Clean Steel Making Initiatives in DRI / EAF Process

Essar Steel Limited
Clean Steel Making Initiatives in DRI / EAF process

at
Essar Steel Limited, India

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Essar Steel Limited

Strategically Located Asset Base
New Delhi
Ba iladila
0 km 613 m
Slu r r y p ip e lin e ro u te
Ben eficia tion Pla nt
W ater Pu mping Statio n
H Y-G RADE P EL LE TS LIM IT ED
R ly L ine
Slack Flo w Stn .
M a in Pu m p in g Station
W ater L in e
113 km 496 m 100 km 434 m
Slack Flow Stn.
180km 696 m
B oost er St n.
205km 91 m
Pellet p lan t
Jamnagar Hazira
Largest concentration of steel users in India
V alve st n .
267km 0m ts
Mumbai
Kirandul Visakhapatanam
Pellet Plant at Visakhapatnam
Essar Steel Complex at Hazira Close to major steel consumers At the landfall point of natural gas All power supply located close to operations of steel complex 2
Port based plant with dedicated pellet handling facilities Close to one of the richest iron ore content mines
Essar Steel Limited

Content
Existing Plant Process Flow Existing Plant Initiatives Future Plant Process Flow Future Plant Initiatives
Essar Steel Limited (4.6 MTPA)

Material Flow Chart
Essar Steel Limited

Raw Material
Mining - Iron ore: Bailadila, India Pelletization - Iron fines: Vishakhapatnam, India Iron ore mix
Calibrated lump ore (10% - 20%) Pellets (80% - 90%)
Iron content: 66%

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Essar Steel Limited

HBI Plant
5 Modules of capacity 5.5 MTPA Input

Pellets + Ore: Natural Gas: Calorific value: 1.5 Ton / Ton 285 Nm3 / Ton 8700 to 8800 Kcal / Nm3
Output
Cold HBI: Hot DRI:
6
40% 60%
Essar Steel Limited

HBI Plant - Process Flow
FEED B USTL E
GAS
ENRICHMENT OXYGEN N.G. INJECTION
REFORMED
GAS
BASIS: PRODUCTION RATE TYPICAL METALLISATION CARBON CONTENT FL UE

GAS
100 tph 93% 1.20%
TOP GAS
MIDREX-HBI PROCESS FLOW DIAGRAM

MAIN
A IR
FLUE GAS TO THE VENT
CARBU. N.G. NA TURAL GA S INPUT
HOT
D IS C H A R G E B OTTOM S EAL GAS P R OC ES S GAS TOP GAS F UE L
PROCESS GAS
PROCESS NA TURA L GA S
FEED GA S
FL UE GAS
COLD HBI
HOT DRI
Essar Steel Limited

Electric Arc Furnace
4 DC Electric Arc furnaces Capacity: 150 Tons per heat (each furnace) Input (175 Tons)
Metallic: HBI (36%), Hot DRI (60%), Scrap (4%) Fluxes: Lime, Dolime Electrical Energy: ~ 515 KWH per Ton
Tap to tap time = 60 minutes

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Essar Steel Limited

Steel Making Plant - Process Flow
DC- ULTRA HIGH POWER EAF
GRAPHITE ELECTRODE ROOF CENTRE WATER COOLED ROOF CARBON INJECTOR FUMES FUMES EXTRACTION SYSTEMS WATER COOLED PANEL FOAMY SLAG OXYGEN INJECTOR CO BUBBLES BOTTOM ELECTRODE SIDE & BOTTOM REFRACTORY EBT
Clean Development Mechanism
Joseph Priestly, 1771
Essar Steel, 2008
Environment: A key Driver

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Clean Development Mechanism The Kyoto Protocol to the convention on Climate Change has developed a Clean Development Mechanism (CDM) Facilitates developing countries to trade Certified Emission Reduction (CER) with the developed countries w.e.f. 16th Feb. 2005 CER corresponds to the extent of reduction in emission of six Green House Gases (GHG) mainly carbon dioxide and methane
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Existing Plant - CDM Projects 1. Hot Direct Reduced Iron 2. Power generation from SMP flue gases 3. 19 MW HBI power plant 4. Digitized walking beam type reheating furnace 5. Installation of Top Burners, Sinter Plant
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Existing Plant - CDM Projects

