alternative iron making

1. COURSE NAME IRONMAKING & STEELMAKING
FACULTY NAME GOUR GOPAL ROY
METALLURGICAL & MATERIALS ENGINEERING, IIT KHARAGPUR
Module 11:
Lecture 56 : Gas based DR Processes (continued)
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2. Schematic representation of the HYL IV M self-reforming process
ØNatural gas is mixed with the recycled gas and fed to the humidifier. Humidity is controlled to adjust the
carburization of DRI.
ØGas passes through a gas preheater where gas temperature is increased to 900oC.
ØBefore the gas enters the reactor, oxygen is injected in the transfer line for partial combustion of NG to
increase its temperature to 1000oC.
ØAfter entering the reactor, the gas undergoes insitu reforming to CO and H2 in presence of nascent
metallic iron.
M stands in Monterrey,
Mexico where it was first
installed.
Developed by HYLSA and
Ferrostaal AG
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3. Features of HYL IV (ZR) Process
ØNo reformer is required. It is also called HYL IV ZR
(zero reforming).
ØGas directly enters the reduction chamber where in-
situ reforming takes place in presence of fresh Fe.
ØProblem with carburizing and poisoning of Ni catalyst
is absent. Freshly generated Fe is available all the time
for in-situ reforming.
ØOxygen is injected in the line to increase the gas
temperature to 1050oC by controlled combustion
ØProcess efficiency is high (87%)
Energy balance of HYL-IV
Process
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4. MIDREX process flow sheet
Insulated
Upper
Reduction
Zone
Un-
insulated
Cooling
Zone
Insulated
Upper
Reduction
Zone
Length=2x
Un-Insulated
Cooling
Zone
Length=1x
Reducing gas
solids
solids
solids
solids
gases
gases
gases
Reduction
Furnace
Off gases
Iron Oxide
Feed
Material
DRI
Details of shaft Furnace
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5. Distinctive features of MIDREX
ØSuitable for the reduction of lump ores that do not decrepitate excessively. Ispat Dolvi (India)
operates Midrex with 50-60 % lump ore (highly reducible). Essar’s five Midrex modules use 20% lump
ore.
ØOxygen carriers from external source (like steam) are not required for producing reformed gas.
Hence investment/operating costs less.
ØWater vapour content of reformed gas is so low that it can be directly injected into the
reduction furnace, without quenching. Saves energy.
ØIn presence of water, Midrex DRI can be prone to reoxidation. So, it is passivated by
forming an outer layer of cementite on the particles. In the cooling section CH4 is
added which react with metallic iron to produce the Fe3C layer.
3 Fe + CH4 = Fe3C + 2 H2
Ø60% of the top gas after cleaning and quenching, is passed to reformer and another 40% is
used as fuel.
ØMore than 60% of world DRI production is through Midrex route
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6. Energy balance in the MIDREX process
(Gcal/t DRI)
ØProcess efficiency: 73%
ØSpecific energy consumption
decreased from 13GJ/ton to
10GJ/ton due to:
ü Higher reduction temperature
ü Enrichment of reduction gas
with methane
ü Utilization of waste heat of
reformer to preheat the
process gas
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7. Element Wt,%
Fe, (total) 91–93
Fe, (metallic) 83–88
Metallization 92–95
Carbon 1.0-4.0
Sulphur 0.005-0.015
Phosphorus 0.02–0.04
SiO2 2.0–3.5
Al2O3 0.5–1.5
CaO 0.2–1.6
MgO 0.005–0.015
Chemical analysis of MIDREX DRI
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8. MIDREX Plants in India
ØJSW, Dolvi, India (2:1 COG/NG based)
1.0 Mtpa
ØEssar Steel, presently Arcelor Mittal
Steel (6 modules, 6.7 Mtpa)
ØJSPL, Angul, Orissa (Lurgi syn gas
based MIDREX) 1.8 Mtpa
ØIt is a fixed bed type in which
course coal (6-40mm) is charged
from the top and gasifying agent
like steam with some oxygen flows
in opposite direction.
ØAfter coal is charged, it gets dried,
volatilized, gasified and combusted.
ØThe process is carried out at 25 to
35 bar and above 1000oC.
ØWater cooled pressure vessel with
typical diameter 3 to 4m is normally
used.
