the MIDREX Shaft Furnace dischargecan be at a significantly lower elevation than the EAF. This hot transport mode is operating at Hadeed Module E in Saudi Arabia.

Figure 6 - Hot Transport Conveyor at HADEED Module E


Part_I | pg-149

Conclusions

• Combining the Lurgi Gasification technology with the MIDREX Direct Reduction Process is a viable solution in India.

• The advantages of the combined the Lurgi Gasification Plant + MIDREX Plant in India include:

• Uses well-proven Lurgi Gasification and Rectisol® technologies. The Lurgi Gasifier can readily use the low rank, highash domestic Indian coals as feed material.

• Uses well-proven MIDREX Direct Reduction Process. This technology can readily use domestic Indian iron oxides asfeed material.

• Produces DRI with quality comparable to natural gas-based MIDREX Plants.

• The DRI can be hot charged into a nearby electric arc furnace (EAF) to significantly reduce the EAF electricity requirementand significantly increase the EAF productivity.

• The Lurgi Gasification Plant + MIDREX Plant combination can be paired with an EAF-based mini-mill to produce highquality long or flat steel products.

• No coke, coke ovens, or sinter plant required.

• Lower specific capital cost than an integrated steel works.

• Lower air emissions than an integrated steel works.

• Ability to capture high purity CO2 for sequestering or injecting into oil and gas fields.

• Much larger capacities than rotary kilns: up to 2.2 Mtpy in a single module.

• Higher quality DRI product than rotary kilns.

Part_I | pg-150


AN OVERVIEW OF DEVELOPMENT PROJECTS, DISPLACEMENT ANDREHABILITATION IN ORISSA

*Prof.A.B.Ota, IAS

* DIRECTOR, Tribal Research Institute, Orissa

OUTLINE -

• OVERVIEW OF DEVELOPMENT PROJECTS AND DISPLACEMENT IN INDIA AND ORISSA

• R&R EFFORTS AND STATUS OF DISPLACED FAMILIES

• TREND CHANGE IN 21ST CENTURY

• WHY POOR R&R?

• MAJOR AREAS OF CONCERN IN R&R AND SUGGESTIONS FOR EFFECTIVE R&R

• ARE POLICY PROVISIONS ENOUGH?

• GREY AREAS IN THE R&R POLICY

OVERVIEW OF DEVELOPMENT PROJECTS AND DISPLACEMENT (Approx. Fig) IN INDIA Upto 2000

CATEGORY OF NO OF DISPLACED FAMILIES PERCENTAGE OFPROJECTS (Approx) TOTAL DISPLACEMENT

Mines 40 Lakh 14.04%

Industries 20 Lakh 07.02%

Dam Projects 200 Lakh 70.18%

Sanctuaries 10 Lakh 03.50%

Others 15 Lakh 05.26%

TOTAL 285 Lakh 100%

OVERVIEW OF DEVELOPMENT PROJECTS AND DISPLACEMENT (Approx. Fig) IN ORISSA (Upto 2000)

CATEGORY OF NO OF DISPLACED PERCENTAGE OFPROJECTS FAMILIES TOTAL DISPLACEMENT

Mines 15000 11.24%

Industries 18000 13.48%

Dam Projects 90000 67.42%

Others (Linear, Urban Infrastructure etc.) 10000 07.49%

Wild Life Sanctuaries 500 0.37%

TOTAL 133500 100%


Part_I | pg-151

R&R EFFORTS AND STATUS OF DISPLACED FAMILIES

A. EVOLUTION OF RESETTLEMENT AND REHABILITATION POLICY (ORISSA)

SL.No PHASE HIGHLIGHTS OF R&R

I Projects Prior to 1973 Only Paid Compensation and were left to themselvesto resettle and rehabilitate

II Projects Between 1973-1980 Basically Land Based Resettlement and Rehabilitation

III Projects Between 1980-1994 Primarily Cash Doll Based R&R Package

IV Projects After 1994 Liberal R&R Package and Definition of DF got expandedand PAPs also became eligible for R.R. Assistance

V Projects After 2006 R&R Policy A very Progressive R&R Package and much stress onParticipatory R&R Planning and Implementation.

VI 2007 National R&R Policy Efforts are made for a possible revision in the 2006 Orissa R&R Policy

B. OVERALL STATUS OF DISPLACED PEOPLE

● MOST OF THE DEVELOPMENT PROJECTS HAVE RESULTED IN POOR AND UNSUCCESSFUL R&R

● MAJORITY OF THE AFFECTED PEOPLE HAVE FAILED TO RECONSTRUCT THEIR PRE-PROJECT/PRE-DISPLACEDLIVING STANDARDS

● AFFECTED PEOPLE HAVE INVARIABLY BEEN MARGINALIZED

● OFTEN SLIPPED BELOW THE THRESHOLD OF POVERTY

● TO BE PRECISE, THE AFFECTED PEOPLE IN MOST OF THE DEVELOPMENT PROJECTS HAVE ENDED UP WITH:

I. LANDLESSNESS

II. HOMELESSNESS

III. JOBLESSNESS

IV. MARGINALIZATION

V. FOOD INSECURITY

VI. INCREASED MORBIDITY

VII. LOSS OF ACCESS TO CPR

VIII. SOCIAL DISARTICULATION.

TREND CHANGE IN DEVELOPMENT PROJECTS IN THE FIRST TWO DECADES OF 21ST CENTURY

I. More Industrial and Mining Projects

II. Increased Linear Projects

III. More Urban Infrastructure Projects

IV. Very Less Number of Dam/Irrigation Projects

V Increased Resistance to Development Projects

VI More Tribals Affected and Displaced

VII Increase participation of MNCs in Development Projects

Part_I | pg-152


WHY POOR R&R?

• Absence of R&R policy with a Human Face

• R&R Policies not backed up by implementation strategy

• Non Participatory Approach

• Poor and Inadequate Institutional Set Up.

• Lack of accountability in the entire process.

• Frequent transfer of the key officials.

• R&R is mostly considered as a Low Key Activity in the Agenda

• Very low percentage of allocation for R&R.

• Lack of Proper Monitoring and Evaluation.

• Lack of a proper Grievance Redressal Mechanism

• No effort to Integrate the Hosts with Resettlers

• Compensation is much less than replacement cost

• Non recognition of customary land right of the tribal

• No Benefit Sharing Arrangement

• Differential treatment to the PAPs & DPs by different projects

• Purchase of land by land mafias in and around the project area

• Entry of outsiders and agitating the PAPs against the project

• Anti Project agitation by Political and vested interest groups

• Infighting among different players/industries setting up units

• Cut off date and updation of DP list

• Considerable Gestation period between the Compensation Payment, R.A payment and Evacuation

• Coercive Action

• False promises by the Project authorities

• Non integration of Ongoing Governmental Programme with R&R Package

ARE POLICY PROVISIONS ENOUGH?

No?● Policies only provide enabling provisions and one has to look beyond this

● Policy only provides a framework and sets minimum standards to extend R&R Package

● One should not read only the lines of the provisions envisaged in the policy document, One has to read between the linesand interpret the provisions in favour of the Impacted Persons

● Provisions in the Policy alone will not be enough for livelihood restoration

● Integration of ongoing income generating & poverty alleviation prorgamme with the R&R Provisions

GREY AREAS IN THE R&R POLICY

• Non Recognition of Customary Land Rights of the Tribals

• Gender Bias in the Policy (18 + Sons and 30+ Unmarried Daughters are treated as a Displaced Family for the purposeof R & R Assistance)


Part_I | pg-153

• PAPs not getting displaced are not extended R&R Support

• No provision of Issuance of pattas jointly in the name of both the spouses

• No provision of any kind of support for the Occupationally Displaced Persons on account of the project

• No mention of official date of evacuation for the DPs.

MAJOR AREAS OF CONCERN IN R&R AND SOME STEPS FOR ENSURING REHABILITATION WITH AHUMAN FACE

❖ Avoid Coercive Action of Any Kind

❖ Look for alternative sites for the Project and the one that displaces least number of people to be selected

❖ Go to the people and do not Stay Away from them

❖ Identify potential youths in the affected and peripheral villages and engage them as Volunteers

❖ Form Women SHGs and provide them Training and Financial Support for undertaking Micro Enterprises. This will alsocontribute for minimizing resistance

❖ Entry of outsiders to the affected and periphery villages to be prevented

❖ Sale and purchase of land to be frizzed in the project affected area

❖ Go from simple area to disturbed areas in acquisition and evacuation

❖ Recognize the Customary Land Rights of the Tribal

❖ Effect replacement cost of land to the land losers

❖ Livelihood Support/Intervention to be given more thrust in R&R

❖ Involve local people for project activities (construction & petty works)

❖ Avoid Divide and Rule Policy among the Affected/Displaced

❖ Basic Services to be continued in the affected/submerged villages till majority of the people are not physically displaced

❖ Physical Displacement only after full receipt of Entitlement

❖ Strict Adherence to the Legal and Regulatory Frameworks

❖ Ensure Benefit Sharing Arrangements

❖ Disclosure of Information including Entitlement to the impacted people in local language

❖ Dovetail/Integrate all the Ongoing Developmental Programmes in the R&R Action Plan in participatory mode

❖ Consultation before finalizing the agenda of activities

● Affected People

● PRI Members

● Host Community where the DPs will be resettled

❖ Identification of the Adverse Effects of the Project to be caused from early stage (Risk Identification)

❖ R&R Package and Action Plan should be prepared incorporating Risk Mitigating Strategies

❖ Vulnerable Groups to be identified and special package for mitigating their adverse effects

❖ Programs for Integrating the Hosts with the Resettlers

❖ Replenishment of CPRs in the new place of resettlement.

Part_I | pg-154


Steam generation – Introduction

Potential of waste heat recovery from steelmaking

* SMS Siemag AG, Germany

Energy recovery technology for EAFsImproving over-all energy efficiency of the EAF process

by generation and usage of steam

* Helmuth Ester


Part_I | pg-155

Converter gas recovery technology

Proven technology: Steam generation at BOF converters

Converter gas recovery plants collect the valuable CO gas from the BOF off-gas and store it for future thermal use

Part_I | pg-156


Temperature levels at the EAF off-gas system

Electrical energy is turned into heat in the EAF _ Hot off-gas Cooling the hot EAF off-gas is necessary

Necessitiy of EAF off-gas cooling


Part_I | pg-157

Options for EAF off-gas cooling

Standard solution: Off-gas duct is cooled by water

Part_I | pg-158


Economic solution: Off-gas duct is cooled by steam

Technical details

Flow chart – Process (animated)


Part_I | pg-159

Economically reasonable usage of steam

Steam can be used in different applications

Example for the usage of steam

Part_I | pg-160


Generation of electric power

Common method

Delivery of electric power from power plant

Disadvantages

§ Incalculable price trends for electric power

§ Change in prices in dependency of carbon credit allocation

§ Alternating security of energy supplies

New alternative method

Generation of electric power with steam-driven generator

Advantages

§ 7 t/h of steam generate 1 MW of electric power

§ Use the electric power e.g. for main drives at fans

§ Sell electricity to the local power net

§ Save carbon credits by CDM

Air separation

Common method

Application of air separation equipment with electrical driven compressors

OR

Delivery of technical gases by external contractor

Disadvantages

§ Dependency on incalculable price trends for electric power

New alternative methodUse steam for substitution of electric drives

Advantages

§ Appl icat ion of steam turbine instead of electr ic dr ives forcompressors inside the air separation plant

§ Delivery of steam from waste heat recovery to the contractor

§ Reduce the price for supply of oxygen, nitrogen and argon

§ Use remaining nitrogen instead of compressed air, reducemaintance costs for condensate removal from pipes


Part_I | pg-161

Refrigeration

Common method

Application of single air conditioners or air conditioning system OR

Application of externally driven absorption chiller units

Disadvantages

§ Equipment requires much electrical power

§ Steam boiler is required (investment)

§ Natural gas is required (operation costs)

New alternative method

Use steam-fired chill units

Advantages

§ Use the steam from waste heat recovery (low costs)

§ Required remaining electrical power is low

§ Generation of cold water at 6°C for cooling purposes

§ Example5.4 t/h steam at 1 bar (behind turbine) generate a refrigerationcapacity of 2.4 MW at electric power of 7.3 kVA

Summary

Ecological and economical aspects of energy recovery

§ The reduction of CO2-emissions by using the waste heat for steam generation is a relevant contribution to environmentprotection

§ For external generation of 1 ton of steam on the basis of natural gas an amount of about 0.13 t CO2 is emitted

§ By substitution of 1 MWh electric power the generation of 0.6 t CO2 can be prevented

§ An important economical effect is the saving of carbon credits

§ Plant operation cost can be significantly reduced

Part_I | pg-162






The enviro-economic angle

• Basic cost + control cost + Unrealized cost = Real cost

• Control + unrealized cost are externalities and do not add value

• Ony solution is to minimise these costs through..

• Economic tools

• Management tools

• Techno-economic tools

• Technological approach


Part_I | pg-163

Minimal footprint approach

=

Process improvement

+

In-process Prevention

+

Minimally invasive pre-treatment/control

+

A parental attitude towards waste

[ Searching a suitable match ]

Improvement / Prevention aspects

Eliminate / reduce generation / emission by controlling as close to source as possible

– Material Substitution

– Product reformulation

– Process/Equipment Modification/Change

– Improvement in process/equipment efficiency

– Recovery and Recycle (Closed-loop)

.. And to discourage

• End of pipe treatment

• Incineration

• Disposal

• Transferring waste from one medium to other

WHY in-process approach?

• Materials savings from more complete processing, substitution, re-use or recycling of products inputs

• Increase in process yields

• Increase in productivity

• Improved utilization of by products

• Conversion of Waste into commercially valuable forms

• Reduced energy consumption

• Reduced waste disposal costs

In-process technological approach make more economic sense than conventional end-of-pipe pollution control

Part_I | pg-164



Part_I | pg-165

Comparison of theoretical minimum energy and actual energy requirement for selected processes

Improvement opportunities

Sl Items Unit/ t sinter BAT parameters Range of parameters inIndian steel plants

INFLOWS

1 Iron ore fines Tonne 0.68-0.85 0.768-0.814

2 Coke Tonne 0.038-0.055 0.07-0.086

3 Limestone Tonne 0.105-0.19 0.114-0.184

4 Electricity MJ 96-114 100-203

5 Other recycled materials Kg 42-113 92-198

6 BF gas / CO gas MJ 57-200 190-238

OUTFLOWS AND EMISSIONS

1 CO2

Kg 188-220 288-364

2 NOx Kg 0.4-0.65 0.23-0.37

3 SOx Kg 0.83-1.7 0.33-0.51

4 Particulates (Dust) Kg 0.16-0.26 0.54-0.92

Yield improvement opportunities

Part_I | pg-166


Treatment improvement aspects

• Wastewater segregation

• Efficient equalization

• Proper reaction

• Controlled conditions

• Clarification improvement

• Expert system for treatment plant operation

• Real time water treatment process control with artificial neural networks

The Classic example

The (MIFSLA) approach to waste water management

• Fairly Clean greywater is mixed with a a polluting mixture, both regarding nutrients and pathogens.

• The resulting mixture is diluted with drainage water in an extensive web of piping.

• Finally, the mixture is expensively purified to a quality comparable with the original greywater, but with a doubled volume.

• Tremendous amount of exergy is wasted in the whole process

• Thus, the MIx-First-and-Separate-LAter (MIFSLA) design of waste water management need to be completely changed

PROPER SEGREGATION

• Before mixing each wastewater source should be sampled and evaluated for parameters of concern (Identification)

• Segregate the stream that is contaminating the entire stream and treat(Reduction in treatment need)

EFFICIENT EQUALIZATION

• Influent wastewater characterisitcs impacted by fluctuations in pH, Temp, Flow surges

Improvement aspects

• Additional dampening

• Proper mixing to avoid waste stratification

• Retrofitting pre-equalization chamber

COMPLETE REACTION

• Incomplete reactions occur due to ..

• Improper mixing

• Fluctuations in input characteristics

• Quantitative mismatch

• Less residence time

• Non-maintenance of process conditions

Improvement in effluent treatment

• Pre-denitrification- nitrification process for removal of nitrogen compound

• Root zone effluent treatment process

• Advanced attached growth systems

• Rotating biological contactors


Part_I | pg-167

• Aeration control processes

• Self aspirating immiscible aerators

• Multi-zone treatment

Few Experiences..

• Recycling of BOF GCP discharge water after pH adjustment

• Sludge drying using waste heat

• Increasing use of Soft water instead of DI water

• Design modifications instead of increasing chemical dosing

• pH maintenance in PETP (BOD) plant

• Fuel value of sludge

Waste Utilization

Partial substitution of BOF slag in Pre-fab concrete

Part_I | pg-168


Improved monitoring..

In BOF shop-

• The primary gases leave the basic oxygen furnace at about 1600 0C with significant dust content

• These gases are cooled and cleaned

• Water is used as both cleaning and cooling media

Relevant issues

• Cooling of gases is carried out through a closed loop water circuit

• Dissolved oxygen is an important parameter for proper functioning of closed loop water circuit

• Dissolved oxygen in responsible for biocide formation, scaling, corrosion etc.

• Choking of tubes, differential flow etc lead to thermal stress, gas side leakage/explosion in cooling tubes ( processissue)

• Inadequate cooling lead to higher discharge temp of gases ( environmental issue )

• Deposition reactions, Corrosion/Scaling are triggered by presence of dissolved oxygen

• Presently chemicals are used, as suggested by vendors to keep microbial growth, deposit formation and corrosion undercheck

• There exists no monitoring facility of critical parameters to determine effectiveness of control/identify improvementopportunities

• There is an imminent need for an integrated and improved scientific approach


Part_I | pg-169

The complex problem cycle of cooling water

SYSTEM COMPONENTS

• On-line DO analyzers/meters

• On-line Corrosion analyzers/meters

• Portable corrater

• Portable DO meter

• Portable ultrasonic flow meter

• Portable data logger

• Portable suspended solids meter

• pH controller

Part_I | pg-170


Emerging tools and approaches

• Environmental burden (EB)

• Eco-efficiency

• Environmental Technology Assessment(EnTA)

• BIO-MIMICRY

ECO-EFFICIENCY

• EVOLVING ENVIRO-ECONOMIC CONCEPT OFNATURAL CAPITALISM where focus shifts from

CAPITAL PRODUCTIVITY TO RESOURCEPRODUCTIVITY…….

Al l i ndus t r i a l p roduc ts a re c rea ted f romresources extracted from nature ( minerals,energy, wood..) but only a t iny fract ion ofresources extracted-about 6% become finalgoods,other 94% become waste byproducts,there are huge potential gains in eco-efficiency

ENVIRONMENTAL BURDEN

• ICI developed method

• Provides a meaningful picture of the emissions from operations

• Help to identify most harmful emissions

• EB = Wa x PFa + Wb X PFb +..

