innovation through recycling / minimizing waste through... · 2/24/2017 · innovation forum 7th...
TRANSCRIPT
Innovation Forum 7th Feb 2017
Innovation through
Recycling / Minimizing Waste
Presented by Mr. N.A. Ansari
CEO
A presentation from Jindal Shadeed Iron& Steel
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Who are we?
• First & Largest Integrated Steel Plant in Oman
Waste–an opportunity for innovation
• JSIS efforts
• Future plans
Support Required
• Government support
• Regulations
Agenda
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Who are we?
• First & Largest Integrated Steel Plant in Oman
Agenda
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First & largest integrated steel plant in Oman
1.5 MTPA
DRI Plant
(HBI/HDRI)
2.0 MTPA
SMS Plant (Square /
Round Billet)
1.4 MTPA
Rolling Mill (8 – 40 mm
Rebar)
771 employees
USD 1.2 Billion Investment
300 Acres
Part of the US $ 18 billion OP Jindal Group
Chairman
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Our Journey
July 2010
Acquisition
Dec 2010
DRI Plant
commissioned
April 2014
SMS Plant
commissioned
April 2016
Rolling mill
commissioned
1
2
3
4
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Waste–an opportunity for innovation
• JSIS efforts
• Future plans
Agenda
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Most favored
Least favored
Reduce
Reuse
Recycle
Disposal
Waste Pyramid
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Steel in the Circular Economy
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Steel and Sustainability
•Steel industry (next biggest to Oil & Gas industry) strictly adheres to environmental responsibility.
Strict Adherence to environment policy
•Steel is the world’s most recycled material & 100% recyclable.
100 % Recyclable
•100% compliance with local/international environmental norms.
•Oman’s first Plant sharing real time data of Continuous Ambient Air
Monitoring Station with Ministry of Environment and Climate Affairs
(MECA)
•Follows world’s most stringent EU BAT Norms i.e.10 mg/Nm3 for dust
against Omani norms 100 mg/Nm3.
•Only plant in GCC treating Slag from EAF for recovery of the metal from
Slag and other uses strongly pursued.
•Recycles different types of by products.
Jindal Shadeed efforts - Going beyond norms
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Principle
Principles of Reduction, Reuse, and Recycling (3’R’s) in Waste Management
Environment friendly
Reuse and Recycling aims at clean, green and zero waste technology
Cost Saving
• Reduce the cost of waste disposal
• Provide substantial amount of iron, flux /other materials
• Fuel rate benefits to the existing process.
Waste Management in Integrated Steel
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Current Initiatives
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EAF Dust and
Bagging
Expected Savings : OMR 30,000 p.a.
Classified as Hazardous due to heavy metal content
Most challenging in handling, transportation and disposal due to cost & environmental concerns.
EAF Dust cannot be directly charged in the furnace.
EAF Dust is agglomerated by mixing definite proportion of dust with bentonite and water to produce 8-18mm Pellets having adequate strength and moisture suitable to be recycled in Electric Arc Furnace
Jindal Shadeed initiated production and recycling 25% EAF dust in Electric Arc Furnace with a target of 100% in next few months.
EAF Dust Recycle
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Refractory Waste - Reuse
Magnesia – Carbon Bricks
Sorting and Crushing of Magnesia-Carbon Bricks to below 50 mm size
This can be used as a substitute to
“Dololime” in Electric Arc Furnace.
Dololime is used as a slag forming material to remove the impurities in Electric Arc furnace.
Expected Savings : OMR 24,000 p.a.
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JSIS is the only
company in Oman
undertaking metal
recovery by HARSCO
Road Aggregate
Fine Aggregate in Precast
Engineering
Cement Application
Engineering Fill
EAF Slag – Recycle / Reuse
Non Hazardous
Future expected Savings : OMR 500,000 p.a.
Under development
Other benefit : Clean Environment
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Energy / Resource Saving initiatives
Hot DRI Gravity Feeding System
• First of it’s kind in the world, less space utilization
• Reduction in Electrode Consumption/ handling loss • EAF productivity increases up to 20%
• Energy savings of 15 KWH/Ton of DRI
Optimizing Hot DRI to SMS Plant Reduction in NG Consumption/Ton of DRI from 10.0 to 9.35 MMBTU/Ton & reduction in power 120-140 Kwh/T
Hot charging of Billets to Rolling Mill Substantial savings in NG consumption up to 40% by hot charging.
Commissioning of Liquid Ring compressor
Energy savings of 1.95 kWh/Ton of DRI Production.
Increased the system pressure from 300 mbar to 500 mbar
Savings in power consumption of Process gas compressors in DR Plant of 7kWh/Ton of DRI production.
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Help the neighbor / create SME
Help the neighbour (Sohar Aluminum)
Trial usage of Spent pot Liner (Cathode) / Spent Anodes which is in SMS
Hazardous Waste - 25,000 Tons in stock
SPL can substitute carbonaceous raw material in the
Electric Arc Furnace for steel making process.
JSIS and Sohar Aluminium are working together to reuse it in the Electric Arc Furnace at Jindal Shadeed.
Creation of SME
Crushing industries for various crushing activities
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Future Plans
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Formed during Continuous Casting and Rolling Mill processes when steel is subjected for thermal gradients in oxidant atmospheres, which promotes the growth of iron oxides layer at the surface of steel
50% Reduction in generation of Mill Scale:
1. Ramp up the production with minimum stoppages in Rolling Mill.
2. Proper balancing of the pressures inside the Reheating Furnace.
3. To maintain minimum required oxygen in reheating furnace.
4. Increase the hot charging % of Billets to Rolling Mill.
Mill Scale Reduction
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Various Future Initiatives
•Briquetting oxide fines, sludge fines and quench fines as “Direct Reduced Briquettes” (DRB) for its use in DR Plant as a partial substitute to “Oxide Feed”.
Fines Briquetting
• Injection of lime dolo fines (or) Briquetting of lime dolo fines, bag filter dust and settling chamber dust for its use in SMS as a partial substitute to flux.
Lime dolo briqueting
•Electrode Waste - After crushing can be utilized as a carbon material in Electric Arc Furnace .
Electrode waste
•CO2 Utilisation in making methanol and other CO2 sequestration.
CO 2 Utilization
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Energy / Saving initiatives
Modification to Extract Power from Flue Gas:
To Generate Power from the Waste Flue Gas (8 -10 MW)
Installation of Turbo Expander:
To generate power from the pressure of Incoming Natural Gas (1-2 MW)
Modification in Ladle Preheating System:
Modification in ladle Preheating system being planned shortly which saves substantial reduction in Natural Gas up to 50% (presently 7750NM3/day).
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Support Required
• Government support
• Regulations
Agenda
Innovation Forum 7th Feb 2017
1. Support from Be’ah for Testing /
certification of usage of Slag.
2. Support from PEIE / universities
research on innovation for future
slag application.
3. Support from Government for
incentivizing energy saving
initiatives.
4. Support from Government to stop
wastages due to frequent start up
(which is due to forced shut down
during peak demand in view of CRT)
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Government Support Requested
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1. MECA approval based on Be’ah
certification for usage of slag.
2. One stop shop for approval as
against Multiple agencies for
approval
23
Regulation Support Requested
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THANK YOU