Transcript Relevance of PSM In Iron & Steel Making

Relevance of PSM in Iron &
Steel Industry
April 2011
DuPont Sustainable Solutions (DSS)
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2
Contents

Iron & Steel Making and process hazards

Top process risks in iron & steel making

Process safety incidents in Steel Industry

DSS Opportunity in the Steel Industry
,
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3
Overview of Iron & Steel Making Process
% Production
3%
66%
6%
Is in decline due to its environmental
and economic disadvantage
25%
DR – Direct Reduction
, Source: World Steel Dynamics – Worldsteel Fact Sheet.
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The Process Safety Management Risk Funnel
Management Systems
All Hazards
ILO Document on Safety and
Health Hazards in Steel
Industry provides more indepth information on hazards.
Basic Safety
+
Low Hazards
PSM Low Hazards
+
High Hazards
PSM High Hazards
+
Very High Hazards
Highly Toxic Materials Requirements
Advanced Risk Analyses, etc.
,
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Low and High hazard Operations in Steel
,
Lowerhazard
operatio
n (LHO)
Any operation that exclusively
manufactures, handles, stores, or uses
any substances with low potential for
death or major irreversible human health
effects, significant property or
environmental impact, or off-site impacts
due to physical or mechanical hazards,
toxicity, or asphyxiation.
Melting, casting, and extrusion.
Tabletting and pelletizing operations.
Compressed gas-assisted transfer operations.
Solids processing using screw or belt conveying
systems.
Spinning or rolling operations with mechanical and
electrostatic shock potential.
Mechanical drying and/or dewatering operations
(e.g., filter press).
Mechanized product packaging (e.g., container
filling, conveying, and palletizing).
Higherhazard
process
(HHP)
Any activity manufacturing, handling,
storing, or using hazardous substances
that, when released or ignited (or when
their energy is released), can result in
death or major irreversible human health
effects, significant property or
environmental impact, or off-site impacts
due to acute toxicity, flammability,
explosiveness, corrosiveness, thermal
instability, or reactivity.
Steam generation and related combustion
Electric Arc Furnace
Sintering
Any process using sources of ionising radiation for
tracking of materials
Very
High
Hazards
Chemicals such as highly toxic or
flammable materials
Blast Furnace, Coke ovens
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Overview of the iron & steel making process
1. Raw material preparation
2. Iron making
3. Steel making
4. Casting and rolling
,
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Raw material preparation
1. Pelletizing – Iron ore is pelletized a forming and thermal treatment
process. This process allows better oxygen flow in the blast
furnace which allows for faster oxidation and melting. This is
typically performed at the mine.
2. Sintering – Iron ore is agglomerated by a vacuum combustion
process to allow for efficient gas pass-through in the blast furnace.
This process is typically performed at the mill.
3. Coke Oven – This process is used to derive coke from bituminous
coal, which is then used as a reducing agent or fuel in a blast
furnace. This process is performed at the mill.
4. Direct Reduction – This process is an is an alternative method of
