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Essar Steel's move towards 100 percent recycling of ferrous waste

Essar Steel's relentless endeavors towards making it a zero waste plant, has yet made another accomplishment through 100% recycling of ferrous waste.
May 24,2018

Essar Steel move towards 100 percent recycling of ferrous waste

At a production rate of 7.2 MTPA, about 1000 MT iron bearing solid waste is generated every day. Of these, about 400 TPD has iron content of more than 65%, and part of this is metallic iron.

Although these iron-rich material can be used directly in Sinter plant, it is economically more sustainable to charge them in steel melt shops. In addition, Sinter plant surfaces with operational issues like hot sinter discharge when metallic is charged with sinter raw material. Besides, such wastes cannot be directly fed into the steelmaking furnaces, and they need to be agglomerated before charging.

To make the re-processing viable, a joint team of R&D, SMP, Projects, Purchase, Contracts, MH and QAQC has developed and implemented a process in-house. This process is of briquetting for dust and sludge generated from Midrex Modules, Steel Melt Shops and Blast Furnace. These were optimally blended so that briquettes could be used as chiller in Conarc.

At present, the production of briquettes is around 25 TPD and it is being charged in SMP #2. Furnace operators have judiciously used these briquettes to control the operation without hampering any productivity.

Another process of making self-reducing briquettes with higher carbon content has been developed. These briquettes can be charged in SMP #1 where the quantity of hot metal is less, hence additional carbon helps in the process. The method has been demonstrated with more than 4000 MT briquettes charged in SMP #1 in the past.

Essar Steel team plans to increase the production of ferrous briquettes to 700 TPD in a few months. To implement this plan, two briquetting machines that were earlier used in Module #1 has been revamped and installed as standalone facility for waste briquetting. Once it is fully operational, it is expected to recycle 2 - 3% of iron through this route, thus improving the overall yield.

Kudos to team Essar Steel!

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