Future Green Steel Manufacturing Relevant to ODISHA SUMMER 2012

2012

Deepak Seemanta Engineering College

4/20/2012

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INDEX

Introduction

PAGE NO.

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Why Green Steel instead of conventional steel ?

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Available Major Sponge Iron Plants in Odisha. 6

Available Major Steel Plants in odisha. 7

Why the Need of New Technology? 8

COREX PROCESS 9

FINEX PROCESS 12

HISMELT PROCESS 15

Future of Odisha in Iron and Steel Industry 17

BIBILOGRAPHY 18

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Introduction: Iron is extremely old and yet very modern. It is perhaps more relevant today that it ever was. The modern world without steel is unthinkable as is steel without iron. In fact the per capita consumption of steel is considered a measure of the affluence of a nation. Although iron is one of the most common elements in the earth’s crust (34.6% by mass, 5% by volume) it is not found there in its elemental form. Iron was known prior to 3000 BC or before recorded history. The first iron implements date from around 3000 BC. The extraction of iron from ores seems to have started in the Near East (Anatolia & Persia) around 2000 BC and by 1000 BC the Iron Age was under way with the smelting of iron ores; it then spread to Europe by 750 BC and reached Spain by 400 BC. Over the same period iron smelting was probably being developed in China. The processes of Iron making rely for their economic success on the availability of cheap natural gas and low priced iron ores and therefore expansion is restricted to particular localities. In this sense Odisha is a state where there is plenty of Iron ores and coal available. Till today INDIA is the LARGEST MANUFACTURE of SPONGE IRON in the whole world. Though it is a developing country we stand ahead as the KING of the steel manufacturing. We are enriched in Iron ore, Coal mines and other resources such as transport facility & human resources in Odisha, which are necessary for the production of Iron and Steel. So in this region the production level is quite so high and it is increasing day by day. Odisha is full of Magnetite (Fe3O4) and Hematite (Fe2O3) in kendujhar, Bolani and Sundargarh region, as well as plenty of coal available in Talcher region. There are many rivers present in this state which is the cheapest water resource available for this type of large industries.

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Why Green Steel ? We know that every step towards the progress also leads to a common problem and that’s POLLUTION. Whatever it may be, when we consider a mass production there arises a problem related to SAFETY of ENVIRONMENT. The Govt. of India has implemented some rules and regulation regarding the pollution control.

1. The Water (Prevention and Control of Pollution ) Act, 1974 2. The Air (Prevention and Control of Pollution ) Act, 1981 3. The Environment (Protection) Act, 1986 4. The Hazardous Waste (Management, Handling, & Trans boundary

Movement) Rules, 2008 and amendments thereafter 5. Manufacture, Storage and Import of Hazardous Chemical Rules,

1989 6. Biomedical (Management & Handling) Rules 1998 7. Chemical Accidents (Emergency Planning, Preparedness and

Response) Rules, 1996 8. The Ozone Depleting Substance (Regulation and Control) Rules,

2000 9. The Batteries (Management and Handling) Rules, 2001 10. Public Liability Insurance Acts, 1991

So in order to facilitate the industry of continuing production without damaging the costly environment we need to find such a process of steel making where there would be less harm to the ecological system. As the name suggests GREEN STEEL PRODUCTION means it is ecofriendly, as well as more economical and sustainable. Today there is a large production of steel throughout the world but the consumption rate is not increasing, so it is creating market instability as the final product sell is not as expected. Now we need to develop such a process which will enable us to produce steel as a lower production cost as well as taking care of post-production and environment issues.

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It has become a regular, to get news of shut down of Iron plants due to poor economy or due to the law of environment protection by the Govt. of India. The small and medium sponge/ steel factory of the state ODISHA are very much affected by such condition.

CONVENTIONAL PROCESS OF STEEL MAKING In the conventional Iron making process the stages are as bellows.

The process starts from finding resources.

We only accept the Ores rejecting the Minerals for economic advantages.

