The presentation contained context of Iron & Steel w.r.t. Climate Change, response of sector in India and Tata Steel. Sustainable solution offered by Tata Steel and brief discussion on Carbon Capture prospects at BF at the National seminar on “Environmental Prisnciples, Policies and Climate Change” organised by Indian Institute of Metals - Kolkata Chapter on 16 Dec 2010 at Taj Bengal, Kolkata

1. Response to Climate Change
& CCS in Blast Furnace
Shibojyoti Dutta
Head(Climate Change & Strategic Planning), TATA Steel, Jamshedpur
National seminar on “Environmental Principles, Policies and Climate
Change”, 16 Dec 2010
Indian Institute of Metals, Kolkata Chapter

2. Content
• Tata Steel’s Response to Climate Change
• Carbon Capture in Blast Furnace
• Expectations
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3. RESPONSE TO CLIMATE CHANGE
Tata Steel
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4. Background – I&S India
• Steel is the most recycled material – but in India recycling rate is inferior
• Primary Steel Making (extraction of Iron from Ore) is Carbon Intensive due to
dependence of fossil fuel, which is used as reducing agents
• Raw material quality in India is not of prime grade
– High Ash in Coal
– High gangue in Ore
Thus fuel requirement and slag rates are higher
• Source of power & energy used for steel making are also mostly fossil fuels
• Until economical source of energy & power is delinked from Carbon, Energy
Conservation remains the mainstay for GHG abatement
• Global I&S Sector contributes ~2.5-3 BTCO2PA i.e. 6.5% of global GHG
emissions (I&S contribution up from 1.4 BTCO2PA in 1995)
• Indian I&S sector contributes ~0.3-0.4% of global emissions ~0.1-0.2 BTCO2PA
• India contributes to 5% of global GHG emissions though per capita emission @
1.1-1.5 tCO2e is way below global average – comparable with global steel
emissions
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5. Background – Tata Steel
• CO2 emission intensity reduced by 36% over past 12 years through installation
of energy efficient equipment & processes, improving by-product fuel usage &
waste heat recovery.
• Ongoing schemes are expected to reduce 1.2 MTPA emissions from BAU
– Coke Dry Quenching with 5 Coke Oven Batteries
– Energy efficient Pelletization for Agglomeration of Ore to be used in Iron Making
– Replacement of 4 Old Blast Furnaces with New Efficient Blast Furnace
– Top Gas Recovery Turbine in New Blast Furnace
– Heat Pipe Waste Heat Recovery System in New Blast Furnace
– Electric Blower with LCI Drive for blowing New Blast Furnace
– Casthouse Granulation facility with New Blast Furnace
– Variable Speed Drives for I.D.Fans of BOF Vessels of LD3
– LDG Recovery and Utilization and
– Thin Slab Caster and Rolling
• Pursuing to improve process efficiency and other in-house initiatives
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6. Background – Tata Steel
• Pursuing development of products that shall help steel consumers to reduce
footprint
• Possible initiatives based on commercially available technologies and best
practices used for assessing future level of JSR
– 10 major projects are being implemented with total potential of 1.2 MTCO2PA
– 7 more potential measures are being assessed with potential of another 1.9 MTCO2PA
– Once roadmap to 2020 is rolled out, further work for post 2020 will be launched
• Best Practice database developed by RD&T, Tata Steel Group
• Tata Steel Group is participating in a major international R&D project - ULCOS
(ambitious objective of reducing carbon intensity by 50% by 2050)
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7. Sustainable solutions
Automotive
•High strength steels/advanced high strength steels
•Low friction engineering steels for gearboxes/engines
Construction
•Light-framed steel housing
•Carbon neutral housing, sustainable construction,
adaptation applications
Power
•Onshore/offshore wind turbines
•Photovoltaic coatings, which have the potential,
based on the surface area of coated steel cladding
currently sold
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8. CCS CASE – B.F.GAS
Pursuing
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9. Appreciation of CCS – BFG Case
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World Coal Institute 2007/08 on CCS
• Enables CO2 capture & storage thereby avoid release to atmosphere
• Cost-effective for large, stationary sources e.g. power plants & steelworks
IPCC
• Power plants with CCS could reduce CO2 emissions by 80-90% net
• Majority of CCS technologies either
– economically feasible under specific conditions or
– part of a mature market now
Cost of Power with or without CCS
US$/MWh Conventional Combined Cycle IGCC
Normal-Without CCS 43-52 31-50 41-61
With CCS 63-99 43-77 55-91
Abatement Cost 30-71 38-91 14-53
With CCS & EOR 49-81 37-70 40-75
Abatement Cost 9-44 19-68 (-7)-31
Source: Special Report of WG-III of IPCC 2005

10. Appreciation of CCS – BFG Case
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Power Plant-CCS Blast Furnace Gas-CCS Remarks
Gas description Boiler Waste Gas Byproduct from BF Both have dust and is cleaned;
S not a problem in BFG case
- CV Nil 800-930 Kcal/Nm3 Boost BFG CV-950-1200
Kcal/Nm3
- CO2 Conc. 10-15% 17-22% High in BFG – better
- Scale 4 MTCO2PA from a
500 MW plant
2 MTCO2PA from BF of
3 MTPA capacity
- Other
constituents
O2 = 4-8%
N2 = 78-79%
CO = traces
CO = 23-30%
H2 = 2-5%
O2 < 1%; N2 = balance
C in CO form to escape for BFG
case (not Good)
Both are saturated with
moisture
- Temperature 140-180°C 40-50°C BFG case less energy & space
intensive (good) – Wet BFG
GCP
- pressure ±100 mmwg +400 to 1200 mmwg
Source: Tata Steel Analysis

