Journal of Scientific & Industrial Research

Vol. 64, September 2005, pp 702-706

Productive recycling of basic oxygen furnace sludge in integrated steel plant

Raj Kumar Agrawal1 and Piyush Kant Pandey2,*
1
Steel Authority of India Limited, Bhilai Steel Plant, Bhilai 490 001
2
Centre for Environmental Science & Engineering, Bhilai Institute of Technology, Durg 491 002
Received 07 March 2005; accepted 20 June 2005

The study describes techniques of recycling the gas cleaning plant (GCP) sludge generated during basic oxygen furnace
(BOF) steel making process. Two different experiments were conducted to gainfully utilize converter sludge in iron making
and steel making. The experiments resulted in two different products namely lime sludge briquette (LSB) and dolomite
sludge mix (DSM). While LSB is used as a coolant in steel making, DSM is used for sinter production. Each one is having
cost effective advantages on one hand and substantially reduced dumping of waste on the other.
Keywords: Recycling, Basic oxygen furnace, Sludge, Blast furnace, Pollution

Introduction Experimental Details

Steel is an exceptionally recyclable material
because steel products and by-products are excellent
in terms of the “reduce, reuse and recycle” principle.
On proper refining, the recycled products compete
favorably with natural materials, improve recycling
and preserve non-renewable resources1. Indian steel
industry is yet to reach the high standards achieved by
its counterparts in developed world in the arena of
waste minimizations and recycling. However, the
Bhilai Steel Plant (BSP), Bhilai has taken some very
bold steps in this area and very encouraging results
are being obtained. One such attempt was the use of
mixed pond ash for manufacturing superior quality
bricks2. In continuation of the task, an attempt was
made to recycle the sludge obtained from the gas
cleaning plant of basic oxygen furnace (BOF) more
popularly known as LD converter.
This research has particularly targeted the slurry
from BOF for it’s recycling. In all major steel
producing countries, this slurry, which contains zinc
content too high to directly recycle, is put into a
settling tank and the water is pressed out of the slurry.
The remaining fraction is either stockpiled or
landfilled. Steel companies are prospecting for the
processes to economically retrieve the zinc and iron
units3. This paper describes a breakthrough achieved
which portents great savings economically and
environmentally.
________________
*Author for correspondence
Tel: 0788-2323997; Fax: 0788-2210163
E-mail: bitdurg@sancharnet.ac.in
Process Description
Integrated steel production relies principally on
virgin ore as the iron source and the use of some iron
scrap is being made. The iron ore, mainly hematite
(Fe2O3) in India, is either sintered or pelletized and is
then reacted with coke, preheated air and auxiliary
fuels in the blast furnace (BF) to yield molten pig
iron. This hot metal is then transformed into steel in
and further processed before casting and rolling. Steel
is an alloy of iron (< 1% carbon). Integrated steel
plants produce steel by refining iron ore in several
steps and produce very high quality steel with well-
controlled chemical compositions to meet all product
quality requirements.
In BSP, three LD converters (capacity, 130 ton
each) are installed. Steel is made in LD converters by
lancing pure oxygen, which converts the carbon
present in pig iron into carbon mono-oxide. Oxygen is
blown through lances into the converter charged with
hot metal, iron scrap, ferroalloys, lime and iron ore.
Iron ore is used as a coolant, which adjusts hot metal
scrap ratio to large extent. High purity oxygen blown
into the furnace removes carbon and silicon in the
molten iron mainly by oxidation. The basic oxide
furnace is fed with fluxes to remove siliceous
impurities. Certain alloying materials may also be
added to enhance the characteristics of the steel.
During oxygen blowing process, a large amount of
fumes and gases are generated, which contain fine
particles of the charged materials and carbon mono-
oxide (CO) gas.
 AGRAWAL & PANDEY: RECYCLING OF BASIC OXYGEN FURNACE SLUDGE STEEL PLANT
Fig. 1Schematic diagram of basic oxygen furnace (LD Converter) and gas cleaning plant (GCP)
Such discharges may vitiate the already stressed
atmosphere existing in steel cities4,5. Hence, this
polluted gas is cleaned before discharge to the
atmosphere. The gas is quenched and cooled using
water and cleaned of suspended solids and metals.
Evaporation of water due to high temperature
saturates the gases with moisture. The trickled down
water along with coarse dust particles is collected in
expansion chamber and drained out to hydraulic guard
tank. Gas, which is partially cleaned and cooled,
passes through a Venturi where it attains high
velocity. This leaves the occluded water particles
behind, which subsequently separates out in elbow
separator by centrifugal action. The wet slurry is
discharged into hydraulic guard tank. The outgoing
gas then passes through a zigzag path in baffle
separator that removes the remaining dust particles
and moisture. In the process of cleaning, the
buoyancy is an unavoidable trade-off. Therefore, the
gases are sucked by an I.D. fan to counter the
negative draft. A change over device finally directs
the outgoing gases either to recovery side or to the
atmosphere. A high content of CO in the gas makes it
suitable for its subsequent use as a fuel gas. Hence, in