In the crusher the Ore is resized as LUMPS (10mm- 20 mm) or FINES (3mm -10 mm). The size of lumps and fines vary as per requirement. For TATA SPONGE lump= +3mm and Fines = 0-3 mm

These lumps are treated by a vibrating conveyor so that the Soil and other impurities are separated. This conveyor takes the Ores to the Kiln.

In the Kiln the sponge Iron manufacturing involves removal of oxygen from Iron ore. The departing Oxygen Creates micro pores in the ore and make it porous. This is as a sponge like structure when seen through microscope. So it is called sponge Iron.

Then this SPONGE IRON is taken to Blast Furnace or Electric Arc Furnace to produce molten Iron. Here we add other metal like chromium, manganese to obtain specific alloy. Stainless steel alloy contains 11% of chromium, which enable it to resist from roasting.

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REACTIONS IN THE BLAST FURNACE : The carbon initially burns in air to give carbon dioxide and the heat, which is necessary for the process. The carbon dioxide then undergoes an endothermic reaction with more carbon to yield carbon monoxide:

C + O2 → CO2 ΔH = -393 kJ mol-1 C + CO2 → 2CO ΔH = +171 kJ mol-1 The oxide ores are then principally reduced by the carbon monoxide produced in this reaction, the reactions involving very small enthalpy changes:

Fe2O3 + 3CO → 2Fe + 3CO2 ΔH = -22 kJ mol-1

Fe3O4 + 4CO → 3Fe + 4CO2 ΔH = -10 kJ mol-1 CaO + SiO2 = CaSiO3 (Slag Formation)

(Diagram of a conventional Blast Furnace)

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Available Major Sponge Plant in ODISHA

NAME and ADDRESS of the PLANT

CAPACITY of the PLANT In TPD

Sri Metaliks Ltd, Liodapara, Keonjhar

(2x50) TPD (4x100) TPD (1x300) TPD

Deepak Steel & Power Ltd, Topadihi

(2x50) TPD (2x100) TPD

Rungta Mines (Sponge Iron Division)

(5x100) TPD

M/s Tata Sponge Iron Ltd, Bileipada

(1x375) TPD (1x375) TPD (1x500)TPD

MSP Sponge Iron (P) Ltd, Haladiaguna, Keonjhar

(2x40) TPD (2x50) TPD

M/s Arati Steels Ltd, Ghantikhal, Cuttack

(1x500) TPD

M/s Bindal Sponge Ltd, Sunakhani, Talcher, Dist-

(1x300) TPD

Angul Orion Ispat (P) Ltd,

RamChandrapur, Keonjhar (3x100) TPD

Orissa Sponge Iron Ltd, Palasapanga, Keonjhar

(1x350) TPD

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Available Major Steel Plants in Odisha:

Name and Address of the Plant Investment in Crore

Capacity in MTA

M/s Bhushan Power & Steel Ltd. Lapanga, Sambalpur

1650 + 1850 (in 2nd phase)

1.2 + 1.6

M/s Aarti Steels Ltd Ghantikhal, Athagarh,

Cuttack

512 + 374 (in 2nd phase)

0.5 + 0.5

M/s Scaw Industries (P) Ltd Gundichapada, Dhenkanal

310 + 514 0.25 + 0.25

M/s Visa Industries Ltd Jhakhapura, Duburi,

Jajpur

345.78 0.35

M/s Orissa Sponge Iron Ltd. Gurla, Govindpur,

Sambalpur

395 + 642 0.35 + 0.60

M/s Jindal Stainless Ltd. Duburi, Jajpur

1612 + 5016 0.80 + 0.80

M/s Rungta Mines Ltd. Kamando, Sundargarh and

Jharaband, Dhenkanal

2275 1.0 + 1.0

M/s TATA Steel Ltd Kalinganagar Industrial Complex,

Duburi, Jajpur

10400 + 5000 3.0 + 3.0

M/s Sterlite Iron and Steel Company Ltd.

