The document discusses the present scenario and vision for the Indian steel industry. It notes that while India is the 4th largest steel producer globally, per capita consumption is still below world averages. The national steel policy aims to increase total steel production to 110 million tonnes by 2019-20 through brownfield and greenfield expansion projects to meet growing domestic demand from infrastructure and other sectors and achieve an annual growth rate of around 7%.

1. Presented by
Mainak Saha
Saumya Ranjan Jha
Sumit Katiyar
Department of Metallurgical and Materials Engineering
NIT Durgapur
Guide: Dr. Amit Ganguly
Ministry of Steel Chair Professor (NIT Durgapur)
Govt of India

2. Primary Energy Mix data
showing Coal as the
majority shareholder as per
2013 statistics
Raw Coal Usage in various
sectors of Industry for usage
as source of energy

3. Role of coal in present scenario in Iron
and steel plants
Coke(composition:Carbon content 80 – 90%, Volatile
Content 1 – 5% and Sulfur Content 0.5 – 1.5%. ) is used
widely as
• main fuel for Blast furnace in ironmaking(0.75-1.5’’).
• Pet coke in EAFs,coke breeze(<0.75’’)
• Fuel in cupola(5’’x2’’)
• Calcined pet coke in induction furnaces.
Its abrasive and this is determined by its M40
index(micum index)

4. Role of coal in present scenario in Iron
and steel plants
• Anthracite Coal – low cost per ton of fixed
carbon, low sulfur content.
• Metallurgical Coke – low cost per ton of fixed
carbon, low sulfur content.
• Calcined Pet Coke – high fixed carbon content
but not normally used because of high price.
• Synthetic Graphite – high fixed carbon
content, low sulfur and gas levels but not
normally used because of high price.

5. Report from Coal India limited
Coal Production
Grades Fiscal
2013 2014 2015 2016 2017
Raw coal
production
Mill Te
% of
Raw coal
production
Raw coal
production
Mill Te
% of
Raw coal
production
Raw coal
production
Mill Te
% of
Raw coal
production
Raw coal
production
Mill Te
% of
Raw coal
production
Raw coal
production
Mill Te
% of
Raw coal
production
Non
Coking
Coal 1
408.56 90.3 413.50 89.4 443.67 89.8 484.93 90.0 499.49 90.1
Coking
Coal 2
43.66 9.7 48.92 10.6 50.57 10.2 53.83 10.0 54.65 9.9
Total 452.21 100.0 462.42 100.0 494.24 100.0 538.75 100.0 554.14 100.0

6. INDIA’S COKING COAL PRODUCTION
SCENARIO

7. Present Status and Future Projections
from Ministry of Steel, Govt. of India
• World Steel Production : 1527 MT
• Indian Steel Production : 72 MT
• World Ranking in Production : 4th
• World Ranking in Consumption : 3rd
• Projected Capacity by 2016-17 : 150 MT
• Projected Capacity by 2019-20 : 200 MT
• Projected Capacity by 2030 : 500 MT

8. SUPPLY SIDE PROBLEMS OF COKING COAL
• The quality of coal is poor with high ash and
moisture content.
• Coking coal is very scarce, being imported
• Coal mining suffers from multiple obstacles
like environmental clearance, tribal resistance,
Left wing extremism domination etc.
• Poor technology is causing excessive wastages.

9. DEMAND SIDE PROBLEMS OF COKING COAL
• Domestic demand is shrinking as their major
buyers i.e. Power companies are suffering
losses due to non recovery.
• With amendment to Coal act there is an
oversupply of coal in the market.
• Dumping of steel in indian market by China
has severely hurt Coal sector.

11. Report from Ministry of Coal, Govt of India

12. Major coking coal supplying countries
to India

13. Coking Coal-future global scenario
• Global metallurgical Coal Supplies are limitedƒ
• Significant investment in Mines and Infrastructure
will be required In traditional and emerging basins to
ensure that adequate supplies will be available after
2017
• ƒAfter 2020, supply will struggle to keep up with
demand–prices will increase in real terms

14. Reduction of Coking coal consumption
in Blast furnace
• Pulverised Coal Injection(PCI): Mixing powdered coal with hot blast to
lower the combustion temperature and also replacing expensive
coking coal with cheaper non-coking coal.
• Oxyfuel injection:
using oxygen enrichment in the air for combustion in the hot stoves
offers three
Advantages:
• First, the hot blast temperature may be increased due to higher flame
temperature which reduces the blast furnace reductant consumption.
• Secondly, the lower volume of flue gas reduces the loss of sensible
heat via the flue gas.
• Thirdly, COG or other higher value fuels may be used more effectively
elsewhere.