• W =Weight in tonnes of a,b,a

• PF = Potency factor of emissions


Part_I | pg-171

Bio-mimicry- an exciting design approach

Termite mounds

• Low energy-intensive materials

• Passive air conditioning

Examples abound..

• Even tall trees do not need pumps to feed the furthest leaf…

Improvement opportunities are immense..

And somewhere somebody is doing it :Redesigning a standard (supposedly optimized) industrialpumping loop cut power from 95 to 7 HP (–92%), cost less tobuild, and worked better.

Is it possible to produce iron & steel at much lower temperature? Is it possible to increase thermal conductivity of water? Is itpossible to let fugitive particles settle in air the way they are settled in water?

Many things seem impossible, and maybe they are. But often, fact is stranger than fiction. During the first industrial revolution,in the span of just 70 years, one person could do what it used to take 200 people to do earlier.

FOR THIS EACH ONE OF US NEED TO KEEP OUR ANTENNAS OPEN AND FOR DOING SO….

Part_I | pg-172


Reduction Gas from Coal : The Economic & Pro- Environmental Solution for Ironmaking in Mini-Integrated Steel Plant Concept in India

Dr. Horst Kalfa1, Mr. Amitava Banerjee1, Mr.Adrian Reeva2

The World of Air Liquide

Air Liquide in brief

< Air Liquide is a world leading international Group specializing in industrial and medical gases and related services.Today they are present in 75 countries

< Founded in 1902, Air Liquide currently combines the resources and expertise of a global Group with a powerful localpresence, based on independent customer-focused teams

< From the start, Air Liquide has based its development on innovation, geographic expansion, creativity andinitiative

< Air Liquide supply oxygen, nitrogen, hydrogen and many other gases and services to many customers (steel and oilrefining, chemistry and glass, electronics and paper, metallurgy and food-processing, aerospace and healthcare). Theirinnovative solutions improve customers’ industrial performance while helping to protect the environment

Main figures & performances in 2008

< •13.1 bn total sales

– 80% outside France (in 72 countries)

< 1 million customers

< Over 8,800 patents and nearly 2,700 protected inventions

< 43,000 employees

< 365,000 individual shareholders

< Profitable growth revenue +11 % and profits +10.8%

< Net profit exceeds •1 bn again

< All activities and geographic zones growing

World Business Lines

1. Lurgi India Co.Pvt.Ltd ,New Delhi2. Lurgi clean Coal Technology ( Pty ), Johannesburg ,RSA

< Industrial Merchant : gases in small or mediumquantities to users in very diverse sectors

< Large Industries : high volumes of industrial gases andenergy solutions (chemicals, refining, metals)

< Electronics : carrier and specialty gases, liquidchemicals and related equipment. Installations andservices for semiconductor and flat screen manufacturers


Part_I | pg-173

AL worldwide engineering activities

< Healthcare : three areas of activity supply of medical gas, services and equipment to hospitals, homecare and hygiene

< In addition to these four major activities, Related Activities with engineering, welding, diving and chemicals.

Company Overview

Lurgi Portrait

Lurgi was purchased by Air Liquide in summer 2007.

Lurgi is a leading technology company operating worldwide in the fields of process engineering and plant contracting.

The strength of Lurgi lies in innovative technologies of the future focussing on customized solutions for growth markets.

The technological leadership is based on proprietary technologies and exclusively licensed technologies in the areas

< gas-to-petrochemical products and synthetic fuels,

< gas generation and treatment,

< refining,

< petrochemical intermediate and end products,

< polymers,

< biofuels,

< food and oleochemicals.

From project development to the turn-key construction of plants through to full plant operation Lurgi globally engineers, builds andcommissions plant complexes from a single source and under its overall responsibility.

Part_I | pg-174


Fields of Activities

Lurgi is successfully active in the following main fields:

< Gas-to-Petrochemicals and Gas-to-Synfuels

< Biofuels

< Gas Production and Purification

< Food and Oleochemicals

< Refining

< Petrochemical Intermediates and End Products

< Polymers

Recently, Lurgi has been able to extend its competence in the field ofpolymers by integrat ing Zimmer’s technologies and herebyconsequently creates whole process chains.

Scope of Services

< Lurgi provides total technology solutions

< full-service operating centers worldwide

< all aspects of project development from financing through start-up and operation

We offer the following comprehensive services:

< Consulting

< Market Studies

< Pre-feasibility and Feasibility Studies

< Product Marketing

< Financing

< Countertrade

< Contracting

< Global Sourcing

< Basic and Detail Engineering

< Value Engineering

< Authority Engineering

< Project Management

< Construction

< Operation and Maintenance

< Revamping/Retrofitting

< Technical Service


Part_I | pg-175

Types of Contracts

Lurgi has extensive experience in performing services based on variouscontract types:

< Reimbursable Contracts

< Alliance/Incentive Contracts

< Lump Sum Contracts

< EPC (Engineering, Procurement, Construction) Contracts

< LSTK (Lump Sum Turnkey) Contracts

for

< Grassroots Plants

< Revamp/Modernization of Plants

< Expansion of Plants

< Relocation of Plants

Lurgi Group Organisation

Part_I | pg-176


Lurgi Product Portfolio

Advanced Fuels and Chemicals Technologies by AL & Lurgi

Integrated Fuels and Chemicals System


Part_I | pg-177

Main Process Streams for Fuels and Chemicals

Lurgi-Technologies for Fuels and Chemicals

Part_I | pg-178


Technology Expertise

Lurgi‘s Technology Portfolio I

< Gas-to-Chemicals and Gas-to-Synfuels

- MegaMethanol®

- Methanol to Propylene (MTP®)

- Methanol Derivatives

- Methanol as an Energy Source (MtPower®)

- Integrated Production Complexes (Megamint®)

- DME

- Coal Gasification

- Fischer-Tropsch

- Gas-based Refinery

Alt

erna

tive

Alt

erna

tive

< Gas Production and Purification

- Steam Reforming

- Autothermal Reforming

- Combined Reforming

- Pre-Reforming

- Synthesis Gas Complexes (MegaSyn®)

- Partial Oxidation (MPG)

- Claus / OxyClaus®

- RECTISOL®

- PURISOL®

- SULFREEN®

- Lurgi Tailgas Treatment (LTGT®)

- OmniSulf®

- AQUISULF®

- MDEA, aMDEA®

Alt

erna

tive

Lurgi‘s Technology Portfolio II

< Petrochemical Intermediates and End Products

- Olefins

- Butadiene

- Phthalic Anhydride

- Terephthalic Acid (E PTA)

- Acrylic Acid

- Polymers

< Selected Refinery Technologies

- Hydrocracker

- FCC

- HDS

- Aromatics

- Upgrading

< Food and Oleochemicals

- Starch and Derivatives

- Sweeteners

- Extraction of Seeds

- Refining of Edible Oil

- Fatty Acids

- Fatty Alcohol

< Biofuels

- Biodiesel

- Bioethanol

- Energy from renewable resources

Trad

itio

nal

Trad

itio

nal

Ren

ewab

leR

enew

able


Part_I | pg-179

FBDB Gasification and Products

Part_I | pg-180


Commercial Applications

Price – The driving force


Part_I | pg-181

Coal Dominates Global Energy Reserves

Indian Energy Reserves

Coal Natural Gas Crude Oil(in Million Tonnes - MT) (in Billion Cubic Metres - BCM) (in Million Tonnes - MT)

253,000 1076 800

106,000 930 800(MMtOE) (MMtOE) (MMtOE)

Source : Coal – Ministry of Coal. Natural Gas : India in Business ,GOI Crude Oil – India in Business ,GOI

India : The Primary Energy Demand

Part_I | pg-182


India : Demand – Supply Gap ( 2001 Price Basis )

India : The Desired / Future Energy Mix

The Energy Mix: India

Primary Fuel Unit Av. Yearly Equivalent Av. Yearly Equivalent Energy Energy SecurityDemand MtOE Demand MtOE Mix (%) Drive EnergyXth Plan (2002-2007) XIth Plan (2002-2007) (2012) Mix (%)

(2002-2007) (2007-2012) (2030)

Low Rank Coal MT 460 190 620 255 46 54.0

Lignite MT 58 155 81.5 22.0 4

Crude Oil MT 134 135 172 173 34 25.7

Natural Gas (NG) BCM 47.5 43 64 58 10.5 5.5

Hydroelectric gKWH 148 12.7 216 18.5 3.3 0.7

Nuclear gKWH 23 6.0 58 1.4 2.6 4.0

❖ Source: Integrated Energy Policy Report, Planning Commission, Govt. of India.❖ The above is based on Commercial Energy Consumption data. The non- conventional energy consumption is at 151 MtOE and 170

MtOE respectively in 2006-2007 and 2011-2012.

Fossil Energy Resources Use Forecast


Part_I | pg-183

Coal Gasification Future Growth in India

The Governing Factors

– Crude Oil & Natural Gas Price

– Coal Price & Grade

– Energy Security

– Technology Selection & Performance

– Environmental Obligations

SLRN Sponge Iron – Flow Sheet

SIIL, 30,000 TPA SLRN Plant

Part_I | pg-184


SLRN Kiln Batteries

Natural Gas based DRI: Process Flow Scheme


Part_I | pg-185

General Battery Limit of the Process Plant

Coal based DRI : Shaft Furnace Technology: Overall Flow Scheme

Part_I | pg-186


Ideal Economic & Environmental Solution Hybrid of DRI + IGCC Power

Process Block Diagram:

Coal Gasification & Reduction Gas for DRI


Part_I | pg-187

The Overall Typical Definition of Gas Island

Gasifier Systems: Feed Coal Characteristics

Gasifier Reactor Fixed Bed Fluidized Bed EntrainedFlow

Commercial SLTC BGL Lurgi - CFB HTW Shell, GE,Gasifier Fixed Bed CP, SiemensSystem Dry Bottom

Preferred Lignite, reactive Bituminous Lignite, bituminous Lignite, reactive Lignite,feed stocks bituminous coals, coals, petcoke, coals, cokes, bituminous coals, bituminous coal,

wastes wastes biomass, wastes wastes petcokes

Ash content No limitation < 25% No limitation 25% (Maximum)

Preferred ash >1200° C <1300°C >1000°C >1100° C <1300° Cmeltingtemperature

Caking / swilling Non-caking to highly caking acceptable Non-caking Non-caking tohighly caking

Ash removed as Ash Slag Ash Ash Slag(Agglomerated)

Part_I | pg-188


Sasol-Lurgi Gasifier

Standard Gasifier Modules & Capacities

➨ Continuous coal feed

➨ Continuous ash removal

➨ Advanced process control

➨ Feedstock flexibility

➨ Biomass gasification

➨ Fundamental & Applied R&D

Performance Growth … … the proven reliability/ availability


Part_I | pg-189

Typical Operational Data … …

➨ Gasifier are in operation for 320 days continuously, 24 hours per day without any standby & spare units

➨ Reliability: annual gasifier availability in excess of 92% for total train (average)

➨ Longest down time period of 30 days for major overhaul

➨ Inherent fail-safe process design

➨ Cold start up to design load within 10 hours

➨ Turn down ratio (design to minimum): 2.7 (Av 35%)

➨ Can accept a wide range of coal characteristics:

● Particle Size : 5-50 mm

● Ash Content : 6-40 %

● (Ash + Moisture) Content : 50 %

● Coal Rank : Bituminous; sub-bituminous; lignite and anthracite

Critical Characteristics for FBDB Gasification

• Total moisture (wt%) 2 – 36

• Proximate analysis (air dry basis wt%)

- Inherent moisture 4 - 34

- Ash content 6- 35

- Volatiles 12 -38

- Fixed carbon 30 - 54

- Total sulphur 0.3 – 1.5

• Calorific value (MJ/kg- air dry basis) 12 – 27

• Free swelling index 0 – 1.5

• Ash fusion temperature (°C) - Oxidizing conditions

• Initial deformation point 1190 - > 1500

• Hemispherical point 1220 - > 1500

• Fluid point 1338 - > 1500

• Types of coal Bituminous; Sub-bituminous, Anthracite; Lignite

FBDB Gasification Application Summary …

➨ The FBDB Coal Gasification Process is:

● Well demonstrated, low risk, proven technology

● Suited to a wide variety of low grade, high ash content coal

● Robust , mature technology – very high reliability and on-line availability factors

● Range of co-products can be upgraded to high value products e.g. Sulphur, Ammonia, Phenolics and Tar/ Oil/Naphtha

● Technology can be deployed for various coal based applications including the production of Fuel Gas/ Town Gas;Substitute Natural Gas (SNG); Electricity or Chemicals i.e. Methanol, Ammonia, DME, FT Products

Part_I | pg-190


● Unsurpassed experience and expertise in the field of coal gasification science and downstream CtL, CtC Products

● Expert input throughout entire project cycle related to a coal gasification venture

Sasol-Lurgi Gasification

Reference List

Plant Name Year Number Productso fGasifiers

Sasol Chemical Industries, Sasolburg South-Africa 1955 17 Liquid Chemicals

Sasol Synfuels, Secunda South Africa 1979 80 Liquid fuels and Chemicals

Dakota Gasification Company, Dakota, USA 1985 14 Substitute Natural Gas

Shanxi-Tianji Coal Chemical Company, People’s Republic of China 1987 5 Ammonia for fertilizer production

Yima, People’s Republic of China 2000 2 China

KFX, Gillette – Wyoming, United states of America 2004 2 Coal beneficiation

Synfuels Gasification Site FBDB Gasification: The Biggest Application


Part_I | pg-191

Proven Multi Train Concept

➨ 80 Gasifiers in operation - 4 Phases of 20 units

➨ Gasifier availability ~ 92% on yearly average

❖ No spare units,

❖ 24 hour – 330 day annual operation ,

Lurgi (LCCT) Coal Gasification - Performance

Consider Reliability and Maintainability…

❖ Expected maintenance down time ~ longest: 30 days

❖ Consider statutory maintenance interval - Extended to: 36 Months

❖ Materials of construction – freely available carbon steel with no exotics i.e. refractory

❖ Operational horizon – life expectancy of plant

❖ Availability of skills and maintenance experience

❖ Technical support for continuous profitability improvement

Consider Environmental footprint…

❖ Option to operate zero effluent plant

❖ Gasification produces concentrated CO2 stream ready for sequestration

❖ Opportunity for Co-Generation for Reliable Operation and to maximize the ROI

❖ Use of Agglomerated Ash : For brick and road construction

❖ Efficient removal/ recovery of pollutants: Sulphur , Ammonia Phenolics,BTX/Gasoline

Typical Row Rank Indian Coal

➨ Proximate Analysis of Coal (Typical Air Dried Coal) (in % Wt)

- Moisture : 6.4 – 7.5 - Volatiles : 26.2 – 26.5

- Ash : 34 – 35.5 - Fixed Carbon : 31.6 – 31.9

➨ Ultimate Analysis of Coal (Typical DAF Basis) (Figures in % Wt)

- Carbon : 76.1 – 76.4 - Nitrogen : 1.8 – 1.9

- Hydrogen : 5.3 – 5.4 - Sulphur : 0.6 – 0.7

- Oxygen : 15.5 – 16.1 (By Diff)

Part_I | pg-192


➨ Ash Characteristics (AFT)

- Initial Deformation/Softening Temp : 1500 – 1550°C

- Hemispherical Temp : 1550 – 1590°C

- Flowing : (+) 1600°C

Ash Composition (% Wt)

- Silica : 60 – 67% - Alkali Metal (CaO+MgO+K2O+Na2O) : 1.8 – 2%

- Alumina : 25 – 25% - Fe2O3 : 2.0 – 4.5%

Reduction Gas Quality Requirement for DRI Shaft Reactor

◗ H2 / CO Ratio : 1.6 – 1.8

◗ Reduction Component {H2 + CO }: > 11.5

◗ Oxidising Component {CO2 + H

2O }

◗ Methane (Clt4) : 5 – 15%

◗ Carbon Dioxide (CO2) : 2 – 5%

◗ Hydrogen Sulphide (H2S) : 50 – 100 ppm

◗ Moisture (H2O-V) : 2.5%

◗ Heating Value (LCV) : 3500 Kcal/Mm3 (Min)

For 2.0 MMTPA of DRI Production / Low Rank / High Ash Coal

Stream Raw SynGas (Cold) SynGas (after H2S removal) Reduction Gas for DRI

Coal Requirement (TPH) 270

Total NM³ / Hr 320,000 315,000 236085.2

Pressure bar/ (g)/Temp°C 26.0/43 25/Amb 24.0 Amb

Composition Wt% Mol% Wt% Mol% Wt% Mol%

CO2

53.682 25.410 54.17 25.58 9.86 3.04

CO 33.105 24.620 33.41 24.79 66.49 32.21

H2

3.767 38.923 3.80 39.19 7.73 52.02

N 2 0.250 0.186 0.25 0.19 0.51 0.25

AR 0.282 0.147 0.28 0.15 0.57 0.19

CH4

7.442 9.663 7.51 9.73 14.20 12.01

Calorific Value (High) Kcal/Nm³ 3033 2880 4300

Calorific Value (Low) Kcal/Nm³ 2739 2600 3900


Part_I | pg-193

Technology Comparison (Typical)

S l Parameter Unit Direct Coal ReductionNo Based Gas from Coal

1 Sp. Thermal Energy GCal/TDRI 4.3 (Net) 2.3

2 Coal Required T/TDRI 1.55 0.8

3 Iron Ore (Lump / Pellet) T/TDRI 1.75 – 1.8 1.55/1.45

4 Oxygen (95% Purity) T/TDRI - 0.055

5 HP Steam (45 Bar) T/TDRI - 0.63

6 Agglomerated ASU T/TDRI ?? 0.26

7 Power Consumption KWH/TDRI 85 90

8 Elemental Sulphur (Recovered) Kg/TDRI - 2.25

9 Ammonia Recovery Kg/TDRI - 7.5

10 Cooling Water Reqd. m³/TDRI 1.5 3.0

Salient Process Advantage for Coal Gasification & Reduction Gas based DRI compared to Direct Coal/Rotary Kiln Process

Coal Requirement in Reduction Gas : Lower by around 45% compared to direct Coal /Rotary Kiln based Process

Iron Ore Requirement : Lower by 25%

Degree of Metallisation : 94% compared to 81% in Rotary Kiln Technology.

Plant Availability / Realiability : > 90%

DRI Quality : Many fold Superior for Flat Steel Products

Environmental Benefits : - No suspended Particulate Emission- Sulphur in Coal Recovered as Saleable

Elemental Sulphur (+ 95% Recovery)- Nitrogen in Coal Recovered as saleable

Liquid Ammonia as Co-Product.

