India was the world’s second largest steel producer, as of 2018.

The
country is slated to surpass USA to become the world’s second
largest steel consumer in 2019.
In FY19, India produced 131.72 million tonnes (MT) and 106.56 MT of
gross finished steel and crude steel.
Indian steel industries are classified into three categories such as
major producers, main producers and secondary producers.
The Arcelor Mittal, which is the largest steelmaker in the world, has
plans of establishing two Greenfield steel projects with capacity of
12 million tonnes annually, in India.
Size of the Industry Nearly 46.575 million tonnes
Geographical Odisha, West Bengal, Chattisgarh, Tamil
distribution Nadu, Chota Nagpur, Vishakhapatnam,
Madhya Pradesh ,Bihar

Output per Annum 28.3 million tonnes

Market 5% of share
Capitalization
References: https://rbsa.in/archives_of_research_reports/RBSA_Indian_Steel_Industry_Analysis
https://www.ibef.org/industry/steel
Steel is manufactured from iron ore mostly using blast furnace (BF) and basic oxygen furnace (BOF) and
using electric arc furnace (EAF) in case of manufactured from scrap materials. Molten iron is produced in
BF in presence of coke and molten steel is produced in BOF in presence of oxygen. Smelting and refining
process involves carbon reduction in BF to produce molten iron and decarburization of molten iron to
produce molten steel. After BF and BOF process molten steel is controlled to a target composition and
temperature for processing into continuous casting machine to produce slabs, billets etc. Finally the
castings are rolled to the required dimensions in the rolling mill to get finished steel products.
The processes involved in making steel in Steel industries are :
1. Raw Material Agglomeration
2. Blast furnace process
3. Basic oxygen furnace
4. Electric Arc Furnace
5. Steel, Stainless steel refining
6. Casting and Milling Process

Reference:
http://nationalphlebotomycolle
ge.com/64cqjj/
An important criterion of justifying strong economic growth in a nation is the
degree of industrialization in it. Although rapid industrialization is a sign of
development, it adversely affects the environment due to the release of large
quantities of toxic.
India is a heavily populated country, and this is the only reason for enormous
wastes being produced. Recycling of waste material saves natural resources,
saves energy, reduces solid waste, reduces air and water pollutants and reduces
greenhouse gases. Waste management is a collection, transportation, and
disposal of garbage, sewage, and other waste products. It is a process of treating
solid wastes and offers a variety of solutions for recycling items that don't belong
to trash. In other words, Waste management is all the activities and actions
required to manage waste from its inception to its final disposal. This includes
amongst other things, collection, transport, treatment and disposal of waste
together with monitoring and regulation.
Presently in India, about 960 million tonnes
of solid waste is being generated annually Reference:
as by-products during industrial, mining, http://www.
municipal, agricultural and other meconlimite
processes. Of this 350 million tonnes are d.co.in/write
organic wastes from agricultural sources; readdata/M
290 million tonnes are inorganic waste of IST_2016/ses
industrial and mining sectors and 4.5 n/tech_4/3
million tonnes are hazardous in nature.
 The solid wastes generated in steel industry can be broadly divided into two categories i.e., ferruginous wastes
and non ferruginous wastes. The ferruginous wastes, i.e. the iron bearing wastes are generated from steel
making viz., mill scale, flue dust, sludges from Gas cleaning plants of Blast Furnaces and Steel Melting Shops,
Blast furnace slag and SMS slag. The non ferruginous wastes are lime fines, broken refractory bricks, broken fire
clay bricks, acetylene plant sludge etc. A list of solid wastes along with their source of generation is depicted
in Table II. The chemical composition of various categories of solid wastes is also presented in Table III.

Reference: International Science Index,

Economics and Management Engineering Vol:9,
No:3, 2015 waset.org/Publication/10001005
 Objective: To develop competitive products by using potential of solid waste

 The major solid waste in steel industry i.e. blast furnace slags are used for the manufacture of cement, road base,
railroad ballast, light weight concrete block, glass and artificial rock, high performance concrete admixtures. EAF
steel making slag can be modified to use in cement making operations.
 Suitable EAF slag generated at SMP can be effectively utilized for filling the low-lying areas. Segregated refractories
at the source of generation can be used as constituents in manufacture of new bricks/mortars.
 Recycled iron and steel scrap is a vital raw material for the production of new steel products requiring much less
energy than the production of iron or steel products from iron ore.
 Blast furnace flue dust and electric arc furnace dust after extracting zinc and other metals can be used as a source
of lime and phosphorous in fertilizers.
 The roads are being repaired by the LD slag having 5-10 mm and 10 - 40 mm particle size. Besides, LD slag with 20-
65 mm particle size is being spread in railway track replacing conventional stone ballast.
 The rejected refractory bricks are used for pavement making. Fly ash can be used in the cement plant for making
PPC and for making fly ash bricks for building constructions.

