Post on 09-Apr-2018
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 1/25
Environmental Issues
Iron & Steel Sector
Ministry of Environment & Forests
Govt. of India
12 February 2011 Committed for Clean Environment 1
Central Pollution Control Board
Delhi
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 2/25
Sector Scenario
12 February 2011
Steel sector development is currently going through an expansionary
phase with domestic demand driven by high investment rate,accelerated growth in manufacturing industry and expansion in physical
infrastructure creation
Capacities created based on diversified technologies aso COREX (JSW Steel Ltd.),o Large-scale hybrid technologies - Electric Steel making with BF hot metal with
downstream rolling of flat products (Ispat Industries Ltd.)
o Large-scale integrated µDRI-EAF-Flat products Rolling¶ (Essar Steel Ltd.) etc.
Improved capacity utilization by steel sector in India
(from 82% in 2001-02 to 91% in 2005-06)
Secondary sector has doubled its contribution to crude steel production
from 23% to 48% and for finished steel from 45% to 64% respectively
2Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 3/25
Sector Scenario
12 February 2011
BF-BOF based integrated steel plants with incorporations of latest
technological innovations to continue to be main route of steel making
State of the Art blast furnace iron making process depend on
metallurgical coke for over 50% of its total fuel requirement
India depend mostly on import of coking coal, and techno-economically viable alternative to blast furnace iron making has
become imperative
India has a reserve of iron ore and non-coking coal and its own
improvised coal/gas based DRI technology. This has led to thesignificant growth rate in DRI route production
Indian Sponge Iron industry - the largest producer of sponge iron in
world had a total production of 12.6 Million Tonnes in 2005-06
3Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 4/25
Sector Challenges
12 February 2011
Environment protection in Iron & Steel plants is essentially linked to
o Technology adopted for iron & steel making
o Adoption of cleaner technologies, and effective operation of PCEs
o Efficient disposal/re-use of generated bye-products and waste
Despite significant progress and intent by stake holders, environmental issues
in Steel sector still continue to be the focus of policy debates, legislation andregulation
Achieving zero waste and zero discharge concepts from this sector are very
relevant, and will be obligatory very soon with stress on
Integrated approach of production process and the surroundingenvironment of the industry
Further reduction in pollutant discharges and generation of Solid /
Hazardous wastes
Develop/adopt designs and processes to avoid pollution rather than
control and its treatment
4Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 5/25
Sector Challenges
12 February 2011
Wastes, particularly solid wastes generated unavoidably, are to be treated as
Resource for its use as value added by-products
Steel sector has to firmly and purposefully adapt to the challenge of being a
acceptable MATERIAL in the integrated concept of ³sustainable
development´.
Technologies, not ³environmentally sustainable´, will be unacceptable even
for expansion of existing plants or creation of new capacities
³Sustainable development´ is to be practiced right from technology
development, design to implementation and operational stages
Towards meet these objectives, initiatives both at level of entrepreneurs and
Government by way of suitable intervention are necessary and demand of the
time
5Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 6/25
Iron & Steel
12 February 2011 6Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 7/25
Material Handling
12 February 2011
Challenges to be addressed for Materials handling to minimise fugitive emissions
includes:
Use of indoor or covered stockpiles
When open-air stockpiles are unavoidable, use of water spray system / Dust
Suppression system
Windbreaks and other stockpile management techniques like simple and linear
layout for material handling operations to reduce the need for multiple transfer points and due consideration of Meteorological parameters at designing stage
APCEs at loading and unloading points and railway sidings
Enclose conveyer transfer points with dust-controls systems
Provision for Clean return belts in the conveyor belt systems to remove loose
dust
Implement routine plant maintenance and good housekeeping to keep small
leaks and spills to a minimum
Implement correct loading and unloading practices.
7Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 8/25
Coke Ovens
12 February 2011
Maintenance and Cleaning of all fugitive emission sources like Doors, Lid,
AP Covers, Levelling doors, Valves Use of Air-cooled self-sealing doors, hydrojet cleaning system for doors,
mechanical cleaning system for door frames
Use of hermetically sealed charging sleeves and screw feeders in charging
car to reduce charging emission and provision for magnetic lid lifter
Good management practices to achieve steady state operation to avoid green
pushing, and computerized controlled battery heating and automation system
is essential for all the coke ovens to improve coke quality and reduce energy
consumption in coke making
Adoption of Smokeless Charging system Adoption of Coke Dry Quenching (CDQ) system
Adoption of non-recovery coke making process
Reduction of coke charge in BF by Pulverised Coal Injection (PCI)
8Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 9/25
Sinter Plant
12 February 2011
Potential source of Dioxin and Furans due to presence of oil content, Chlorinated
compounds, organic carbon, chlorides ions in waste materials like mill scale, dustand sludge from APCEs ETP etc. and conducive temperature and process
operation environment.