Part_I | pg-194


Lurgi (LCCT) Gasifier Train with 7 Gasifiers

Lurgi (LCCT) Gasifier Train for Reduction Gas


Part_I | pg-195

Gas Island for Reduction Gas- Typical GAD

IGCC Environmental Benefits:

Air Emission Factors

COMPONENT CONVENTIONAL PC (Kg / MW hr) IGCC (Kg / MW hr)

Particulate (SPM) 0.939 0.024

Sulphur Dioxide 2.9 0.125(0.25 % wt. in Coal)

Carbon Dioxide 870 – 950 675 - 730

Part_I | pg-196


Administrative Perspectives onDISPLACEMENT, RESETTLEMENT, REHABILITATION

It is a Long Story of Very Slow Evolution

I. Pre-British India:

(a) Development Induced Displacement did not exist

(b) Emperors/ Kings/ Queen/Noblemen were content with building Forts, Places, Tombs and Temples or Mosques

(c) Very Few Rulers Built Roads (Shersha Suri), Irrigation Canals (Vijayanagar Emperors), Tanks

(d) Population was Small

❖ All lands belonged to local communities

❖ Royal Prerogative was enough

❖ Roads, Drinking Water, Health, Education, Irrigation were all matters of Philanthropy and local community initiative.

DISPLACEMENT WAS RARE

II. British Period:

British Rulers began building

❖ Ports in Chennai, Kolkotta

❖ Roads, Railways later Tramways in Cities

❖ During Famine Canals, Navigation

These required Lands


Part_I | pg-197

British Followed:

i. Royal Prerogative

British Patternii. Compensation to Owners

❑ 1824: Regulation I of Madras

❑ 1870: Some Extension & Consolidation

❑ 1894: LA Act

Foundation ofAdministrative

Approach

1. Public Interest Paramount

2. Compensation

3. Civil Courts

III. Post Independence Period (1954-1984)

❑ Stress on Development

❑ More Displacement

❑ But our attitude was

“Greater Good of Greater Number”

Displaced were Not considered seriously

● Ethos on Planned Development

❑ Big Steel Plants

❑ Big Dams/Canals for Irrigation & Power

❑ Expansion in Roadways /Railways / Ports / Airports

❑ Growing Cities

❑ LA Act – the Main Instrument

◆ “HAVEs GOT COMPENSATION”

◆ “HAVENOTs GOT KICKED OUT”

◆ Public Agitations Started Sporadically

❑ Major Amendments to HUMANISE LA ACT in 1984

Univers i t ies

Educational Institutions

Town Development

i. Time Limits on LA Stages

ii. Private Companies brought in

iii. Solatium raised from 15 to 30%

iv. Additional Market Value Added

v. Interest Rate Raised

vi. Section 28-A added

vii. Consent Award Instituted

ONLY FOR HAVEs

Part_I | pg-198


Narmada Andolan

Tehri Andolan

Sporadic Cases

◆ World Bank Entry

❑ Resettlement Aspects

HAVEs + HAVENOTs

i. House Sites

ii. Houses

iii. Transit Sheds

iv. Shifting Cost

v. Drinking Water

vi. Roads

vii. Subsistence Grants

viii. Land Grants

viii. Court InterventionsNarmada Case

ix. Tribal Rights

x . SEZ Act

xi. LA Act AmendmentBill 2008

xii. R&R Bill 2008

a. NPRR 2003

b. NPRR 2007

c. LA Amendment Bill

R & R

Globalization, Privatisation, Liberlisation

ii. Growth with Equity

iii. Inclusive Development

iv. Human Right

v. Right to Information

vi. “Civil Society”, NGOs, INGOs

vii. Decentralization of Adiministration(73rd/74th Amendment to ConstitutionEPR to Scheduled Areas)

More Attension to Displaced

COMMON VIEWS

a. Development is a paramount necessity SO Displacement is inevitable

b. R&R is necessary but should NOT negate the very project itself – by making it too costly

c. We are going from One Extreme of total neglect of PDFs/PDPs to the Other Extreme of Negating development itself:

i. Right of Enchroachers Vs Right to Property

ii. Compensation Far in excess of Market Price Greed Vs Fair Price


Part_I | pg-199

iii. Too much politicization of R & R issues

iv. Too many NGOs, Self Proclaimed defenders of PDPs

v. Tribals Vs Development

vi. Gender and Development

vii. Orphans/Widows/Handicapped

d. Role of Government only as a Watch Dog

NPRR- 2007 i) Privatization of R & R

SEZ Act ii) Purchase of Land Vs. Acquisition of Land

iii) Employment/Land/Share/Training/Housing /Infrastructure /Subsistence/Plot + Compensation

COMMON APPROACHES

1. Blue Print – Not Flexible nor Evolutionary

2. Less Participatory – Some Consultation

3. More Regulatory than Development Orientation (RD+LAO+Police)

4. Project Speedier than R & R Works

5. No Specialized Agency – RD/ID/Fwd

6. Not Much Concern for Grievance Redressal

7. Poor Funding

8. Govt. is Weak- Unable to Coerce Private Industires

9. Lack of Sensitivity / Empathy

10. Top Heavy Bottom Loose – Organization + Sup——-

11. Use of Force:

12. Centralized / Hierarchical Vs. Horizontal

❑ Reactive Vs. Proactive

❑ Process Oriented Vs. Result Oriented

❑ Authoritarian Vs. Consultative & Participatory

❑ Reaching Out Vs. Let them come

❑ Adhocism Vs. Holistic & Long Term

❑ Problems of Honesty, Secrecy, Delay, Parochialism, Politics

❑ Opposition to Caste, NGOs, Civil Society

❑ Yield to Political Pressure, Courts

What is Required ?

1. Good Policy

2. Proper Organization

Kalinganagar

Nandigram

Haryana- Rel iance

Part_I | pg-200


3. Adequate Funding

4. Systematic Approach from the Start of the Project

5. Training of Staff

6. Consent Awards

7. Monitoring + Evaluation

8. Grievance Redressal

i. Empathy

ii. Problem Solving

iii. Participatory

iv. Transparency

v. Honesty

vi. Consultative Decision Making

vii. Adequate Information

viii. MIS- Surveys

ix. Evaluation and Monitoring


Part_I | pg-201

Broad issues related to CSR and R & RIbrahim Hafeezur Rehman1

1 . Director, Tata Energy Research Institute (TERI)

Value of CSR to organisations

❑ Business value of CSR….

❑ Social license to operate….

❑ Risk management….

❑ Access to capital….

❑ Reputation/Brand……

Emerging trends in the field of CSR

❑ Changing public image of corporations…….

❑ Legal strategies and activism…….

❑ Companies need to demonstrate ……….

❑ Increasing regulation of CSR…….

❑ Societal trends…….

❑ Industry response…….

Emerging International Standards and Benchmarks

Global Compact

● Signatories of this compact has to conform their business activities to Compact’s 10 principles on human rights, labourstandards, the environment and anti-corruption

Global Reporting Initiative (GRI)

● Most used, credible and trusted framework in the world

§ Created: through a multi-stakeholder, consensus seeking approach

§ Followed by more than 1500 organizations from 60 countries for reporting

§ Allows organization to measure, track and improve their performance

GRI Sustainability reporting guidelines:

● Promotes transparency and accountability

● Allows stakeholders to track organization’s performance

● Makes cross sectional & time-series comparison of outcomes, achievements & failures possible

Part_I | pg-202


What to report? How to report?

Standard disclosures Principles for defining Principles for(a report should contain) report content defining quality

1. Strategy and Profile

2. Management approach

3. Performance indicators

1. Relevance & Materiality

2. Stakeholder inclusiveness

3. Sustainability context

4. Completeness

1. Balance

2. Comparability

3. Accuracy

4. Timeliness

5. Clarity

6. Reliability

Global Reporting Initiative

Accountability 1000

● Accountability 1000 is an accountability standard

● Guidelines for ensuring social and ethical accountability and high-quality auditing and reporting practices

● offers standard processes for

❖ Planning

Process 1: Establish commitment and governance procedures

Process 2: Identify stakeholders

Process 3: Define/review values

❖ Accounting

Process 4: Identify issues

Process 5: Determine process scope

Process 6: Identify indicators

Process 7: Collect information

Process 8: Analyze information, set targets and develop improvement plan

❖ Auditing and Reporting

Process 9: Prepare report(s)

Process 10: Audit report(s)

Process 11: Communicate report(s) and obtain feedback

❖ Embedding

Process 12: Establish and embed systems

Equator Principles

● Categorization of projects according to risk,

● Social & environmental assessment,

● Applying international social & environmental standards,


Part_I | pg-203

● Preparation of action plan, consultation & disclosure,

● Grievance mechanism, application of covenants

● Independent review & monitoring.

● Demonstrates importance of CSR in procuring finance & relevance of following international social & environmental standardsin mainstream business operations.

CSR in Indian context

❏ The global framework and standards of CSR will need to be continuously fine–tuned by CSR practitioners

❏ Focus on issues like poverty, inadequate livelihood options, lack of quality health care and education and illiteracy andthe challenges arising from these issues

❏ CSR not only a way of doing good business - to go much beyond business to actively participate in helping resolve someof the above mentioned issues.

❏ The Indian CSR model has evolved over the last few decades to give rise to some innovative ways to address developmentissues.

Steps for a successful CSR model

❏ Reach out to remote villages and urban slums in positively impacting the lives of people.

❏ Partnering with local NGOs as implementers of the projects.

❏ Focus on the issue of livelihood creation with communities.

❏ Minimize negative impact on environment and people.

❏ Responsibly manage the company’s manufacturing process.

❏ Auditing and reporting such activities voluntarily.

❏ Creating awareness within various stakeholder groups about company’s products and how they impact the environmentand societies.

Salient Features

❏ Bring balanced development by avoiding undesirable social and environmental consequences

❏ Takes into consideration the lessons of the past policies, best practices through several consultative processes

❏ Follow democratic process in Policy formulation

❏ Concise, practical, flexible, and implementable approach

❏ Recognize the voices and choices of the vulnerable groups: indigenous communities, women, physically challenged.

Part_I | pg-204


“Empower a village”

The Context

Life for the poor…

…is often without…

• Safe Drinking Water

• Nutritious Diet

• Sanitation & Toilets

• Electricity & Lighting

• Adequate Fuel Supply

• Education

• Adequate Medical Facilities

• Reliable sources of income

Is there a Solution? - an integrated approach to development

Improve basic amenities

❏ Energy - modern energy usage – lighting, cooking, power

❏ Improved sanitation

❏ Availability of purified drinking water

❏ Education and information/awareness generation

❏ Access to health services/facilities

❏ Communication and IT

Enhance livelihoods

❏ Improved agriculture practices

❏ Create new opportunities for income generation

❏ Value addition at local level


Part_I | pg-205

The Development Philosophy

Aim…

The concept is aimed to promote sustainable rural livelihoods and improve living conditionsthrough integration of natural resources management with development of village infrastructure.

Objectives

❏ to strengthen the capacities of different stakeholders (communities, local institutions,etc) for managing the local resources in a sustainable manner;

❏ to demonstrate the effectiveness, and potential of renewable energy devices fordecentralized electrification and promote rural interventions for integratedsustainable development;

❏ to create sustainable livelihoods opportunities at the village level throughintroduction of irrigation, improved agricultural and farm practices; and to enhancethe quality of living through improved incomes, health and sanitation.

Basic principles

Where can the concept be implemented…

❏ Areas with an under-developed status

❏ Un-electrified households

❏ poor communication

❏ absence/non-functioning of drinking water and sanitation

❏ lack of irrigation options

❏ low agriculture productivity and limited on- and off- farm income generating activities

Part_I | pg-206


Sectoral Gaps that challenge development

Water, Health & Sanitation

• No access to clean drinkingwater

• No toilets in houses

• No hospital or pharmacy

Livelihood

• Seasonal labor

• Lack of income options

• No access to financial credit

• Low market awareness

Agriculture/ Farm Sector

• Marginal farmers

• Low yield per hectare

• No irrigation facilities

Energy

• No electricity

• Rel iance on inef f ic ient cookingdevices

Approach

❏ Active participation of local community and Panchayat members at every stage

❏ Demand driven

❏ Partial cost sharing by the community

❏ Central focus on ensuring project sustainability

❏ Integration of environment protection with all the activities undertaken

The INSTEP* Perspective

Energy Interventions for Lighting


Part_I | pg-207

Energy Interventions for Cooking

Cost of energy technologies

Intervention Cost USD Units Total cost USD

Individual Household level

Solar home lighting systems 366 25 9150

Solar lantern 87.5 100 8750

Solar torch 12.5 100 1250

Improved cook stoves 31.3 75 2343.75

Parabolic solar cooker 160 10 1600

Biogas plants 244 1 2440

Community level

Centralized lighting system – BiomassGasifiers (20 KWe) 53659 100 53659

Improved Watermills 1875 50 3750

Part_I | pg-208


Water, Health and Sanitation Interventions

Drinking water Interventions


Part_I | pg-209

Cost of Water, Health and Sanitation technologies

Intervention Level Cost Units TotalUSD

Water intervention

Drip irrigation device (I acre) Household 500 50 25000

Low pressure sprinkler (I acre) Household 495 50 24750

Pressurized treadle pump Community 125 50 6250

Rainwater harvesting (USD/1000 lit.) Community 79 25 1975

Centralized SPV water supply Community 11525 - 11525

Health and sanitation interventions

Sanitary Toilets Community 250 75 18750

Disposal of waste water through soak pit Community 150 50 7500

Awareness Community - 100 6000

Agriculture/ Farm sector Interventions

Part_I | pg-210


Cost of Agriculture/ farm sector technologies

Intervention Level Cost USD Units Total cost USD

Improved bullock operated plough Individual household 1000 10 10000

HYV seeds - wheat (USD/acre) Individual household 37.5 50 187.5

Bio-compost pit (per unit) Individual household 200 75 15000

Income generation Activities

Cost of technologies for IGA* and Capacity Building

Intervention Cost USD Units Total cost USD

Entrepreneurship development

Eco-bag making machine 625 1 625

Chicks rearing 12.5 25 312.5

Pickle making (5-10 persons) 250 1 250

Mushroom cultivation (5-10 persons) 125 2 250

IT centre 4268 1 4268

Rope/sutli making machine (per unit) 100 1 100

Herbal, medicinal, aromatic plants, fruit trees. 1000 10 10000

Awareness and Capacity Building (at the level of the community)

Capacity building for all above technologies - 100 5000


Part_I | pg-211

The Collaborative Work Plan

The approach would be modular, allowing mid-course corrections and would consist offour phases.

❏ Phase I

■ Construction of baseline

■ Participatory Need/Demand Assessment

■ Identification of Sectoral gaps and issues

❏ Phase II

■ Identification of ‘drivers of change’

■ Development of ‘QOL* enhancement strategy’

❏ Phase III

■ Demonstration of ‘technologies’ and ‘Livelihood Enhancement Strategies (LES)’

■ Customization of technologies and streamlining of LES

❏ Phase IV

■ Implementation

■ Withdrawal

■ Up scaling

R & R concerns and recommendations

Issues

❏ No mechanism in place to minimize large scale displacement

❏ No mechanism in place to minimize multiple displacement

❏ No special provision for people undergoing multiple (involuntary) displacement

❏ Outdated land records

❏ No standard criteria to assess the market value of the land to be acquired

❏ Lack of transparency & objectivity in determining the market value of the land

❏ No in-depth Social Impact Assessment

❏ Lack of expertise to handle the land acquisition and R&R processes

❏ Vulnerable groups( SC,ST, women) are marginalized in access to the R&R benefits

❏ Tenants and forest dwellers are not included for compensation/benefits

❏ Lack of local participation in entire R&R processes (from planning to implementation)

❏ Lack of time bound compensation payment and other R&R benefits to the PAPs

Some desirable contours of an R&R package

§ Old Age Pension

§ Vulnerable/destitute pension

§ Sustenance Allowance

Part_I | pg-212


§ Free Education Facility with stipend

§ Free Medical Facility

Facilities in the R&R colony

§ Fair Price Ration Shop

§ Provision for religious places, cremation ground

§ Anganwadi, ration shop

§ Roads, play ground, drainage system and street lights

§ Ponds, wells and grazing ground

Employment/training for PAPs

§ Provision of one livelihood opportunity for displaced family/member

§ Formation of Labour cooperatives – for unskilled jobs

§ Provision for employment oriented training (e.g. ITI)

§ Provision of shop allotments in the R&R colony and in township area (In following order)

❖ Self Help Group,

❖ Physically challenged (Differently abled)

❖ SC/ST/OBC,

❖ Landless labourers

Thrust areas…

❖ Renewable energy interventions

❖ Agriculture and Horticulture development

❖ Drinking water and sanitation

❖ Integrated water resource management, promotion of farm ponds etc.

❖ Forestry programme in village fringe areas and fallow lands.

❖ Capacity building initiatives


Technical papers | Part- II


Part_II | pg-1

1.0 Introduction

Hematite is the most prominent of the iron ores found in India and belong to Pre-Cambrian iron ore series. The ore is withinbanded iron ore formations occurring as massive, laminated friable and also powdery forms in a variety of geological conditionsthroughout the world. It is the red oxide crystallizing in hexagonal system. Ideally, hematite contains 69.94% iron and 30.06%oxygen. The specific gravity varies from 4.9 to 5.3 whereas the hardness from 5.5 to 6.5 depending on the associated impurities andtype of formation. India possesses hematite resources of 14,630 million tones of which 7,004 million tones are reserves. Majorhematite resources are located mainly in Jharkhand (4,036 million tones) 28%, Orissa (4,761 million tones) 33%, Chhattisgarh(2,731 million tons) 19%, Karnataka (1,676 million tons) 11% and Goa (713 million tons) 5%. The balance 4% reserves are spreadover in the states of Andhra Pradesh, Madhya Pradesh, Maharashtra, Rajasthan and Assam. The hematite and lateritic ores arehighly friable and during mechanized mining and crushing operation, large quantities of fines, which are rich in Al2O3, gets generated.During beneficiation/washing process, products which have alumina less than 2% are recovered as prime products and a fractionwhich is known as slime having size less than 0.15mm (150 microns) gets accumulated and having high percentage of alumina(around 4% and above), hence, the slime cannot be used for the production of BF grade pellets. This fraction is almost 12 to 15%of the total quantity of ore mined and is being dumped in large size slime ponds/dams. If suitable application for the slime is not foundquickly or identify the proper processing technology to reduce the alumina, there is a danger of the need, to stop the mining activitydue to lack of space to dump the same besides the environmental hazards.