15. Alternatives
• Non-coking coal usage : RKDR/Corex/Hismelt,etc.(smelting Redn.)
• Coal Gasification Based DR :
1. SAIL-CSIR Project (Dr AG as Coordinator in 1983: Iron & Steel
International,London, Univ Of Miami Energy Conf., etc.)
2. MXCOL Process for Midrex(originally NG-based)
3. Iron Carbide Research(AG’s group)
4. Fine coal, both as energy and reducer, Injected into recirculating
molten iron bath , for smelting of iron ore fines(AG, U of Minnesota
clean coal project : Steel Research, Germany, 1992).

16. Carbon utilisation in direct smelting
systems - Minnesota gas lift mechanism
• Coal fines, injected directly into vigorously
moving molten iron bath, along with iron ore
and oxygen.
• Serves 2 functions:
- coal fines undergo easy combustion
- Reduction of iron ore by coal fines
Not yet commercialised.

17. Iron Carbide process
• Originally, a process developed in Chicago, USA as
fluid bed process utilising iron ore fines and Natural
Gas producing Fe3C.
• Work done at MME dept involved theoretical
analysis utilising coal gasification since natural gas
allocation is a problem to steel sectors in India.
• While the modelling showed its feasibility, hot
model study(at pilot scale) is awaited for signal
from CFRI, Dhanbad (CSIR).

18. advantages
• Bonus 6-7% carbon content, injectable.
• Foamy slag possible
• No problems like Scrap, DRI.
• Environmental friendly.
• Not yet commercialised like in FINEX or FIOR.

19. 2016 world DRI production
MIDREX
HYL/energiron
other gas
Rotary Kiln(coal based)

20. DRI production over the years by
different processes
process/percentage 2014 2015 2016
MIDREX 63.2 63.1 64.8
HYL/Energiron 16.2 16 17.4
Other Gas 0 0.7 0.3
Rotary Kiln/coal-
based) 20.6 20.2 17.5

21. 0
10
20
30
40
50
60
70
percentageproduction
process
process vs percentage production
Series1
Series2
Series3

22. COG to produce DRI
• COG(Coke oven gas) contains valuable
components to be used for shaft furnace base
on DRI.
• The first one in India has been set up at JSPL,
Angul.
• Challenge: long chain and cyclic hydrocarbons in
COG may be detrimental to the gasification
process.

23. MXCOL Plant
Air separation
plant
Coal gasifier
O2
Gas cleaning and
conditioning
Gas heater
coal
Syngas
Shaft furnace
DRI/HBI
Iron Oxide
Scrubber
CO2 removal

24. MXCOL COG flow sheet
COG
preheater
Thermal reactor
Syngas
MIDREX shaft
furnaceIron oxide
Scrubber CO2 removal
Gas heater
Air separation
plant
O2
Coke oven gas
DRI/HBI

25. COREX-CEMENT-POWER PLANT COMPLEX
ORE COAL FLUX OXYGEN
COREX HOT METAL
SLAG
EXPORT GAS
POWER PLANT
POWER
CEMENT POWER
POWER
SLAG CEMENT
COREX coals should have at
least 25% ash, 35% volatile
matter, about 67% carbon

26. Direction of project work
• Utilisation of as much less energy as possible
in steel plants else live with the reality.
• Search for alternatives.

27. Energy consumption trends with
technological advancement

28. • Energy constitutes a significant portion of the cost of steel
production, from 20% to 40% in some countries. Thus,
improvements in energy efficiency result in reduced production
costs and thereby improved competitiveness.
• The energy efficiency of steelmaking facilities vary depending on
production route, type of iron ore and coal used, the steel product
mix, operation control technology, and material efficiency.
• Energy is also consumed indirectly for the mining, preparation,
and transportation of raw materials (about 8% of the total energy
required to produce the steel - including raw material extraction
and steel production processes.
• About 50% of an integrated facility’s energy input comes from
coal, 35% from electricity, 5% from natural gas and 5% from other
gases
Energy inputs and associated costs