reduction for use in an EAF or low volume operations for
economic reasons. In the process, reducing gas or coal is used to
create high quality iron for steel-making. The use of this step
depends on customer quality requirements.
,
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Pelletizing
All Hazards
Low Hazards
High Hazards
Very High Hazards
Noise, Vibration, Radiant Heat, Slips, Trips
and Falls, Ergonomics, Eye protection,
Asbestos in byproduct, Insulation Wool,
Confined spaces, Isolation of energy sources,
Falling Objects
Mechanical Hazards
Dust Explosion
None
,
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Sintering Process
All Hazards
Noise, Vibration, Radiant heat, Slips, Trips and
Falls, Ergonomics, Asbestos, Insulation Wool,
Confined spaces, Isolation of energy sources
Mechanical Hazards
Low Hazards
High Hazards
Very High Hazards
Dust Explosion, Gas explosion, fire, Sinter offgassing (polychlorinated dibenzoparadioxin –
PCDD, polychlorinated dibenzofuran – PCDF,
potential source of hexachlorobenzene – HCB,
polychlorinated biphenyl – PCB)
None
,
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Coke Oven
All Hazards
Noise, Vibration, Radiant Heat, Radiation,
Slips, Trips and Falls, Ergonomics, Asbestos,
Insulation Wool, Confined spaces, Isolation of
energy sources, Falling Objects, Hot Surfaces
Low Hazards
Mechanical hazards – including confined
space coal powder silo break-up fatalities.
High Hazards
Dust Explosion, Fire, Carbon Monoxide
exposure, Coal Dust Exposure
Very High Hazards
Coke Oven Gas exposure, which includes
Hydrogen Sulfide, Ammonia, benzene and
other carcinogenic hydrocarbons
,
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Direct Reduction
All Hazards
Noise, Vibration, Radiant Heat, Slips, Trips
and Falls, Ergonomics, Eye protection,
Asbestos, Insulation Wool, Confined spaces,
Isolation of energy sources, Falling Objects
Mechanical Hazards
Low Hazards
Dust Explosion, Hydrogen explosion
High Hazards
Very High Hazards
Reduction Gas exposure, which includes
Hydrogen Sulfide and Carbon Monoxide.
,
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Overview of the iron & steel making process
1. Raw material preparation
2. Iron making
3. Steel making
4. Casting and rolling
,
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Iron making stage
Superheated oxygen is blown into the blast furnace with
Iron ore, coke and lime to produce liquid iron often called
'hot metal‘ with a typical temperature as high as 1480–
1520 °C at tapping.
Coke is used for combustion to attain the high
temperatures required for reduction. It generates carbon
monoxide during the combustion, which acts as the
reducing agent and converts the iron oxides into molten
iron. Fluxes are used to make low melting slag and control
the quality of Hot Metal.
,
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Iron Making Process
All Hazards
Low Hazards
Noise, Vibration, Radiant Heat, Radiation,
Slips, Trips and Falls, Ergonomics, Glare
protection, Asbestos, Insulation Wool,
Confined spaces, Isolation of energy sources,
Falling Objects, Abrasive blasting, Hot
Surfaces
Mechanical Hazards
High Hazards
Very High Hazards
Blast Furnace Gas explosion, Dust Explosion,
Handling molten metal, Superheated steam
explosion
Blast Furnace Gas (Carbon Monoxide and
Nitrogen) exposure
,
