| | Best Available Techniques Reference Document on the |
| | 8,81 | | MB | Production of Iron and Steel |
| | 383 | | stron |
| | 1096 | | ID | JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS) |
| | 2002 | | rok |
| | Executive summary i |
| | Preface .xii |
| | Scope .xxv |
| | 1 GENERAL INFORMATION.1 |
| | 1.1 Overall Steel production in Europe and Worldwide.1 |
| | 1.2 Geographical distribution of steel production in the EU 3 |
| | 1.3 Investments and employment in the EU iron and steel industry 8 |
| | 1.4 Economic situation9 |
| | 1.5 Environmental relevance of the iron and steel industry .10 |
| | 2 STORAGE AND HANDLING OF RAW MATERIALS.15 |
| | 3 STEEL-MAKING - OVERVIEW 16 |
| | 3.1 Steel-making process routes.16 |
| | 3.2 Integrated steelworks17 |
| | 3.2.1 Process overview17 |
| | 3.2.2 Interdependency of the different production processes/units in terms of energy, |
| | byproducts/residues, air and water 19 |
| | 3.2.2.1 Energy 19 |
| | 3.2.2.2 Solid residues/by-products .22 |
| | 3.2.2.3 Water 23 |
| | 4 SINTER PLANTS24 |
| | 4.1 Applied processes and techniques 24 |
| | 4.1.1 Purpose of the sinter process 24 |
| | 4.1.2 Blending and mixing of raw materials24 |
| | 4.1.3 Sinter strand operation25 |
| | 4.1.4 Hot sinter screening and cooling.27 |
| | 4.2 Present consumption/emission levels .28 |
| | 4.2.1 Mass stream overview and input/output data28 |
| | 4.2.2 Information on single emission mass streams.32 |
| | 4.2.2.1 Detailed information about emissions to air.32 |
| | 4.2.2.1.1 Particulate matter emissions from handling, crushing, screening and conveying of sinter |
| | feedstock and product 32 |
| | 4.2.2.1.2 Waste gas emissions from the sinter strand .32 |
| | 4.2.2.1.2.1 General.32 |
| | 4.2.2.1.2.2 Dust33 |
| | 4.2.2.1.2.3 Heavy metals34 |
| | 4.2.2.1.2.4 Alkali chlorides36 |
| | 4.2.2.1.2.5 Sulphur oxides (SOx).36 |
| | 4.2.2.1.2.6 Fluorides 38 |
| | 4.2.2.1.2.7 Nitrogen oxides (NOx).39 |
| | 4.2.2.1.2.8 Hydrocarbons.39 |
| | 4.2.2.1.2.9 Polychlorinated dibenzo-p-dioxins and - furans (PCDD/F).40 |
| | 4.2.2.1.2.10 Polychlorinated Biphenyls (PCB)42 |
| | 4.2.2.1.2.11 Further organohalogen compounds43 |
| | 4.2.2.1.2.12 Polycyclic aromatic hydrocarbons (PAH)43 |
| | 4.2.2.1.3 Particulate matter emissions from sinter cooling .43 |
| | 4.2.2.2 Information about emissions to water.43 |
| | 4.2.2.2.1.1 Rinsing water .43 |
| | 4.2.2.2.1.2 Cooling water.44 |
| | 4.2.2.2.1.3 Waste water from waste gas treatment.44 |
| | 4.2.2.3 Information about solid waste 44 |
| | 4.2.2.4 Information about energy aspects.44 |
| | 4.2.2.5 Information about noise emissions .45 |
| | 4.3 Techniques to consider in the determination of BAT 46 |
| | 4.3.1 Process-integrated techniques 47 |
| | 4.3.2 End-of-pipe-techniques 63 |
| | 4.4 Conclusions. 85 |
| | 4.5 Emerging techniques and future developments . 88 |
| | 4.5.1 PCDD/F removal 88 |
| | 5 PELLETISATION PLANTS 90 |
| | 5.1 Applied processes and techniques 90 |
| | 5.1.1 Grinding and drying/de-watering . 91 |
| | 5.1.2 Green ball preparation 91 |
| | 5.1.3 Induration . 91 |
| | 5.1.3.1 The straight grate process 92 |
| | 5.1.3.2 The grate kiln process 92 |
| | 5.1.4 Screening and handling 93 |
| | 5.2 Present consumption/emission levels. 94 |
| | 5.2.1 Mass stream overview and input/output-data. 94 |
| | 5.2.2 Information about single emission mass streams . 96 |
| | 5.2.2.1 Particulate matter emissions from grinding . 96 |
| | 5.2.2.2 NOx emissions from induration and drying 96 |