29. Hydrogen
as an alternative
source of energy

30. In 2009, R & D dept of TATA Steel conducted a pilot trial on
the H2H process, hydrogen-rich gas is produced by the
thermo-chemical decomposition of water in the presence
of catalytic fluxes. The hot slag plays two roles:
(1) It provides heat for the water decomposition reaction
(2) It prevents the reverse reaction between hydrogen and
oxygen gases as the metal particles and suboxides present
in the slag react with the oxygen.
The team opted for simulation of the conditions inside the
H2H reactor, using computational fluid dynamic modelling
tools, with the help of Tata Research Development and
Design Centre, to simulate the rate and flow of products of
various reactions inside the reactor.
Pioneering work in Hydrogen recovery

31. Hydrogen Production Technologies
 Reforming of Carbonaceous Sources
 Pyrolysis of Biomass and reformation of bio-
oil and gaseous products
 Gasification of Renewable Biomass and its
Reformation
 Electrolysis of Water
 Bio-Hydrogen Process
 Thermochemical splitting of water

32. Advantages of using Hydrogen as fuel

33. The success of the hydrogen harvesting process has several
remarkable implications for the steel industry:
• It creates a clean fuel source at a low cost by using waste
heat and waste water.
• Hydrogen fuel cells are a new product area with uses in
transport and other industries.
• The process has the potential of increasing revenue as well
as added benefits in terms of carbon credits and patents.
• The gas can be used as a fuel in drying furnaces, reheating
furnaces, ladle pre-heaters, captive power plants, etc.
With this, consumption of coal and other fossil fuels
reduces and CO2 emissions can come down by about 25kg
per tonne of steel.
Advantages of using Hydrogen as fuel

34. PLASMA
as an alternative
source of energy

35. What is Plasma?
A plasma is a hot ionized gas consisting of approximately equal
numbers of positively charged ions and negatively charged
electrons. The characteristics of plasmas are significantly different
from those of ordinary neutral gases so that plasmas are
considered a distinct "fourth state of matter."

36. Diatomic gases like H2, N2
Plasma subjection
Dissociated atoms
which are chemically more active
than root diatomic molecules
Temperature at which gases significantly ionised:
5000 – 25000 K
This large temperature could be exploitable for
carrying out smelting operations

37. Iron & Steel industry
Thermal Plasma category
High intensity arcs
(based on)
shockwaves
High pressure
radio frequency
discharges
(field strength to
pressure ratio is small)

38. In such conditions, thermodynamic equilibrium may not
prevail causing other product formation not predicted in
conventional routes.
Oxides predicted thermodynamically unreducible can be
reduced to metal in plasma reactor.
Eg: Chromite ore Ferrochrome alloy
SSP (Sustained Shockwave Plasma)
reactor
RECENT DEVELOPMENTS USING RF PLASMA DEVICES:
1. Material synthesis by sintering green refractory rods of Al2O3
2. Production of nitrides (AlN, Si3N4) & carbides (SiC)

39. Schematic of plasma powered reducer

40. Orbitting plasma for iron smelting
 Attempts made at University Of Minnesota to
utilise plasma produced through electrical
shockwaves not only as a heat source but also
as a thermodynamic & kinetic medium for
smelting, using iron ore and coal fines.
 Also for circulation, a magnetic system is
utilized between cathodic and anodic segments.
(Ref. AG, U of M, steel times
international, London, 1986.)

41. Orbitting plasma for iron smelting

42. NATURAL GAS
as an alternative
source of energy

43. Availability of Natural Gas is a limitation

44. Availability of Natural Gas is a limitation
in Indian context

45. Availability of Natural Gas is a limitation
in Indian context

46. Natural gas application in iron carbide process
 Utilising iron ore fines in fluid bed with natural
gas
 Iron carbide produced is A substitute material
for charging into EAF (Chicago, USA)
 However for Indian conditions, NG being not
available and naphtha being not suitable, coal
gasification has been resorted to in a
conceptual project by Dr A.G. Group. (CFRI,
Dhanbad under CSIR). (Presented at EEC, Venice
2016)

47. NUCLEAR ENERGY
as an alternative
source of energy

51. Schematic showing generation of electricity
by Nuclear reactor

53. Unique features of fission energy & nuclear fuels
 High energy density
 Carbon free minimum volume of waste generation
 High base load electricity and plant load factor
 High capital cost but low maintenance costs
 Produce new fuel/fissile material from fertile
material, consuming fissile one
 Radioactivity & health hazard

55. Sources
of energy
used for
Industry
and
manufacturing,
2010

56. Predicted Energy resource consumption

57. Conclusively,
Deeper investigative studies shall be
undertaken to bring out ways and means
of establishing areas of application in the
ferrous sector, during the span of my
research project.