Hot Direct Reduced Iron
Collection and transportation done by specially designed containers
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cont.
Capacity of Vessel: 90 Ton Hot DRI Temperature: 675 oC Vessel Travel distance: 1 Km Designed in-house (patented) Charged through EAF top
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cont.
Introduce the Hot DRI along with hot briquetted iron into the electric arc furnace Energy saving upto 100 KWH / Ton liquid steel Reduced emission by saving electrical energy CO2 Reduction = 237,683 CER per annum
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cont.
Project is expected to fetch financial benefit to the company Project is being pursued in consultation with M/s Ernest & Young Project Methodology has been successfully submitted to UNFCCC
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cont.
UNFCCC Website
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Power generation from SMP flue gases
Initial proposal has been received from Transparent Energy Systems Looking for Technology CO2 Reduction = 359,345 CER per annum
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19 MW HBI Power plant
Power generation from HBI module hot gases Temperature of Hot gases = 350 to 400 oC Contract signed by HBI with ECL and Essar Engineering Centre CO2 Reduction = 82,126 CER per annum
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Reheating furnace
Digitized walking beam type reheating furnace Saving in energy consumption as compared to conventional furnace CO2 Reduction = 10,080 CER per annum
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Installation of Top Burners, Sinter Plant
Side fired burners are replaced by new energy efficient top burners CO2 Reduction = 3,962 CER per annum Already implemented
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Future Plant - Essar Steel Hazira Limited

Product Flow Chart
Corex 2 Modules 1.74 MTPA (Hot metal)
Blast Furnace 1.74 MTPA (Hot metal)
Mod VI 1.7 MTPA (DRI)
SMP 4.63 MTPA (Liquid Steel)
CSP 3.55MTPA
Slab Caster 1.03 MTPA
Coils
Slabs
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Future Plant - CDM Projects 1. Use of Hot metal from Corex 2. Use of Corex gas 3. Compact Steel plant (CSP) 4. Top gas pressure Recovery Turbine (TRT) for Blast furnace 5. Blast furnace gas utilization
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Future Plant - CDM Projects

Use of Hot Metal
Hot metal from COREX to EAF Nos 2 & 3 Liquid charge : 35% Reduction in energy rate: 120-130 KWH/Ton
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Use of Corex gas
Natural Gas to be replaced by Corex gas Energy savings in HBI, Lime plant, Dolime plant and other various projects CO2 Reduction = 1,643,137 CER per annum
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Compact Steel plant (CSP)
Thin continuous strip to be heated from 900 950 oC to 1100 oC as against from ambient temperature CO2 Reduction = 45,258 CER per annum
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Top gas pressure Reduced Turbine (TRT) for Blast furnace
Exhaust pressure from blast furnace of steel mill to be utilized to produce power CO2 Reduction = 43,224 CER per annum
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Blast furnace gas utilization
Exhaust heat from the blast furnace of steel mill to be utilized for process heating CO2 Reduction = 15,966 CER per annum
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kg CO2/t of liquid steel

1000 1500 2000 2500 500 0
CO2 Emission
Alternative Iron EAF Route
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1922
BF-BOF
441
100% Scrap
912
50% HI C CDRI 50% HBI 20% HBI+30%PI 50% ITMK3 50% BF HM 50% FASTIRON 50% FASTEEL 50% COREX
991 1320 1198 1507 1085 1041 1880
1259
50% HISMELT
Thank you
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Essar Steel Limited

Slurry pipe line route
0 km 613 m
Beneficiation Plant, Kirandul

Water Pumping Station
Main Pumping Station
Slack Flow Stn.
Bailadila
Water Line
Rly Line
113 km 496 m 100 km 434 m
Slack Flow Stn.

180km 696 m
Booster Stn.
205km 91 m
Pellet plant
Valve stn.
267km 0mts
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Clean Steel Making Initiatives in DRI / EAF Process

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Essar Steel Limited