GREEN STEEL & ITS PRODUCTION

TECHNOLOGIES

PRESENTED BY:
ADITYA SHANKAR ROUTRAY
ROLL NO-26614
REGD NO-0701105140

1 Metallurgical & Materials Engg. Dept.

 INTRODUCTION
WHAT IS “GREEN”
Leaving minimal carbon footprint ,or minimal CO2
emission during production and processing.
 SUTAINABLE
Minimum usage for the present generation ,leaving a
lot of earth’s resources for the future

2 Metallurgical & Materials Engg. Dept.

 ESSENTIAL ROLE OF STEEL
Use Shift – Replaces a current application that uses steel with another
technology that uses steel and serves the same purpose but is less GHG
intensive.
For example : Wind generated power, rail travel
Material Shift – Substitutes steel for other material that have higher energy
requirements or otherwise produce higher GHGs
For example: Steel in buildings, replacing timber, Packaging
New Steel Shift – Replaces traditional steel with new grades of steel that
are stronger , lighter and more durable , thus lowering total emissions
For example : Advanced steel rather than mild steel, vehicles,bridge
New production technologies: So ,in order to produce steel we need newer
and better technologies which can reduce the GHG emissions and also
other environmental issues. Thus , steel is the solution to global warming
and environment sustainability.

3 Metallurgical & Materials Engg. Dept.

 NEED FOR NEWER
TECHNOLOGIES
WHY STEEL INDUSTRY NEEDS A NEW
TECHNOLOGY
Fresh sources of raw materials like iron ore and coal,
especially of high quality , are dying up.
Pressure is building up for the use of low grade iron
ore, or fines, and coal , which traditional technology
doesn’t use.
The traditional blast furnace route ranks high in
pollution . New technologies promoted as
environment friendly.
Focus on technologies that need less land to
4 implement.
Metallurgical & Materials Engg. Dept.
 HOW THE NEW TECHNOLOGIES FARE BETTER
Use of ore fines , while blast furnaces use only lumps.
India has hundreds of million tones of fines lying
unused.
If left unused, fines can be environmentally harmful.
Thus the new technologies also help use them.
Plants using the new technology need less land; as
much as one-third of the land needed for a blast
furnace-based plant.
The average cost of setting up a steel plant comes
down to Rs.1,000 crore a tone from Rs. 4,500 crore a
tone.
5 Metallurgical & Materials Engg. Dept.
 THE WEAK LINK
Large capacity plants ,like those more than 5 million
tones per year capacity , can’t be set up using the new
technologies,
Tests are yet to be conducted to check if the new
technologies suit the iron ore and coal found in india.

6 Metallurgical & Materials Engg. Dept.

 FINEX PROCESS
The FINEX process is an innovative, next generation iron
making technology developed by Siemens VAI and POSCO.
Molten iron is produced directly using iron ore fines and non-
coking coal rather than processing through sintering and coke
making which had been essential to traditional blast furnace
methods. Because the preliminary processing of raw materials is
eliminated, the construction of the FINEX plant costs less to
build than a blast furnace facility of the same scale. Furthermore,
a 10-15% reduction in production costs is expected through
cheaper raw materials, reduction of facility cost, pollutant
exhaustion, maintenance staff and production time. In addition, it
is eco-friendly in that it produces less pollutants such as SOx,
NOx, and carbon dioxide than traditional methods.

7 Metallurgical & Materials Engg. Dept.

 COMPARISION

8 Metallurgical & Materials Engg. Dept.

 PROCESS

9 Metallurgical & Materials Engg. Dept.

 PROCESS EMISSION

10 Metallurgical & Materials Engg. Dept.

 ADVANTAGES
Flexibility in Raw Materials
Elimination of sintering and coke-making processes.
No blending of ore and coal.
Use of Low-grade ore and low-ranked coal.
 
Easy and Flexible Operation
Independent control of reduction and melting processes
Easy and hassel-free operational control.
 