the recovery part, the gas is stored in a gasholder.
However, CO content is variable therefore, a portion
of the gas in different stages of the furnace operation
is exhausted to the atmosphere through flare stack
after combustion (Fig. 1).
703
Slurry water from saturator, expansion chamber,
elbow and baffle separator is collected in hydraulic
tank guard. It is then discharged to radial settling tank
through launder. Radial settling tank deposits,
henceforth called ‘GCP Sludge’, is dumped in the
landfill. Large production of this sludge has made it
an environmental nuisance for the steel industry.
Materials and Methods
GCP sludge contains primarily iron oxide and free
lime. Although BOF sludge is not suitable revert for
use in BF because of high zinc content in other
countries, whereas in India scrap is largely free from
zinc. GCP sludge, analyzed by X-Ray fluorescence
method, showed presence of high Fe content, which
on recycling produced two types of products. (i) Lime
sludge briquette (LSB); and (ii) Dolomite sludge mix
(DSM). The major difficulty encountered when
recycling sludge to iron or steel making is the
moisture removal and material handling.
Lime Sludge Briquette (LSB)
Chemically, GCP sludge was found rich in iron
oxides and total Fe content. CO used for drying is
produced as a by-product in coke manufacturing in
the coke ovens. CO gas burners were installed in an
in-house furnace specially designed for the
elimination of water component. Converter sludge
was dried at 200oC in CO gas fired furnace for
704 J SCI IND RES VOL 64 SEPTEMBER 2005
appropriate time. The dried sludge was screened and
the size fraction (≤ 5 mm), collected after
demagnetization, was charged into mixer of
briquetting machine. Lime, used as the binder in
briquetting process, was charged through a separate
line into the mixer, and proportion was adjusted to
form briquettes of adequate handling strength in
briquetting machine. These briquettes were used as a
coolant and replacement of iron ore in converter
during steel making.
Dolomite Sludge Mix (DSM)
In LSB manufacture, CO, a by-product from coke
ovens, was used to dry sludge. In this experiment,
moisture and handling problem were overcome by a
unique process of dehydration. Sludge dehydration
was achieved by mixing sludge with hot dolomite
collected from dust chamber of rotary kiln during
calcination/sintering of raw dolomite. Calcination of
dolomite, an essential step during sinter making
operation, is carried out in sintering plants. The
process of calcination/sintering of dolomite is carried
out in the rotary kiln where the pulverized coal is
supplied with a jet of the compressed air. Thus, large
amount of fines, which are carried away by hot flue
gases, is unavoidable in this process. Theses fines are
separated from the flue gases in the dust chamber
(temp, 600°C). At the time of disposal, these fines are
generally at 200°–250°C. BSP envisaged using this
heat energy for dehydration of GCP sludge. These
outgoing gases from rotary kiln comprise of flue
gases, ash, and dolomite fines. The rate of generation
of rotary kiln fines is more than 40 ton/d. Prior to this
experiment, these fines were cooled and then sent to
dump yard as landfills.
GCP sludge from converter was sprayed on the
dolomite fines obtained from the rotary kiln. To
achieve the same, a recycling process was developed
in the plant premises. BOF sludge was supplied in
tippers to the dolomite plant. Blending of the hot
dolomite (~400°C) with sludge was done layer by
layer with the help of grab bucket. The sludge was
blended with dolomite in a predetermined mix ratios
using layering effect of sludge–dolomite–sludge and
so on. The mix ratios are not divulged here in view of
the commercial significance of this process.
The process uses available heat from hot dolomite
to dehydrate the sludge and it resulted in a huge
savings in drying costs. The treated mix is then
allowed to cool for approx 16-20 h. The undersize
mix was then transported in rail wagons to the ore
handling and preparation plant where it was mixed
with the iron ore fines. Care was taken that in the
preparation of iron ore fines, the moisture should not
exceed (7%) in so prepared mix. Thus, the sludge was
converted to non-dusting, free flowing material
suitable as iron ore fines to be used in sinter making
machine for sinter production. These sinters were
charged in BF for making iron.
Results and Discussion
The major issues in GCP sludge recycling effort
are economy and probable effects on the quality of
steel produced. Generation of GCP sludge is 8 kg/ton
of crude steel productions. For producing 1.8 million
ton steel per annum, BSP dumps about 14400 ton
sludge every year at a rate of production of
40 ton/d. After implementation of this scheme, entire
quantity is utilized and the generation rate has
reduced to 7.4 kg/ton. Chemically, GCP sludge
contains mainly iron (50%), calcium oxide (16%), and
magnesium oxide (4-5%), besides alumina, silica,
basic oxides and zinc. Operationally, the final
moisture content of mix is critical for proper handling
and charging. Too low moisture may cause dust
generation and too high may cause plugging of
hoppers and bins. Presence of moisture may lead to
the following problems: (i) Explosion in converter
vessel may take place because the presence of O2 and
high temperature generation of H2; (ii) Disintegration
of briquettes will take place due to hydration of lime;
