248225329-M-N-Dastur.ppt vers une industrie minière vertueuse

industrie minerale propre

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

2. 2
Indian Steel Industry –Indian Steel Industry –
Future ProspectsFuture Prospects

3. 3
0
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Q
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,

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.

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s
Apparent Steel Consumption TrendApparent Steel Consumption Trend
Steady growth Accelerated growth
Take-off point !

4. 4
0
100
200
300
400
500
600
700
800
900
1,000
1,100
1,200
1,300
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1981 1985 1990 1995 2000 2005 2009
World
India
Apparent Steel Consumption – India vs World
China
542

5. 5
Likely Future Steel Demand Scenario in India
2009-1055 mill. tonsActual consumption
2011-1265 mill. tonsConsidering 7.5% CAGR between
2009-10 & 2011-12
2019-20120 mill. tonsConsidering 8% CAGR between
2011-12 & 2019-20
140 mill. tonsConsidering 10% CAGR between
2011-12 & 2019-20
40
60
80
100
120
140
2009-
10
2011-
12
2019-
20
Q
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,
m
ill. t
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s
2015-
16
Indian Steel Industry on a Strong Growth Path

6. 6
Year
Population, millPer capita steel, kg Total steel, mill. tons
Urban Rural Urban Rural Urban RuralNational
2009-10 345 810 153 3 53 2 55
2011-12 370 825 166 461.5 3.5 65
2015-16 430 835 210 6 90 5 95
0
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2009-10 2011-12 2015-16
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Rural
The Rural-Urban SteelThe Rural-Urban Steel Divide in IndiaDivide in India
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160
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2009-10 2011-12 2015-16
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66
88
Scope for Increasing Rural Steel Consumption !

7. 7
Environmental Aspects Environmental Aspects
of Indian Steel Industryof Indian Steel Industry

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

9. 9
SPECIFIC ENERGY CONSUMPTIONS IN
INDIAN INTEGRATED STEEL PLANTS
4
5
6
7
8
9
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s
BSP
BSL
DSP
RSP
TATA
VSP
JSW
ESSAR
2008-092007-082006-072005-062004-05
Average of Integrated Plants  6.5 Gcal/tcs

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

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

12. 12
CO
2
EMISSION BY STEEL INDUSTRY–
INDIA VS OTHER COUNTRIES
(2008/2009 figures)
W
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13. 13
W
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P
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C
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F
E
0
10
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30
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50
60
70
80
90
100
%

R
e
-
u
s
e
d
India
<80%
EXTENT OF BY-PRODUCTS REUSE–
INDIA VS OTHER COUNTRIES
(2008/2009 figures)

14. 14
Making Indian Steel Industry More EnvironmentMaking Indian Steel Industry More Environment
Friendly :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. 15
International Efforts at Developing International Efforts at Developing
New Technologies/Processes:New Technologies/Processes:
• POSCO: substantially reduce CO
2
emissions
in 10-12 years through hydrogen-based
steelmaking.
• ULCOS (Ultra Low CO
2 Steelmaking) program
in EU since 2004 to develop ‘breakthrough’
technologies.

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

17. 17
Salient Features of ULCOS Program:Salient Features of ULCOS Program:
• Objective - R&D initiative to reduce CO
2

emissions by developing new breakthrough
technologies
• Consortium of major European steelmakers
& Rio Tinto.
• Involves Carbon Capture & Sequestration (CCS).

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

19. 19
Smarter SteelsSmarter Steels

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

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

22. 22
0
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020040060080010001200140016001800
Tensile Strength, MPa

E
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a
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%
D
P
T
R
IP
IF
M
ild
Austenitic-BasedAustenitic-Based
Steels, e.g. TWIPSteels, e.g. TWIP
MECHANICAL PROPERTIES OF SOME
HIGH STRENGTH AUTO-GRADE STEELS

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

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

25. 25
Few Action Points forFew Action Points for
Indian Steel IndustryIndian Steel Industry

26. 26
Better Utilisation of Iron Ore Resource: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. 27
Better Operating PracticesBetter Operating Practices forfor Reducing Reducing
Energy Intensity: 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. 28
Utilisation of Iron & Steel Making Slags: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. 29
Green Buildings & Energy Optimisation:Green Buildings & Energy Optimisation:
• 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.
• Use of energy saving materials & equipment like heat resistive
paints, fly ash blocks, insulation materials, lighting controls,
BIPV (Building Integrated Photo Voltaics), etc.
• Maximise use of solar power; explore wind energy possibility.
Typical Energy Consumption
Pattern in Buildings:
Source: CII-Sohrabji Godrej Green
Business Centre
Misc. Equipment

30. 30
Stricter Monitoring of Air & Water Pollution: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. 31
Concluding RemarksConcluding Remarks

32. 32
• 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.
• Indian steel industry already on high growth path.
• Industry competitiveness to be ensured by
balancing economic & environmental aspects.

33. 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 CO
2
emissions possible
by developing ‘breakthrough’ technologies.

34. 34
Thank you for your kind attention!Thank you for your kind attention!