The generation of fines is undesirable but unavoidable and these fines are relatively low grade and cannot be utilized directlyin blast furnace due to high alumina content. However, it has been reported in the literature that by upgrading the ore fines usingappropriate beneficiation techniques and utilizes the fraction in the sinter feed up to 40% by micro-balling of the sinter mix prior tosintering1. The management of tailings from iron ore mines is an important issue not only the environmental point of view but also theresource conservation perspective2.

Although several R&D initiatives have been taken at different institutions to beneficiate this fraction with suitable techniques anda viable option for removing the gangue such as alumina and silica based on the characterization supplemented by exhaustiveexperimental observations are yet to establish. Earlier, efforts were made by Das et al to reduce the alumina and silica to 3.5% &1.4% respectively using the hydro cyclone3 followed by Wet High Intensity Magnetic Separator4 (WHIMS). Whereas Srivastava et.aldemonstrated experimentally that it is possible to reduce the iron ore slimes alumina to 1.17% with a yield of 37% using hydrocyclone followed by spiral concentrates1. After the introduction/inception of the hindered settling classifier, the beneficiation strategieswere changed and tried to see the efficacy of this equipment for removal of alumina from the iron ore slimes. Recently Sarkar et.alachieved the concentrate having plus 66% total iron, 1.57% of silica and 1.67% of alumina could be produced with a yield of 56.7%from the feed assaying 60.14% of Fe, 4.15% of SiO2, 4.28% Al2O3.

Due to the depleting of high-grade ore at the mines and increasing loss of mineral values during processing, along with the lackof space to store these rejects it has become an essential to develop efficient and cost-effective methods to recover iron values fromthe ore fines. Conversely, it is not easy to process the slime ores mainly because of the micronized size range typically present in afinely disseminated form. Further, the iron minerals are associated with the clayee minerals, kaolinite and coupled with poor liberation7.Hence, the present work assumes importance of sufficient characterization of the ore fines essential for process/equipment selectionto recover the iron values suitable for blast furnace operations.

Technology for utilization Iron ore fines of Noamundi depositSunil Kumar Tripathy1, C.Raghu Kumar2, and T.Venugopalan3

1,2 R&D Tata Steel, Jamshedpur.3. Technology Group Tata Steel, Jamshedpur


Part_II | pg-2

2.0 Raw material

The iron ore fines sample was collected from M/s Tata Steel captive mines. This deposit mainly contains hematitic and goethiticiron ore. The ore fines obtained from the working plant and wet sieved at 500 microns. The under size of sieved sample contained59.77% of total iron, 5.89% alumina and 4.71% silica.

3.0 Characterization

Characterization of the iron ore fines consist of of various steps including its size wise chemical analysis and density, X-raydiffraction (XRD) study, scanning electron microscopy (SEM) with EDS (Energy Dispersive X-Ray Spectroscopy), microscopicstudies. These steps are described in detail in the following sections and corresponding observations are discussed.

3.1 Size and size –wise density measurement

Particle-size measurement of the iron ore fines was performed using the standard laboratory sieve shaker and the results arepresented in figure 1. From the figure it is revealed that the ore fines average particle size (i.e d50) was 127 microns.

Figure 1. Size distribution curve.

Representative sample has been taken from each size fraction and measured for specific gravity as per the standard procedure(Wills, 2006). The specific gravity of each fraction has been tabulated in Table 1. From the table it is evident that the density of all sizefractions are below 4.5 that means the sample contains more of goethite (4.28) mineral and minor quantity of hematite (5.2) gains andfurther it is also marked from the table 1 that the specific gravity of the grains are increasing as particle size decreases up to 37microns and the size fraction below 37 microns particles are less than 4.0 Sp.Gr which indicates the fraction is rich of ferruginousclayee material i.e. Koalinite type of particles.

Table 1. Sp.Gr. of the different size fractions

Size (microns) >500 250 to 500 150 to 250 105 to 150 75 to 105 53 to 75 37 to 53 25 to 37 <25

Sp.Gr. 3.86 4.04 4.25 4.36 4.42 4.46 4.50 3.94 3.90

3.2 Chemical Analysis

The chemical analysis of each size fraction was carried out and the analysis data is tabulated in Table 2. From the table it isillustrated that above 150 micron size fractions are rich iron content where as less than 150 micron fractions are relatively high inalumina and silica content. The iron content is varied from 59.64% to 64.1% in plus 25 micron size frac-tions. However, a sharpdecrease is observed in below 25 micron size frac-tion’s iron content i.e 52.9%. Further the distribution of iron, alumina and silica atthis size fraction is 21.5%, 36.22% and 42.3% respectively. Which indicates the segregation of alumina and silica at this size fractionis possible.


Part_II | pg-3

Table 2. Size wise chemical analysis

Size in Wt% % Assay Value % DistributionMicrons Retained

Fe(T) SiO2 Al2O3 Fe(T) SiO2 Al2O3

+355 4.60 63.65 3.20 4.20 4.90 3.13 3.23

-355+250 13.55 62.79 4.00 4.85 14.23 11.50 10.99

-250+210 8.02 63.70 3.22 4.73 8.55 5.48 6.35

-210+150 7.90 63.71 3.00 4.87 8.42 5.03 6.43

-150+105 7.16 60.48 3.36 5.43 7.24 5.10 6.50

-105+75 6.88 60.67 3.10 5.26 6.99 4.53 6.05

-75+63 5.41 60.04 3.52 5.58 5.43 4.04 5.04

-63+53 5.04 59.64 4.62 5.15 5.03 4.94 4.34

-53+45 3.60 60.05 3.62 5.46 3.62 2.77 3.29

-45+37 8.20 61.50 3.89 5.34 8.44 6.77 7.33

-37+25 5.35 63.21 3.92 4.73 5.65 4.45 4.23

-25 24.29 52.90 8.20 8.92 21.49 42.26 36.22

3.3 XRD Study

The XRD study was carried out to identify mineral phases present in the sample. The diffractogram is shown in Figure 2. Fromthis figure, it can be seen that the major iron-bearing mineral phases are goethite and hematite and gangue mineral phases areGibbsite, quartz and kaolinite.

Figure 2. Diffractogram of the head sample

3.4 SEM Study

The mineralogical studies were conducted using SEM with an EDS (Energy Dispersive Spectroscopy) attachment. The studywas focused mainly to identify the minerals and elemental composition of the mineral grains present in the sample, throughphotomicrographs and microanalysis was discussed.


Part_II | pg-4

Figure 3. Diffractogram of the sample

A number of images were processed and it can be seen from the Figure 3(a) that most of the iron-bearing minerals are fully orpartially weathered, resulting Alumina substitution in most of the iron oxides mineral grains as shown in the Figure 3(b) of 1. Furtherit is observed that the point 2 is free of silicate minerals and more porous but alumina rich compared to point1 grain. This substitutioncan normally occur in goethite grains which are of iron hydroxide, this may be attributed to the weathering of iron oxide particles(Hematite). It was also observed from the figure 3b point 3 that kaolinite and gibbsite are the major gangue phases.

3.5 Microscopic Studies

The sample comprise of the minerals such as hematite, goethite, gibbsite, quartz, and kaolinite. From the mineralogy it is evidentthat the sample having two distinct types of valuable minerals i.e., predominantly crystalline hematite grains (fine to medium grained)that carry disseminated inclusions. Further the micro-crystalline hematite particles intermixed with micro-crystalline goethite which isof porous material and gibbsite mineral. Vitreous goethite particles are abundant in the sample. Goethite replaces hematite in differentdegrees (Figure 4a and 4b) and fills up the voids and fractures during weathering. Whereas, kaolinite occurs in intimate associationwith goethite but free quartz grains are very rarely observed therefore it is assumed that the silica is available in the form of Kaolinite.Colloform texture of the weathered goethite was observed in the Figure 4(D).


Part_II | pg-5

Figure 4. SEM photomicrograph iron ore fines sample

Predominant alumina-contributing mineral is gibbsite and occurs as intimately intermixed with goethite (Figure 4C) and hematite.More over association of gibbsite with goethite is more than that of hematite and free gibbsite/clay minerals (Kaolinite) grains are veryfew. Gibbsite and clay are present as microcrystalline to cryptocrystalline aggregates and are thoroughly intermixed with goethite,and other silicate minerals. Majority of the kaolinite grains are embedded with iron oxide/ hydroxide minerals as shown in Figure 4D.

4.0 Beneficiation studies results and discussion

For the beneficiation of iron ore fines, new generation equipment such as Floatex density separator followed by wet gravityconcentrating table were used. The Floatex density separator is one such counter-current, autogenous teetered bed separator.Particles are separated based on the hindered settling and fluidization principle. The experimental campaign was undertaken in anFDS (Model No. LPF-0230, supplied by Outokumpu) of 230 ×230 mm cross-section and 530 mm high (square tank height) followedby a 200 mm high conical section. The feed distributor location is 230 mm from the top. The under flow thus obtained, again subjectedto concentrating table for further concentration of the product. The beneficiation strategy was made to get the concentrate of pellet/sinter grade by treating the iron ore fines using floatex density separator to recover maximum amount of iron values. The floatexdensity separator product was further treated on wet gravity concentrating table to achieve the desired quality.

4.1 Concentration of Iron ore fines by Floatex Density Separator

Numbers of tests were conducted by varying the set point and all other process variable such as teeter water flow rate (around5 LPM), feed rate (0. 5TPH of dry solids) and feed pulp density (25% solids by weight) were kept constant. After each test, both theunderflow and overflow fractions were collected and analyzed for grade and yield. The weight distribution percentage of theunderflow fractions of 36, 38, 40 set points were 78.5, 71.7 and 64.2 respectively. It is illustrated from the Figures 5 & 6 that about83% of the iron present in the feed material was recovered as under flow fraction of floatex density separator with about 63.5% ironpurity at the 36 set point. Whereas 69% of the iron present in the feed material was recovered as under flow fraction of floatex densityseparator with about 64.2% iron purity at the 40 set point. But it was also evident that the impurities like alumina & silica were pushedto the over flow fraction in the order of 30-58% alumina and 48-65% silica at set points 36 & 40 respectively.

Figure 5. Under flow fraction assay value at different set points


Part_II | pg-6

This can be attributed that as the set point i.e teeter bed density increases the recovery of iron to underflow fraction decreasesmarginally whereas substantial quantity of alumina and silica were rejected to overflow. Further it may be noticed that floatex densityseparator under flow fraction contains about 64%±0.5% iron content which could not be improved further due to its wide size rangeand narrow density difference. Hence, thus obtained underflow fraction was treated on gravity concentrating tables to improve thequality of the product by reducing the Al2O3 content.

Figure 6. Under flow fraction elements distribution at different set points

4.1 Concentration of Floatex Density Separator underflow fraction by gravity concentrating table

The underflow fraction of the floatex density separator was subjected to the gravity concentrating table for further improvementin the quality of the product. Series of tests were conducted by varying the process variables such as feed rate, pulp density, deckinclination and wash water flow rate. Typical test results are tabulated in Table 3.

Table 2: Test results of the gravity concentrating table

From the table it is observed that the iron values was enriched to 66.42% from 64% but the alumina & silica content wasdecreased to 2.85% & 1.76% from 3.94% & 2.62% respectively. Though substantial quantity of free alumina and silica wasrecovered as tailing fraction partial weathered particles are entered into the concentrate due to which the concentrate aluminacontent was 2.85%. Hence, this fraction was cleaned using another stage of table operation. The result of the cleaning stage tablingoperation was tabulated in Table 3. The results of the cleaning stage table revealed that the quality of the product was improved to67.37% along with the silica and alumina 1.67% and 1.73% respectively. The overall iron distribution was about 17.59% withrespect to the head sample.

Table 3: Test results of the gravity concentrating table cleaning operation.

4.0 Summary and Conclusion

The present work explains about exploring the possibility of beneficiating the iron ore fines produced at the beneficiation plantof Tata Steel, India. Detailed particle characterization of iron ore fines revealed the following distinctive properties that are helpful fordeveloping the process flow sheet

a) The XRD study reveals that goethite and hematite are the main iron-bearing phases. Gibbsite, kaolinite, and Quartz are


Part_II | pg-7

the main gangue phases. From size wise density analysis it can be concluded that the sample is goethitic rich fraction.

b) The size wise chemical analysis illustrates that the major impurities are silica and alumina are concentrated at the finersize (less than 25 microns) fraction, also having the density of less than 4.0 illustrates ferruginous clayee material suchkaolinite etc. Moreover this fraction is of substantial quantity having 28% by weight.

c) SEM study revealed that the iron bearing grains (hematite and goethite) are highly weathered due to the surfaceweathering of the bulk ore in the deposit. During sizing and washing this weathered portion being accumulated as slime.This is also evident through the microspic studies that the hematite is altered to partially/fully to goethite. Further thekaolinite occurs in intimate association with ochreous goethite. The gibbsite is dominant at finer fraction by coating on theiron bearing minerals.

d) The separation of very fine ferruginous clayee material (less than 45 micron size) from the iron fines becomes moreefficient with the use of Floatex Density Separator. Also further segregation of iron minerals of underflow fraction can beachieved with simple gravitational techniques. This results the number of unit operations employed in the circuit would becondensed and hence treating this ore fines becomes more compact and simpler.

Acknowledgement

The authors are thankful to Tata Steel Ltd., management for all support, encouragement and permission to publish this work.

References

1. Srivastava, M. P, Pan, S. K, Prasad, N, and Mishra, B. K, 2001, “Characterization and processing of iron ore fines ofKiriburu deposit of India” International Journal of Mineral Processing, 61(2), pp. 93–107.

2. Bhattacharya, P., Ghosh, S.R., Srivastav, J.P., Sinha, P.K., Sengupta, S.K., Maulik, S.C., 1997. Beneficiation studies ofBolani iron ore. Proc. National Seminar on Processing of Fines, NML Jamshedpur, India, pp. 156–162.

3. Das, B., Prakash, S., Mohapatra, B.K., Bhaumik, S.K., Narasimhan, K.S., 1992. Beneficiation of iron ore slimes usinghydrocyclone. Miner. Metall. Process. 9 _2., 101–103.

4. Das, B., Mohapatra, B. K., Reddy, P. S. R., and Das, S., 1995, ‘‘Characterisation and beneficiation of iron ore slimes forfurther processing.’’ Powder Handling and Processing, 7(1), pp. 41–44.

5. Sarkar, B.;Das, A.; Roy, S.; Rai, S.K.:”In depth analysis of alumina removal from iron ore finesusing teeter bed gravityseparator” (2008) Mineral Processing and Extractive Metallurgy (TIMMC), Vol.: 117(1)

6. Pradip, 1994, ‘‘Beneficiation of alumina-rich Indian iron-ore slimes.’’ Metallurgical and Materials Processing, 6(3), pp.179–194.

7. Pradip, Ravishankar, S.A., Sankar, T.A.P., Khosla, N.K., 1993. Beneficiation studies on alumina-rich Indian iron oreslimes using selective flocculants and flotation collectors. XVIII International Mineral Processing Congress, Sydney,Australia, pp. 1289–1294.


Part_II | pg-8

Measures taken by A.P. Pollution Control Board in Controlling Air Pollution fromSponge Iron Industries

B. Raghavendra Rao1

1. Senior Environmental Engineer (Cleaner Production Cell), Andhra Pradesh Pollution Control Board

The conventional process of iron making is through blast furnace route where the iron oxide is reduced to metallic iron in liquid form.This liquid iron is refined in BOF route to obtain steel. The second method of steel making is by melting and refining of available steelscraps in electric arc furnaces/induction furnaces. The second method has been more economical and has gained importance in thesecond half of the 20th century. Limitations in the availability of steel scrap has resulted in the advent of sponge iron as an alternativeto the scrap. The Sponge Iron is now popularly derived by direct reduction of high grade iron ore (Hematite, +65 % Fe content) bynon-coking coal and dolomite at desired temperature and pressure under controlled atmospheric condition in rotary kilns. Duringsolid state reduction about 27 % oxygen is removed from the ore body to achieve about 82-85 % metallization thus making numberof tiny pores or cavities in the solid. The term sponge iron justifies due to the spongy appearance of the porous solid. It is also termedas DRI (Direct reduced iron) as the iron ore is directly reduced in solid state and the sponge iron produced retains the size andshape of the iron ore.

The non availability of coking coal and high rise in the prices of metallurgical coal and coke has forced the blast furnaceoperators to reduce the coke consumption rate. The integrated steels plants of the country have also started using sponge iron in theblast furnaces to reduce use of coke and enhance the productivity in a techno-economic manner.


Part_II | pg-9

The sponge iron-EAF route has emerged as the alternate choice in steel making because-

Sponge iron acts as an alternative to the scrap in the EAFs.

It requires low capital investment and early pay back periods

The process can be operated with non-coking coal and gaseous reductants.

The coal based sponge iron plants (through Rotary Kiln process) have relatively smaller capacities varying from 50 to 500Metric Ton (MT) per day, i.e. 15000 to 150000 MT per annum.

There are 23 sponge iron industries in A.P. located in Mahaboobnagar, Nalgonda, Krishna, Vizianagaram, Chittoor, Kurnooland Ananthapur Districts. There is a mushrooming growth of Sponge Iron Industry especially in Mahaboobnagar District after 2002without proper care for environment.

POLLUTION IMPACTS:

Sponge iron units are highly air polluting industries. The hot gases contain huge amount of fine dust comprising oxides andunburnt carbon and toxic carbon monoxide. It needs treatment before discharging into the atmosphere. In case on no pollutioncontrol is installed then the particulate matter emission is around 25 – 30 gm/Nm3. This indicated that installed pollution controldevices need more care and close monitoring and they are capable of meeting the present general emission norms. The pollutioncontrol devices installed are ESPs, Bag filters, and wet scrubbers. They also generate huge amount of solid waste as char from theprocess and fine dust retained in the air pollution control devices. Most of the fugitive dust and source emission from sponge ironprocess are invisible micro fine respirable particulate matter which causes varieties of human ailments like respiratory ailmentsleading to loss in work efficiency.

