STEELMAKING THROUGH EAF ROUTE

AND ITS EFFECT ON ENVIRONMENT

BY
DURBA TALUKDAR & SOMNATH GUPTA

M.N.DASTUR & COMPANY (P) LTD,

KOLKATA

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23rd -24th MARCH 2012
 CO2 EMISSIONS BY GLOBAL STEEL INDUSTRY

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 ENERGY INTENSITY OF STEEL INDUSTRY

7
Energy Intensity, Gcal/tcs 6
5
4

India

S. Korea
World-avg

Japan
3
2
1
0

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 SPECIFIC ENERGY CONSUMPTION (Unit : GCal/TCS)

Plant 2007-08 2008-09 2009-10 2010-11

(Apr – Dec 2010)
SAIL 6.95 6.74 6.72 6.82
BSP 6.72 6.5 6.56 6.66
DSP 6.94 6.5 6.55 6.78
RSP 7.39 7.09 6.97 6.89
BSL 6.89 6.83 6.74 6.88

ISP 8.14 8.18 8.18 8.23

RINL 6.21 6.54 6.09 6.18

(GCal/TLS)

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 SPECIFIC ENERGY CONSUMPTION(Unit : GCal/TCS)
(Continued)
Plant 2007-08 2008-09 2009-10 2010-11
(Apr – Dec 2012)
TaTa Steel 6.555 6.587 6.173 NA
(Apr-Dec 2009)

JSW Steel 6.847 6.704 6.495 6.31

JSPL 7.68 7.25 7.14 6.98

Essar Steel 5.99 5.81 NA NA

IIL 5.73 5.42** 5.46 Merged with

(Apr-Sept 2009) JSW
Source: 1. Sail News – February – June 2010
2. Annual report 2010-11, Ministry of Steel, Govt. of India
Note: **BF and Sinter Plant were under capital repair for approx 6 months.
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 STEEL PRODUCTION THROUGH ELECTRIC
FURNACES IN INDIA

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Total Crude 27.291 28.814 31.779 32.626 45.780 49.450 53.468 57.791 63.527 68.321
Steel Production
(Million tons)

Production 9.980 10.850 12.680 14.300 24.780 27.650 31.300 34.800 36.200 41.300
Of Crude
Steel in Electric
Furnaces
(Million tons)

% of Steel 36.5 37.7 39.9 43.8 54.1 55.9 58.5 60.2 57.0 60.4
Production in
Electric Furnaces

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 MAJOR WASTE GENERATED FROM EAF

• Solid waste
 Slag
 Dust
 Sludge
 Refractory debris
 Skull

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 MAJOR WASTE GENERATED FROM EAF ( Continued)

• Gaseous waste
 Carbon-monoxide
 Carbon-dioxide
 Sulphur-dioxide
 Oxides of Nitrogen
 Particulate matter
• Liquid waste
 Polluted water

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 EAF SLAG

• COMPOSITION
 Main constituent – Calcium Oxide and Iron
 Other minor constituents - Magnesium, Manganese, Silicon, Aluminium

• APPLICATION
 Land Filling
 Road Construction
 Aggregate for concrete
 Clinker Kilns as a replacement for mined limestone
 Reuse in internal processes
 Soil conditioner
 Making prefabricated shapes for sewerage
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 EAF DUST

• COMPOSITION
 Main constituent – Iron
 Other constituents – Zinc in the form of oxide/sulphide/chloride
Lead as oxide, Cadmium, other metals, halides
and fluxes
• Treatment
 Recycling back into the furnace
 High temperature metal recovery processes
 Hydrometallurgical and pyro-metallurgical processes

• APPLICATION
 Reuse in EAF
 Landfilling
 Extraction of Zinc
 Use in rotary hearth furnace

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 GASEOUS EMISSIONS

• Harmful Substances
Oxides of carbon
 Oxides of nitrogen
 Oxides of sulphur
 Cyanides
 Fluorides
• Measures adopted
 Improved Fume extraction system and control
technologies
 Furnace off gas analysis system

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 DEVELOPMENTS IN EAF PROCESS ROUTE

• Development of Shaft Furnace, Consteel

Process and other processes

• The processes developed lead to :

 Lower noise level
 Lower dust content in off gases
 Reduced off-gas volume
 Full heat incineration of carbon-monoxide

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 TECHNOLOGICAL DEVELOPMENTS IN EAF

Period Technological Tap-to-Tap Electricity Electrode

Development Time Consumption Consumption
(kWh/t) (kg/t)
1965-70 Oxygen lancing 180 630 6.5
1970-80 -Water cooled panels 105 490 3.5
-High power operation
(UHP)
1980-85 - Ladle furnace 80 450 2.5
- Foamy slag
- Eccentric bottom tapping
- Scrap pre-heating
1985-95 -Oxygen carbon injecton 60 410 2.0
( lance manipulator)
- Pneumatic bath stirring
1995-2005 -Oxygen carbon/oxyfuel 55 250-300 1.6
side wall injection
-Use of hot metal as charge
material

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 TECHNOLOGICAL DEVELOPMENTS IN EAF
(Continued)

• The technological developments lead to :

 Reduced energy consumption
 Resource savings
 Reduction of carbon footprints
 Cost savings

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 THANK YOU

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