Palasponga, Keonjhar

9782 + 2720 3.4 + 1.7

M/s ESSAR Steel Orissa Ltd. Paradeep

10,721 4

M/s POSCO India (P) Ltd. Paradeep

51,000 12

M/s Bhushan Steel Ltd. Meramundali, Dhenkanal

5828 3

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Why the Need of New Technology? In today’s scenario consumer always want a product which is a result of a new technology. Old technology is not sufficient to meet all the criteria that we must satisfy in those days. Now we need to produce a lot, within a very low time window and we also have to take care of the quality and safety as well as reliability of the product. We have to follow the guidelines of the Industry Dept. regarding pollution and use of resources. We need to stand ahead of this competitive market so that the business life will be longer. So in order to increase the productivity, maintain the supply chain, and to meet all the guidelines we need a developed technology for Iron and Steel manufacturing. Considering the old steel manufacturing plants we need to develop a technique so that the equipment can be upgraded to a newer one with less modification on the entire plant. This will save time as well as money. Ex : DRI – BF – EAF can co-exist. The time has arrived to adopt new techniques in ODISHA, as we can see news of FINE/ BAN/ SEIZE of plants due to the noncompliant of necessary pollution control. New technique will allow the industry to compete in the international market as the production cost will be low. The production rate will increase which will allow the plant to satisfy the demand of customer in a limited time. By the waste energy recovery process we can run several by product plant, which is an extra benefit. New technique enhances safety so the employee can stay secured or we can minimize industrial accident to a maximum level. Today we are having NEW TECHNOLOGY such as COREX, FINEX and HISMELT as a solution to those entire problems stated above.

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COREX PROCESS: Corex is an industrially and commercially proven smelting-reduction process developed by Siemens VAI for the cost-efficient and environmentally friendly production of hot metal from iron ore and coal. In the Corex process, all metallurgical work is carried out in two separate process reactors:

The reduction shaft and

The melter gasifier. Since coking and sintering plants are not required for the Corex process, substantial cost savings of up to 20% can be achieved in the production of hot metal. ENVIRONMENTAL FFEATURE: Regarding environmental concerns, Corex plant emissions contain only insignificant amounts of NOx, SO2, dust, phenols, sulfides and ammonium. Emission values are already far below the maximum values allowed by future European standards. Furthermore, waste-water emissions from the Corex process are far lower than those in the conventional blast-furnace route.

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Main benefits of the Corex process:

Far lower investment costs and operating costs with respect to conventional blast furnace.

Outstanding environmental compatibility

Highest operational flexibility, i.e., production output

Use of Corex export gas for many applications

Process Economy:

Since coking and sintering plants are not required for the Corex process, substantial cost savings are achieved in the production of hot metal. The extent of such savings depends, of course, on local conditions, but can be up to 20% as has been shown under actual operating conditions.

Use of Export Gas: Once the top gas which exits the reduction shaft has been cleaned and cooled, it is then available for use in numerous industrial applications.

These include electrical power generation, production of DRI (direct-reduced iron), and for heating purposes throughout the iron and steel works. In the chemicals industry the Corex export gas can also serve as a feed stock for many other applications.

Commercial units in operation:

Korea: POSCO (COREX C-2000 – Capacity: 0.8 Mtpa)

India: JSW Steel, India (2 Units) (COREX C-2000)

South Africa: Mittal-SALDANHA, (COREX C-2000)

China: Baosteel, (COREX C-3000) – Capacity 1.5 mtpa

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The latest generation of Corex plants, the C-3000, can replace the blast furnace or can be used as a source of virgin iron for mini mills. The economics of the Corex plant already provide an answer to future scrap and coke shortages, and the continually increasing demands placed on steel quality. Another alternative is the installation of a Corex C-3000 plant as a stand-alone merchant plant for the production of hot metal and/or pig iron. Currently JINDAL has started using this technology and ESSAR plant is in construction. This is going to be a very productive way for steel manufacturing with less pollution and less production cost.

