essar hbi, dri plants

Essar Steel LimitedEssar Steel Limited

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Clean Steel Making Initiatives Clean Steel Making Initiatives in in

DRI / EAF processDRI / EAF processatat

Essar Steel Limited, IndiaEssar Steel Limited, India

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Essar Steel Complex at Hazira

Close to major steel consumersAt the landfall point of natural gasAll power supply located close to operations of steel complex

Pellet Plant at Visakhapatnam

Port based plant with dedicated pellet handling facilitiesClose to one of the richest iron ore content mines

Largest concentration of steel users in India

●New Delhi

●Visakhapatanam

Hazira●Jamnagar●

●KirandulMumbai●

H Y-G RADE PEL LE TS LIM IT EDSlurry p ipe l ine rou teBa iladila

B oost er St n.

V alve st n .

Slack Flo w Stn .

100 km434 m

113 km496 m

205km91 m

267km0mts

0 km613 m

Slack Flow Stn.

180km696 m

Ben eficia t ionPlant

Ma in Pum ping

Stat ion

W ater L ine

W ater Pumping

Stat ion

Pellet p lan t

R ly L ine

Essar Steel LimitedEssar Steel LimitedStrategically Located Asset Base

Essar Steel LimitedEssar Steel LimitedContentContent

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• Existing Plant – Process Flow

• Existing Plant – Initiatives

• Future Plant – Process Flow

• Future Plant – Initiatives

Essar Steel Limited (4.6 MTPA)Essar Steel Limited (4.6 MTPA)Material Flow ChartMaterial Flow Chart

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Essar Steel LimitedEssar Steel LimitedRaw MaterialRaw Material

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• Mining - Iron ore: Bailadila, India

• Pelletization - Iron fines: Vishakhapatnam, India

• Iron ore mix– Calibrated lump ore (10% - 20%)– Pellets (80% - 90%)

• Iron content: 66%

Essar Steel LimitedEssar Steel LimitedHBI PlantHBI Plant

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• 5 Modules of capacity 5.5 MTPA

• Input– Pellets + Ore: 1.5 Ton / Ton– Natural Gas: 285 Nm3 / Ton– Calorific value: 8700 to 8800 Kcal / Nm3

• Output– Cold HBI: 40%– Hot DRI: 60%

Essar Steel LimitedEssar Steel LimitedHBI Plant HBI Plant -- Process FlowProcess Flow

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FEED ENRICHMENT REFORMEDOXYGEN N.G. G A S BASIS: PRODUCTION RATE 100 tph

INJECTION TYPICAL METALLISATION 93%BUSTLE CARBON CONTENT 1.20%

G A S FLUEG A S

T O PG A S

MAIN A IR

FLUEGASTOTHEVENT

CARBU.N.G.

NATURAL GAS

HOT INPUTD IS C H A R G E

B O T T O M P R O C E S S T O P PROCESS FLUES E A L G A S G A S PROCESS NATURAL FEED GASG A S F UE L GAS GAS GAS

MIDREX-HBI PROCESS FLOW DIAGRAM

COLD HBI HOT

DRI

Essar Steel LimitedEssar Steel LimitedElectric Arc FurnaceElectric Arc Furnace

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• 4 DC Electric Arc furnaces

• Capacity: 150 Tons per heat (each furnace)

• Input (175 Tons)– Metallic: HBI (36%), Hot DRI (60%), Scrap (4%)– Fluxes: Lime, Dolime– Electrical Energy: ~ 515 KWH per Ton

• Tap to tap time = 60 minutes

Essar Steel LimitedEssar Steel LimitedSteel Making Plant Steel Making Plant -- Process FlowProcess Flow

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DCDC-- ULTRA HIGH POWER EAFULTRA HIGH POWER EAF

•WATER COOLED PANEL

•SIDE & BOTTOMREFRACTORY

•GRAPHITE ELECTRODE

•WATER COOLEDROOF

• ROOF CENTRE •FUMES

•CARBON INJECTOR

• OXYGENINJECTOR

•FOAMY SLAG

•CO BUBBLES•EBT•BOTTOM

ELECTRODE

•FUMES EXTRACTIONSYSTEMS

Clean Development MechanismClean Development Mechanism

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Environment: A key Driver

Joseph Priestly, 1771 Essar Steel, 2008

Clean Development MechanismClean Development Mechanism

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• “The Kyoto Protocol to the convention on Climate Change” has developed a Clean Development Mechanism (CDM)

• Facilitates developing countries to trade Certified Emission Reduction (CER) with the developed countries w.e.f. 16th Feb. 2005

• CER corresponds to the extent of reduction in emission of six Green House Gases (GHG) mainly carbon dioxide and methane

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1. Hot Direct Reduced Iron

2. Power generation from SMP flue gases

3. 19 MW HBI power plant

4. Digitized walking beam type reheating furnace

5. Installation of Top Burners, Sinter Plant

Existing Plant Existing Plant -- CDM ProjectsCDM Projects

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• Collection and transportation done by specially designed containers

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsHot Direct Reduced IronHot Direct Reduced Iron

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• Capacity of Vessel: 90 Ton

• Hot DRI Temperature: 675 oC

• Vessel Travel distance: 1 Km

• Designed in-house (patented)

• Charged through EAF top

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsHot Direct Reduced IronHot Direct Reduced Iron ……cont.cont.

