Innovation through Recycling / Minimizing Waste A presentation from Jindal Shadeed Iron& Steel Presented by Mr. N.A. Ansari CEO Innovation Forum 7 th Feb 2017
Agenda Who are we? First & Largest Integrated Steel Plant in Oman Waste an opportunity for innovation JSIS efforts Future plans Support Required Government support Regulations Innovation Forum 7 th Feb 2017 2
Agenda Who are we? First & Largest Integrated Steel Plant in Oman Innovation Forum 7 th Feb 2017 3
First & largest integrated steel plant in Oman Chairman Part of the US $ 18 billion OP Jindal Group 1.5 MTPA DRI Plant (HBI/HDRI) 1.4 MTPA Rolling Mill (8 40 mm Rebar) 2.0 MTPA SMS Plant (Square / Round Billet) 771 employees USD 1.2 Billion Investment 300 Acres Innovation Forum 7 th Feb 2017 4
Our Journey April 2016 Rolling mill commissioned 4 April 2014 SMS Plant commissioned 3 Dec 2010 DRI Plant commissioned 2 July 2010 Acquisition 1 Innovation Forum 7 th Feb 2017 5
Agenda Waste an opportunity for innovation JSIS efforts Future plans Innovation Forum 7 th Feb 2017 6
Waste Pyramid Most favored Reduce Reuse Recycle Disposal Least favored Innovation Forum 7 th Feb 2017 7
Steel in the Circular Economy Innovation Forum 7 th Feb 2017 8
Steel and Sustainability Strict Adherence to environment policy Steel industry (next biggest to Oil & Gas industry) strictly adheres to environmental responsibility. 100 % Recyclable Steel is the world s most recycled material & 100% recyclable. Jindal Shadeed efforts - Going beyond norms 100% compliance with local/international environmental norms. Oman s first Plant sharing real time data of Continuous Ambient Air Monitoring Station with Ministry of Environment and Climate Affairs (MECA) Follows world s most stringent EU BAT Norms i.e.10 mg/nm3 for dust against Omani norms 100 mg/nm3. Only plant in GCC treating Slag from EAF for recovery of the metal from Slag and other uses strongly pursued. Recycles different types of by products. Innovation Forum 7 th Feb 2017 9
Waste Management in Integrated Steel Principle Principles of Reduction, Reuse, and Recycling (3 R s) in Waste Management Environment friendly Reuse and Recycling aims at clean, green and zero waste technology Cost Saving Reduce the cost of waste disposal Provide substantial amount of iron, flux /other materials Fuel rate benefits to the existing process. Innovation Forum 7 th Feb 2017 10
Current Initiatives Innovation Forum 7 th Feb 2017 11
EAF Dust Recycle EAF Dust and Bagging Classified as Hazardous due to heavy metal content Most challenging in handling, transportation and disposal due to cost & environmental concerns. EAF Dust cannot be directly charged in the furnace. EAF Dust is agglomerated by mixing definite proportion of dust with bentonite and water to produce 8-18mm Pellets having adequate strength and moisture suitable to be recycled in Electric Arc Furnace Jindal Shadeed initiated production and recycling 25% EAF dust in Electric Arc Furnace with a target of 100% in next few months. Expected Savings : OMR 30,000 p.a. Innovation Forum 7 th Feb 2017 12
Magnesia Carbon Bricks Refractory Waste - Reuse Sorting and Crushing of Magnesia- Carbon Bricks to below 50 mm size This can be used as a substitute to Dololime in Electric Arc Furnace. Dololime is used as a slag forming material to remove the impurities in Electric Arc furnace. Expected Savings : OMR 24,000 p.a. Innovation Forum 7 th Feb 2017 13
EAF Slag Recycle / Reuse Non Hazardous JSIS is the only company in Oman undertaking metal recovery by HARSCO Road Aggregate Fine Aggregate in Precast Engineering Cement Application Engineering Fill Under development Other benefit : Clean Environment Future expected Savings : OMR 500,000 p.a. Innovation Forum 7 th Feb 2017 14