Lurgi Coal Gassifier
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9. REFERENCES
1) Allon Brent, Peter L. J. Mayfield and Thomas A. Honeyands: Fluidized bed production of high
quality hot briquetted iron for steelmaking, conference paper, 1997, AusIMM International
Conference on Alternative Routes of Iron and Steelmaking (ICARISM ’99), At Perth
2) Amit Chatterjee: Sponge Iron Production by Direct reduction of Iron Oxide, PHI, New Delhi, 2012
3) Ghosh & Chatterjee: Ironmaking & Steelmaking: Theory & Practice, PHI, New Delhi, 2008
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10. CONCLUSION
Ø Various gas based DR processes are Finmet, Circored, HYL-I, HYL-III, HYL IV, MIDREX
Ø Finmet and circored are based on Fluidized bed reactor and rest are shaft furnace based
reactor. All the FB reactors are not in operation today.
Ø HYL-I is a batch type process involving 4 reactors and it is obsolete today. All other
processes are based on continuous single reactor.
Ø HYL Process uses a steam reformer; while Midrex process uses off gas CO2 as oxidizing
agent in the reformer. Both the reformer uses Ni as catalyst.
Ø HYL IV eliminates the external reformer and introduced in-situ reforming inside the
reactor using fresh iron as the catalyst.
Ø To exploit the cheap fuel resource like non-coking coal, Midrex is retrofitting its process
by replacing conventional natural gas reforming unit by coal based syn gas generation
unit. JSPL’s Angul plant has 1.8Mt coal syn gas based Midrex plant.
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12. COURSE NAME IRONMAKING & STEELMAKING
FACULTY NAME GOUR GOPAL ROY
METALLURGICAL & MATERIALS ENGINEERING, IIT KHARAGPUR
Module 11:
Lecture 57&58 : Smelting Reduction (SR) Processes
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13. CONCEPTS COVERED
Ø Concept of Smelting Reduction Process
Ø COREX Process
Ø FINEX Process
Ø ROMELT Process
Ø HISMELT Process
Ø HISARNA NPTEL

14. • In an ideal SR reactor, in the strictest sense, all the reduction reactions
should take place in the liquid state in a single step.
• Any SR process involve the extraction of metal values from the ore following
liquid phase reduction by non-coking coal.
• In actual practice, most SR processes utilise two steps – the removal of
oxygen from the ore in the solid state to varying extents in step one,
followed by removal of the remaining oxygen in liquid phase reduction
reactions in step two.
• Compared with DR processes, the principal advantage of high temperature
operation in SR processes is: faster rates of reaction and prevention of
sticking problems associated with solid-state reactions (intrinsic in DR
processes).
• With reference to BF process, it separates the two functions of BF in two
separate reactors, thus eliminating the major irregularities of BF.
SALIENT FEATURES OF SR
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15. Ore
Slag
O2
Coal
Metal
Reduction
and
melting
Gas
Single stage
DRI
Slag
O2
Coal
Metal
Gas
Reduction
Melting
Ore Gas
DRI
Slag
O2
Coal
Metal
Gas
Reduction
Melting
Ore Gas
Gasification
Gas
Coke
Coke
Three stage
Two stage
Flowsheet of single stage, two stage and three stage SR processes
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16. • Smelting reduction processes are thus two-step processes with separate
pre-reduction and smelting reduction steps (such as Corex and Finex),
• Simpler one-step processes involving simultaneous reduction and
smelting (such as Romelt, Hismelt).
• All SR processes consume fairly large volumes of coal that generates large
amount of export gas, the effective utilisation of the generated by-
product gas is extremely important.
• Generally, the use of export gas makes or breaks the cost structure of SR
processes .
Salient features of SR contd..
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17. • Unless the net export gas from any Corex plant can be utilised (extent of
generation 1650 Nm3 / thm with calorific value 1800 Kcal/Nm3 ,compared to
BF gas 700 kcal/Nm3), the process itself becomes totally uneconomical.
• If no credit is given to the off- gas, the cost of the hot metal made can be as
much as 50% higher than blast furnace hot metal.
• Adequate credit can be obtained by selling co-generated electrical power from
the Corex off gas.
• Another use of the export gas is in shaft furnace, DRI production adjacent to
the Corex furnace.