Adoption of partial or total recirculation of waste gas in the sinter plant
may reduce pressure on end-of pipe treatment
Use of hybrid ESP (ESP cum fabric filter) and high pressure wet
scrubbing system for waste gas de-dusting
Use of clean scrap, additional burnt lime and control of mill scale oil
content
Adoption of fine feed materials (dust) in agglomerated forms
Use of oxygen to ensure complete combustion
9Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 10/25
Sinter Plant
12 February 2011
Existing sintering and pelletisation capacity in the country is not sufficient to
make full use of the fines and concentrates being generated
Indian steel producers to make larger use of fines and concentrates instead of
being over dependent on lumps
Pellet sintering technology, which combines pelletisation and sintering process holds promise to take care of the availability of finer grade iron ore
fines
Energy saving measures like increased use of multi slit burners, ³proper MgO
addition¶ etc. needs to be adopted by all to make them more energy efficient
10Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 11/25
Blast Furnace
12 February 2011
U p-gradation of cast house equipment, implementation of pollution control
devices for tap holes, runners, skimmers, ladle charging points to meet the
stipulated norms
Adoption of cast house slag granulation system for 100% granulation of slag
and reduction of water consumption
Use of BF slag as resources in Cement making, civil engineering, road
construction Incorporation of technologies for injecting pulverized coal (+200 kg/thm),
used oil (100 kg/thm), Natural gas (100 kg/thm)
Use of tar free runner lining, reducing agent such as waste plastics granules
injection for reducing coke requirement and resource conservation
Technologies to be adopted for cost effectiveness, energy savings and
reduction in pollution load
Top Gas Recovery Turbine,
Use of waste heat stove gas for preheating of gas,
High efficiency stoves
11Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 12/25
BOF Process
12 February 2011
Efficient use of primary control system for flue gas including venturi
scrubbers with or without complete combustion
Use of secondary control system to capture off-gas escaping from BOF
process
Encapsulation of metal pouring lines with extractors
Control of emission from hot metal pre-heating, desulphurization andde-slaging process and charging emission
Recovery of metallic waste from SMS slag for reuse as resources by
installing waste recycling plants
U
se of SMS slag as rail ballast, road making, civil engineering works Reuse of dust and slag from APCEs by adopting pressing, drying and
granulation in palletisation plants
12Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 13/25
EAF Process
12 February 2011
Use of direct off-gas extraction and canopy hood enclosure followed by
adequate and effective APCEs for Flue gas de-dusting system and reuse of high content dust/sludge
Refurbishment and satisfactory operation and maintenance of installed
APCEs to meet stipulated norms at all medium and small size furnaces
Post combustion of off gas to achieve 1200°C with adequate residence timefollowed by quick cooling of gas and de-dusting through bag filter primed
with absorbents (Lime or Carbon) to capture volatile impurities and control
formation of PCDD/F
Secured land filling of EAF slag considering local topography and
geographical condition Reuse of dust from APCEs by adopting pressing, drying and granulation in
palletisation plants
Cleaning of galvanized scrap before using in EAF to control Zn emission
13Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 14/25
General
12 February 2011 14
Environmental monitoring activities based on direct or indirect indicators of
emissions, effluents, and resource use applicable to particular industry Continuous On-line monitoring system for emission and discharge needs to
be adopted for better transparency
Monitoring frequency to provide representative data for the parameter being
monitored and compared with operating standards for corrective measures
Dedicated and skillful team of resources to handle environment issues
Replacement of obsolete and high energy intensive process and equipments
with less energy intensive ones
Programs for addressing pollution load due to associated activities
Needs for more innovative in-house exploration for reuse and recycle of
waste products
Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 15/25
Iron & Steel
12 February 2011 15Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 16/25
Legislations
12 February 2011
The Water (Prevention and Control of Pollution ) Act, 1974
The Air (Prevention and Control of Pollution ) Act, 1981
The Environment (Protection) Act, 1986
The Hazardous Waste (Management, Handling, & Transboundary
Movement) Rules, 2008 and amendments thereafter
Manufacture, Storage and Import of Hazardous Chemical Rules, 1989 Biomedical (Management & Handling) Rules 1998