Air Pollution Point Sources

Kiln Flue Gases after ABC ( Control equipment ESPs / Bag Filters/ Wet Scrubbers)

Emergency Stack / Safety Cap above the ABC to maintain positive pressure inside kiln and avoid CO related explosions

Cooler Discharge

Product House

Iron Ore and Coal Crushing

Fugitive emissions sources

Raw material handling yard ( Unloading, stacking, reclaiming operations)

Product discharge system (Cooler discharge conveyers transfer points, junction house, screens, magnetic separators,storage silo, truck loading and parking operations- Control equipment of water sprinklers, bag filters, covered producthouse, covered conveyor belt). The source of fugitive emissions and their control measures are given below:

SI .No Sources of fugitive dust emission Control measures prescribed

1 Raw material handling & preparation area Automised water spraying system.Work zone should be concreted

2 Crushing and screening of coal (Coal circuit) Pulse jet Bag Filter & automised water spraying nozzles

3 Crushing and screening of iron ore (Iron ore circuit) Pulse jet Bag Filter & automised water spraying nozzles

4 All material transfer points and conveyor belt Enclosures and Pulse jet Bag Filter

5 Discharge points of Raw material storage bins Pulse jet Bag Filter

6 Raw material feeding point into kiln Pulse jet Bag Filter

7 Coal injection point into kiln Pulse jet Bag Filter with recycling of coal finesback into the coal injection system

8 Leakage from slip rings of the rotary kiln Realignment of the kiln and changing of seal/ packingmaterials during shutdown period


Part_II | pg-10

9 Cooler discharge circuit Pulse jet Bag Filter

10 Intermediate bins in between cooler discharge Pulse jet Bag Filterarea and product separation unit

11 Product separation unit Pulse jet Bag Filter

12 Wind blown dust from solid waste dump yard Provision of boundary wall around the dump yard,covering by earth and automised water spraying onthe dump area by rotating nozzles

13 Handling of fine dust retained in the hoppers Air locking valves, enclosures, pneumatic conveyorof the bag filters and ESP system / pug mill/ mechanical dust handling system

14 Transport roads Construction of Black topped/ concrete internal roadsand approach roads. Installation of rotating type watersprinkling nozzles along the roads.

15 Transport of materials/ solid waste Vehicles should be covered

Even after installation all pollution control devices in the plant, the ambient air quality with regard to SPM and RSPM, do not meet thestandard many times due to the following reasons:

1. Bad house keeping,

2. Internal and approach roads not black topped/ concreted, work zone not concreted. Loose dust periodically not removedfrom roads, which become airborne.

3. Unloading of raw materials, loading of chars and fined carelessly. Trucks not covered and there is spillage of materialson the road during transportation.

4. Fine loose dust form the work zone and raw material and solid waste dump yards become wind borne during stormyweather.

5. Leakage of flue gas through kiln cap in between power failure and start up of D.G.

6. Bad maintenance and malfunctioning of ESP/ Bag Filters/ dust handling systems.

7. Inadequate water sprinkling.

8. ESP/ BF dust handling system not mechanized. Dust collection points under the hoppers properly not enclosed.

9. Most of the sponge iron industries do not have dedicated team for proper house keeping and attending to pollutionproblems.

Solid Waste Generation

Char & Dolo Char

Flue Dust,

GCT /GCP Plant sludge,

Fly Ash and

Kiln accretions

Pollution Control Cost

The project cost of a DRI plant, as per information available, ranges from Rs. 4 - 5 crores for 50 TPD plant to Rs.7 - 8 croresfor 100 TPD plant to Rs.11 - 12 crores for 200 TPD plant (all without WHRB and power generating system). Whereas with additionof WHRB, turbines and comprehensive pollution control facilities are present, the project cost will be over Rs 50 crores for 300 TPDplant and over Rs. 90 crores for 500 TPD plant.

Legal issues on Air Pollution from Sponge Iron Units

A Writ Petition No. 2951/2005 was filed by Sri T. Veerender Reddy, Papi Reddy (V), Shadnagar (M), Mahaboobnagar Districtand eight others on air pollution caused by the 16 sponge iron units in Mahaboobnagar district, in the Hon’ble High Court. The


Part_II | pg-11

petitioners prayed to shift the existing units to other industrial development areas as they are located amidst agricultural fields andhuman habitations.

In addition to the industries the following were also made respondents.

1. Govt. of A.P, represented by Secretary (Industries)

2. Prl. Secretary, EFS&T Dept.,Govt. of A.P.

3. Member Secretary, AP Pollution Control Board.

4. Commissioner of Industries, A.P.

5. MD, APIIC, Hyderabad

6. The Dist. Collector, Mahaboobnagar Dist.

The Hon’ble High Court, while hearing the case on 06.04.2006 issued orders directing the APPCB to constitute SpecialCommittee for the purpose of monitoring of industries in Mahaboobnagar District on day to day basis and to file a comprehensivereport to the Hon’ble Court. The Hon’ble Court also directed the Dist. Collector to collect Rs. 3 crores proportionately from theindustries who are respondents. The amount collected is to be disbursed towards damage of crops. The APPCB constituted a SpecialCommittee with four monitoring teams for monitoring of Respondent industries in Mahaboobnagar District, w.e.f 04.05.2006 to31.05.2006

§ Joint Chief Environmental Engineer, APPCB, Zonal Office, Hyderabad.

§ Senior Environmental Engineer, APPCB, Task Force, Hyderabad.

§ Environmental Engineer, APPCB, Regional Office, Hyderabad.

§ Junior Scientific Officer, Air Laboratory, Board Office, Hyderabad.

The monitoring teams under the supervision of the Special Committee, have inspected the respondent Sponge Iron units inMahaboobnagar District in the month of May, 2006. The Special Committee report was submitted to the Hon’ble High Court in the 1stweek of June, 2006.

General Observations of the Committee

During the inspections, the teams carried out stack (chimney) and Ambient Air Quality Monitoring and observed that,

(i) The main sources of Fugitive emissions are from

§ Product separation

§ Raw material crushing

§ Conveyor belt

§ Product stock yard areas.

(ii) Many industries have not provided separate shed for by product i.e., Char & Dolochar yard. The shed for raw materialyard i.e., iron ore yard.

(iii) Many industries have not yet completed the laying of Bitumen/concrete roads within their premises.

(iv) Many industries have not developed green belt along the compound wall.

After constant persuasion and rigorous monitoring most of the units have installed required air pollution control equipment andthey are operated very well.

APPCB Guidelines For Setting Up Of Sponge Iron Units :

With experience gained from above PIL, Board has formulated the following guidelines for establishing the sponge iron plantsin the state:

1) No Population shall exist within 1 km from the periphery of the unit.

2 ) In case of recreational areas the distance shall be 2 km from the periphery.


Part_II | pg-12

3) No other Sponge iron plants shall be located within 1km.

4) The distance between the boundary of the site and the boundary of the

a. National Highway and State Highway shall be - 500 m

b. Major District roads - 100 m, other roads - 25 m.

5) The distance between the boundary of the site and the boundary of the gardens / horticulture / orchards / agriculturallands - 1 km.

6) The built-up area of the plant shall not be more than 50% of total area.

7) Greenbelt of 10 m width all around the plant premises shall be developed. In the case of sensitive areas the greenbeltshall be 25 mts width in the prevailing wind direction. The greenbelt development shall be done with “Locally SuitableEVERGREEN plants”.

8 ) The SPM emission concentration in stack shall not be more than 100 mg/NM3. The control equipments ESP or bag filterswill have 25% addition stand by stages for ESP or bag cells for bag filter.

9 ) The height of the stack attached to the Rotary Kiln shall be minimum 75 m from the ground level for 100 T/day and 100 mfor 200 T/day capacities.

10) All sources of fugitive emissions i.e., loading and unloading operations, stock yard, transfer points of conveyors andretreat points shall be controlled fully i.e., with total enclosures and all transfer emissions shall be connected withExtractor inlet point and shall pass through a high efficiency Bag filter before discharging into the atmosphere.

11) The collected dust from air pollution control equipments shall be disposed in a well designed land fill. Until capping of landfill, top surface shall be kept in wet condition with water sprinklers to avoid re-entrainment into surroundings.

12) All internal roads shall be paved with Bitumen or Concrete.

13) Separate energy meter for air pollution control equipment shall be provided

14) Iron ore and coal stocks shall be with totally covered shed.

Further, Technical Committee in its meeting held on 31-08-2005 recommended that the Environmental Management Plan(EMP) of sponge iron units shall consist of the following information to process their applications.

The industry shall submit detailed EMP consisting of the following information:

a. Justification to select the present site among the alternative sites available.

b. Location Map indicating the site with approach road including neighbouring industries, human habitation etc.

c. Site layout plan drawn to scale clearly showing the greenbelt provision, immediate surroundings, north direction etc.

d. Copy of Survey of India Topo Plan indicating scale covering an area of 10 km radius indicating water bodies, agriculturelands, reserved forest, monuments, IDA / IE, industries, residential areas, and villages, etc.

e. Quantity of each raw material required per day and their storage capacity.

f. Daily and annual production capacity of each product, their storage capacity in the premises.

g. Detailed process description and flow chart with material balance.

h. Quantities of water consumed for various purposes and quantities of wastewater generated from various sections.

i. Details of Effluent Treatment Plant (ETP) and the final point of disposal of treated effluent.

j. Details of sources of air pollution, air pollution control equipment and calculations for stack height and including thosecontrol measures proposed to arrest fugitive emissions at storage yards.

k. Quantity of solid waste generated from various sections, treatment and mode of disposal.

l. Wind Rose diagrams indicating prevailing wind direction. Details of features existing in the prevailing wind direction, viz.,agricultural fields, orchards, human habitation, etc. and their distance from the proposed stack of the industry.

m. Detailed monitoring schedule during operational phase of the industry.


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n. Measures to control noise pollution.

o. Details of fire protection system.

p. Details of environment management cell.

q. Details of greenbelt on sides of factory, its width and type of plantation proposed.

Seminar On Cleaner Production Options In Sponge Iron Industry

The Cleaner Production Cell of APPCB has organized the above seminar to evolve with Cleaner Production options and wasteminimization techniques for the benefit of Sponge Iron sector. This seminar was graced by Dr. B. Sen Gupta Member Secretary,CPCB who has also made a presentation. Hundred delegates have attended this seminar from sponge iron industry sector, TechnicalCommittee and Scientific officers, and members of Taskforce of the Board etc. Sri. Rajeshwar Tiwari, I.A.S., Member Secretary,APPCB addressed the gathering. All the delegates were given with the course material. The outcome of the seminar evolved with thefollowing recommendations.

The following recommendations / suggestions were made during the Seminar:

A. By providing pre-heating system coal consumption for 50 TPD and 100 TPD plant the benefits are:

1. Coal consumption 10% will be reduced

2. Production of sponge iron will go by 15%

B. Coal fines collected in the coal crushing Dedusting system can be mixed with char fines and made into briquettes can be usedas a fuel in any system.

C. Either 2X100 TPD with FBC boiler or 3X100 TPD and more with FBC boiler will give consistency in power generation whichcan be used for production of steel as a downstream facility to make the project viable. This will also help in gaining carboncredits for more financial gains. This will ensure continuous operation of the pollution control equipments.

D. Iron ore fines of less than 5mm generated in the plant can be used either in the smaller down draft kilns for DRI production orfor agglomeration as pellets which can further be used in reduction process.

E. Management of waste products:

1. The solid waste such as Char & Dolchar shall be collected and stored in a covered shed and to avoid fugitive emissions& contact with water, so that it is easily saleable to brick kilns and power generation units.

2. Process dust emissions: Secured storage in concealed sections is necessary to avoid contamination which can be usedby oil refineries in replacement of activated carbon.

F. kiln accretions and slag may be used in filling the low levels/mine pits and for road making.

G. Fly ash collected from the waste gas can be used for making fly ash bricks.

H. Sponge Iron plants of 2X100 TPD / 3X100 TPD and more capacities with FBC boiler will give consistency in power generationwhich can be used for production of steel as a downstream facility to make the project economically viable. This will also helpin gaining carbon credits for more financial gains. This will ensure continuous power supply for plant operation.

I . Most of the managements are assigning the plant operations to the private contractors for producing the sponge iron ontonnage basis. These contractors are concentrating only on production and not on maintenance of pollution control equipments.These contractors are employing less manpower without any technical background and not able to justify neither to theproduction nor to control of emission levels resulting in damage to the environment and incurring losses to the company.

The managements need training / awareness on different aspects of operational and maintenance of the entire plant forsustainable development of sponge iron sector.

J. Due to rapid growth of the Sponge iron plants, there is a severe shortage of skilled persons. Most of the units are employingnon-technical persons. These unskilled & non-technical persons are not aware of the process thoroughly and not conscious ofenvironmental regulations. Hence the industry should employ technical persons only for operation of production units andpollution control equipments.

K. Entire process may be automated through Programmed Logic Control (PLC) to eliminate human errors causing pollution and


Part_II | pg-14

affecting the quality of the product. The opening and closing of the cap of bypass stack shall be electronically recorded with timeand duration. Interlocking facility should be provided between ESP operation and raw material feeding.

L. All the Sponge Iron Units can share the information on the better maintenance of air pollution control equipment and cleanerproduction options.

M. All the sponge iron/steel plants must aim at obtaining ISO 14001 certification which reflect on better EMP.

N. There are already iron ore mines in AP located in Khammam (Bayyaram), Krishna (Jaggaiapeta), Kurnool, Ananthapur andCuddapah Districts. M/s A.P. Mineral Development Corporation or Private Entrepreneurs may be encouraged to set up IronOre Benefication, crushing and pellatisation plants which will cut down transportation cost in addition not to depend on otherstates for procurement of raw material.

Conclusion: The steel making through sponge iron route is inevitable to meet to meet the planned steel target of the country.However the economic growth vis-à-vis environmental degradation should be balanced and sustenance needs to be maintained withthe following emerging concepts.

1. All the sponge iron plants/ steel plants (DRI route) should operate with adequate pollution control measures.

2. Continuous power supply from the grid is essential. Alternatively the industries should install captive power plant alongwith Waste Heat Recovery Boiler to ensure continuous supply of power to the pollution control devices to prevent airpollution.

3. Technical solution should be evolved to provide appropriate pollution control device to prevent direct emission of flue gasthrough the chimney of the Kilns without during start up and shut down of the kilns, when the flue gas cannot be takenthrough existing ESP/ GCP.

4. Better technology for proper sealing of ABC cap is essential to control cap leakages.

5. Coal based DRI process has been proved to be highly air polluting. Alternative clean process technology should beadopted.

6. Complete recycling of cooling, scrubbing water, settling tank and rainwater harvesting structure will minimize waterconsumption. Wet scrubbing should be replaced with dry system.

7. Maximum utilization of solid waste like char, fines, slags for briquitting, brick making, cement making should be emphasized.Rest should be filled in mine pits/ low lying area. Prime agricultural land should not be used for dumping of wastes.

8. Most of the proponents leave the environmental issue to their consultants. The proponents need training/ awareness ondifferent aspects of pollution control and possible impact of their projects on environment and consequences thereof.Pollution control and production activities should go side by side. The proponents should be personally serious about thepollution control activities and local environmental issues to avoid exploitation by the litigant publics, penal action andclosure direction from statutory authorities and to build up public image and gain confidence of the financers in order toachieve better production and business promotion.

9. Cleaner production and industrial growth with better environment practices may normalize various socio-economicissues.

10. Mushrooming growth of this type of polluting industries is neither a healthy growth in the interest of environment norbusiness promotion. Coal based DRI technology should be reviewed. Policies should be formulated to encouragingindustry for switching over to cleaner production technologies to prevent waste and pollution rather than their control andtreatment.

11. All the sponge iron/steel plants must adopt ISO 14000 international standards for environmental practices to improve theirhouse keeping, environmental management system and productivity.

12. Employment generation and revenue collection should not be done at the cost of environment and public health at large.

Cleaner production is the final answer in any waste reduction, pollution prevention and it holds the key to sustainable industrialization


Part_II | pg-15

Advanced Power Generation Technology in Steel IndustryNeelachal Ispat Nigam Limited – A Case Study

Sri N G Banarjee1, Sri A.Lahiri2, Sri Kalyan Mohanty3

1. ED (Works), NINL2. GM (Project), NINL3. AGM (Project), NINL

Neelachal Ispat Nigam Limited (NINL), a joint sector of MMTC & Govt. of Orissa is an Integrated Steel Plant with capacity 1.1MT, units like Blast Furnace, Coke Oven, Sinter Plant, and Power Plant are already in operation & Steel Melting Shop with Caster,Oxygen Plant, Lime Plant & Mills are in the advance stage of implementation.

Power Plant capacity is 62.5 MW (1X 24 MW GTG & 2X19.25 STG) and is basically a combined cycle co-generation plant. ThisPower Plant is unique among all other integrated steel plants in India with high plant efficiency, low heat rate.

Generally Integrated Steel Plants have Thermal Power Plants with Coal, surplus BF Gas & Coke Oven Gas as fuel to theBoilers & the steam generated there of utilized for Power generation & process use. These plants works on ‘Open cycle’ principlewith Plant efficiency at best to 35%.But NINL adopted one of the best advanced technology for Power generation in the Steelindustry, i.e. ‘Combined Cycle’ principle (first of its kind in India) utilizing low calorific fuel Coke Oven Gas (CV- 4300 Kcal/Nm3)directly in the Gas Turbine to generate power, with an overall plant efficiency close to 50% and above all a ‘Green Technology’maintaining coal, dust & fly ash pollution free Power generation. In addition, this Gas Turbo Generator has Black Start provision i.e.can be rolled & synchronized to a dead bus to cater plant critical load requirement with a support of a small DG set in case of Gridfailure & black out condition. This increases the Power system stability & less dependency on the Grid supply.

The above two figures shows the difference between the Power Generation in both open & combined cycle principles i.e. equalto 11 MW & NINL enjoys the unique advantage of later one.


Part_II | pg-16

Brief Description on Gas Turbine System

The Fuel:

Energy Requirement: 74 GCal /hr input to gas Turbine to generate 24 MW/hr & 46 TPH HP steam

Start up fuel: LDO

Continuous run-up fuel: Coke Oven Gas (Calorific value- 4300 Kcal/Nm3), major constituent of the gas are N2-5.5%, CO2-3.5%,CH4-24%, C2H6-2.5%, H2- 55.5%, CO-6.5%, O2-0.5%, Napthalene – 150 mg/Nm3, Tar – 30 mg/Nm3.

Major Systems:

a) CO Gas Cleaning Plant

b) CO Gas Compressor

c) Gas Turbine

d) Heat Recovery Steam Generator

GAS CLEANING PLANT

It is necessary to clean the Coke Oven Gas to remove Naphthalene & Tar contents before it is sent to compressor & Gasturbine, otherwise it may damage the turbine & compressor blades. For this purpose a Gas Cleaning Plant in included in the system.

This system is designed, supplied, erected & commissioned by Thermax ltd in technical assistance with irh Engg. France.

The main purpose of the Gas Cleaning Plant is to reduce Naphthalene, Tar & Dust content of CO Gas to the required limitsbefore compression & admission to Gas Turbine.

The treatment is made in 3 steps:

Low Pressure Scrubber: The naphthalene from CO Gas is reduced by two stage solar oil circulation.