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Overview of the iron & steel making process
1. Raw material preparation
2. Iron making
3. Steel making
4. Casting and rolling
,
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Steel making stage
In this stage, the liquid iron plus recycled scrap are
converted to molten steel by blowing oxygen through the
metal in a converter to remove the carbon, silicon, sulphur
and phosphorous content.
Alternatively, the Electric Arc Furnace (EAF) is used to remelt scrap iron and steel as a secondary process or can
be used as a primary method. EAF’s are typically used in
conjunction with a direct reducing process.
,
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Steel Making Process
All Hazards
Noise, Vibration, Radiant Heat, Radiation,
Slips, Trips and Falls, Ergonomics, Glare
protection, Asbestos, Insulation Wool,
Confined spaces, Isolation of energy sources,
Falling Objects, Abrasive blasting, Hot
Surfaces
Low Hazards
Mechanical Hazards
High Hazards
Handling molten metal, Superheated steam
explosion, Dust explosion, Toxic Dust
exposure (lead, cadmium, etc.), High Current
Electrical (for Electric Arc Furnace)
Very High Hazards
Off-gas exposure (Carbon Monoxide, Nitrogen,
vaporized heavy metals, ozone, alloy offgassing)
,
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Overview of the iron & steel making process
1. Raw material preparation
2. Iron making
3. Steel making
4. Casting and rolling
,
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19
Casting and Rolling
Casting – converts the steel into solid slabs, blooms or
billets.
Rolling - are applied to continuous cast slabs, blooms and
billets achieve large shape changes.
,
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Casting
All Hazards
Noise, Vibration, Radiant Heat, Radiation, Slips,
Trips and Falls, Ergonomics, Asbestos, Insulation
Wool, Confined spaces, Isolation of energy
sources, Falling Objects, Abrasive blasting, Hot
Surfaces
Low Hazards
Mechanical hazards, Hydraulic oil exposure
High Hazards
Handling molten metal (including break-outs),
Nitrogen asphyxiation, Fire due to Hot oils
Very High Hazards
None
,
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Rolling and Finishing
All Hazards
Noise, Vibration, Radiant Heat, Radiation, Slips,
Trips and Falls, Ergonomics, Asbestos, Insulation
Wool, Confined spaces, Isolation of energy
sources, Falling Objects, Abrasive blasting, Hot
Surfaces
Low Hazards
Mechanical hazards, Hydraulic oils + rust
inhibitor exposure, tracking sensors and
thickness sensors using ionising radiation
High Hazards
Pickling agents (strong acids) and Hydrogen
peroxide, Nitrogen asphyxiation, Fire due to Hot
oils, metal coating processes with hot metal
baths ( explosion, zinc exposure), organic
coating processes using solvents (exposure),
gas fired furnaces (explosion)
Very High Hazards
None
,
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22
Molten Metal Transport
All Hazards
Noise, Vibration, Radiant Heat, Slips, Trips
and Falls, Ergonomics, Eye protection,
Asbestos, Insulation Wool, Confined spaces,
Isolation of energy sources, Falling Objects
Low Hazards
Mechanical Hazards
High Hazards
Handling/loss of containment of Molten Metal,
Superheated Steam explosions (at slag dump
and in plant)
Carbon monoxide exposure
Very High Hazards
,
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Contents