Salient features of SR contd..
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18. Flow sheet of the COREX process
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19. ØThe process is designed to operate at a pressure of up to 5 bars.
ØIt can accept high alkali containing ores without any build-up inside the reactor.
ØThe specific melting capacity is very high – at least twice that of blast furnaces so
that productivities of the order of 3.0-3.5 t/ m3/d can be achieved.
ØAs is the case of blast furnaces, almost 100% of the phosphorus input reports to the
hot metal – thus, the phosphorus content of the ore (and coal) used should be as low
as possible.
ØDifferent modules of Corex units are in operation viz. Posco, South Korea, Saldanha
Steel, South Africa; JSW Steel, Essar Steel, India and Bao Steel, China. Capacities 2000
tpd except Bao Steel 3000 tpd.
Features of COREX process
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20. Flow sheet of the FINEX process
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21. Ø Posco developed this process to utilise iron ore/non-coking coal fines in SR
Process.
ØIron ore fines are reduced in a fluidized bed
Ø Reduced iron after fluidised bed, is hot briquetted before charging into the
melter gasifier.
Ø Non-coking coal dried and is also briquetted before charging into the melter
gasifier.
Ø Hot metal composition same as BF.
Ø Posco has installed 1.5 Mtpa plant – third SR commercialised (after Corex /
Hismelt).
Some features of FINEX
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22. Material flow diagram in ROMELT process
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23. The Romelt furnace scheme: 1 - agitated slag, 2 - sump for slag, 3 - sump for hot metal, 4 -
hearth with refractory lining, 5 - channels for slag and hot metal, 6 - feed tunnel, 7 - gas-
escape branch pipe, 8 - lower tuyeres, 9 - upper tuyeres, 10 - calm slag, 11 - water-cooled
panels [1]
Details of Romelt reactor
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24. Features of ROMELT
ØSingle stage process
ØSteel plant wastes like mill-scale, blast furnace and LD dusts, dried sludge from gas cleaning
plants, iron bearing non-ferrous smelter slags, oily steel turnings can also be used.
ØNon-coking coals (0 - 20 mm) with moisture less than 10% are acceptable; VM less than 20%
preferred, but higher VM coals can also be used.
ØSmall scale of production of 200,000 to 1,000,000 tpa of hot metal is possible along with
flexibility of operation.
ØExcellent hot metal quality – C - 4%, Si – 0.6%, Mn – 0.05%, S – 0.040% and temperature –
1400-1450 °C.
ØRomelt hot metal contains 60% of input phosphorus, 30% P goes to slag and 10% forms a
part of the exit gas.
ØCoal and oxygen consumptions are high – typically coal 1500 - 2000 kg/THM (against 950 kg
for corex ), oxygen 1100 - 1200 Nm3 per thm.
ØRussian Technology, first pilot plant at Novolipetsk Irron & steel Works, NLMK, 1985, a
commercial plant is also erected at Mayanmar of 0.2Mtpa capacity.
ØNot of much success today.
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25. Flow sheet of HISMELT process
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26. Hismelt overview
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27. ØSingle stage process
ØThe method of solid injections using high speed lances ensure that the capture
efficiency in the melt is high and even ultra fines can be used directly.
ØInstead of pure oxygen, oxygen enriched hot air blast is charged using a top lance
ØUtilisation of export gas not as critical as in the case of Romelt / Corex.
ØThe 5 % to 6 % FeO level in the slag in conjunction with the metal carbon at 4 %
creates conditions for strong partition of phosphorus from metal to slag. Typically
around 80 % to 90 % of phosphorus goes to slag.
ØPre-reduction of iron oxide and top lancing of oxygen enrichment of hot air
(1200°C) blast provides substantial productivity enhancement.
ØProcess can use 50% high phosphorus iron ore and 50% plant wastes like mill-scale,
BOF dust, BF sludge, etc.
ØHot metal produced contains 4.3 ± 0.15% carbon, phosphorus and silicon levels are
extremely low viz. < 0.05% P and <0.05 Si%.
