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CLEAN TECHNOLOGY
Amit Chatterjee
Adviser to the MD
Tata Steel
Secondary CC slabs
Metallurgy
980
Million Tonnes
820
Economic
Developments BOF
660
CC
Billets
500
Eco
Efficiency
Customer
Engineering
Cost Management
Quality
Hot Strip Mill
340
180
CC thin
slabs
Business
Developments
EAF
Mass Production
Year
2005
2003
2001
1999
1997
1995
1985
1975
1960
1940
1920
1900
20
Production (mt)
59.8
56.1
60
49.45
45.1
40
33.25
27.37
20.51
20
37.09
43.2
38.6
54.6
40.27
36.18
30.67
17.68
23.65
19.32
0.79
1970
1992
1995
1998
2001
2004
2007
Year
25
20.1
20
16.27
15
10
5
0.2
1.3
2.3
4.2
7.1
5.3
6.5
5.4
10.06
8.1
11.82
0
89- 91- 93- 95- 97- 9990 92 94 96 98 00
Year
India
Venezuela
Mexico
Iran
Trinidad & Tobago
South Africa
Canada
Saudi Arabia
Russia
2005
Production, Mtpa
2006
2007
11.1
8.95
5.98
6.85
2.25
1.78
0.59
3.63
3.34
14.7
8.6
6.2
6.9
2.1
1.8
0.5
3.6
3.3
19.06
7.7
6.3
7.4
3.5
1.7
0.9
4.3
3.4
Coalbased
22.60%
Midrex,
59.10%
% of total
2006
2007
Midrex
59.7
59.1
HYL/Energiron
18.4
16.8
Other gas
2.2
1.6
Coal-based
19.7
22.6
59.8 Mt
67.2 Mt
17
Coal
5.3
Gas
Production, Mt
15
4.3
13
4.19 4.5
11
9
7
2.9 3.3
3.4
3.6
3.4
3.26
3.45
3.62
14.2
11
5
3
1
95-96
97-98
5.6
7.5
99-00
01-02
03-04
05-06
07-08
Year
Year
Initially, gas based processes were
adopted.
Coal based DRI then became gradually become more popular.
Coal
based
2004-05
6.1
6.0
12.1
2005-06
6.1
8.5
2006-07
7.1
2007-08
2008-09
Production, (Mt)
Coal
based
Total
4.6
5.5
10.1
14.6
5.7
6.5
12.2
11.0
18.1
7.0
8.5
15.5
7.1
13.0
20.1
7.0
10.0
17.0
7.1
15.0
22.1
7.0
11.0
18.0
2009-10
7.1
18.0
25.1
7.0
14.0
21.0
Three large gas-based units (Essar Steel, Ispat Industries and Vikram
Ispat) have capacities of 3.60, 1.60, and 0.9 Mtpa.
Over 700 coal-based plants with capacities ranging from 30-400 ktpa
are in operation in Orissa, Chattisgarh, Jharkhand and West Bengal.
2003-04
2004-05
2005-06
2006-07
BF-BOF
19.8
19.8
21.7
22.2
EAFs
8.2
10.2
11.3
13.3
IFs
6.0
8.2
13.5
15.4
34.3
38.5
46.5
50.9
Share of
EAF/IF,%
41.6
48.0
53.3
56.4
Calorific
value,
kcal/Nm3
Years of
life
Petroleum
Natural gas
Coal
11,500
8500
1400
40
65-70
165-170
Unit price,
$/thousand
kcal
6.25
3.88
1.75
CHINA, 1%
INDONESIA,
34%
SOUTH
AFRICA, 65%
Gas-based technology is intrinsically cleaner; coalbased DR plants have to contend with fine coal as dust
as well as extensive waste generation.
system.
Not the best solution; but tolerable.
Conformation to this ACT NOT a matter of choice.
IT IS THE ONLY MEANS OF SURVIVAL.
fully.
This implies a completely different energy system.
BLUE Map,
%
Power generation
-60
-89
Transport
63
-8
Industry
49
-26
-38
-78
-50
Total
Mt CO2
15000
10000
5000
0
2005
2030 (if no
change is
made)
2050 (if no
change is
made)
1400
1200
Mt / year
1000
800
600
400
200
0
2005
2030 (if no
2050 (if no
2050 (if the Act
change is made) change is made) stipulations are
followed)
CO2 Emissions
(t/TJ)
(lbs / MM Btu)
49
115
Bituminous
metallurgical coal
90
212
Bituminous coal
94
220
200
Energy
CO2
150
Energy
Intensity
100
CO2
Intensity
50
0
2030 (if no
change is
made)
2050 (if no
change is
made)
Primary process,
1.54 t
Reduction,
0.86 t
Recycling
0.68 t
10.6
9.87
10
Primary process
Recycling process
Reduction
8
5.5
3.52
4
2
1.54
1.95
0.68 0.86
0.73
Steel
Aluminium
Copper
Country
Qatar
Emissions
(000 t/1000 people)
42.96
29.10
3
4
Kuwait
Bahrain
26.80
26.65
5
9
79
United States
Canada
China
19.84
16.18
2.69
116
India
0.96
Country
United States
5,762,054.0
China
3,473,597.3
3
4
Russia
Japan
1,540,365.0
1,224,737.4
India
1,007,978.9
6
7
Germany
United Kingdom
837,424.8
558,225.1
CHINA
2500
18.1
16.8
16.6
2000
1959
14
10.8
12
10
1140
8
6
10.6
1500
1175
1033
1000
6.3
713
4
2
11.6
784
468 500
0
BF-BOF
kgCO2/tls
20
The total solid disposal load per 100 tpd DRI production can be as
high as 40-50 tpd.
CLEAN TECHNOLOGY
THANK YOU