1. Committed for Clean Environment
Environmental Issues
Iron & Steel Sector
Ministry of Environment & Forests
Govt. of India
Central Pollution Control Board
Delhi
27 March 2017
Committed for Clean Environment

2. Committed for Clean Environment
Sector Scenario
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 as
COREX (JSW Steel Ltd.),
Large-scale hybrid technologies - Electric Steel making with BF hot metal with downstream rolling of flat products (Ispat Industries Ltd.)
Large-scale integrated ‘DRI-EAF-Flat products Rolling’ (Essar Steel Ltd.) etc.
Improved capacity utilization by steel sector in India
(from 82% in to 91% in )
Secondary sector has doubled its contribution to crude steel production from 23% to 48% and for finished steel from 45% to 64% respectively
27 March 2017
Committed for Clean Environment

3. Committed for Clean Environment
Sector Scenario
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 the significant 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
27 March 2017
Committed for Clean Environment

4. Committed for Clean Environment
Sector Challenges
Environment protection in Iron & Steel plants is essentially linked to
Technology adopted for iron & steel making
Adoption of cleaner technologies, and effective operation of PCEs
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 and regulation
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 surrounding environment 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
27 March 2017
Committed for Clean Environment

5. Committed for Clean Environment
Sector Challenges
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 “sustainable development”.
Technologies, not “environmentally sustainable”, will be unacceptable even for expansion of existing plants or creation of new capacities
“Sustainable 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
27 March 2017
Committed for Clean Environment

6. Committed for Clean Environment
Iron & Steel
Prevailing Challenges
for
implementation
27 March 2017
Committed for Clean Environment

7. Committed for Clean Environment
Material Handling
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.
27 March 2017
Committed for Clean Environment

8. Committed for Clean Environment
Coke Ovens
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)
27 March 2017
Committed for Clean Environment

9. Committed for Clean Environment
Sinter Plant
Potential source of Dioxin and Furans due to presence of oil content, Chlorinated compounds, organic carbon, chlorides ions in waste materials like mill scale, dust and 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
Presence of fine dust consisting alkali and lead chlorides limit the efficiency of ESPs
27 March 2017
Committed for Clean Environment 9

10. Committed for Clean Environment
Sinter Plant
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, “proper MgO addition’ etc. needs to be adopted by all to make them more energy efficient
27 March 2017
Committed for Clean Environment

11. Committed for Clean Environment
Blast Furnace
Up-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
Presence of fine dust consisting alkali and lead chlorides limit the efficiency of ESPs
27 March 2017
Committed for Clean Environment 11

12. Committed for Clean Environment
BOF Process
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 and de-slaging process and charging emission
Recovery of metallic waste from SMS slag for reuse as resources by installing waste recycling plants
Use 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
27 March 2017
Committed for Clean Environment 12

13. Committed for Clean Environment
EAF Process
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 time followed 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
27 March 2017
Committed for Clean Environment 13

14. Committed for Clean Environment
General
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
27 March 2017
Committed for Clean Environment

15. Committed for Clean Environment
Iron & Steel
Regulatory
Provisions
27 March 2017
Committed for Clean Environment

16. Committed for Clean Environment
Legislations
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 or www. cpcb.nic.in
Corporate Responsibility on Environmental Protect Commitments from IISI
27 March 2017
Committed for Clean Environment

17. Committed for Clean Environment
Iron & Steel
Status of CREP Commitment
27 March 2017
Committed for Clean Environment

18. Committed for Clean Environment
CREP Commitments
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
27 March 2017
Committed for Clean Environment

19. Committed for Clean Environment
CREP Commitments
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 %
By %
By %
Partially achieved by some industry
27 March 2017
Committed for Clean Environment

20. Committed for Clean Environment
CREP Commitments
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
27 March 2017
Committed for Clean Environment

21. Committed for Clean Environment
CREP Commitments
General
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 adequate knowledge and skill to manage Environment Management responsibilities
Unsatisfactory improvement
To improve overall housekeeping
Significant scope of improvement prevail
27 March 2017
Committed for Clean Environment

22. Committed for Clean Environment
Iron & Steel
Environmental Challenges
Going Forward
27 March 2017
Committed for Clean Environment

23. Committed for Clean Environment
General
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.
27 March 2017
Committed for Clean Environment

24. Committed for Clean Environment
Challenges
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
27 March 2017
Committed for Clean Environment

25. T H A N K Y O U YES - With INTENT & DELIVERABLE APPROACH
WE Can achieve THE DESIRED GOALS T H A N K Y O U