Features of HISMELT
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28. HISARNA=ISARNA(Iron)+HISMELT
Developed by Tata Steel, Europe and Rio Tinto
CCF: Cyclone Converter Furnace (fine ore
feed get partially reduced and molten
and falls through the wall to SRV
SRV: Smelting Reduction Vessel
Iron ore fines are injected in
the CCF. It instateneously melt
and partially reduce iron ore
fines that trickles through the
wall of CCF to the SRV for
reduction
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29. Features of HISARNA
ØCAPEX and OPEX lower compared to BF
ØWider range of raw material (ore: P, Zn, Ti, S, alkali)
ØIron bearing solid waste from plant
Ø20% lower energy usage and CO2 emission per ton
ØPilot plant demonstration with 6 month continuous production
ØCommercialization yet to be established
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30. REFERENCES
1) https://www.totalmateria.com/page.aspx?ID=CheckArticle&site=kts&NM=516
2) Amit Chatterjee: Smelting Reduction Process, PHI, New Delhi, 2012
3) Ghosh & Chatterjee: Ironmaking & Steelmaking: Theory & Practice, PHI, New Delhi, 2008
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31. CONCLUSION
ØAlthough SR process should complete reduction at molten state only in single reactor, several
commercialized processes are based on two stage units. In stage 1, partial reduction takes
place in a reduction unit using off gas from second unit, called Melter Gasifier (MG). In MG,
coal is burned with oxygen to generate intense heat to melt partially reduced ore and rest of
the reduction takes place there.
ØHigh off gas credit and to be utilized to make the process cost effective
ØCan use wide variety of raw material including solid waste and non coking coal
ØCommercialized single stage Hismelt –more energy efficient and less off gas credit.
But, higher capital investment per unit.
ØTwo stage Corex most popular. It needs to be connected to Power plant/midrex unit.
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33. COURSE NAME IRONMAKING & STEELMAKING
FACULTY NAME GOUR GOPAL ROY
METALLURGICAL & MATERIALS ENGINEERING, IIT KHARAGPUR
Module 11:
Lecture 59&60 : Ironmaking & Steelmaking in India
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34. CONCEPTS COVERED
Ø Evolution of Global & Indian steel
Ø India’s potential in Steel
Ø Problems in Indian Steel industry
Ø Steel education & research in India
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35. Evolution of Global vis a vis Indian steel
• Production increased gradually upto 1970’s and
then there was a stagnant period during 1970 to
1990 and there after the growth is exponential
• Early steel making in India started with the
Bengal Iron & Steel Company at Barakar in 1875
and then Tata Iron and steel company at
Jamshedpur in 1907.
• In early 1980’s spurt in domestic demand and
economic boom in south east asia, saw
development of new steel making companies
and expansion of existing companies.
• However, soon the situation worsen and demand
fall.
Crude steel production from
1960 to 2018 (courtesy: World
Steel report 2019)
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36. Evolution of Global vis a vis Indian
steel contd…
• In 1990 with liberalization of Indian economy,
private parties were encouraged into steel.
• Significant decline in interest rate, and public
investment in infrastructural development,
increased the steel demand during 2000-
2005.
• In 2018, India become the 2nd largest
produces of steel with 106 MTPa
• Steel consumption wise India is also growing
fast.
Share of global steel production
Share of global steel consumption
Courtesy: World Steel report 2019
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37. Major steel producers in India
Name Location Operator Capacity
Jindal Steel and
Power Ltd.
Raigarh, Chhattisgarh
Angul, Orissa
JSPL 3.6+6 MTPA
Captive power plant
Rail and plate mill
Tata Iron & Steel
Company
Jamshedpur,
Jharkhand+Kalinganagar,
Orissa+BSL (Maharastra,
UP, Orissa)
Tata Steel 10 +3+5.6 MMTPA
Flat products (Auto grade steel, structural steel),
long products
Steel Authority of
India (SAIL)
SAIL(Durgapur, Bokaro,
Bhillai, IISCO, Rourkella),
SSP (Durgapur, Salem,
Visvesvarya), Ferro-alloy,
refractory
GoI 16 MTPA
Product: Rail ,structural, flat and long products,
special steel
JSW Steel Bellery, Dolvi, Salem JSW 18 MTPA (leading steel producer in India)
Leading exporter of steel in 100
countries(>3 MTPA). Conarc steel melting.