Iron & Steel Making and process hazards

Top process risks in iron & steel making

Process safety incidents in Steel Industry

DSS Opportunity in the Steel Industry
,
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24
Top risks
 Fire and explosions
 Molten metal breakouts
 Other Molten metal losses of containment
 Dust Fires and Explosions
 Toxic gas exposure and release
,
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Explosions
• What are the causes of explosions in furnaces?
1) Explosive items in the scrap and
2) Mixing of water and molten steel
• What contributes to explosions?
With scrap materials, there is a potential for explosives, pressure
vessels and pockets of water to be introduced into the furnace. The
roofs and sides of electrical furnaces are water-cooled and the
accidental introduction of water onto the surface of the pool of molten
slag/steel happens from time to time, usually without damage. It is when
water somehow becomes trapped beneath molten steel or slag that
damage and injury can occur.
,
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26
Breakouts releasing molten metal

What is a breakout?
A breakout specifically refers to the liquid steel at the center of a
cooling billet/slab escaping from the surrounding skin.

What can lead to a breakout?
Typically caused by inadequate cooling to the billet or slab. This
may be due to ambient conditions, increased rates or other
variables.

What is the consequence of a breakout?
The primary consequence is exposure to molten metal that will be
greater than 1500 Celsius.
Contact of molten metal with materials that burn or explode is very
likely in a breakout scenario.
,
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27
Other Molten Metal Losses of Containment
Can be caused by Compromised vessel integrity, including:
1. Refractory Failures – This is the internal lining of molten metal
containment vessels. When the lining fails, the integrity of the
vessel is compromised and deterioration of the vessel wall begins,
ultimately resulting in a loss of containment.
2. Ladel/Transport Failures – This type of failure can either come
from crane failures, weak spots in ladel or trench walls, or unsafe
transport practices.
,
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28
Dust Fires and Explosions
1.
Like all fires, a dust fire occurs when fuel (the combustible dust) is exposed to heat
(an ignition source) in the presence of oxygen (air). Removing any one of these
elements of the classic fire triangle eliminates the possibility of a fire.
2.
A dust explosion requires the simultaneous presence of two additional elements—
dust suspension and confinement. Suspended dust burns more rapidly, and
confinement allows for pressure buildup. Removal of either the suspension or the
confinement elements prevents an explosion, although a fire may still occur.
3.
Further, the concentration of suspended dust must be within an explosible range
for an explosion to occur. This is analogous to the flammability range commonly
used for vapors (such as natural gas and propane).
4.
Within a steel mill, coal dust, iron ore dust and coke dust are present, all of which
can lead to a dust fire or explosion.
,
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29
Gas Exposure/Release
 What kinds of gases are we talking about?
Carbon Monoxide, Ammonia and Hydrogen Sulfide are
all present in the process. Nitrogen, which can also
become lethal in a closed atmosphere, is also
generated.
 What contributes to a gas exposure?
Leaks from equipment, pressure changes in furnaces,
inadequate venting/purging, bypassing/failure of
scrubbing devices before a vessel entry.
 What is the consequence of a loss of containment?
Potential fires/explosions or employee exposure or
death.
,
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30
Contents

