1. TOWARDS A CLEANER, GREENER & SMARTER INDIAN STEEL INDUSTRY
S. Das Gupta٭& Bhaskar Roy٭
٭ The authors are with M. N. Dastur & Company (P) Ltd, Consulting Engineers,
Kolkata
Presentation made at 4th India Steel Summit organised by ASSOCHAM in
New Delhi on 11th August 2010.

2. Indian Steel Industry –
Future Prospects

3. Apparent Steel Consumption Trend
Steady growth
Accelerated growth
Take-off point !
Apparent Steel Consumption Trend

4. Apparent Steel Consumption – India vs World
1981
1985
1990
1995
2000
2005
2009
World
India
China
542
Apparent Steel Consumption – India vs World

5. Indian Steel Industry on a Strong Growth Path
55 mill. tons
Actual consumption
65 mill. tons
Considering 7.5% CAGR between
&
120 mill. tons
Considering 8% CAGR between &
140 mill. tons
Considering 10% CAGR between &
2015- 16
Likely Future Steel Demand Scenario in India

6. Scope for Increasing Rural Steel Consumption !
Year
Population, mill
Per capita steel, kg
Total steel, mill. tons
Urban
Rural
National
345
810
153 3 53 2 55
370
825
166 4
61.5
3.5 65
430
835
210 6 90 5 95
Urban
Rural
Urban
Rural 2 4 6 8
The Rural-Urban Steel Divide in India

7. Environmental Aspects of Indian Steel Industry

8. Major Factors in Ensuring Steel Industry Sustainability ٭ :
Energy intensity.
Greenhouse gas emissions.
Material efficiency, i.e. % of by-products re-used.
٭ As defined by World Steel Association member companies.

9. Average of Integrated Plants  6.5 Gcal/tcs
SPECIFIC ENERGY CONSUMPTIONS IN
INDIAN INTEGRATED STEEL PLANTS

10. SPECIFIC ENERGY CONSUMPTION – INDIA VS OTHER COUNTRIES
Considerable potential to reduce energy intensity in India.
SPECIFIC ENERGY CONSUMPTION –
INDIA VS OTHER COUNTRIES
(2008/2009 figures)

11. STEEL INDUSTRY & GHG EMISSIONS
Source: Meeting the Challenge of Climate Change by Ian Christmas, Secretary General, World Steel Association, 5th China International Steel Congress, Shanghai, 2nd June 2008.
STEEL INDUSTRY & GHG EMISSIONS

12. CO2 EMISSION BY STEEL INDUSTRY– INDIA VS OTHER COUNTRIES
(2008/2009 figures)

13. EXTENT OF BY-PRODUCTS REUSE– INDIA VS OTHER COUNTRIES
<80%
EXTENT OF BY-PRODUCTS REUSE–
INDIA VS OTHER COUNTRIES
(2008/2009 figures)

14. Making Indian Steel Industry More Environment
Friendly :
Domestic steel production bound to grow
substantially in future.
Inevitable impact on the environment.
Indian steel producers seized of the situation -
concerted efforts to mitigate harmful effects.
However, need for more R&D efforts to develop
‘break-through’ technologies.
Explore possibility of collaborating with agencies
involved in R&D activities.

15. International Efforts at Developing New Technologies/Processes:
POSCO: substantially reduce CO2 emissions
in years through hydrogen-based
steelmaking.
ULCOS (Ultra Low CO2 Steelmaking) program
in EU since 2004 to develop ‘breakthrough’
technologies.

16. CONCEPTUAL SCHEME OF HYDROGEN-BASED
Iron Ore
CONCEPTUAL SCHEME OF HYDROGEN-BASED
STEEL MAKING OF POSCO

17. Salient Features of ULCOS Program:
Objective - R&D initiative to reduce CO2
emissions by developing new breakthrough
technologies
Consortium of major European steelmakers
& Rio Tinto.
Involves Carbon Capture & Sequestration (CCS).

18. Salient Features of ULCOS Program cont’d:
Some of the process routes identified:
Top Gas Recycling
Blast Furnace (TGR-BF).
Smelting reduction process –
HIsarna; incorporating some
features of HIsmelt process.
Others:
Shaft furnace DR process – ULCORED.
Electrolysis variants – ULCOWIN & ULCOLYSIS.

