Mr. Shuaib Salman

Report
Effective Waste Management in
Steel Manufacturing
Career summary
Possess +20 years of experience in the field of Environmental
and IH Engineering
Educational
• Masters in Environmental & Water Resources from KFUPM,
Dhahran, KSA - 1996
• Dip in Business Administration – Bangalore University - 1992
SHUAIB SALMAN
Professional Certification
• Qualified Environmental Professional ( QEP) from Pittsburg –
USA - 2005
• Radiation Safety Officer from KACARE - KSA, 2011
Senior Environment Engineer
Saudi Iron and Steel Co. (Hadeed)
Table of content
 Introduction
 Overview of Steel Process
 Mission and Vision
 Challenges
 Onsite Storage
 Waste Classification
 Type of By Products / Waste (DR Plant , Steel Plant & RM)
 Disposable Wastes
 Key to Success
 Acknowledgement
Introduction
Waste Management is a global problem - each year millions of
hectares are lost …
Industrial operations generate waste, must find proper reuse /
recycling options, Exercise control during storage / disposal and
must opt for Environmental friendly options
Consequently, effective waste management is a crucial part
within the operations of all organization's
Overview of Steel Process
Steel Industries generate large quantity of by-products/wastes.
Generation of byproducts/waste during industrial activity is
inevitable. However with efforts and innovative ideas potential
reuse/recycle options can be explored to conserve the natural
resources.
Saudi Iron and Steel Co (HADEED) Affiliate of SABIC is the only
steel making subsidiary of SABIC. Its an integrated steel making
company that comprises of
 Direct Reduction (DR) Plant
 Steel Plant (SP) (Long Product & Flat Product Facility)
 Rolling Mill (Hot Strip Mill & Cold Rolling Mill)
Mission & Vision
Mission : To be provider of competitive steel products through
employees empowerment with Safe and environmentally
sounds practices
Vision : To be the leading producer and marketer of steel
products in the middle East & North Africa
Challenges
As a commitment to the protection of natural resources, company
made efforts in carrying out research to find potential reuse option
that is sustainable and environmental friendly.
Waste Classification
During the steel making the following :
• Municipal Waste: Includes refuse, food waste, paper, carton,
etc. from offices and cafeteria.
• Inert Waste : Ex., Construction materials, wood, paper etc.
• Industrial waste: Generated from production process.
Types of Byproducts/wastes
Plant
Type of byproducts / Waste
DR
DR
SP
SP
RM/SP
CMC
Maintenance
Oxides Fines
Slurry
EAF Dust
Slag
Mill Scale
Ferric/Red Oxide
Mixed Miscellaneous Waste
Byproducts /Waste from DR Plant
Oxide Fines (<6 mm)
Iron Ore
DR Plant (+6 mm)
Slurry
Oxide Fines ( < 6mm)
Iron Ore is screened , +6mm containing (96%-97% Fe2O3) is
used for Production. Less than 6mm is the byproducts
which is called as Oxide fines
Oxide Fines ( < 6mm) Management
Current Use:
300000
Oxide Fines are used in cement
industries as a raw material to
manufacture cement.
251212
250000
212539
195230
200000
160415
150000
Oxide Fines are also used in making
briquettes and used back in the
furnace.
100000
50000
0
2013
Generated
2014
Sold
Slurry
Process and Thermal fragmentation in the reduction process
generate fines within the furnace. The fines are diverted to
clarifier where it is sedimented as sludge.
Slurry is predominantly similar to Ore fines but finer and
laden with moisture.
Slurry Management
120000
Slurry is used in cement industries
as a raw material to manufacture
cement.
115197
96405
100000
96608
84233
80000
60000
Also used in Making Iron Pellets by
pelletizing plants
40000
20000
0
2013
2014
Generated
Sold
Byproducts /Waste from Steel Plant
Slag
EAF Dust
Mill Scale
SLAG
Slag is a major byproduct generated
steel production from EAF & LF.
Until potential option were found the
generated quantity of slag was being
stored within the premises .
SLAG Management
Solution:
R&D work was carried in Research labs such as Ministry of
transport Riyadh, KFUPM and German Slag Research Institute.
 Based on studies and field trials, it was found Slag is excellent
feed/additive for the following:
Mno
3%
• Road Asphalt Pavement
• Road sub base
Cao
30%
Feo
37%
• Concrete for Nuclear Radiation Shielding
• Production of Silico Manganese & Ferro Silica
• Used as Filter bed Media
Al2O3…
SiO2
15%
MgO
10%
SLAG Management
It is successfully used in the following
projects/areas:
• Ministry of Roads and Transport Dammam Airport Road
• Dammam Kuwait Road
• Municipality of Dammam, Khobar,
Jubail Roads.
• Gazlan Power Plant
• Sabic Industries
740000
720000
700000
680000
660000
640000
620000
600000
580000
560000
726555 726555
623428
2013
Generated
2014
Sold
623428
EAF Dust
Melting operation in Electric Arc Furnace (EAF) generates
fumes with dust.
Dust is filtered off from flue gas/fumes via bag filters and
stored onsite for recycling.
Hadeed together with Sabic conducted research at king
Saud University to find the reuse options.
Continued…
The research studies concluded the material has advantages
when used as additive with cement.
Property
Setting time of concrete
Effect
Increased
Compressive strength
Increased (10 - 20%)
Flexural and Bond Strength
Concrete Corrosion Potential
Improved
Reduced
can be used as an effective set retardant for concrete and can
substitute the chemical retardants used presently
Uses as a set Retarder
1. US Patent for use of
EAF Dust
Use of Electric Arc Furnace
By-products in concrete
2. European Patent for
use of EAF Dust
(Austria, Germany,France, Italy and
UK)
Site Studies
40000
39162 39162
35000
30000
23088 23088
25000
20000
15000
10000
5000
0
2013
Generated
2014
Sold
Mill Scale
Mill scale is byproduct generated during casting and rolling
operation of steel billets and slabs.
Mill Scale
Mill Scale Management
Current Uses:
• Utilized by cement manufacturing
companies
• Mill scale is recycled back into the
furnace for steelmaking
• Used for the manufacturing of
ceramics.
90000
83173
80000
69476
70000
66519
56994
60000
50000
40000
30000
20000
10000
0
2013
2014
Generated
Sold
Red Oxide
Red Oxide is generated
from pickling (Cold
Rolling Mills)
Generation is about 2500
t/year. It is packed in jumbo
bags and sold to Paint,
Construction and Brick
manufacturing companies.
Summary
Up to 3rd Qtr. 2014
2013
1152
2494
1072280
1348758
1390263
Generated
Sold
Disposed
1110234
Generated
Sold
Disposed
Disposable Waste
Waste generated from production & maintenance are stored in
designated areas and sent to disposal companies.
•
•
•
•
•
•
Oily Sludge
Fluorescent Tubes
Liquid Waste Chemical
Expired Paints & Chemicals
Oil Absorbent
Clinic Waste, etc..
<1 % of total byproducts/waste are sent as waste to disposal
companies for landfill, incineration etc..
Key to Success
• Compliance with Regulations.
• Adherence to company EHSS Policy
• Commitment towards continual
improvement of our environment
• Non value added byproduct/waste to
value added commodity.
PREVENT/REDUCE
REUSE
RECYCLE
TREAT
DISPOSE
Today we are proud 96% of generated byproducts/waste
are sold to other industries.
Acknowledgement
• Would like to thank HADEED Management for their commitment
and support in achieving this success.
• Thanks to RC for their encouragement and support in promoting
waste reduction programs and giving us the opportunity.
Thank you
Every Gift to the Environment makes a difference

similar documents