Vizag Steel Visakhapattnam, AP RINL 7.3 Mtpa
Largest producers of bar & rods
ØSecondary steel sectors
(EAF, EIFs) produces about
30% of the annual steel
production in India
ØA large number of such
units produce easily
saleable TMT bars
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38. India’s Potential in Steel
ØAt present India’s per capita steel consumption is meager 70 kg compared to world
average of 225 kg.
ØThis low average steel consumption of India is due to rural population (around 70%
of total population) who does not have purchasing power (per capita steel
consumption is about 2 kg).
ØTo enhance the rural steel consumption, government has taken some rural oriented
policies. This has increased steel demand in rural India.
ØLarge availability of good quality of iron ore reserve
ØPotentiality in global market. Study indicated India is the most competitive place for
outsourcing metal based manufactured products.
ØAlready Indian is second largest producer of steel.
ØThere is large scope to enhance the steel production much above the present
capacity.
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39. Challenges
ØShortage of coking coal
ØInfrastructure
ØAncillaries (MSMEs)
ØInefficient management (huge expenditure on social overheads, poor
management, poor industrial relation, especially in public sector)
ØLow labour productivity (Labour productivity in advanced countries is about
600-700 tonnes per man per year whereas in India it is only 90-100 tonnes).
ØEnergy efficient technology
ØGlobal competitiveness in steel price
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40. Problems: Coal Scenario of India
Ø Total proven coal reserve in world exceeds 1 trillion and 50% of which are coking coal.
Ø India’s total coal reserve is 7.6% to that of the world and coking coal is only 15% of the
reserve. This meager amount also exhibits problems of high ash (upto 30%) and low rank.
Ø Thus coal is a big concern in India towards enhancing the steel production.
Ø With increase in steel production, coking coal demand always outstripped the supply.
Besides this limited availability, high ash and low rank has been addition constraints.
Ø Therefore, integrated steel producers had no option but to import high quality coal from
Australia amounting 30 to 50% of total coal requirement.
Ø Another limitation of larger ports capable of handling 1,50,000 tons of coal in a large cargo
ship.
Ø With development of such ports , imports from other countries like USA, Canada, poland,
and low ash non coking coal from SA and Indonesia can find increasing use in in Indian
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41. Iron Ore Scenario in India
• Current Indian commercial mining capacity of iron ore is 175 Mtpa.
• In 2005, 145 Mt was mined and 78 Mt was exported.
• Iron mining capacity need to enhance in future and export of high
grade ore need to be stopped. It is already under severe scrutiny of
the government.
• For 180 Mt steel production in future, 330 Mt of iron ore needed to
be mined.
• It will not be difficult to meet such demand for next 50 years if no
export are put in place.
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42. Alternative Ironmaking in India
• While India has major advantage over many other countries including china, in terms of
rich iron ore for next 50 years, India is crippled with limited and poor quality coking
coal.
• This prompted India to explore alternative routes of iron making using non-coking coal,
natural gas.
• Largely available non coking coal and off shore gas along with rich iron ore, have
prompted several direct reduction and smelting reduction routes successfully in India.
• This also helped to disperse Indian steel production from eastern India because of
proximity of both coking coal and iron ore.
• DR that entered in 1981, has grown at a faster rate. Today more than 180 DRI units.
• India has surpassed the DRI production over that is produced in gas rich countries like
venezuela, mexico ,where DRI is produced exclusively by gas based Midrex and HYL
process.
• India produces DRI based on both coal and gas and today is the largest producer of DRI
in the world (30 Mtpa).
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43. DR/SR units in India
Ø During 1985-1995 three major gas based DR units were: Essar (Hazira, Gujrat; presently
Arcelor Mittal) 3.6 Mtpa (1990), Ispat Industries (Mumbai, Mittal) 1.6 Mtpa (1994), and
Bikram Ispat (now Welspan maxsteel, Goenka): 0.9 Mtpa (1993)
Ø Domestic DRI capacity increased by about 280% in eight years during 2005-13.
Ø Essar is the largest single location gas based DRI/HBI plant in the world (3.6 Mtpa).
Ø JSPL is the largest single location coal based DRI plant in the world (1.32 Mtpa coal based
DRI+2Mtpa syngas based DRI).
Ø No greenfield natural gas based DRI/HBI plant came up after 1994.