Reference: International Science Index, Economics and Management Engineering Vol:9, No:3, 2015
waset.org/Publication/10001005
Solid waste management in steel industry is broadly classified in “4 Rs” i.e. reduce, reuse, recycle and
restore the materials. Reuse and recycling the entire solid waste generated in the process of steel making
is a viable solution in targeting a clean, green and zero waste technology leading to sustainable
development of the steel industry. Solid waste management has gained importance in steel industry in
view of its uncertainty, volatility and speculation due to world competitive standards, rising input costs,
scarcity of raw materials and solid waste generated like in other sectors.
Advantages: Old thermal methods of Solid waste disposal :
1. Minimizes Pollution • Methods include incineration, gasification, pyrolysis.
2. Protects Environment • Pyrolysis is form of gasification carried out in the
3. Minimizes Global Warming complete absence of oxygen
4. Conserve Natural Resources • There are 3 main stages in the process: Waste
breakdown, gas cleaning, conversion to power
5. Creation of New Jobs
6. Cuts down amount of waste in landfill sites Incineration
 Emits gas and small particles from smoke stack
 Usually have pollution control technology:
Disadvantages: scrubbers, lime injection, bag filtration
1. High upfront Capital costs  Produces heat, bottom ash, and fly ash: Ash must
2. Sites are unhygienic, unsafe be landfilled
3. Products from recycled waste may not be durable References:
4. Recycling is not widespread on large scale World Academy of Science, Engineering and Technology,
Vol:9, No:3, 2015
https://www.conserve-energy-future.com
METHODOLOGY:
The project involved four phases described as follows:
 Phase I : Information dissemination on proper solid waste management
 Phase II. Development/improvement of composting technology
 Phase III. Evaluation of produced organic fertilizer and compost tea as major sources of plant
nutrients for intensive vegetable production
 Phase IV. Technology promotion and utilization
Tentative Conclusion :
I. The economics of organic fertilizer production from solid waste indicate an initial investment of
Rs.34,643.
II. For one cycle (27 to 30 days) with a production of 100 bags, gross sale was Rs.21,210 with total
expenses of Rs.8,017.38.
III. The initial investment for the MRF can be recovered within 2.68 years.
Limitation :
a) The technology requires drying of soil prior to treatment.
b) Pyrolysis is not effective in either destroying or physically separating in organics from the
contaminated medium.
c) Volatile metals may be removed as a result of the higher temperatures associated with the
process, but they are not destroyed.
References: Fertilizer and Pesticide Authority, State Colleges of Agriculture, NY.
Sherive Chemical Process Industries, by George T. Austin
 Plasma created using almost any type of gas heated extreme temp.
 Breaks down waste on a molecular leaving little behind
 About double the price of traditional methods of landfilling and
incineration
 Produces energy at a smaller ratio to used energy than a traditional
waste to energy to energy incinerator facility
 Procedure a very stable glassy rock that is non-leachable, non-toxic.
 Great for use as gravel-another way plasma torch generates income
 Reduces gas volume requiring treatment

Control devices used to create clean Synthesis-

Gas
BYPRODUCT USES
Comparison of Plasma Torch and Incineration
COST Factor
 Expensive to operate plasma torch at 3000 °C
 A 100(2x50) tpd plant should cost around Rs. 35 crores
 If government helped fund could be viable option
 Cost depends on size of facility if energy were to be sold
 Would require a 30-40% high equity contribution
 Electricity, tipping fees, and sale of other outputs
 The cost per unit of power will be around Rs. 12.50
 Tipping fees depend on magnitude, operation cost
 Currently tipping fees is Rs. 750 per ton
 Sale of ash, slag is Rs. 12,700.59 per ton
Air Pollution Regulations
References:
• Yando, A.(n.d.) Plasma Energy Pyrolysis System
• Sioux City Journal(2005) Plasma Torch
Technology
• Iowa DNR Waste Management
• Franz man, D. (2005). Alternative in Landfill Battle
• Beck, R.W.(2003). City of Honolulu review of
Plasma Arc Gasification and Vitrification
Technology for waste disposal
 Slag management comprises the whole processing route of steel slag, from clearing away the hot
slag, transportation and processing to final recycling or disposal. Concept and implementation of
the slag management are adapted to specific customer demands and local conditions.
 After tapping, in accordance with the furnace working cycle the hot slag is loaded onto special
vehicles, which are designed to withstand the high thermal and mechanical stresses in these
areas. We use the Clean-Pit-Method to load and transport the slag away from the steel mill.
 Modern processing technology is used to separate the cooled slag into metallic and mineral
components and to process by-products. Metal contents can be separated from the steel slag
using magnetic separator systems.
 The materials are then sorted by hand to separate non-magnetic, metallic, and other fractions from
the slag. If a slag cannot be classified as a by-product, when necessary, we ensure that it is
removed in connection with an adequate waste disposal treatment.

Reference: https://www.horn-co.de/en/steel-services