| | 5.2.2.3 Particulate matter and gaseous emissions from the induration strand 96 |
| | 5.2.2.4 SO2 emissions from induration 96 |
| | 5.2.2.5 HCl and HF emissions . 96 |
| | 5.2.2.6 Wastewater. 96 |
| | 5.2.2.7 Solid waste. 97 |
| | 5.2.2.8 Energy demand 97 |
| | 5.3 Techniques to consider in the determination of BAT 98 |
| | 5.4 Conclusions. 104 |
| | 5.5 Emerging techniques 107 |
| | 5.5.1 Process-integrated NOx abatement at the induration strand . 107 |
| | 5.5.2 Cold bonded pellets/briquettes . 107 |
| | 5.5.3 Other possible techniques. 108 |
| | 6 COKE OVEN PLANTS . 109 |
| | 6.1 Applied processes and techniques 109 |
| | 6.1.1 Coal handling . 110 |
| | 6.1.2 Coke oven battery operations . 111 |
| | 6.1.2.1 Coal charging. 112 |
| | 6.1.2.2 Heating/firing of the chambers. 112 |
| | 6.1.2.3 Coking. 114 |
| | 6.1.2.4 Coke pushing and quenching . 114 |
| | 6.1.2.5 Coke handling and screening . 115 |
| | 6.1.3 Collection and treatment of coke oven gas (COG) with recovery of by-products . 115 |
| | 6.1.3.1 Gas cooling 117 |
| | 6.1.3.2 Tar recovery from the coke oven gas. 117 |
| | 6.1.3.3 Desulphurisation of coke oven gas 117 |
| | 6.1.3.4 Recovery of ammonia from the coke oven gas 118 |
| | 6.1.3.5 Recovery of light oil from coke oven gas 118 |
| | 6.1.4 Coke oven water flows . 119 |
| | 6.2 Present consumption/emission levels. 121 |
| | 6.2.1 Mass stream overview and input/output data . 121 |
| | 6.2.2 Information on emissions to air 125 |
| | 6.2.3 Information on emissions to water . 125 |
| | 6.2.3.1 Continuous emissions to water 125 |
| | 6.2.3.1.1 Quantities. 125 |
| | 6.2.3.1.2 Wastewater from the coke oven plant 126 |
| | 6.2.3.1.3 Wastewater from wet oxidation desulphurisation processes . 126 |
| | 6.2.3.1.4 Cooling water 127 |
| | 6.2.3.2 Discontinuous emissions to water 127 |
| | 6.2.3.2.1 Wet coke quenching 127 |
| | 6.2.4 Energy demand. 127 |
| | 6.2.5 Soil pollution 128 |
| | 6.3 Techniques to consider in the determination of BAT 129 |
| | 6.4 Conclusions. 166 |
| | 6.5 Emerging techniques and future developments170 |
| | 7 BLAST FURNACES 172 |
| | 7.1 Applied processes172 |
| | 7.1.1 Charging .174 |
| | 7.1.2 Hot stoves .174 |
| | 7.1.3 Blast furnace .176 |
| | 7.1.3.1 General description.176 |
| | 7.1.3.2 Blast furnace top gas (BFgas).176 |
| | 7.1.3.3 Zinc and lead 177 |
| | 7.1.4 Direct injection of reducing agents .177 |
| | 7.1.5 Casting.177 |
| | 7.1.6 Slag processing .178 |
| | 7.1.6.1 Slag granulation processing178 |
| | 7.1.6.2 Slag pit process.179 |
| | 7.1.6.3 Slag pelletising process 180 |
| | 7.2 Present emission and consumption levels 181 |
| | 7.2.1 Mass stream overview and input/output data181 |
| | 7.2.2 Information about single emission mass streams and energy demand.185 |
| | 7.2.2.1 Waste gas emissions.185 |
| | 7.2.2.1.1 Waste gas emissions from the hot stoves .185 |
| | 7.2.2.1.2 Emissions from charging and conveying .186 |
| | 7.2.2.1.3 Blast furnace gas (as an indirect emission) 186 |
| | 7.2.2.1.4 Emissions from the cast house .187 |
| | 7.2.2.1.5 Emissions from slag processing .187 |
| | 7.2.2.2 Solid wastes/by-products emissions .188 |
| | 7.2.2.2.1 Particulate matter from casting 188 |
| | 7.2.2.2.2 Dust and sludge from BFgas treatment 188 |
| | 7.2.2.2.3 Slag from blast furnaces.189 |
| | 7.2.2.3 Wastewater emissions 190 |
| | 7.2.2.3.1 Overflow water from BFgas treatment.190 |
| | 7.2.2.3.2 Wastewater from slag granulation .191 |
| | 7.2.2.3.3 Blow down from cooling water circuit 191 |