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• Introduce the Hot DRI along with hot briquetted iron into the electric arc furnace

• Energy saving upto 100 KWH / Ton liquid steel

• Reduced emission by saving electrical energy

• CO2 Reduction = 237,683 CER per annum

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsHot Direct Reduced IronHot Direct Reduced Iron ……cont.cont.

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• Project is expected to fetch financial benefit to the company

• Project is being pursued in consultation with M/s Ernest & Young

• Project Methodology has been successfully submitted to UNFCCC

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsHot Direct Reduced IronHot Direct Reduced Iron ……cont.cont.

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UNFCCC Website

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsHot Direct Reduced IronHot Direct Reduced Iron ……cont.cont.

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsPower generation from SMP flue gasesPower generation from SMP flue gases

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• Initial proposal has been received from Transparent Energy Systems

• Looking for Technology

• CO2 Reduction = 359,345 CER per annum

Existing Plant Existing Plant -- CDM ProjectsCDM Projects19 MW HBI Power plant19 MW HBI Power plant

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• Power generation from HBI module hot gases

• Temperature of Hot gases = 350 to 400 oC

• Contract signed by HBI with ECL and Essar Engineering Centre

• CO2 Reduction = 82,126 CER per annum

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• Digitized walking beam type reheating furnace

• Saving in energy consumption as compared to conventional furnace

• CO2 Reduction = 10,080 CER per annum

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsReheating furnaceReheating furnace

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• Side fired burners are replaced by new energy efficient top burners

• CO2 Reduction = 3,962 CER per annum

• Already implemented

Existing Plant Existing Plant -- CDM ProjectsCDM ProjectsInstallation of Top Burners, Sinter PlantInstallation of Top Burners, Sinter Plant

Future Plant Future Plant -- Essar Steel Hazira LimitedEssar Steel Hazira LimitedProduct Flow ChartProduct Flow Chart

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Corex – 2 Modules 1.74 MTPA

(Hot metal)

Blast Furnace 1.74 MTPA(Hot metal)

Mod VI 1.7 MTPA

(DRI)

SMP 4.63 MTPA (Liquid Steel)

CSP3.55MTPA

Slab Caster1.03 MTPA

Coils Slabs

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1. Use of Hot metal from Corex

2. Use of Corex gas

3. Compact Steel plant (CSP)

4. Top gas pressure Recovery Turbine (TRT) for Blast furnace

5. Blast furnace gas utilization

Future Plant Future Plant -- CDM ProjectsCDM Projects

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Future Plant Future Plant -- CDM ProjectsCDM ProjectsUse of Hot MetalUse of Hot Metal

• Hot metal from COREX to EAF Nos 2 & 3

• Liquid charge : 35%

• Reduction in energy rate: 120-130 KWH/Ton

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• Natural Gas to be replaced by Corex gas

• Energy savings in HBI, Lime plant, Dolime plant and other various projects

• CO2 Reduction = 1,643,137 CER per annum

Future Plant Future Plant -- CDM ProjectsCDM ProjectsUse of Corex gasUse of Corex gas

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• Thin continuous strip to be heated from 900 –950 oC to 1100 oC as against from ambient temperature

• CO2 Reduction = 45,258 CER per annum

Future Plant Future Plant -- CDM ProjectsCDM ProjectsCompact Steel plant Compact Steel plant (CSP)(CSP)

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• Exhaust pressure from blast furnace of steel mill to be utilized to produce power

• CO2 Reduction = 43,224 CER per annum

Future Plant Future Plant -- CDM ProjectsCDM ProjectsTop gas pressure Reduced Turbine (TRT) for Blast furnaceTop gas pressure Reduced Turbine (TRT) for Blast furnace

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• Exhaust heat from the blast furnace of steel mill to be utilized for process heating

• CO2 Reduction = 15,966 CER per annum

Future Plant Future Plant -- CDM ProjectsCDM ProjectsBlast furnace gas utilizationBlast furnace gas utilization

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CO2 Emission Alternative Iron – EAF Route

1922

441

912 991

13201198

1507

1085 1041

1880

1259

0

500

1000

1500

2000

2500B

F-B

OF

100%

Scr

ap

50%

HI C

CD

RI

50%

HB

I

20%

HB

I+30

%P

I

50%

ITM

K3

50%

BF

HM

50%

FA

STI

RO

N

50%

FA

STE

EL

50%

CO

RE

X

50%

HIS

ME

LT

kg C

O2/

t of l

iqui

d st

eel

Thank youThank you

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Essar Steel LimitedEssar Steel LimitedSlurry pipe line routeSlurry pipe line route

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Bailadila

Booster Stn.

Valve stn.

Slack Flow Stn.

100 km434 m

113 km496 m

205km91 m

267km0mts

0 km613 m

Slack Flow Stn.

180km696 m

BeneficiationPlant, Kirandul

Main Pumping

Station

Water Line

Water Pumping

Station

Pellet plant

Rly Line

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