11. Appreciation of CCS – BFG Case
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Power Plant-CCS Blast Furnace Gas-CCS Remarks
Gas
description
Boiler Waste
Gas
Byproduct from BF Both have dust and is
cleaned; S not a problem in
BFG case
- SOx Present Negligible
- Gas hazards Asphyxiation,
corrosive
Toxic, Inflammable Explosion hazards in BFG
case
- Contaminants Yes Yes
Post CCS
performance
- GHG
Emission
GHG free power 40% C captured
(additional* coverage
needed for 100%)
* At the consumption points
(i.e.after combustion), the
CO2 concentration in waste
gases are likely to vary
between 15-24% based on
application & process control
Source: Tata Steel Analysis

12. Appreciation of CCS – BFG Case
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Forecast of Cost of CCS-2020
• For power generation: US$40-90/tCO2 avoided
• With most cost effective technology, Capture cost ≥ US$15/tCO2 avoided min. (for
other applicable capture it would be ≥ US$5/tCO2 avoided min.)
• At the most cost effective storage site, Storage cost ≥ US$2/tCO2 avoided
CCS sub-Activities US$/tCO2 net
Capture-Power Plants 15–75 Additional cost over per unit avoided
Capture-H2 & NH3 plants 5–55 Only drying & compression
Transportation 1–8 250 km pipeline or by ship 5-40 MTPA
Geological storage 0.5–8 EOR / ECBMR not considered
Monitoring & verification 0.1–0.3 Baseline & post verifications
Source: IPCC 2007
Policy Push needed
• Legalization, share cost / public funding
• Mass acceptance
CCS for BFG cost:
US$18-35/tCO2 avoided
Source: Farla et al., 1995 and Gielen, 2003
Capture from DRI:
US$10/tCO2
Source: Gielen, D.J., 2003: CO2 removal in I&S industry,
Energy Conversion and Management, 44 (7), 1027-1037.

13. Appreciation of CCS – BFG Case
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Process No.of
Sources
Emissions
MTCO2PA
Power 4,842 10,539
Cement 1,175 932
Refinery 638 798
Iron & Steel 269 646
Petrochemical 470 379
Oil & Gas NA 50
Others 90 33
Biomass 303 91
Source: Special Report of WG-III of IPCC 2005
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Emissions Intensity
(MTCO2PA/source)
Highest
330 sources with emissions above 10 MTCO2PA/source. In this segment,
• Power plants contributed 78%
• Iron and Steel plants 5%
• Balance areas 17%
Average from integrated I&S site emitted 3.5 MTCO2PA

14. Appreciation of CCS – BFG Case
IEA GHG, 2000
• Integrated steel plants - > 80% of CO2 emissions from steel
production
• ~70% of the carbon input to an integrated steel mill is present in
the Blast Furnace Gas (BFG)
• BFG is used as a fuel gas within steel plant
• Combustion of BFG can result in flue gases with high CO2
concentrations
Both CCS techniques are feasible:
• oxy-fuel application based post-combustion capture and
• DRI - H2 as fuel and pre-combustion capture
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15. Tata Steel’s Pursuit of Breakthrough
Groundbreaking €55m part-EU funded R&D project: 48 EU partners
incl.Tata Steel, 13 countries, 80 different potential technologies;
Targeted to identify & develop technologies that could enable ~50%
reduction in CO2 emissions from Ore-based steel production by 2050
Example breakthrough technology: Top gas recycling blast furnace (with carbon capture)
Schematic: Ian Rodgers, Director, UK Steel, On behalf of EUROFER, OECD Steel Committee, May 2008
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Phase-II (2010-15) – Large scale demo > €300 million

16. ULCOS & Other Technologies
2015-20 To develop first commercial scale plant
2020 onwards Deployment
ISARNA: bath smelting using less coal and
possibly biomass, allied with CCS.
Advanced direct reduction: Reduced gas consumption, allied with
CCS.
Electrolysis:
– Most revolutionary;
– Reliant on source of low carbon electricity
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17. EXPECTATIONS
Peer Industry, State & Union Government
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18. Expectations & Partnership
• Pool of technology solution
• Directing research work
– e.g. value added application of CO2 (reduction to C, Mine Fire abatement
etc.) – so that Capture can gain natural momentum etc.
• Technology independence
– e.g. Economic solution to low temperature waste heat recovery, high
efficiency solar solutions etc.
• Organized scrap market
• Chart out long term energy roadmap
• Speed up deployment of nuclear power
• Fiscal benefits to promote GHG abatement – through taxes -
accelerated depreciation, import duty
• Firming up policy - say to promote albedo etc.
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19. THANK YOU
Disclaimer
Contents of this presentation do not necessarily reflect the current stance of Tata Steel - some of the
contents may be purely the views of the presenting author