19. Smarter Steels

20. Major Demand Drivers for Indian Steel Industry:
Construction, Automotive & Infrastructure sectors
– major drivers of steel demand in India.
Automobiles - Second fastest growing market
after China.
Need to develop/produce ‘smart’ steels with
desired properties to support sectoral growth.
Typical requirements:
For automotive steels - superior formability,
without compromising on weldability.
For structural applications - high strength, high
corrosion resistance, better weldability.

21. High-Strength Steels for Automotive Applications:
High-strength steels provides better mechanical properties
or greater resistance to corrosion than carbon steel.
Few grades developed:
Dual phase steel
TRIP steel
TWIP steel
Evolving AHSS grades:
Nano steels
Ultra-fine grain steels

22. MECHANICAL PROPERTIES OF SOME HIGH STRENGTH AUTO-GRADE STEELSDP
TRIP IF
Mild
Austenitic-Based
Steels, e.g. TWIP
MECHANICAL PROPERTIES OF SOME
HIGH STRENGTH AUTO-GRADE STEELS

23. Development of steel foam:
Metal foams with controlled porosity - emerging class of
ultra-lightweight materials receiving increased attention.
Weight reduction, improved fuel efficiency & increased
passenger safety in transportation systems.
Safer vehicles due to crash energy absorption capabilities.

24. Status of Developmental Work in India:
Work on TRIP / TWIP & other high strength steels in
progress.
R&D activity on development of steel foam.
Bulk production of high strength steels for automotive
application still to take off.

25. Few Action Points for
Indian Steel Industry

26. Better Utilisation of Iron Ore Resource:
India endowed with large reserves of iron ore – need for
a policy for better resource utilisation.
Lowering cut-off grade from 55-58% to ~45% & exploration
to greater depths for resource estimation.
With advances in beneficiation techniques, lower grade
in-situ material, reject dumps & slimes can be economically
upgraded & gainfully utilised.
Lowering environmental degradation – 2.5 mtpy washing
plant impacts 5 acres of forest land & about 12,500 trees
annually.

27. Better Operating Practices for Reducing Energy Intensity:
Higher agglomerates in BF burden  lower Si in hot metal
for 1 mt hot metal – 7,000 Gcal less energy required
for every 0.1% lowering in Si content.
Greater application of heat recovery systems –
introduction of modern, energy efficient technologies.
maximising waste energy recycling, e.g. CDQ, TRT,
sinter waste heat recovery, BF stoves waste heat
recovery.
Wider utilisation of NNS casting
beam blank
strip casting

28. Utilisation of Iron & Steel Making Slags:
At ThyssenKrupp Stahl, BF & SMS slags processed
into valuable materials for use in cement making, road
construction, or as soil conditioner.
ArcelorMittal in Brazil has developed a new way of
producing construction bricks from steel mill slag.
What Nippon Steel is doing:

29. Green Buildings & Energy Optimisation:
Misc. Equipment
Typical Energy Consumption
Pattern in Buildings:
Source: CII-Sohrabji Godrej Green Business Centre
Potential for energy savings 40 – 50% in new buildings; for
existing buildings, the potential can be 20-25%.
Design should ensure building gets maximum day lighting.
Maximise use of solar power; explore wind energy possibility.
Use of energy saving materials & equipment like heat resistive
paints, fly ash blocks, insulation materials, lighting controls,
BIPV (Building Integrated Photo Voltaics), etc.

30. Stricter Monitoring of Air & Water Pollution:
Mandatory environmental audit to identify & prioritize
areas for short, medium & long term addressal through
appropriate mitigation measures.
Formation of dedicated & specialised Environment
Management Divisions at corporate & plant levels.
Stricter enforcement of relevant provisions of Environment
(Protection) Acts & Rules, with severe penalties for
deliberate non-compliance.

31. Concluding Remarks

32. Indian steel industry already on high growth path.
Enhanced domestic steel production will call for
higher demands on various inputs & also entail
greater emissions.
Indian steel industry required to adhere to
commitments made at Kyoto & Copenhagen.
Industry competitiveness to be ensured by
balancing economic & environmental aspects.

33. Indian steel industry seized of the matter &
various steps already initiated.
However, considerable potential exists to
improve sustainability of Indian steel industry.
Significant reduction of CO2 emissions possible
by developing ‘breakthrough’ technologies.

34. Thank you for your kind attention!