Wet Electrostatic Precipitators: CO Gas coming out of LP scrubber passes through two wet electrostatic precipitators.Where tar & dust is reduced from the gas. After ESP, gas streams goes to a tank called Dry catch put to separate anycondensate present. From dry catch pat gas goes to 1st stage suction of Compressor.

High Pressure scrubber: After 4th stage of compressor the gas is cooled and flows through the High Pressure Scrubberwhere Naphthalene is reduced further due to high pressure, and then the gas is sent to a Coalscer filter to removeresidual solar oil, water and tar droplets and then Gas goes for the last stage compression.

Gas Cleaning Principle

Coke oven gas coming from Coke Oven first taken into LP scrubber to decease Naphthalene content. The scrubber systemconsists o two beds fed by two loops of solar oil cooled in exchanges to keep coke oven gas 1 to 20C above final condenser temp.The solar oil feed coming from HP scrubber is mixed with top circulating loop of solar oil at the top of the scrubber. The overflow ofsolar oil at bottom of scrubber contains rich naphthalene sent to spent solar oil tank. The gas then flows through two wet electrostaticprecipitations where tar & dent removed. The gas enters the shell & flow downwards. At bottom gas enters vertical to less where tar& dust is caught by electrostatic field. After two ESP, the two gas streams are gathered towards the Dry catch pot B1. From dry catchpat gas is piped to compressor 1st stage suction.

Coke oven gas coming from stage 4 cooler & separator is fed to the bottom of HP scrubber S2. There gas flows through 6bubbles caps tray. Fresh solar oil pumped by P1A/B to the top of the scrubber washes gas in a counter current flow. Solar oil levelof the scrubber is controlled control valve. Gas coming out of HP scrubber passes through coalescent filter, small drops of solar oil,water, tar, dust etc. colleted by filter media. The treated gas then sent to last stage of compressor.

Inlet Gas Condition to LP Scrubber:

PR: 500 MMWC, GAS VOLUME: 20700 m3/hr (Max)

NAPHTHALENE: 150 mg/Nm3 (Max), TAR: 30 mg/Nm3 (Max)

Outlet Gas Condition of LP Scrubber:

NAPHTHALENE: 70 mg/Nm3 (Max), TAR: 30 mg/Nm3 (Max)


Part_II | pg-17

Outlet Gas Condition of ESP:

NAPHTHALENE: 70 mg/Nm3 (Max), TAR: 1.7 mg/Nm3 (Max)

Outlet Gas Condition of HP Scrubber outlet:

NAPHTHALENE: 9 mg/Nm3 (Max), TAR: 1.7 mg/Nm3 (Max)

COKE OVEN GAS COMPRESSOR

The Coke Oven Gas has to be fed to the GT at a higher pressure as per the design criteria of GT so that proper distribution oratomization and mixing of fuel can be achieved. At the inlet of the combustor due to pressure of COG and shape of the distributor aswirling motion imparted to the COG, which helps in proper combustion. For this purpose a CO Gas Compressor (electric motordriven- 3.75MW) is also employed in the system.


Part_II | pg-18

Technical Data of COG Compressor

CONDITION NORMAL

PHASE STAGE - I STAGE - II STAGE - III STAGE - IV STAGE – V

Capacity Nm3/Hr 17500 17500 17500 17500 17500

INLET CONDITION @ Compressor flange

Molecular Weight (wet) 11.8 11.55 11.39 11.27 11.23

(Cp/Cv) t (K)t 1.356 1.358 1.361 1.364 1.368

Compressibility (Zt) 1.00 1.00 1.00 1.001 1.001

Pressure(ata) 1.033 1.7 2.82 5.54 8.32

Relative humidity (%) 100 100 100 100 100

Inlet volume(Am3/Hr) 22575 13529 7792 4100 2520

DISCHARGE CONDITION @ Compressor flange

Pressure (ata) 1.94 3.07 5.79 8.58 19.30

Temperature (OC) 120 117.3 135 100 167

Rated Speed (rpm) 9400

Driver rating 3750KW/1490 rpm

Function of the unit

It is one of the major equipment in the coke oven gas path to GT. CO Gas coming out from the Low Pressure Scrubber entersIst stage compression through Dry Catch Pot. The CO gas coming out of the 4th stage and again enters again inside the high PressureScrubber where, max amount of Naphthalene is removed. Then it enters the 5 th stage of COG Compressor.

The coke oven gas booster compressor consists of 3 machines, comprising of five compression phases. The final dischargepressure of 19.3 ata is obtained by passing the gas through these phases. The 1st and 2nd phases are accommodated in onecasing(2BCL508 LP),THE 3rd and 4th phases are arranged in the second machine(2BCL508 IP),while the 5th phase is housed in thethird machine(BCL509 HP).Four gas coolers together with moist separator are employed to cool the gas between these phases.1st

& 2nd phase consists of 4 stage( impeller & diffuser assembly) each. Like wise 3rd & 4th phase also consists of 4 stage each and 5th

phase consists of 9 stages. So it is a total 25-stage machine.

The train is driven by an induction motor through a speed increasing gear box and dry flexible type couplings. The compressorruns at speed of 9400 rpm with a suction pressure of 1.033 ata giving a final discharge pressure of 19.3 ata .

Gas Turbine

Technical data of GT:

Designed & manufactured in India by BHEL under technical collaboration with M/S General Electric, USA

Frame: V

Gas turbine Model: -MS 5000

Shaft rotation: -Counter clockwise

Turbine shaft speed: 5100 rpm

Generator shaft speed: 3000 rpm

Base Load :23590 KW

Compressor stages: 17

Power turbine stages: 2


Part_II | pg-19

Fuel: CO gas, LDO and mix

No of combustors: 10

Both axial flow Compressor and Gas turbine mounted on single shaft.

Heavy duty GT unit driving an synchronous generator.

Inlet end of rotor shaft: - coupled to accessories like, hydraulic pump, and lube pump through gear and pinion assembly.

Brief Functional Description of Gas Turbine

When the turbine starting system is actuated and the clutch is engaged the compressor and turbine is rotated by diesel engine,ambient air is drawn through the inlet plenum assembly, filtered & compressed in the 17 stage axial flow compressor. For pulsationprotection during start up the 10th stage extraction valves of compressor remains openn and variable inlet guide vanes (IGV) remainsin the low flow startup position (42 deg).

The Gas Turbine will use clean CO Gas as its main fuel. LDO will be used for supplementary fuel firing in the systemduring start up/emergencies.

The diesel engine brings the turbine rotor to ignition speed (approx 18%) when the spark plugs are energized and fuel isturned on. In the case of liquid fuel, equal amounts are distributed to each combustor (10 in nos) by an external flow divider. In thecase of gaseous fuel, the gas metering holes in the fuel nozzles control the distribution. The resulting fuel/ air mixture is ignited in thechambers (2 in nos) containing spark plugs and flame propagates through the crossfire tubes to the rest of the combustors. When allchambers are lit, as indicated by the flame detectors (4 in Nos), the acceleration continues. During acceleration diesel enginecontinues to assists till 2750 rpm (approx) when it disengages.

When the high speed relay actuates at 95 percent speed, the 10th stage extraction bleed valve closes automatically and the


Part_II | pg-20

variable inlet guide vane actuator energizes to open the inlet guide vanes to the normal turbine operating position (55 deg). Air fromthe compressor flows into the annular spaces between the outer combustion casings and the combustion liners in a reverse flow, andenters the combustion zone through the combustion liners.

The hot gases from the combustion chambers flow through the ten separate transition pieces. The gases then enter the two-stage turbine section of the machine. Both stages consist of a row of fixed nozzles followed by a row of rotating turbine buckets. Ineach nozzle row, the kinetic energy of the jet is increased, with an associated pressure drop. In the following row of moving buckets,a portion of the kinetic energy of the jet is absorbed as useful work on the turbine rotor.

After passing through the 2nd stage buckets, the gases are directed into the exhaust hood and diffuser which contain a seriesof turning vanes to turn the gases from an axial direction to a radial direction, to minimize exhaust hood losses. The gases then passinto the exhaust plenum and are introduced to HRSG through the gas duct or to the atmosphere through exhaust stack dependingupon plant conditions.

Resultant shaft rotation is used to turn a generator rotor for electrical power generation.

HEAT RECOVERY STEAM GENERATOR (HRSG)

HRSG is one of the major equipment in the combined cycle co-generation plants which plays the role of recovering the sensibleheat from GTE (Gas Turbine exhaust gas) & generates steam. This steam is utilized either for power generation.

It is designed to generate steam at 4820C,62 ata at a flow rate of 45 TPH.

This is manufactured & erected by BHEL under technical collaboration with VOGT- NEM, USA.

Predicted performance of HRSG:

Condition-I

1 Ambient temperature,Deg C 30 40

2 GT load KW 23590(Base) Base

HRSG Fuel

3 GT exhaust flow,kg/hr 420000 397000

4 GT exhaust temp,Deg C 499 508

Steam parameters at NRV outlet in M S line

5 Flow,tph 45.0 45.0

6 Pressure,kg/cm2 62.0 62.0

7 Temp,0C 482.0 482.0

Condition-II

1 Ambient temperature,Deg C 30 40

2 GT load KW 17700(75%) 24410(peak)

HRSG Fuel

3 GT exhaust flow,kg/hr 347000 417852

4 GT exhaust temp,Deg C 499 523.3

Steam parameters at NRV outlet in M S line

5 Flow,tph 37.5 48.7

6 Pressure,kg/cm2 62.0 62.0

7 Temp,0C 482.0 482.0


Part_II | pg-21

The HRSG consists of following main components:

a) Super heater & components.

b) Evaporator & components.

c) Economiser & components.

d) Condensate preheater & components.

e) Attemperator.

f) Expansion joints.

g) Steel chimney.

h) Rotary soot blowers(15 nos)

General Arrangement of HRSG

HRSG Vs Conventional Boilers:

HRSG use exhaust from GT as heat source, hence no need for firing.

HRSG do not use fans, as draft is from GT.

Heat transfer is predominantly by convection rather than radiation.

HRSG do not generally use membrane wall construction.

HRSG use finned tubes to maximize heat transfer.

HRSG is capable of faster startup

HRSG uses low auxiliary power

Conclusion

NINL has successfully commissioned & running the Gas Turbine along with all accessories with Coke Oven Gas since 2006.Though initial investment is little higher in comparison with open cycle Power Plant, the pay back period is very less. Steel industrieswith surplus CO Gas & BF Gas may adopt this advanced technology for clean & higher power generation as this is a proventechnology on Indian context.

Part_II | pg-22


INTRODUCTION

Directly or indirectly refractories are used in every industry needing high temperature operation. However, iron & steel Industriesare the biggest consumers of refractories. It takes away about 70-72% of the total production of refractories. Refractory & steelindustries are so internally connected that perhaps one may not exist without other. Today development of refractory industry is fullyinfluenced & dependent on the progress of iron & steel industries.

Presently, total refractory production around the world is about 21.0 million ton out of which 14.0 million tons are being consumed bythe iron & steel industries. This shows that an enormous quantity of refractories are being handled by iron & steel industrieseveryday & one can think that if these are not handled properly then how severely it is going to affect our environment.

Eco-Friendly Refractories for Iron & Steel Industries* Anupal Sen, B Prasad, Dr N Sahoo & JN Tiwari

* OCL India Limited, Rajgangpur, Orissa

Refractory & steel industries are so internally connected that perhaps one may not exist without other. Today, development ofrefractory industry is fully influenced & dependent on the progress of iron & steel industries. Newer processes with stringent processmonitoring systems have been introduced to produce cleaner steel at lower cost. This has compelled the refractory manufacturers todevelop suitable refractories that can perform consistently at rigorous operating conditions.

The environmental aspects and their impacts in steel plants are also considered by the refractory industries. This paper elaboratesthe different actions taken by the refractory industries to facilitate the endeavor of steel plants in maintaining global ecologicalbalance.

REUSE, RECYCLING & WASTE ELIMINATION - THE FIRST STEP

To take care of the environment, refractory makers along with steel industry have made an immense progress to improve usage,reuse, recycling and waste elimination of refractories in different area of its application. This is considered as the first step taken bythe refractory makers towards supply of eco-friendly (ecologically friendly) refractories.

From 1950 to till date the usage of refractory has declined significantly in all industries, with the steel industry showing the biggestdecrease (80%). As an example, introduction of repair system to improve the life span of converter & ladle has reduced refractoryconsumption & as a result the tonnage of refractories available for disposal & recycling is reduced substantially. In 1950, 60% of therefractories used ended up in a landfill, while in 2007 that figure was mere 18%.


Part_II | pg-23

Study shows that the steel industry has the highest rate of refractory recycling (55%) compared with other industries (32%). The iron& steel industry has not only developed the practice of reuse of used-refractories in their process but also collaborated withrefractory makers to recycle the used refractories. For example used slide gate refractories, mag carbon refractories, magnesiterefractories are sent from steel industries to refractory makers for crushing & recycling in many cases. However monolithics /unshaped refractories can not be recycled.

Disposal of steel plant wastes like fly ash and BF slag is a matter of major concern. Though BF slag is extensively used in cementindustries, still the amount of generation is far ahead than that of consumption. Several researches are going on for effective use ofthese materials in refractory industries which will not only reduce the waste generation, but will also produce economical products.

REDUCE EMISSION OF GREEN HOUSE GASES

Emission of greenhouse gases like CO, (NO)X etc is a common phenomenon in iron & steel industries especially in the area of Cokeoven. Special types of refractories like high density and high thermal conductivity silica bricks are developed for these types of criticalapplications to reduce the generation of these greenhouse gases. High density silica bricks have high thermal conductivity whichhelps in completion of reaction at comparatively lower temperature which in turn reduces the emission of these greenhouse gases.Moreover, this also ensures lower consumption of energy which reduces the depletion of natural resources. Comparison of propertiesof different types of silica bricks are tabulated below:

USE OF ECO-FRIENDLY RAW MATERIALS & BINDERS

The use of some environment-polluting toxic raw materials & binders are rapidly being replaced by some alternate eco-friendly rawmaterials for manufacturing of refractories. For example, spinels are being used in place of chrome in refractories to avoid thepollution of water by hexavalent chromium compounds after disposal of used bricks. Comparative data of Spinel and Mag-Chromebricks are given in the following table:

In some cases, the designs of the refractories are suitably modified to reduce the leakage of these gases. Earlier the coke ovensdoors were made by lining the silica bricks. Present trend is to use precast doors having almost no joints. Its excellent sealing effecthas reduced the leakage of these harmful gases. The pictorial view of precast made coke oven doors along with data sheet are givenbelow:

Part_II | pg-24


Carcinogenic asbestos fibers are gradually replaced by insulating ceramic fibers for back-up insulation of ladles, tundishes, etc.Fiber-free insulating coating is already developed in place of conventional ceramic fiber to cover the subentry nozzles. This newcoating has excellent heat insulation & obviously it is eco-friendly.

For the similar reason pitch is being replaced by resin in refractory manufacturing. Vacuum pressure impregnation of tar and pitch inlow carbon containing refractories is a common process to induce anisotropic carbon that will increase strength, oxidation resistanceand decrease elasticity. But, burning of these refractories releases carcinogenic aromatic compounds like benzo- -pyrene (BaP).New generation BaP-free resins have been developed that can replace tar & pitch and the desired properties can still be incorporatedin the refractories. These resins are thermoset polymers whose burning products are CO2 and water vapor, which are absolutelynon-toxic.

CONCLUSION

This is all about what is already achieved. The refractory industry will continue their R & D efforts to develop materials & systemstogether with the refractory consuming industries in order to

● Minimize refractory wear in the different industrial processes for less specific consumption

● Minimize infiltration in refractories in contact with liquid phases to increase the recycling

● Reduce heat losses in the industrial processes to decrease specific energy consumption

● Invent alternate eco-friendly raw materials

Today, in order to cope up with the needs of steel industry, refractory makers have not only made an improvement in its durability andreliability but also made a serious effort to develop and cater eco-friendly refractories to the steel industry. The achievements till datehave given a solid base to refractory makers for further progress in this direction.


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INTRODUCTION:

With continuous increase in global steel demand, hot metal production through blast furnace route will play a dominant role. Metallurgicalcoke, therefore, will hold the key to growth in the steel industries. Existing global cokemaking capacity will fall short of the requirementand additional coke making capacity need to be set up to meet the demand. One of the major challenge to cokemakers will be to makegood quality coke at low cost with minimum environmental impact. Huge additional investment is required to meet the stringentpollution control norms worldwide . Tata steel took up this challenge by stetting up its first Heat Recovery (HR) coke making facilityat Haldia , to cater to its additional coke demand . This technology is having the unique advantage of being not only cost effectivecompared to conventional slot ovens, but also has the added advantage of meeting the stringent pollution control standards, becauseof its basic design and process of operation . Over and above, it delivers coke of superior strength and size . This paper describesthe major advantage of this technology compared to the conventional slot ovens and how it helps to meet the environmental normswith minimum investment along with experience of Haldia plant.

ADVANTAGES OF HEAT RECOVERY COKEMAKING:

Energy efficiency: The process is simple and energy efficient compared to slot ovens. Heat is transferred through the refractorywalls of the coking chambers in slot oven while in case of HR ovens this is achieved by conduction from the sole flues and radiationand convection of gases undergoing combustion in the oven. Direct contact of hot gases with coal leads to less heat loss.

The cooling of raw coke oven gas in the hydraulic mains and subsequently in the down stream byproduct gas cleaning plant leadsto a loss of about 30% of heat input for coke production in conventional slot ovens. While thermal efficiency in slot oven is around80%, the actual efficiency is around 50% considering the additional heat loss during gas cooling as mentioned above. Thermalefficiency of HR cokemaking is much higher, close to 70%, if sensible heat is extracted for steam/power generation .

Cost effectiveness: Capex for HR ovens are about 30% lower as compared to that of conventional by-product ovens. Forexample, Capex of HR coke plant at Indiana Harbour (USA) was reported to be around $263/ ton of coke compared to byproductrecovery oven with $350/t of coke.

A variety of coals can be used in heat recovery cokemaking including a large quantity of inferior coal, for blending. For example, itis reported that a maximum of 20% non coking coal is used in the blend for HR cokemaking, without affecting coke propertyadversely. Introduction of coal stamping to increase bulk density in this process allows higher proportion of inferior coking coals inblend and thereby reduce coke cost.

Less pollution: Heat recovery ovens are operated at negative pressure, leading to minimum emission resulting in less pollution.There is no generation of effluents unlike by-product recovery coke ovens wherein coke oven gas purification generates effluentsthat need effluent treatment/ BOD plant. Solid wastes are totally absent as there is no processing of crude tar or benzol involvedwhich generates toxic sludge.

As HR ovens operate at sufficiently high temperatures, it prevents emissions of Hazardous Air Pollutants which are fully broken downinto its components and combusted.