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FINEX PROCESS: Finex is an innovative iron making process developed for the production of hot-metal based on the direct use of fine ore and non-coking coal. In the Finex process, fine iron ore is charged in a series of fluidized-bed reactors passes in a downward direction where it is heated and reduced to direct-reduced iron (DRI) by means of a reduction gas – derived from the gasification of the coal – that flows in the counter-current direction to the ore. The DRI fines are then transferred to a charging bin positioned above the melter gasifier and then charged by gravity into the melter gasifier where smelting takes place to produce HCI (Hot compacted Iron). The tapped product “liquid hot metal” is equivalent in quality to the hot metal produced in a blast furnace or Corex plant.

ENVIRONMENTAL BENEFITS: 1. SOx, NOx and dust emissions are significantly lower in the Finex

process than in the blast furnace route. This is due to the elimination of the coke oven and sinter plants, both major sources of emissions.

2. The sulfur contained in the coal reacts with limestone to form CaS, which is bound in the slag. Therefore, there is almost no opportunity for SOx to escape into the environment.

3. NOx emissions hardly occur in the Finex process because the metallurgical reactions take place in a reducing atmosphere, unlike the oxidizing atmosphere inherent in the sinter plant, coking plant, and hot-stoves of the blast-furnace route.

4. Dust emissions are also low, due to the integrated and closed nature of the Finex process.

5. It has also been shown that no dioxins are generated in Finex operations.

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Economic Considerations: 1. The unique characteristics of the Finex process are its ability to

use low-cost raw materials. Means both capital investment and production costs are much lower than in the blast furnace route. A 1.5-million-ton-per-year Finex plant can produce hot metal more cost effectively than a modern three-million-ton-per-year blast furnace.

2. When oxygen and power plants are included in the comparison, the capital and operating costs of a Finex plant are approximately 20% and 15% lower, respectively, than in the blast furnace route.

Main benefits of the FINEX process: It Can directly Use iron Ore Fines up to 8mm.

Direct Use of Non Coking Coal.

Elimination of sintering & coke-making processes

No blending of ore & coal

Use of Low-grade ore & low-ranked coal

COMMERCIAL UNITS IN OPERATION: Commercial unit of 1.5 Mtpa at Pohang, Korea

POSCO plant ODISHA (Being Considered) There is no OTHER PLANT IN THE WORLD using FINEX, as POSCO is NOT INTERESTED in SELLING the TECHNOLOGY.

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HISMELT PROCESS: This Technology is developed by Hismelt Corporation, Australia.

One Stage hot air based Smelting Reduction Process using metal bath as primary reaction medium which is unique.

No OXYGEN is used but only preheated AIR is used. The Core of the HIsmelt technology is the Smelt Reduction Vessel (SRV), which replaces the function of a blast furnace. Iron ore fines are injected deep into the bath where they are reduced instantly on contact with carbon dissolved in the bath. This reaction produces iron (Fe) and carbon monoxide (CO).

Coal is also injected into the bath, where it is absorbed in the metal to replenish the carbon used in the reduction reaction. Reaction gas (CO) and coal gasification products are generated from deep within the bath and form a fountain of mostly slag and some metal.

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Hot air at 1200°C, which is enriched with oxygen to 35%, efficiently combusts the gases generated within the bath - releasing large amounts of energy. Combustion energy is carried back to the bath via a fountain of slag and metal. The primary product from the HIsmelt process is hot molten metal. Liquid iron is tapped continuously through an open fore hearth and is free of slag.

MAIN BENEFIT OF FINEX PROCESS: The biggest advantage of the process to iron makers is the fact that it

produces hot metal without the need for coke ovens and sinter plants.

The direct use of low-value grades of iron ore fines without pre-treatment increases the flexibility of raw material supply for steel producers, ensuring greater competitiveness.

The use of non-coking coals also brings substantial cost advantages, and the flexibility to vary feedstock with productivity demands allows the operator freedom to continuously optimize operating costs.