58. By-
Sumit Katiyar
Guided By-
Dr. Amit Ganguly

59. Introduction:
Iron and Steel Industry in India is on an
upswing because of the strong global and
domestic demand. India's rapid economic
growth and soaring demand by sectors like
infrastructure, real estate and automobiles,
at home and abroad, has put Indian steel
industry on the global map. According to the
latest report by International Iron and Steel
Institute (IISI), India is the 4th largest
steel producer in the world.

60. The present scenario of the industry
India has one of the richest reserves of all the raw
materials required for the industry, namely land, capital,
cheap labour, iron ore, power, coal etc. Yet we are 4th in
the world ranking for production of steel. We produced
66.8 million tonnes in 2010-11, while China, at the top
of the list, produced 626.7 million tonnes. Our per
capita consumption of steel in India (at 50 kg per
annum) is well below the world average (at about 200
kg per annum) and much below that of the developed
world (around 350 kg per annum).

61. Vision of the Steel Industry in India
The National Steel Policy – 2005 aims at increasing the
total steel production of the country to 110 million
tonnes per year (in 2019-20) from 38 million tonnes
(in 2004-05). This was supposed to require a
compounded annual growth of about 7.3%. The total
production in 2010 was 66.8 million tonnes. The
compounded annual growth from 2005 to 2010 has
been more than 9% which is better than the expected
growth. But most of these are a result of the
brownfield expansion projects of the existing steel
companies. But to continue with the same growth
rate, we need new Greenfield projects.

62. As per report of Ministry of Steel ,India
National Steel policy setup a production target of 110 million tonnes. Domestic
Demand of steels as tabulated follows:
Item 2010-11(Million tonnes) 2016-17(Million
Tonnes)
Carbon steel 62.14 108.3
Alloy/Stainless steel 3.47 5.0
Total domestic demand 65.61 113.3
Export 3.34 2.0
Net production 62.27 115.3

63. India’s export of Iron and Steel

64. Imports:
 Iron and steel are freely important as per extant policy.
 Last five year’s import of total finished steel (alloy +non alloy)
is given below:-
Indian steel Industry :Imports( in million tonnes)
Category 2007-
08
2008-
09
2009-
10
2010-
11
2011-
12*
Total Finished
steel (alloy +non
alloy)
7.03 5.84 7.38 6.66 6.83
Source: Joint Plant Committee; *provisional

65. Industry structure
The Iron and steel Industry in India has two separate divisions:
 Integrated producers
 Secondary producers
Integrated Producers: Amongst the Integrated producers, the
major producers include Tata Iron and Steel Company Limited (TISCO),
Rashtriya Ispat Nigam Limited (RINL) and Steel Authority of India
Limited (SAIL), who generate steel by converting iron ore.
Secondary Producers: The Secondary producers like Ispat
Industries, Lloyds steel and Essar Steel, create steel through the
process of melting scrap iron. These are mainly small steel plants and
produce steel in electric furnaces, using scrap and sponge iron. They
produce both mild steel and alloy steel of given specifications.

66. Main Problems of steel Industries
 Raw Materials Issues - depletion of iron ore and coal reserves
A. Iron Ore
 Resources and Reserves of Iron Ore in India as on 1.4.2010
(Million Tonnes)
Grade Reserves Remaining
Resources
Total
Resources
Haematite 8093.5 9788.6 17882.1
Magnetite 21.8 10622.3 10644.1
Total 8115.3 20410.9 28526.2

67. B. Coals
 As on 01.04.2011, India has total coking coal reserves of 33.474 billion
tonnes, out of which 17.67 billion tonnes is of proved category. Out of
this, prime coking coal is only 4.61 billion tonnes. Majority of coking
coal reserves in the country have high ash content, which is not
suitable for steel industry.
 As on 01.04.2011, India has total non-coking coal reserves of 252.39
billion tonnes, out of which 96.33 billion tonnes is of proved category.
 Coking coal quality problems, consequently, have forced the Indian
blast furnace based steel makers to get increasingly dependent on
imported coking coal and the high price of this critical raw material in
the international market has sharply eroded their competitive position.