Flat bed quenching car minimizes pushing emissions as incandescent coke glides in to the quenching car on the same level and thereis no fall of coke from a height of up to five/six meters as in case of tall ovens.

Heat Recovery Cokemaking - Environmental friendly Technology by choiceB.Biswas1, Anil Kumar1, Sanjoy Paul2, Prosenjit Sarkar2 & Ashok Kumar1

1 Tata Steel Limited, India2 Hooghly Met Coke & Power Ltd., India

Part_II | pg-26


Pollution control at Haldia:

Lower pollution is expected from this ovens due its design & operating process as described earlier. Recent performance of Haldiaovens in this regard are summarized in Table- 1 and trended in fig-1, 2 & 3 respectively, showing the actual pollution level muchbelow the norm.


Part_II | pg-27

Other advantages:

In case of slot ovens, coal exert pressure on the wall during carbonization. This puts a restriction on the type of coals used as toomuch pressure damages oven wall. However in HR cokemaking, no pressure is exerted on side walls since coal expands upwards.This gives cokemakers a choice to use a wide range of coals, without the fear of higher push force & wall damage.

Also, it is easy to build this ovens as number of brick shapes required are much less compared to slot ovens.

In the new generation ovens at Haldia, suction inside the oven is controlled through damper adjustment . Dampers PLC controlled.Thermocouples in oven chambers measure crown & sole temperature continuously and give feedback though PLC for damperopening/closing. Electro-hydraulic regulating valves are used for branch headers suction control . Flue tunnels are equipped withgate valves for suction adjustment. This automatic arrangement helped in improving working efficiency of the plant and reduced laborcost.

Superior coke quality:

Compared to slot ovens, coke from HR ovens differ in quality: Generally for similar blend , Micum strength (fig-4) & CSR are higherfor HR coke. Comparative study of M40 and coke size (table-2) of heat recovery coke from Haldia, top & stamp charge coke of TataSteel, Jamshedpur plant confirms the same ( stamp charge cokemaking uses a much leaner blend than HR cokemaking) . Theimproved strength parameters are ascribed to mainly slow heating rate, higher temperature and longer soak time. The slow heatingimproves coke strength in the following way:

Low coking rate would lower swelling of coal, mitigating transmission of intergranular pressure on the semi coke layer, therebycontrolling the formation of minor lateral micro fissures. Then at later stage of carbonization, it would help lower the temperaturegradient in the post plastic temperature zone, thereby controlling development of major fissures. This would result in improvement inimpact resistance coke properties and improve coke size. Low coking rate would also provide longer time for structural orderingallowing anisotropy to appear at lower carbonization temperature which would imply better wetting, bonding, inter and intra particleinteraction and subsequently development of thicker cell wall.

Part_II | pg-28


IMPACT OF HALDIA COKE ON BLAST FURNACE:

The presence of higher pyrolytic carbon in HR coke indicate that the volatiles escaping from plastic layer, passing through a thick bedof semi coke/coke of higher temp., possibly provide nuclei for carbon deposition. This helps improving CSR.

Also, the carbon form is also different. We can see more acicular and ribbon carbon forms in HR coke rather than isotropic andcircular carbon form in the slot oven coke. This gives lower reactivity of coke ( higher CSR) made through HR cokemaking. HigherCSR values coupled with higher M40 , arising out of slower heating , and bigger coke size makes this coke highly preferable fromuser ( blast furnace) point of view.

USE OF HR COKE IN BLAST FURNACES :

HR coke is being used partially and fully in many blast furnacesaround the world and fully in a few furnaces.( fig-5) The usageof this coke varies from 20 to 100% in furnaces.

Though its use in Indian Blast Furnaces is less so far, JSWsteels' #1 Blast Furnace is the first one to use 100% HR coke.H BF of Tata Steel is also going to use 100% HR coke as itsfuel.

Due to ramping up of Haldia plant , H blast furnace of Tata Steelwas constrained to use a maximum of 80% HR coke Theperformance of the furnace so far is excellent and is expectedto go up further with use of 100% Haldia coke.

CONCLUSION:

Blast Furnace / BOF route will continue to predominate the global crude steel production scene. Metallurgical coke, one of the keyinputs in an integrated Steel Works, both qualitatively and quantitatively, will be critical to sustained growth of steel industry. Lowercost, superior quality & less environmental impact will be the key factors in deciding choice of cokemaking technology in future. HeatRecovery technology fulfills all the above criteria and becomes technology by choice of future.

Reference:

1) Transition of Ispat Inlands #7 BF from conventional to heat recovery coke by E Knorr et al, ECIC Paris 2000.

2) Experience with Heat recovery coke use at Ispat Inlands #7 BF-M Dutler et al 2001 Iron making conf proceeding.

3) Quality of coke vis-a vis BF operation-Alka U. Bhaita & Ashok Kumar, One day course on cokemaking at Tata Steel, 2004

4) Coke production utilizing HR technology-Dr H.S.Valia, 4th Mcmaster cokemaking course

5) Heat Recovery coke ovens-Technology for the future-B. K.Singh, Course on HR cokemaking , 2006

6) Heat recovery coke oven design & operating principle-S K Haldar, Course on HR cokemaking ,2006


Part_II | pg-29

An Overview of Eco-Friendly Technology in Iron & Steel IndustriesS.K. Naskar1, Kumud Ranjan2, P.K. Paul3, K.K. Mehrotra4

Introduction

India has a long experience in iron and steel production and was one of the cheapest steel producers till mid of twentieth century. Withthe availability of significant quantity of Iron ore, limestone, non-coking coal and cheap labour, the country has the potential tobecome one of the major steel producers in the world.

India has increased their production of steel from 1.5 million tonne steel in early 50's to about 54 million tonne in 2007-08. Productionof steel is energy intensive in nature. The share of energy cost in total production cost of steel is very high particularly in Indian steelplants. The main source of energy items in steel plant are coking coal, non coking coal, electricity, etc. The Indian steel sector isstriving for state-of-the-art technology in production of quality steel with improved specific energy consumption and thereby reducedenvironmental degradation.

The current CO2 emission from Indian integrated steel plant is around 2,300 - 3,000 kg /tonne of crude steel and specific energyconsumption is around 7.0 Gcal/tonne of crude steel while the same for developed countries like Japan, USA, Germany, etc. are atthe level of 1,500 - 2,000 kg/t of steel and about 5.0 Gcal/t of crude steel. As such adoption of environment-friendly technologies arenot only relevant but necessary to energy saving with respect to global warning.

1. Design Engineer2. Sr. Manager3. Dy. General Manager4. General Manager, MECON Limited

Part_II | pg-30


Since the emergence of the Kyoto Protocol on reduction of green house gases, it has generated enormous opportunities for iron &steel projects in developing nations to reduce the carbon dioxide emission intensity per unit product by incorporating energy efficienttechnologies, which are already in operating condition in developed nations. After power and transport sector, steel sector comes to3rd rank in generation of Green House Gases (GHGS) in India.

The world commission on Environment and Development (Brundland Commission) defined sustainable development as "Developmentthat meet the needs of the present without compromising the ability of future generation to meet their own needs."

This paper presents the potential of saving the energy as well as reduction in carbon dioxide emission in the Indian iron and steelindustries by adopting state-of-the-art-technology in various area of iron and steel making. While estimating reduction in CO2emission, a conversion of 1 kWh into 0.9 kg CO2 has been envisaged taking into account that power is met through thermal powerplant.

Coke oven complex

Coke Dry Quenching (CDQ) technology

● CDQ technology consists of shaft like cooling unit, waste heat boiler and gas recycling system.

● The sensible heat of hot coke contains approximately half of the energy input to the coke making process.

● After post carbonisation process, hot coke pushed out from coke oven at 1,0000 C -1,0500C is cooled to about 100 - 2000C.

● Normally, there are two processes by which hot coke is cooled.

❐ Wet quenching

❐ Dry quenching

Wet quenching

In normal practice, the hot coke is water quenched immediately after discharge from coke oven in order to avoid oxidation. Thesensible heat of hot coke is lost to atmosphere and also polluting the environment.

Dry quenching

Dry quenching is generally done by inert circulating gas (i.e., nitrogen gas) in a closed system. The CDQ technology was developedto recover the sensible heat of hot coke as steam for use in the works or for generation of power, whilst not compromising coke yieldand quality.

● About 11 - 12 MW power will be generated from a CDQ plant of cooling capacity of 100 tonne hot coke per hour.

● Energy saving up to 1,700 MJ/t (406.12 Mcal/t) of dry coke is possible.

● There is no coke dust emission. The collected coke dust can further be utilized in their sinter plant as a fuel.

● Emissions into ground water are close to zero.

Flow scheme view of a typical coke dry cooling installation


Part_II | pg-31

Recovery of the sensible heat of Coke Oven By-Product Gas (COG)

● The crude COG entering the ascension pipes above the ovens has a temperature of 800 - 9000 C, which is sufficientlyhigh to allow efficient recovery as steam or via suitable thermal medium heat exchanger.

● The COG sensible heat may be recovered and used for either coal moisture control process (CMCP) or fuel gaspreheating.

● It is estimated that this system can recover up to 300 MJ (71.67 Mcal) of steam per t of dry coke.

Recovery of the sensible heat of Waste Gas

● The temperature of the waste gas is also sufficiently high to allow recovery of waste heat as steam via a suitable heatexchanger.

● This system may allow 100 MJ/t (23.89 Mcal/t) of dry coke to be recovered.

Coal Moisture Control Process (CMCP)

● CMCP is a process to reduce coal moisture from 8 - 12 % to 4 - 6 %, thus providing for reduction in energy consumption,increase in productivity, improvement in coke quality and reduction of environmental emissions.

● According to operational results, the CMCP can reduce energy consumption of the process by 94 - 151 MJ/t (22.46 -36.07 Mcal/t) of dry coke/% moisture.

● The additional energy required to operate the CMCP equates to 64 - 105 MJ/t (15.29 - 25.08 Mcal/t) dry coke/%moisture reduction, depending on the process operated.

● CMCP may not save energy directly, but will lower the specific energy requirement of the coke making process throughproductivity enhancement between 4.5 - 7 %.

Fuel Gas Preheating

Fuel gas preheating can provide savings of the order of 32 MJ/t (7.64 Mcal/t) of dry coke assuming the fuel gas temperature is raisedfrom 200 C to 50-60 0C.

Summary of energy saving technologies/measures in coke making

Technology Energy saving/t of production Reduction in CO2

emission per annum fora million tonne plant, tonne

CDQ plant 1700 MJ (406.12 Mcal) 128,000

Recovery of the sensible heat of coke oven 300 MJ (71.67 Mcal) 22,600by-product gas (COG)

Recovery of the sensible heat of waste gas 100 MJ/t (23.89 Mcal/t) 7,500

Coal moisture control process (CMCP) 94 - 151 MJ/t (22.46 -36.07 Mcal/t) of drycoke/% moisture 9,200

Fuel gas preheating 32 MJ/t (7.64 Mcal/t) 2,400

In non-recovery coke ovens, unlike conventional recovery type coke ovens, all the by-product gas is burnt within the process. Theonly energy recovered from the process is the sensible heat of the waste gases. The ~ 10000C flue gas is put through a waste heatboiler which makes steam for electricity generation. A 1.0 Mt/yr non-recovery coke plant can produce 88 MW and correspondingreduction in CO2 emission per annum is 629,200 tonne.

Sinter plant

Sinter cooler exhaust gas waste heat recovery

● The temperature of sinter entering the crusher at the end of the strand is ~ 500 - 7000C and is transported to the sintercooler where it is air cooled to ~100 - 1500C.

Part_II | pg-32


● Historically, this cooling air used to be discharged directly into the atmosphere, but now it is more common to recover theenergy from it.

● The sensible heat of sinter at the discharge point can vary between 400-850 MJ/t (95.56 - 203.06 Mcal/t).

● The heat recovery is used as a means to reduce directly the fuel rate of the sinter plant by providing preheated (3000 -3500C) combustion air to the ignition hood.

● Preheating of combustion air to the ignition hood from 300C to 3500C, can save 25 % of the normally used mixed gas.

Material segregation charging

● For the sintering process, it is important to control process variables such as pressure drop across the sinter bed, cokebreeze combustion, heat transmission and melting in order to optimize sinter strength and yield.

● Material segregation charging is one process that is used to exert this control and several systems are in operation,incorporating slit and sloping chutes. These systems modify the trajectory of the sinter feed as it is laid down on the strand,depending on particle size, in order to increase the mean particle diameter towards the bottom of the bed to improvepermeability.

● The mean coke diameter to the sinter machine can be optimised, therefore, to increase its distribution towards the top ofthe bed, thereby increasing the temperature in this zone to promote melting.

● Multi-segment gates may also be installed between surge hopper and roll feeder to improve the uniformity of chargingacross the bed. The installation of these systems will provide energy savings both by increasing the permeability of thebed, reducing the electrical requirement of the main exhaust fan, and by improving the yield of the process.

● Actually, energy saving for material segregation charging is of the order of 8 - 12 MJ/t (1.91 - 2.87 Mcal/t) of sinterproduced.

Summary of energy saving technologies/ measures in sinter making

Technology Energy saving/t Reduction in CO2 emissionof production per annum for a million

tonne plant, tonne

Sinter cooler exhaust gas waste heat recovery Temperature of combustionair to the ignition hood canbe raised to 3500C(3.75 Mcal/t) 1200

Material segregation charging 8-12 MJ/t (1.91-2.87 Mcal/t)of sinter produced 750

Pellet plant

● In pelletisation process, ultra iron ore fines and dumped iron ore rejects, which are otherwise waste, are gainfully utilizedafter beneficiation to produce pellets, a feed to blast furnace as iron bearing material. This reduces pollution drastically atmines head.

● In pelletisation process, waste gas coming out from induration furnace is utilised in preheating the feedstock in pelletmachine itself and sensible heat of hot pellets is extracted and utilised in preheated the combustion air in indurationfurnace. Therefore, pelletisation is energy-efficient process with respect to utilization of sensible heat waste gas.

Blast furnace

Although ironmaking accounts for 60 % of total energy consumption, the possibilities for improvement are small owing to quite highefficiency of the-state-of-the-art blast furnace and savings of 0.5 GJ/thm (0.12 Gcal/thm) are typical over the last 30 years. Thesesavings have resulted from improvements in stove and blower operation, injection of auxiliary fuels, controlled use of process steam,improved burden preparation and furnace control, and installation of top gas recovery turbines.


Part_II | pg-33

Heat recovery from waste gas of stoves

● The recovery and use of waste heat from the stove waste gases to preheat either combustion air or gas is now common.Three types of heat exchangers are in use. These are as follows.

i) A plate heat exchanger- a direct counter current air/gas heat exchanger

ii) A rotating wheel heat exchanger - wheel rotates over the waste gas and air stream

iii) A circulating thermal medium

The first two systems are susceptible to gas leaks and are, therefore, not used to preheat fuel gas. The third has theadditional advantage that the heat recovery section and the preheating section can be sited separately, which can beimportant when space is restricted. Typically, an installation will heat the combustion air to about 150 - 2000C for carrying100 kJ/thm (23.89 kcal/thm) into the stoves. Less frequently, the stove fuel gas is also heated.

● The use of recovered heat for preheating the combustion air will, of course, replace part of the stove fuel gas. Blastfurnaces of less than 1000 m3 volume are too small for economical installation of heat recovery unit. However, it ispossible for a single unit to serve more than one BF (in Japan each unit serves, on an average, 1.5 BF).

● Use of waste heat recovery on stoves is widespread in Japan where over 80 % of furnaces are now equipped. It is alsocommon in Europe, but less so in N. America.

Use of Slag for cement

Slag can be used as a replacement for cement clinker in the ratio 1:0.9 and in doing so can save the fuel energy normally requiredto produce the clinker, equivalent to ~ 5GJ/t (1.19 Gcal/t) of clinker. Thus, each tonne of slag used for cement production reduces theenergy demand of the cement process by ~ 4.5 GJ (1.08 GCal), as well as the limestone requirement by ~ 1.4 t.

Top Pressure Recovery Turbines (TRT)

● The present demand of clean technology has necessiated the need of TRT for all blast furnaces of large capacity. It willnot only reduce GHG emission but also boost up the power generation with environmental-friendly technology. The TRTis now being envisaged by various steel makers in India for additional power generation as well as to reduce GHGemission. The advantages are very high compare to the investment and it also contributes to the sustainable developmentof iron and steel industries in India.

● TRT converts residual pressure energy of exhaust gas coming out from BF to mechanical energy and, subsequently, toelectrical energy via a directly driven generator.

● About 20 - 30 % power consumed by BF blowers could be recovered depending on the type and system adopted forTRT.

● TRT is installed prior to septum value to recover energy. It also reduces noise level significantly.

A typical blast furnace equipped with TRT is shown as follows.

Sl. No. Items BSL, SAIL BSSL(Bhushan group)

1. Size of blast furnace, m3 2,365 1,681

2. BF gas flow per TRT, Nm3/h 290,000 258,000

3. Gas top pressure at outlet of wet scrubber, kg/cm2 (g) 1.5 1.5

4. Gas temperature at outlet of wet scrubber, 0C 50 50

5. Gas pressure At outlet of TRT, kg/cm2 (g) 0.1 0.12

6. Power generated from each TRT, MW 6.37 5.1

7. Status Planning Planning

Part_II | pg-34


Advantages of installation of TRT

● No additional fuel consumption is required.

● BF gas can be utilised for further processes as CV is not altered during expansion in a TRT.

● Pollution free and environment friendly.

● Reduce noise pollution.

● Payback period for investment is usually 2-3 yrs.

Blast Furnace Gas Recovery from top charging bins

● BF is fitted with a two- bin charging system, a volume of gas is lost to atmosphere every time the furnace is charged. It ispossible to recover most of this gas and thus saving ~ 35 MJ/thm (8.36 Mcal/thm) energy.

Summary of energy saving technologies/ measures in ironmaking

Technology Energy saving/t Reduction in CO2

of production emission per annum for amillion tonne plant, tonne

Heat recovery from waste gas of stoves 100 kJ/thm 7,500(23.89 kcal/thm)

Top Recovery Turbines (TRT) 20 - 30 kWh/thm 22,500

Use of Slag for cement 4.5 GJ(1.08 Gcal) per t

of slag used

Blast Furnace Gas Recovery from top charging bins 35 MJ/thm 2,630(8.36 Mcal/thm)

Oxygen enrichment of combustion air in stove 50 MJ/thm 3,750(11.94 Mcal/thm)

Steelmaking and casting, and rolling technologiesIn case of HR coils production, thin slab casting technology occupies many advantages like lower investment cost, higher yield, lowerenergy consumption and lower production cost as compared to that of conventional slab caster. In India, thin slab casting technologyhas been adopted by M/s Ispat Industries Limited at their Dolvi works and now, other steel producers like BSL, SAIL and BSSL havealso envisaged thin slab casting route under their modernization/ expansion plan.