A further advantage is that a HIsmelt facility uses much of the same equipment as a blast furnace, enabling a HIsmelt plant to be easily retro-fitted into an integrated site.

The metal can be mixed directly with blast furnace iron or alloyed to provide precise low silicon content for the BOF charge. So, compared to a blast furnace hot metal, HIsmelt hot metal:

Reduces flux consumption

Increases liquid steel yield

Increases productivity due to a reduced blowing time

Produces higher quality (low phosphorus) grades

Reduces refractory consumption

Use of Export Material: Secondary products from the SRV are slag and offgas.

Slag from the HIsmelt process can be utilized as a raw material in a variety of applications in the construction and agricultural industries.

Offgas from the process still has energy value and is cleaned, cooled and used as a fuel and for power generation.

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Environmental Benefits: The environmental benefits of the HIsmelt process are considerable. By

reducing the demand for coke, sinter and pellets, and improving the energy efficiency of the iron making process, it reduces emissions of greenhouse gases and other damaging environmental pollutants such as SOx, NOx and dioxins.

Overall, a commercial HIsmelt facility, equipped with ore preheating, can reduce carbon dioxide emissions per tonne of hot metal by close to 20% when compared to the typical blast furnace route. Furthermore, the operating conditions within the SRV generally preclude the formation of dioxins - a fact substantiated at the pilot plant.

The HIsmelt process is revolutionary for the iron and steel industry, and will make restructuring of the steel industry easier and provide an attractive option for developing countries. A HIsmelt facility can directly replace a blast furnace within an integrated mill, eliminating the need to upgrade or replace sinter plants, pellet plants and coke ovens. The technology significantly improves iron making environmental performance and could well become the iron making technology of choice in the 21st century.

FUTURE OF ODISHA IN IRON and STEEL INDUSTRY: Orissa is the most prospective state in India due to having huge iron ore resources and government’s intention to develop state with attracting maximum possible business proposals. The government is all set to facilitate the investors with all possible means including with favorable policy planning. Hence, the state which was neglected at a time for foreign direct investment is a preferred choice today. In future too, the state will be considered as a destination for foreign and domestic investors.

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Posco, BHP Billiton plans a plant: South African steel maker Posco and Australia’s mining major BHP Billiton have jointly approached the Orissa government with a proposal to set up a 10 mt integrated steel plant in the state. Apart from this the two foreign giants have submitted proposals for iron ore mining and setting up of a coke plant. The projects envisage an investment of about Rs 39,000 crore. A high-level delegation from the two companies held long discussions with the Chief Minister, Naveen Patnaik, recently for the same purpose. The proposed steel plant will possibly be set up either at Duburi in Jajpur district or at Dhamra in Bhadak district, according to Priyabrata Panaik of IPICOL, which plays a key role in facilitating investments in the State. The proposed steel plant, to be developed fully in nine years, would have a production capacity of three MT initially. It would have a production capacity of 10 MT per annum by the end of the ninth year, and would help create employment for about 42,000 people.

Eight deals through, 15 are in pipeline The state has been succeeded in signing MoUs with eight steel manufacturing companies and there are 15 proposals in pipeline for which Orissa has been seriously considering to inking the deal. Surprisingly, approximately 15 more proposals are on card apart from the aforementioned proposals. These companies have shown keen interests in setting up steel plants in the state. The state is now close to signing MoUs with Maharashtra Seamless, SPS Sponge Iron, Sunflag Industries, Orissa Sponge Iron and Jindal Stainless Ltd for setting up steel plants in the state. Arsseller Mittal is also planning for a huge Steel Industry in Kendujhar.

BIBILOGRAPHY: http://www.steelworld.com/orissa.htm http://www.tatasponge.com/products/sponge-iron.asp http://www.jindalsteelpower.com/ http://www.industry.siemens.com/datapool/industry/industrysolutions/metals/simetal/en/SIMETAL-COREX-en.pdf http://www.monnetgroup.com/sponge-iron

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