Iron & Steel Making and process hazards

Top process risks in iron & steel making

Process safety incidents in Steel Industry

DSS Opportunity in the Steel Industry
,
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31
Bethlehem Steel – Burns Harbor Mill - Fire
What happened?
On February 2, 2001, a fire killed
one Bethlehem Steel millwright
and one contractor supervisor
died. Four Bethlehem Steel
millwrights were injured, one
seriously. Workers were
attempting to remove a slip blind
and a cracked valve from a coke
oven gas line leading to a
decommissioned furnace. During
removal of the valve, flammable
liquid was released and ignited.
Investigated by CSB
Why?
Management systems for the
supervision, planning and execution
of maintenance work inadequate.
Did not have a system for monitoring
and controlling hazards that could be
caused by changes in COG
condensate flammability or
accumulation rates.
Did not have a program to identify
and address hazards that might be
created by decommissioning and
demolition operations.
Relevance of PSM application?
PHA, MIQA, MOC, SWP, ER,
Training
,
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32
Cato Bridge Durban - Explosion
What happened?
The Department of Labour
closed the Assmang plant in
Cato Ridge Durban, following the
death of five workers in the
massive explosion, in late
February 2008
The accident took place at a time
when the plant was under inquiry
for exposing 50 workers to
poisonous fumes in 2007.
Findings by the department’s
inspectors indicated that a water
leakage into the furnace may
have led to the explosion which
caused the side of the control
room, facing the furnace, to
collapse, allowing flames to
engulf the room.
Why?
Mechanical integrity and quality
assurance that allowed leakage of
water
Relevance of PSM application?
MIQA, PHA, ER
,
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33
Slovak Steel – Gas release/Explosion
What happened?
Thirteen people were killed and
at least 170 were poisoned by
carbon monoxide on Friday after
a gas pipeline exploded at a steel
plant in eastern Slovakia. Impact
of an earlier explosion was
underestimated.
Why?
Use of PHA for identification of PSM
Critical Equipment and Emergency
Response
Relevance of PSM application?
PHA, MIQA, ER
,
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34
Jindal Vijayanagar Steel – India – Gas Release
What happened?
Chemical Accident occurred at a
integrated steel facility involving
exposure to toxic and poisonous
gas while clearing the sludge pit
of the scrubber system, resulting
in the death of three workmen.
The net work of pipelines of the
said system ends at the sludge
pit with water seal arrangement.
Reduction in water level resulted
in breaking of water seal and
release of Corex gas containing
more than 40% carbon
monoxide.
Why?
Training and awareness on hazards
associated with carbon monoxide.
Safe work procedures for high risk
operations
Identification of hazards and risks of
Corex gas
Relevance of PSM application?
PHA, SWP/SOP, ER, Training
,
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35
Qinghe Steel, China, - Molten Metal
What happened?
The Qinghe Special Steel
Corporation disaster was an
industrial disaster that occurred
on April 18, 2007, in Tieling,
Liaoning Province, China.
Thirty-two people were killed and
six were injured when a ladle
used to transport molten steel
separated from an overhead rail.
Why?
Mechanical integrity and quality
assurance on overhead rail.
Use of PHA for identification of
foreseeable scenarios
Operating procedures and safe work
practices of working below overhead
rails
Relevance of PSM application?
MIQA, PHA, SWP/OP
,
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36
Kremikvtzi – Gas release/Explosion
What happened?
An operator reported that the pressure in
the water pipeline supplying the blast
furnace's gas-purifying machinery was
falling.
A breakdown team was sent to the scene
without coordinating with the operational
management of the blast furnace and the
firm's 'gas-rescue' service. Gases from
the blast furnace, containing a high level
of carbon monoxide, started to escape
from a broken pipe. Twelve firefighters
were sent in, without being given
sufficient information on the concentration
of carbon monoxide. More gases then
started leaking due to a rapid decrease in
the water level and the elimination of the
machinery's 'water barrier'. As a result of
this series of human errors, the noxious
gases killed three people, including one
firefighter. Another 22 suffered various
levels of poisoning and were hospitalised.
Why?
Safe work practices and operating
procedures in terms of work
permitting process
Emergency response in terms of
assessment of potential risks before
undertaking rescue operations
Mechanical integrity and quality
assurance to ensure pipes carrying
toxic gases are classified as PSM
critical
PHA to ensure that risks associated
with level of water to prevent failure
of water barrier
Relevance of PSM application?
SWP/OP, PHA, MIQA, ER
,
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37
Hoeganaes – Iron Dust Explosion
What happened?
On January 31 two maintenance
mechanics on the overnight shift
inspected a bucket elevator that had been
reported to be malfunctioning due to a
misaligned belt. The bucket elevator,
located downstream of an annealing
furnace, conveyed fine iron powder to
storage bins.
The two mechanics were standing alone
on an elevated platform near the top of
the bucket elevator, which had been shut
down and was out of service until
maintenance personnel could inspect it.
When the bucket elevator was restarted
the movement immediately lofted
combustible iron dust into the air. The
dust ignited and the flames engulfed the
workers causing their injuries. A dust
collector associated with the elevator was
reported to have been out of service for
the two days leading to the incident. One
worker later died.
Why?
Safe work practices and operating
procedures in terms of work
permitting process
PHA in terms of assessment of
potential risks before undertaking
rescue operations
Mechanical integrity and quality
assurance regarding routine
maintenance of the dust collector.
Relevance of PSM application?
SWP/OP, PHA, MIQA
,
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38
Contents