In the direct strip casting technology, liquid steel from ladle via tundish is poured into a twin-roll casting barrel to produce solid caststrips which is finally rolled in in-line hot rolling single stand finishing line to make HR coils. This process developed by Nucor Steeland it is named as CASTRIP technology. Another process technology developer, Thyssen Krupp Steel, named this technology asEURO STRIP technology. However, Direct Strip casting technology is still under development with regard to production of qualitysteel and also has limitation on its capacity. A comparison of these technologies with respect to its energy consumption level isfurnished as follows.

Variation inspecif ic energyconsumption, GJ/tonne rolled steel

0 .20

1.08

1.80

Accordingly, there will be substantial reductionin CO2 emission also.


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Indian scenario

In India, after introduction of coke dry quenching technology, top recovery turbine, continuous casting technology in integrated steelplants, the improvement in energy efficiency from 35.58 GJ/t (8.5 GCal/t) of crude steel to 30.35 GJ/t (7.25 GCal/t) of crude steel hasbeen achieved.

Visakhapatnam Steel Plant (VSP), RINL has already set up coke dry quenching facilities. VSP, RINL is also utilising their TRTefficiently by producing on an average of 10 MW per blast furnace. TATA Steel has also introduced the same.

The effectiveness of waste heat recovery system is well appreciated. As a result, this has become an integral part of almost all Indiansinter plants installed in recent times. The sinter plants envisaged under modernization programme of SAIL, RINL and other privatesteel producers have also been foreseen with heat recovery facility.

Most of the Indian blast furnaces are having low top pressure. Therefore, only a few blast furnaces have the potential to extractenergy through TRT. All new large size blast furnaces are coming with TRT facility.

PCI is also recommended in almost all BFs of integrated steel plant to save the energy as well as to reduce CO2 emission.

In case of implementation of modernisation and expansion of Bhilai Steel Plant to about 7.0 Mt/yr crude steel capacity where most ofthe above environment friendly technologies have been considered, energy consumption level will be brought down to ~ 6.0 Gcal/t of crude steel from present around 6.7 Gcal/t of crude steel and accordingly, there will be substantial reduction in CO2 emission.

Conclusion

On introduction of aforesaid environment-friendly technologies not only reduce the CO2 emission from steel industry but also save lotof energy, which in turn, will enhance the profitability of the plant.

References

1. " Energy use in the steel industry" IISI, Committee on technology, published in September 1998

2. "Challenges of fluid system engineering in iron & steel plant under CDM platform", International Seminar on CleanDevelopment Mechanism Opportunities in Iron & Steel Sector, CDM Steel 2006, held in Ranchi, Jharkhand, India

3. www.aist.org

4. www.steeltimes.com

5. www.cea.nic.in

6. www.unfccc.int

7. www.cdm.nic.in

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SVC for Industrial applicationImproving the Power Quality and Productivity in Metal Industry

Rakesh Singh1

1. AREVA T&D India, HVDC & FACTS Group

Current scenario

We are in a world were energy requirement is increasing rapidly, energy prices are going up even faster and CO2 rejects are lessand less accepted (while more and more costly). In this scenario energy quality becomes a must.

AREVA T&D is a solution provider and not single components supplier with a good reputation for high quality and an extensive salesnetwork. With technology and production center based in US /Finland / UK combined with existing AREVA technology and manufacturingcapabilities AREVA T&D has the capability to quickly deploy our manufacturing capacity.

Metals and related Industries - A few facts

Consumption - Worldwide (per annum)

● Steel: 960 million metric tons (2003)

● Aluminium: 21.9 million metric tons (2002)

● Copper: 14.9 million metric tons

● Portland Cement: 87.8 million metric tons (2000)

● Timber: 300 million cubic meter (2001)

Energy Consumption

Electrical Power requirements:

Steel Process : About 750 to 800 kWh/ ton

Melt Shop : About 500 to 550 kWh/ ton

Additional Chemical Energy : Electrical represents 70% to 75%.

Four to five levels of transformations.

Switchgear requirements multiplies at each transformation.


Part_II | pg-37

EAF

Major consumables are Power, Refractory, Electrodes, Oxygen, Lime, Chemicals etc.

Power System and Load

The impact of Dancing Electrodes and Shifting Arc are many :

" Low Power Factor

" Voltage Fluctuations

" Harmonics

" Flicker

" Voltage Unbalance

The Solution : Voltage (var) Compensation systems:

Static Var Compensator (SVC) is the only viable solution. New technologies such as Statcom still has limited applications

Part_II | pg-38


SVC

An SVC deals with reactive power (MVAr). A continuously adjustable impedance from capacitance (+ve: generation) through toinductance (-ve: absorption), SVC can quickly respond to network changes to precisely counterbalance the reactive power variationscaused by a load or a fault.

SVCs are shunt compensation systems. They are independent devices connected at appropriate points on the transmission system.The location of SVC is determined by network studies.

Two markets for SVC

Transmission/Utility


Part_II | pg-39

Distribution / Industrial

Utility SVCs

Reason to use Utility SVCs:

Part_II | pg-40


SVCs dynamically regulate the network by providing or absorbing reactive power. Transmission line capacity is increased.

Industrial SVCs

Reason to use Industrial SVCs

Industrial SVCs are used to improve the output in industrial processes that present a large rapidly fluctuating load, to reduce flickerissues from getting back into the AC network and to enable industrial processes to obtain a grid connection.

Industries concerned:

● Steel Industry

● Arc Furnaces

● Rolling Mills

● Large Pumping Stations

● Mining

● Traction Substations

● Arc Welders

Benefits of SVC

For the Steel Plant

● Increases Steel Production by Stabilizing Voltage and Decreasing Heat Time

● Increases Power Factor

For the Utility System

● Limits Flicker Level

● Limits Harmonic Voltage Distortion

● Limits Voltage Unbalance

SVC Ratings

SVC Sizing Criteria :

● Power factor

● Harmonics

● Flicker


Part_II | pg-41

Static Var Compensation for EAF

Customer benefits

● Economical System design (transformer ratings , etc.)

● Reduced Power losses and enhanced reliability.

● Reduced Tap to Tap timeat least two to three extra heats 12%

● Reduced Electrical Power Consumption20 to 30 kWh/ton

● Reduced Electrode Consumption1 to 1.5 lbs/ton

● Reduced Refractory consumption2 to 2.5 lbs/ ton

Productivity improvement

Return-on-Investment : More active power leads to less tap-to-tap time which, in turn increases steel production

Part_II | pg-42


Productivity improvement example

● Electrical energy 380 kWh / ton / heat

● Heat consists of two charges

● Tap - To - Tap time 53min

● Fault Level at MV bus is 1020MVA

● �Q 33-70Mvar

● �U ~ 6%

Productivity improvement example

● SVC 70Mvar for reactive powercompensation

● EAF power increase


Part_II | pg-43

Savings due the SVC system:

Increased production k• / year

Electrode k• / year

Losses k• / year

Total k• / year

Investment cost of typical 70Mvar SVC is 3 M• including needed civil work

Pay back time of investment: 12 months

Electrical Arc Furnace

Conventional Industrial SVC : Typical Arrangement

Plant supply, e.g. 34.5kV ac

Part_II | pg-44


● Fast Response

● Smooth Output

● No transformer, connect directly to plant supply

● Designed to meet:

❏ Power Factor Limits

◆ 0.95 lagging or better

❏ Harmonics

◆ IEEE Std 519 or equivalent

❏ Voltage Flicker

◆ IEC (Pst, Plt)

❈ Standards becoming more onerous

SVC - Main Components

SVC - For Melting


Part_II | pg-45

Control Network & Interface w/ Customer Network

+200MVAr SVC for Jindal , Raigarh, India

Part_II | pg-46


0/+250MVAr, 34.5kV SVC for Steel Dynamics Inc & American Electric Power, Indiana

Sonasid, Morocco - 30kV, 130MVAr Industrial SVC Arc Furnace Application

Function: Power Factor improvement, Flicker reduction

Benefits : Energy savings, Voltage distortion reduction

Rautaruukki Steel, Finland - 10.5kV, 60MVAr Industrial SVC Rolling Mill Application

Benefit: Increase in productivity

GUEST

GUEST

Organising Committee Multi Disciplinary Centre on Safety, Health & Environment

GUEST

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The Organising Committee

Chairman - Shri Ajit Kumar Tripathy, IAS

Chief Secretary & Chief Development Commissioner, Orissa

Co-Chairman - Dr. Ashok Dalwai, IAS

Commissioner-cum-Secretary, Steel & Mines Dept., Orissa &

Chairman-cum-Managing Director, Orissa Mining Corporation Ltd.

Working Chairman - Shri B. K. Panda,Managing Director, NINL(Ex-CMD, RINL)

Vice Chairman - Shri G. S. Khuntia,Director, OMC Ltd.(Ex-ED, SAIL)

Convener - Shri G. D. Rath,Secretary, MDC on SHE

Members - Shri Tarun Kanti Mishra, IASDevelopment Commissioner and Addl. Chief Secretary, OrissaChairman, State Pollution Control Board, Orissa

Dr. Ashok Dalwai, IAS

Commissioner-cum-Secretary, Steel & Mines & Industries Dept., Orissa

Shri Aditya Prasad Padhi, IASCommissioner-cum-Secretary, Home Dept., Orissa

Shri Jagar Singh, IASCommissioner-cum-Secretary, Labour & Employment Dept., Orissa

Shri G. OjhaDirector (PI & Raw Material),SAIL, New Delhi

Shri Rajesh Kumar JhaExecutive Director, Jindal Steel & Power Ltd., Angul

Shri B.K. SinghVice President, Orissa Projects, TATA Steel Ltd.

Shri Vivekananda BiswalOrissa Power Generation Corporation Ltd., Bhubaneswar

Shir S. K. MishraDirector of Factories and Boilers, Orissa

Dr. C. R. Mohapatra, IFS (Retd)Vice President, MDC on SHE

Shri G. UpadhyayaEx-CMD, NALCO & Ex-Director I /C, SAIL

Shri S. N. PadhiDirector, OMC Ltd.

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Editorial Board

Chairman - Dr. Ashok Dalwai, IASCommissioner-cum-Secretary, Steel & Mines Dept., Orissa &Chairman, OMC Ltd.

Convener - Shri G. D. RathSecretary, MDC on SHE

Member - Shri B. K. PandaManaging Director, NINL, Duburi, Jajpur

Member - Shri G. S. KhuntiaDirector, OMC Ltd. (Former ED, SAIL)

Member - Shri Rajesh Kumar JhaExecutive Director, Jindal Steel & Power Ltd., Angul

Member - Shri Ajay Pal SinghGeneral Manager, Jindal Steel and Power Ltd., Angul

Finance Committee

Chairman - Shri B. K. SinghVice President, TATA Steel Ltd., Orissa Projects

Convener - Shri G. D. RathSecretary, MDC on SHE


Member - Shri Siddhanta Das, IFSMember Secretary, State Pollution Control Board, Orissa

Member - Shri S. K. MishraDirector of Factories and Boilers, Orissa

Member - Shri S. SahuDirector of Mines, Govt. of Orissa

Member - Shri G. S. KhuntiaDirector, OMC Ltd. (Former ED, SAIL) & Vice President, MDC on SHE

Equipment & Exhibition Committee

Chairman - Shri B. K. PandaManaging Director, NINL, Duburi, Jajpur

Member - Shri G. D. RathSecretary, MDC on SHE

Member - Shri B. K. SinghVice President, TATA Steel Ltd.

Member - Shri Rajesh Kumar JhaExecutive Director, Jindal Steel and Power Ltd., Angul

Member - Shri Rajesh ChintakChief Residence Executive, TATA Steel Ltd.

Member - Shri Amit Kumar ChatterjeeChief Electrical Maintenance, Orissa Project, TATA Steel Ltd.

Member - Shri B.N. PalaiGeneral Manager, IPICOL

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Hospitality Committee

Chairman - Shri Siddhanta Das, IFSMember Secretary, State Pollution Control Board, Orissa



Member - Shri B. K. SinghVice President, TATA Steel Ltd., Orissa Projects

Member - Shri Rajesh Kumar JhaExecutive Director, Jindal Steel and Power Ltd., Angul


Member - Shri S. K. MishraDirector of Factories and Boilers, Orissa

Member - Shri S. SahuDirector of Mines, Govt. of Orissa

Member - Shri G. S. KhuntiaDirector, OMC Ltd. (Former ED, SAIL)Vice President, MDC on SHE

Member - Dr. A. K. SwarSr. Env. Engineer, State Pollution Control Board, Orissa

Member - Shri Sanjib KothariGM, Jindal Steel & Power Ltd.

Event & Media Management Committee

Chairman - Shri B. K. PandaManaging Director, NINL, Duburi, Jajpur



Member - Shri B. N. PalaiGeneral Manager, IPICOL

Member - Shri Ajay Pal SinghGeneral Manager, Jindal Steel and Power Ltd., Angul

Member - Shri Vikas AgarwalAsst. Manager, Jindal Steel and Power Ltd., Angul

Member - Shri Mohit DasChief of Corporate Communication, TATA Steel Ltd.

Member - Shri Abhijit A. NanotiHead Projects (Sinter & Pellet)2B Fortune Towers, Chandrasekharpur, Bhubaneswar

Member - Shri Sanjay RaichHead, Electrical, Orissa Project, TATA Steel Ltd.

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Multi Disciplinary Centre on Safety, Health & Environment – A Birds Eye View

INTRODUCTION

The MDC on SHE created and sponsored by the Govt. of Orissa wasregistered as an autonomous Institute under the Society Registration Act –1860 on 01.02.1994 at Bhubaneswar, Orissa, India.

VISION

To provide professional expertise in the field of Safety, Health &Environment, Pollution Control, Technological Disaster Management,Chemical Accidents, Hazardous Substance Management, Bio-Medical WasteManagement and all such issues to all Stakeholders including the Factories, Mines, Administration, Regulating Agencies, NGOs andSimilar Other Organizations.

AIM

To create awareness among the employees, employers, administrators, opinion Makers, NGOs and Students in the field ofSafety, Health and Environment, Technological Disaster Management, Hazardous Substance Management, Chemical AccidentManagement etc. through education, training, seminar, workshop and action oriented programmes.

OBJECTIVES- Impart education and training on a continuous basis in the fields of safety, health and environment to the industrial

workers, supervisors, managers & trade union leaders.

- To act as a R&D Centre

- To develop an industrial hygiene laboratory.

- To develop an updated library

- To serve as a Think Tank and

- To promote a modern training centre for the benefit of all concerned.

ISSUES ADDRESSED

- Industrial Safety

- Occupational Health

- Pollution Control

- Working Environment

- Energy Management

- Technological Disaster Management

- First Aid

- Hazardous Substance Management (MoEF, GOI Programme)

- Municipal Solid Waste Management (MoEF, GOI Programme)

- Plastic management (MoEF, GOI Programme)

- Lead Acid Battery Management (MoEF, GOI Programme)

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- Biomedical Waste Management (MoEF, GOI Programme)

- Prevention and Management of Chemical Accidents (MoEF, GOI Programme)

- Quantitative and Qualitative Risk Assessment in Process Industries

- Humanizing Work Environment for Creating a Positive Safety and Health Culture in Industries

- Safety Appreciation for Safety Committee Members of the Industries

- Industrial Relations and Industrial Safety Scenario in Orissa

LONG TERM GOALS

- Conduct regular Diploma / Degree courses on Industrial Safety & Environment Management and Occupational Health.

- Regular Training to the Supervisors of the Factories and Mines covered under the Factory Act, 1948 and Mines Act,1952.

- Regular Training to the Industrial Manager, Officers of the District Administration, Regulating Agencies in the field ofSafety, Health, Environment, Chemical Hazards etc.

- Develop Equipment testing & Certification facilities.

- Develop Mobile Occupational Health Check-up & monitoring facilities.

- Develop referral occupational health centre for specialized treatment of occupational diseases etc. on contemporarysubjects.

- Establishment of Emergency Response Centre.

FINANCE

- MDC on SHE is not a profit making organization and not in receipt of regular grants from any source.

- It’s finance is met from the surplus generated from different programmes carried out from time to time.

- It’s accounts are audited regularly by the Charted Accountant appointed by the Executive Committee.

MANAGEMENT

- The programmes and activities of the MDC on SHE are carried out by an Executive Committee headed by the ChiefSecretary, Orissa as it’s President and Principal Secretary, Labour and Employment, Secretary, Industries, Secretary,Health, Secretary, Forest & Environment, Chairman, OMC, Chairman, SPCB, Director of Factories and Boilers, LabourCommissioner, Transport Commissioner are prominent ex-officio members.

- The Executive Committee has also representation from prominent industries and Central Trade Union Organizations.

- The founding members of the MDC on SHE are the Life Time Members.

- State Labour and Employment Department is the Administrative Department.

ACHIEVEMENT

NO. OF SEMINAR/WORKSHOPS ORGANISED:-

National Level : 11

State Level : 09

Regional/Divisional Level : 42

NO. OF TRAINING CONDUCTED:-

First Aid Training to Industrial Employees : 68 Batches

Training on Home Safety & Home Health to House Wives : 10 Batches

Training on First Aid to School Students : 02 Batches

Training on First Aid to College Students : 05 Batches

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INFRASTRUCTURE

- The Institute Building with a built up area of 10,000 (ten thousand)Sq.ft. has Conference Hall, Training Halls, Board Room, InformationCentre (Library), OHS (Occupational Health Service) Centre andAdministrative Departments including the Offices of it’s President, VicePresident and Secretary.

- The Hostel named as Neelachal Bhawan with a built up area of 7,500(seven thousand f i ve hundred) Sq. f t . has the prov is ion o faccommodating the visiting faculty and the participants of short termprogrammes, catering facility and has also the provision of housingthe proposed ERC.

- The Industrial Museum is in the office.

SPECIALISATION

- Conducting First Aid Training for the employees of Factories and Minesa t t h ree l eve l i . e . Bas i c , Re f reshe r and Advanced .(The certificates issued to successful participants are recognized underthe Factory Act, 1948 and Mines Act, 1952)

- Preparation of Off-site Emergency Plan.

ANNOUNCEMENT

I . With the Resource Support from MoEF, Govt. of India, State Govt., Orissa and Industries, the Emergency ResponseCentre at MDC on SHE will be a reality soon.

II. Post Diploma Course in Industrial Safety from the academic year 2009-10.

international convention on clean, green & sustainable

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