Environmentally Friendliness
Far less emission of SOx ,NOx and dust
Applicability to the CO2 sequestration
Cost competitiveness
Lower cost in both capital investment and operation vs. BF
 

11 Metallurgical & Materials Engg. Dept.

 PILOT PLANT

12 Metallurgical & Materials Engg. Dept.

 FUTURE DEVELOPMENTS
Co2 absorption using ammonia solution &
sequestration ocean gas field.

Iron ore reduction of Finex using hydrogen enriched

Syngas.

13 Metallurgical & Materials Engg. Dept.

 ITMK3 PROCESS
ITmk3 stands for iron making technology mark three. It
represents the third generation of iron making , with the
first generation being the Blast furnace and second being
gas-based direct reduction. ITmk3 uses iron ore fines and
non-coking coal to produce a premium quality pig iron
product, thus avoiding the need for oxide pellets or sinter
or coke.

14 Metallurgical & Materials Engg. Dept.

 Why ITmk3
It uses iron ore fines, either magnetite or hematite , non coking coal. It
can be used to produce a high quality pig iron from lower grade iron
ores ,and thus is ideal for adding value to marginal iron ore reserves.
ITmk3 typically uses iron ore fines and non coking coal, thus
avoiding the need for iron oxides pellets or sinter and metallurgical
coal.
Owners of small mines can extend the lives of their properties and
add value to lower-grade ore resourses. Steelmakers can either
purchase ITmk3 nuggets or invest in production facilities in return for
guaranteed product offtake. 
ITmk3 has environmental benefits , including considerably lower
emissions of CO2 , SO2, NOx and other constituents than blast
furnace and avoids problems of coke ovens and sinter plants.

15 Metallurgical & Materials Engg. Dept.

 RHF CONCEPT
The hearth is generally a large turntable that rotates
within a toroidal enclosure. The feed pellets
(composite agglomerates made from iron oxide and a
carbon source) are charged to the hearth , one or two
layers deep, and as they move on the hearth, are heated
by burners firing above the hearth and combustion of
gases liberated from the pellets. One revolution of the
hearth takes approximately 10 minutes. In ITmk3 , the
pellets are melted in the last zone of the hearth to
produce a premium quality pig iron product with a slag
by-product

16 Metallurgical & Materials Engg. Dept.

 RHF

17 Metallurgical & Materials Engg. Dept.

 PROCESS

18 Metallurgical & Materials Engg. Dept.

19 Metallurgical & Materials Engg. Dept.
20 Metallurgical & Materials Engg. Dept.
 FEATURES
The one step process produces iron nuggets in a very
short time– reduction , melting and slag removal are
completed in only about 10 minutes.
The process is flexible as far as the type of iron ore
that can be used . Magnetite , hematite as well as
pellets made from taconite have been processed.
The process emits at least 20 % less CO2 than that
emitted by blast furnace. Since it doesn’t require either
coke ovens or sintering plants, there would be less
NOx, SOx.

21 Metallurgical & Materials Engg. Dept.

22 Metallurgical & Materials Engg. Dept.
 Product Iron nuggets

23 Metallurgical & Materials Engg. Dept.

 ADVANTAGES
Reduction and slag separation occur within one step
Super-heated temperatures are not needed
There is no FeO attack to the refractory
Slag is cleanly separated from the metal
Fine ore and low grade ore can be used

24 Metallurgical & Materials Engg. Dept.

 CONCLUSION
Thus these two processes as promised can change the
iron making scenario altogether. And these can reduce
GHG emissions and also eliminate other problems of
existing ironmaking.
But , we have to see its effectiveness in Indian conditions
and on Indian iron ore and coal.

25 Metallurgical & Materials Engg. Dept.

 REFERENCES
www.forbesindia.com
www.industry.seimens.com
www.posco.com
www.kobesteel.com
www.midrex.com
Hot Metal Production by Smelting reduction Of iron
Oxide by Amit Chaterjee
Sponge Iron Production by Direct reduction of Iron
Oxide by Amit Chaterjee

26 Metallurgical & Materials Engg. Dept.

27 Metallurgical & Materials Engg. Dept.
28 Metallurgical & Materials Engg. Dept.