Environmental issues pertaining tosteel industries

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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



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



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




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




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




Iron & Steel

12 February 2011 6Committed for Clean Environment



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.




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)




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




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




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




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




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




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



Iron & Steel




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




Iron & Steel




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




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




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




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




Iron & Steel




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.




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




THANK YOU

YES - With INTENT & DELIVER ABLE APPROACH

WE Can achieve THE DESIRED GOALS

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Environmental issues pertaining tosteel industries

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