68.  Infrastructure problem for steel industry and associated mining industry
 Steel manufacturing involves bulk movement of raw
materials and finished products over long distances and
across the country. Movement of raw materials requires
special attention as extraction of mineral resources is
largely confined to remote and relatively inaccessible
areas in the eastern and southern regions of India. Mining
areas in general are characterized by poor transport and
logistics network, power shortage and water scarcity.
These infrastructural constraints continue to dent steel
industry‘s competitiveness on account of higher
transportation cost, higher tariffs, and long delays.

69. Process Routes of Production of Iron & Steel
i) Coke Oven - Blast Furnace (BF) -Basic Oxygen Furnace (BOF) using Coking
Coal and Iron Ore (Lumps/Sinters) as basic inputs for production of steel flat
& long products.
ii) COREX – Basic Oxygen Furnace (BOF) using non-coking coal and iron ore
(lumps/pellets) as basic inputs for production of steel flat product.
iii) Direct Reduced Iron (DRI) – Electric Arc Furnace (EAF)using Natural
Gas/Non coking Coal and iron ore (lumps/pellets) as basic inputs for steel
production.
iv) Mini Blast Furnace (MBF) – Energy Optimizing Furnace (EOF) using coke and
iron ore lumps and scrap as basic inputs for steel production.

70. vi) Stand-alone Electric Arc Furnaces using steel scrap and purchased sponge iron
as basic inputs mainly for production of steel semis & long products.
vii) Standalone Electric Induction Furnaces using steel scrap and sponge iron as
basic inputs mainly for production of steel semis & long products.
viii) Standalone Mini Blast Furnaces using mostly iron ore lumps and coke as basic
inputs for pig iron and ductile iron spun pipe production.
ix) Stand alone Gas/Coal DRI Furnaces using iron ore lumps/pellets and Natural
Gas/ Non Coking Coal as basic inputs for production of Direct Reduced Iron
(Sponge iron).
x) Stand alone Rolling /Processing Mills using purchased/imported inputs for
production of long & flat rolled steel products including coated sheet products.

71. A TYPICAL CASE STUDY FOR INNOVATIVE TECHNOLOGIES LEADING TO
PROFITABILITY
 Improving operating parameters in EAF based on HBI utilization.
 HBI (HOT BRIQUETTED IRON) Developed based on preventing DRI re-
oxidation problems (spontaneous combustion resulting from high porosity
of DRI).
 The compact, dense material became a better charge material for
substituting scrap (HBI) in EAF which was developed by collaboration of
Industry named MIDREX, USA and UNIVERSITY OF PITTSBURGH in whose
team Dr. Amit Ganguly was one of the participants from UNIVERSITY OF
PITTSBURGH as a post-doc fellow.
 While utilising HBI, a great deal optimisation had to be struck to improve
consumption figures , through radical improvements in design and
development.

72. HOT BRIQUETTING SYSTEM

73. Controlling HBI related factors to control Energy rise in EAF
Superior DR Technology
HBI of high DOM
Less Impurities
Suitable ReductantHigh Grade Iron Ores
Optimum Charge
Control of energy in HBI-EAF Route
Continuous charging of HBI
Optimum HBI Ratio
In Charge mixture

74. Effect of continuous charging on HBI

76. EAF Steel Making Improvements

77. Future Plans for steel Plants
 Iron-making process which does not require coking coal –
Emerging Alternative Iron making processes
 Conversion of non-metallurgical coal into coking variety
 Improve washing to increase yield and reduce ash for coking and
non coking coals
 Beneficiation of lean / fine and friable iron ores and suitable
agglomeration for iron making
 Use of mine wastes
 Recycling of Steel Plant wastes to reduce / conserve the raw
material inputs
 Refractory life of steelmaking furnace e.g. refractory quality,
sintering characteristics, brick making, recycling etc.
 Standardization and optimization of EAF with hot metal charge to
improve overall performance of EAF

78.  Re-use and recycling of LD slag
 . New process/technology for ferro-alloy making to reduce the cost and CO2
emission
unit Co2 t/ton steel
Mining 0.2
Coking 0.1
Sintering 0.3-0.4
Iron making 0.7- 1.1
Steel making 0.1-0.2
Continuous casting 0.1
Hot rolling 0.1-0.2
Total 1.2-2.3
Co2 emission in integrated steel plant

79. Conclusion :
EAF has adopted HBI as feed constituent to supplement scrap
when needed and to dilute residuals to enhance steel quality when
required.
The rising trend in energy consumption generally confronting the
steelmaker while utilizing HBI needs to be largely offset to make it
a viable charge.