Ø Major growth in coal based sector from 2003-04 to 2008-09.
Ø Presently, no small coal based plants (50 PTD, 100 TPD) are allowed by State Governments.
Ø Total DRI production in India today 30 Mtpa (leading producer in the world)
Ø Shortage of NG are being replaced by coke oven gas, Corex gas (JSW) and coal based syn
gas (JSPL)
Ø Two Corex SR units (C-2000 model of capacity 0.8 Mtpa each) at JSW Bellary, Karnataka
and two similar units at Essar, Hazira, Gujrat, exist today.
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44. Comparative data of Indian Iron & steel sector Vs Global bench mark
Parameters Unit Indian I&S sector Global Bench mark
BF Productivity t/day/m3 1.5-2.5 2.5-3.5
Energy
Consumption
Gcal/tcs 6-6.5 4.5-5.5
Coke rate Kg/thm 350-500 300-350
PCI Kg/thm 50-200 150-250
SMS slag rate Kg/tcs 180-200 <100
CO2 emission t/tcs 2.8-3.0 1.7-1.9
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45. Education/Research in India
ØWhile the country is gearing for 200 Mtpa steel in near future, the steel education
and research has taken back seat
ØThe slump of steel market in 1990 and migration of graduating engineers to IT
sectors and management jobs, has inflicted irreversible damage resulting in acute
shortage in qualified engineers in plant and R&D sectors
ØReluctance of bright students adopting for iron & steel as a viable career option has
largely affected academia, since the expertise available in academia in 80s’ has
cease to exist now.
ØThe number of professionals working in iron and steel research and education has
diminished significantly today. This subsequently affected the post graduate
teaching and research program in many departments and it has formed a vicious
circle of lower and lower iron and steel research in India.
ØSome initiatives has taken by Ministry of steel.
ØBut country seems to lack critical man power today.
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46. Evolution of Iron and steel research and education in India
Ø The first Metallurgy program in the country was established in BHU in 1923, subsequently at BE college,
Shibpur in 1939
Ø During 1960 and 70s various IITs and NITs introduced undergraduate program in Metallurgy.
Ø However, between 1970 and 2010, only six other colleges added to Metallurgy.
Ø First PhD from BHU in 1955 and regular PhDs from 1960s from many departments
Ø From 1990, many metallurgy departments changed its name to the Department to Metallurgical and
Materials Engineering and tuned the research more towards emerging materials and de-emphasing
traditional metals.
Ø Traditional subjects on extractive metallurgy, fuel and mineral engineering are cut short to make places for
courses related to materials (electronic materials, nano materials, biomaterials).
Ø As a result new engineering graduates remains under-exposed to metal processing and allied
subjects
Ø Several Industrial R&D have also been established, but innovative and path breaking
technology is yet to emerge
Ø High quality manpower, world class infrastructure, and creative environment are pre-
requisite to novel R&D outputs.
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47. REFERENCES
1) World steel report 2019
2) Amit Chatterjee: Smelting Reduction Process, PHI, New Delhi, 2012
3) Ghosh & Chatterjee: Ironmaking & Steelmaking: Theory & Practice, PHI, New Delhi, 2008
4) Dipak Majumdar: A First Course in in iron and steelmaking, UP, 2015
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48. CONCLUSION
ØIn 2018, India become the 2nd largest produces of steel with 106 MTPa
Ø Major steel making companies in India today are JSW steel, JSPL, Tata Steel, SAIL, RINL
ØLarge domestic market and availability of rich iron ore for next 50 years indicate a bright future of India in
steelmaking.
ØIndia’s total coal reserve is 7.6% to that of the world and coking coal is only 15% of the reserve. This meagre
amount also exhibits problems of high ash(upto 30%) and low rank.
ØIndia is dependent largely on the import of good quality of coking coal from abroad and this dependence will
increase with larger production of steel
ØIndia has diverted its attention to alternative routes of ironmaking through DR and SR routes to utilize non-
coking coal, off shore gas, coke oven gas, corex gas, coal based syn gas.
Ø India is the global leader in DRI production with 30 Mtpa today
ØThe number of professionals working in iron and steel research and education has diminished significantly
today.
ØHigh quality manpower, world class infrastructure, and creative environment are pre-requisite for novel R&D
outputs.
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