STEELMAKING THROUGH EAF ROUTE
AND ITS EFFECT ON ENVIRONMENT
BY
DURBA TALUKDAR & SOMNATH GUPTA
M.N.DASTUR & COMPANY (P) LTD,
KOLKATA
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CO2 EMISSIONS BY GLOBAL STEEL INDUSTRY
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ENERGY INTENSITY OF STEEL INDUSTRY
6
5
1
Japan
2
S. Korea
3
India
4
World-avg
Energy Intensity, Gcal/tcs
7
0
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SPECIFIC ENERGY CONSUMPTION (Unit : GCal/TCS)
Plant
2007-08
2008-09
2009-10
2010-11
(Apr – Dec 2010)
SAIL
6.95
6.74
6.72
6.82
BSP
6.72
6.5
6.56
6.66
DSP
6.94
6.5
6.55
6.78
RSP
7.39
7.09
6.97
6.89
BSL
6.89
6.83
6.74
6.88
ISP
8.14
8.18
8.18
8.23
RINL
(GCal/TLS)
6.21
6.54
6.09
6.18
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SPECIFIC ENERGY CONSUMPTION(Unit : GCal/TCS)
(Continued)
Plant
2007-08
2008-09
2009-10
2010-11
(Apr – Dec 2012)
TaTa Steel
6.555
6.587
6.173
NA
(Apr-Dec 2009)
JSW Steel
6.847
6.704
6.495
6.31
JSPL
7.68
7.25
7.14
6.98
Essar Steel
5.99
5.81
NA
NA
IIL
5.73
5.42**
5.46
Merged with
JSW
(Apr-Sept 2009)
Source:
1. Sail News – February – June 2010
2. Annual report 2010-11, Ministry of Steel, Govt. of India
Note: **BF and Sinter Plant were under capital repair for approx 6 months.
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STEEL PRODUCTION THROUGH ELECTRIC
FURNACES IN INDIA
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Total Crude
Steel Production
(Million tons)
27.291
28.814
31.779
32.626
45.780
49.450
53.468
57.791
63.527
68.321
Production
Of Crude
Steel in Electric
Furnaces
(Million tons)
9.980
10.850
12.680
14.300
24.780
27.650
31.300
34.800
36.200
41.300
% of Steel
Production in
Electric Furnaces
36.5
37.7
39.9
43.8
54.1
55.9
58.5
60.2
57.0
60.4
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MAJOR WASTE GENERATED FROM EAF
• Solid waste
 Slag
 Dust
 Sludge
 Refractory debris
 Skull
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MAJOR WASTE GENERATED FROM EAF ( Continued)
• Gaseous waste
 Carbon-monoxide
 Carbon-dioxide
 Sulphur-dioxide
 Oxides of Nitrogen
 Particulate matter
• Liquid waste
 Polluted water
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EAF SLAG
• COMPOSITION
 Main constituent – Calcium Oxide and Iron
 Other minor constituents - Magnesium, Manganese, Silicon, Aluminium
• APPLICATION
 Land Filling






Road Construction
Aggregate for concrete
Clinker Kilns as a replacement for mined limestone
Reuse in internal processes
Soil conditioner
Making prefabricated shapes for sewerage
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EAF DUST
• COMPOSITION
 Main constituent – Iron
 Other constituents – Zinc in the form of oxide/sulphide/chloride
Lead as oxide, Cadmium, other metals, halides
and fluxes
• Treatment
 Recycling back into the furnace
 High temperature metal recovery processes
 Hydrometallurgical and pyro-metallurgical processes
• APPLICATION
 Reuse in EAF
 Landfilling
 Extraction of Zinc
 Use in rotary hearth furnace
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GASEOUS EMISSIONS
• Harmful Substances
Oxides of carbon
 Oxides of nitrogen
 Oxides of sulphur
 Cyanides
 Fluorides
• Measures adopted
 Improved Fume extraction system and control
technologies
 Furnace off gas analysis system
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DEVELOPMENTS IN EAF PROCESS ROUTE
• Development of Shaft Furnace, Consteel
Process and other processes
• The processes developed lead to :
 Lower noise level
 Lower dust content in off gases
 Reduced off-gas volume
 Full heat incineration of carbon-monoxide
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TECHNOLOGICAL DEVELOPMENTS IN EAF
Period
Technological
Development
Tap-to-Tap
Time
Electricity
Consumption
(kWh/t)
Electrode
Consumption
(kg/t)
1965-70
Oxygen lancing
180
630
6.5
1970-80
-Water cooled panels
-High power operation
(UHP)
105
490
3.5
1980-85
- Ladle furnace
- Foamy slag
- Eccentric bottom tapping
- Scrap pre-heating
80
450
2.5
1985-95
-Oxygen carbon injecton
( lance manipulator)
- Pneumatic bath stirring
60
410
2.0
-Oxygen carbon/oxyfuel
side wall injection
-Use of hot metal as charge
material
55
250-300
1.6
1995-2005
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TECHNOLOGICAL DEVELOPMENTS IN EAF
(Continued)
• The technological developments lead to :
 Reduced energy consumption
 Resource savings
 Reduction of carbon footprints
 Cost savings
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THANK YOU
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