Iron & Steel Making and process hazards

Top process risks in iron & steel making

Process safety incidents in Steel Industry

DSS Opportunity in the Steel Industry
,
Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates.
39
DuPont SWOT in Steel Industry
Strengths
Weakness
Existing relationship with clients in
Steel industry
PSM Work in Tata Steel/NatSteel
DuPont brand recognition in PSM
Global Presence for consistency of
implementation in multinational
companies
Opportunity
Perceived as "Chemical" Company
Understanding of process/operational
risks in steel industry
SWOT
Increased perception and
understanding of risks
MOC-T and MOC-F processes
Developing Regional Steel Entities
Perceived value of PSM experienced
by steel industry players such as
Tata/NatSteel
Threat
Commodity cost control impacts
Safety Performance
Low use of Process Safety Consulting
OSHA and EPA have been driving
improved performance in US.
,
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40
List of Steel Companies
 Review the list of Steel companies
 Identify the top potential companies for various
practices
 Develop account strategies
 Define how practice can help
,
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41
Discussion with select steel industry
community
 Create a Community network for Steel Industry of
interested stakeholders
 Brainstorming session to discuss value proposition for
Steel Industry
 Gather additional relevant information
 Document and share with interested stake-holders and
generate additional business
,
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42
Supporting Slides
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43
Further reading
Worldsteel.org
Steeluniversity.org
,
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44
Potential Segmentation Criteria
1. Revenue/Firm Size
2. Multi-national/National
3. Level of PSM familiarity/PSM performance
,
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45
Porter’s 5 Forces Industry
Analysis Framework
Metals and Mining Industry
Force Drivers
• Threat of New Entrants
Threat of New
Entrants
•
High transportation/energy costs
Increased Environmental Regulation
and Fines
•
Integrative trends have resulted in
increased value chain control for
incumbent companies
•
Bargaining
Power of
Suppliers
Competitive
Rivalry within an
Industry
•Competitive Intensity
•
Commodity pricing
Industry is characterized by large
multinationals with limited
diversification
•
Bargaining
Power of
Customers
Threat of
Substitute
Products
•
High Exit costs
Economy of Scale Cost advantage
is central to industry
•
• Threat of Substitutes
Stone, brick, fiberglass provide
better performance in some
applications
•
In most markets, consumers would
bear high switching costs.
•
,
Source: Datamonitor: Global Metals and Mining 2009
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46
Porter’s 5 Forces Industry
Analysis Framework (cont’d)
Metals and Mining Industry
Threat of New
Entrants
Force Drivers
• Bargaining Power of Customers
•
Lack of product differentiation
Forward Integration in related
markets occurs regularly
•
Buyers tend to buy bulk quantities
and are large
•
Bargaining
Power of
Suppliers
Bargaining
Power of
Customers
,
Competitive
Rivalry within an
Industry
Threat of
Substitute
Products
A myriad of applications ensures
large numbers of consumers
•
• Bargaining Power of Suppliers
•
Non-renewable input materials
•
Supply is price dependent (ex. 2009)
Backward integration into mining can
relieve some pressure but is capital
intensive
•
Source: Datamonitor: Global Metals and Mining 2009
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47
Asia dominates Steel Production Volumes, led
by China and Japan
2009 Production (%) by Region
11.4%
European Union
2.4%
Other Europe
Former Soviet Union
8.0%
North America
6.8%
65.6%
3.1%
1.2%
1.4%
South America
Africa
Middle East
Asia
Source: Worldsteel Statistical Yearbook 2010
,
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48
Steel Production Primary Process
Iron Making Stage
Superheated oxygen is blow into the blast furnace
with Iron ore, coke and lime to produce liquid iron
often called 'hot metal‘ with a typical temperature
as high as 1480–1520 °C at tapping.
Coke is used for combustion to attain the high
temperatures required for reduction. It generates
carbon monoxide during the combustion, which
acts as the reducing agent and converts the iron
oxides into molten iron. Fluxes are used to make
low melting slag and control the quality of Hot
Metal.
Steelmaking Stage
In this stage, the liquid iron plus recycled scrap
are converted to molten steel by blowing oxygen
through the metal in a converter to remove the
carbon, silicon, sulphur and phosphorous content.
Alternatively, the Electric Arc Furnace (EAF) is
used to re-melt scrap iron and steel.
Casting & Rolling
Casting – converts the steel into solid slabs,
blooms or billets.
Rolling - are applied to continuous cast slabs,
blooms and billets achieve large shape changes.
,
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© 2011 DuPont.
All rights
reserved.
The DuPont Oval Logo, DuPont™, and The miracles of science™ are registered trademarks or trademarks of DuPont or its affiliates.
Source:
World
Steel
Association
Sintering,
Pelletizing, or a
combination
used here.
49
Secondary Steel Making
• Secondary steel is produced in an
electric arc furnace (EAF) or in an
induction furnace (IF) using scrap.
• Scrap metal with limited amount of
other iron-bearing material is
melted by using an electric current.
• Because scrap can contain a wide
range and higher percentage of
contaminants, steel produced
using this process requires
additional refining.
• Direct reduction of iron and use of
an EAF is a viable alternative in
primary steel making for low
volume plants with energy
constraints.
,
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50
Arc Furnace Failures
 What are Arc Furnace Failures?
Arc furnace failures arise due to erratic loading, short
circuiting, or unusual load patterns of the transformer
causing mechanical stress on the transformer.
 What are the consequences?
Fires or explosions due to uneven heating or arc
flashes.
,
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