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Iron & Steel Manufacturing Process:

Iron making process essentially consists of three main stages which include coking of coal which is used for iron making, sintering of the iron ore fines to form agglomerated sintered ore and finally reduction of iron ore to form molten iron in a blast furnace. Steel is made by oxidizing molten iron in a converter or/and in an electric arc furnace to produce steel. Further the raw steel produced is refined and cast into slabs and rolled into sheets to form finished steel.

To produce 1 ton of finished steel about 0.987 ton of iron ore, 1.385 tons of coke, 0.075 ton of limestone are required. In iron and steel production electricity, coal and natural gas are the common energy types consumed. In addition to the four processes, heaters and scrubbers are installed, usually at or near the wellhead. The scrubbers serve primarily to remove sand and other large-particle impurities.

Process Flow Diagram

Iron & Steel Manufacturing - Process

Energy Efficiency Improvement:
 
Activity
Name
Existing Technology replaced Efficient Process
/Technology penetrated
Energy Savings (ES) GJ/yr Monetory Equivalent of ES (Million INR) Investment Cost (Million INR) Simple Payback (Years) GHG Emissions reduced (tCO2e/yr)
Coking Coke Oven Coke dry Quenching  194400 485 1500 3.1 45900
Sintering Sintering Furnace Sintering machine cooler waste heat recovery device 315000 68 1500 22.1 29799
Steel making  Basic Oxygen Furnace Hot stove waste heat recovery device 126000 27 75 2.8 11920
 
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