Chemical Accidents (Emergency Planning, Preparedness and Response)
Rules, 1996
The Ozone Depleting Substance (Regulation and Control) Rules, 2000
The Batteries (Management and Handling) Rules, 2001 Public Liability Insurance Acts, 1991
Stipulated Regulatory Norms www.moef .nic.in or www. cpcb.nic.in
Corporate Responsibility on Environmental Protect Commitments from IISI
16Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 17/25
Iron & Steel
12 February 2011 17Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 18/25
CREP Commitments
12 February 2011
COKE OVEN
COMMITMENTS STATUS
To meet fugitive emission norms by
all operating coke ovens by
December 2005
Compliance by all are yet to be
achieved
To rebuild at least 40% of the coke
oven batteries in next 10 Years
(December 2012)
Partially achieved by some industry
Charge of tar sludge / ETP sludge to
Coke Oven by June 2003
Complied
18Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 19/25
CREP Commitments
12 February 2011
STEEL MELTING SHOP
COMMITMENTS STATUS
Fugitive Emission reduction by 30 %
(March 2004)
Installation of Secondary de-dusting
facility (March 2008)
Not achieved
Utilisation of Slag
By 2004 - 70%
By 2006 - 80%
By 2007 - 100%
Partially achieved by some industry
19Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 20/25
CREP Commitments
12 February 2011
BLAST FURNACE
COMMITMENTS STATUS
Direct Injection of Reducing agents
(June 2013)
Progress has been made
Energy recovery from top BF gas No significant progress
Use of Tar free runner liners Few are yet to adopt especially to
smaller units
De-dusting of Cast house at tap holes,
runners, skimmers ladle and charging
points
No installation so far
Suppression of fugitive emission using
nitrogen gas or other gases
No satisfactory progress
100% BF slag granulation facilities Not achieved by many industry
20Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 21/25
CREP Commitments
12 February 2011
COMMITMENTS STATUS
To reduce specific water consumption to 5 m3/t of long
products and 8 m3/t of flat products by December 2005
Satisfactory progress made
Better CO-BP ETP to meet the notified standards by July
2003
Except cyanide all
parameters are within norms
Installation of Continuous Stack Monitoring System and
Ambient Air quality monitoring station by June 2005
Not complied
Set targets for Resource Conservation such as Raw
material, Energy and Water Consumption to match
International Benchmark
Unsatisfactorily reporting
practiced
Engage environmental professional with adequateknowledge and skill to manage Environment
Management responsibilities
Unsatisfactory improvement
To improve overall housekeeping Significant scope of
improvement prevail
GENERAL
21Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 22/25
Iron & Steel
12 February 2011 22Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 23/25
General
12 February 2011
Steel - by itself is one of the most eco-friendly of all materials, invented by
Man.
By adopting Improved process and pollution control technology, their
satisfactorily practices of PCE operation and Environmental Management
approach and policies have addressed substantially in advance steel making
countries like Japan, Germany, South Korea.
In India most of the causes of higher pollution are attributed to usage of old
technologies, various constraint in retrofitting and implementation of
pollution control and poor environmental management practices besides
inherent raw material constraints
Lack of dedicated team efforts comprising professionally trained manpower for handling of complex environmental issues associated with iron & steel
sector is another major bottleneck in achieving the desired objective.
23Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 24/25
Challenges
12 February 2011
Co-processing of suitable waste material from other sector as alternate fuel or
reducing agents like Plastic and Incinerable hazardous waste in various high
temperature processes
Harmonizing energy and raw material consumption with international benchmarks
Incorporation of effective GHG reduction and measures for Environmental
Management at project development stage
Achieving Zero discharge by adopting sustainable and cleaner technologies
Framework to achieve 33% Green Belt Cover and Rain Water Harvesting system
aggressively
Exploring scope for better utilisation of slag as resource instead of dumping as
landfill suitable in India condition
Develop cost effective small capacity pellet plants (in lakhs tons) to utilize fine iron
ore for resource conservation and pollution reduction
Target based approach to reduce waste generation and pollutant emission
Community reporting of Performance and Monitoring of Environmental Indicators
24Committed for Clean Environment
8/7/2019 Environmental issues pertaining tosteel industries
http://slidepdf.com/reader/full/environmental-issues-pertaining-tosteel-industries 25/25
THANK YOU
YES - With INTENT & DELIVER ABLE APPROACH
WE Can achieve THE DESIRED GOALS