Energy / Resource Saving initiatives Hot DRI Gravity Feeding System First of it s kind in the world, less space utilization Reduction in Electrode Consumption/ handling loss EAF productivity increases up to 20% Energy savings of 15 KWH/Ton of DRI Optimizing Hot DRI to SMS Plant Reduction in NG Consumption/Ton of DRI from 10.0 to 9.35 MMBTU/Ton & reduction in power 120-140 Kwh/T Hot charging of Billets to Rolling Mill Substantial savings in NG consumption up to 40% by hot charging. Commissioning of Liquid Ring compressor Energy savings of 1.95 kwh/ton of DRI Production. Increased the system pressure from 300 mbar to 500 mbar Savings in power consumption of Process gas compressors in DR Plant of 7kWh/Ton of DRI production. Innovation Forum 7 th Feb 2017 15
Help the neighbor / create SME Help the neighbour (Sohar Aluminum) Trial usage of Spent pot Liner (Cathode) / Spent Anodes which is in SMS Hazardous Waste - 25,000 Tons in stock SPL can substitute carbonaceous raw material in the Electric Arc Furnace for steel making process. JSIS and Sohar Aluminium are working together to reuse it in the Electric Arc Furnace at Jindal Shadeed. Creation of SME Crushing industries for various crushing activities Innovation Forum 7 th Feb 2017 16
Future Plans Innovation Forum 7 th Feb 2017 17
Mill Scale Reduction Formed during Continuous Casting and Rolling Mill processes when steel is subjected for thermal gradients in oxidant atmospheres, which promotes the growth of iron oxides layer at the surface of steel 50% Reduction in generation of Mill Scale: 1. Ramp up the production with minimum stoppages in Rolling Mill. 2. Proper balancing of the pressures inside the Reheating Furnace. 3. To maintain minimum required oxygen in reheating furnace. 4. Increase the hot charging % of Billets to Rolling Mill. Innovation Forum 7 th Feb 2017 18
Various Future Initiatives Fines Briquetting Briquetting oxide fines, sludge fines and quench fines as Direct Reduced Briquettes (DRB) for its use in DR Plant as a partial substitute to Oxide Feed. Lime dolo briqueting Injection of lime dolo fines (or) Briquetting of lime dolo fines, bag filter dust and settling chamber dust for its use in SMS as a partial substitute to flux. Electrode waste Electrode Waste - After crushing can be utilized as a carbon material in Electric Arc Furnace. CO 2 Utilization CO2 Utilisation in making methanol and other CO2 sequestration. Innovation Forum 7 th Feb 2017 19
Energy / Saving initiatives Modification to Extract Power from Flue Gas: To Generate Power from the Waste Flue Gas (8-10 MW) Installation of Turbo Expander: To generate power from the pressure of Incoming Natural Gas (1-2 MW) Modification in Ladle Preheating System: Modification in ladle Preheating system being planned shortly which saves substantial reduction in Natural Gas up to 50% (presently 7750NM3/day). Innovation Forum 7 th Feb 2017 20
Agenda Support Required Government support Regulations Innovation Forum 7 th Feb 2017 21
Government Support Requested 1. Support from Be ah for Testing / certification of usage of Slag. 2. Support from PEIE / universities research on innovation for future slag application. 3. Support from Government for incentivizing energy saving initiatives. 4. Support from Government to stop wastages due to frequent start up (which is due to forced shut down during peak demand in view of CRT) Innovation Forum 7 th Feb 2017 22
Regulation Support Requested 1. MECA approval based on Be ah certification for usage of slag. 2. One stop shop for approval as against Multiple agencies for approval Innovation Forum 7 th Feb 2017 23
THANK YOU Innovation Forum 7 th Feb 2017 24