and (iii) Wet sludge/briquette does not flow smoothly
through Vibro-feeders and can cause chute jamming
and lump formation in the bunker. Experiments
showed that sludge (moisture, 3-4%) is optimum to
avoid the above problems. A moisture level (< 3-4%)
causes excessive fugitive dust, and moisture level
(> 7%) starts choking in the flow line and equipments.
Two tests, Shatter and Tumbler, were carried out to
find out the suitability of the briquettes for industrial
applications. In Shatter test, 20 kg of briquettes was
allowed to fall 5 times from a height (2 m) on a steel
plate (40 mm thick). The percentage fraction
(≥5 mm), which remained intact, was reported as
Shatter Index, which for 5 samples was found as
follows: sample I, 89.2; II, 89.4; III, 90.1; IV, 91.0;
and V, 88.6. For Tumbler test, 15 kg of briquette was
subjected to tumbling in a drum (diam, 1000 mm;
height, 500 mm). The drum was rotated at 25 rpm for
8 min. The percentage fraction (+6.3 mm) was
reported as Tumbler Index, which for 3 samples was
found as follows: sample I, 75.8; II, 79.2; and III,
 AGRAWAL & PANDEY: RECYCLING OF BASIC OXYGEN FURNACE SLUDGE STEEL PLANT
Fig. 2 Composition of lime sludge briquette (LSB)
Fig. 3.Chemistry of dolomite fines
Fig. 4 Composition of dolomite sludge mix (DSM)
74.4. Results of both indexes show a high degree of
suitability for the respective applications.
Major components of LSB are CaO and Fe (Fig. 2).
Initially, LSB (1 ton) was fed to the converter. On
satisfactory performance, the quantity was increased
(2, 5, 10 and now 15 ton) of LSB, which is being
supplied every day. Thus, BSP is able to consume
entire sludge this way. The use of iron rich GCP
705
sludge has reduced the iron ore addition in the BOF
converter. The reduced oxygen consumption is
another benefit; as the presence of oxides is high in
the GCP sludge. Further, the converter sludge, having
high percentage of lime, would reduce lime
consumption also. The most significant engineering
benefit was in the form of a good vessel coating,
which was achieved in using LSB. A better coating of
the BOF directly results into a longer life of the
coating of the converter.
Experiments using dolomite fines have provided
even better results (Fig. 3). In this process, the sludge
dehydration was achieved by mixing it with hot
dolomite fines (~400OC) to produce low moisture
material suitable for charging in sinter machine as a
replacement of iron ore fines.
The presence of an appreciable percentage of CaO
and MgO in DSM (Fig. 4) makes it a suitable feed for
the BF. In blast furnace, DSM is used in the form of
pellet, which is manufactured by supplying DSM
through vibro-feeders. In this process, the chute
jamming and lump formation in the bunker are the
major problems. To avoid these problems, the optimal
moisture content (5%) in the DSM was maintained.
This resulted in a proper flow ability of the mix
ensuring a smooth operation.
Greater economy by the use of otherwise wasted
heat and the chemical properties of the DSM have
proved the advantages, which can be accrued by such
researches. Fiscal calculation shows that a saving of
more than $10 per ton of steel produced is easily
attained by this method. Thus, this research has
successfully invented the method of waste recycling
suitable to the Indian conditions.
Another major technological issue concerns the high
cooling effect of the oxidized by-products of BOF. The
dust, scales and sludge from iron- and steel making
processes, which usually have high iron content, are in
oxidized form virtually without exception. Iron oxide
containing material can be used as a substitutive
coolant during converter blowing process.
Traditionally scrap and iron ore (usually pellets or
sinter) are used as coolants. Charging iron oxide to
converter may also speed up slag formation in the
beginning of the process and decarburization reactions.
One of the biggest problems concerning utilization of
oxidized by-products in BOF-steel making is probably
a high cooling effect. This decreases the scrap melting
capacity of a converter, which may reduce total amount
of steel produced. Adding a reductant with the by-
706 J SCI IND RES VOL 64 SEPTEMBER 2005
product charge could diminish this problem. It is also
possible to prevent oxidation of dust in some cases,
when the cooling effect decreases. Anyway, at least
sinter, which is used as a secondary coolant, could be
replaced by a by-product with a high iron oxide
content. The cooling effect of sinter is close to cooling
effects of several dust, scales and sludge. The amount
of dust produced during converter process may be
increased when by-products are added. Some elements
are also enriched in the dust. These factors may
increase scaffold formation on the inner surface of the
flue gas duct. Using by-products as raw material may
increase content of some elements in raw steel.
However, this experiment has successfully countered
the problems identified as above because the actual
trials in both BOF and BF have shown no adverse
effect on the product quality and quantity. In this study,
there was no negative cooling effect in either of the
furnace following the mix proportions devised.
Both experiments have developed a unique
technology of sludge recycling in BSP in an
environment-friendly way. Owing to its simplicity
and visible benefits, the DSM technology has already
been adopted by BSP. Overall, the use of LSB or
DSM is advantageous due to the following reasons:
(1) Iron ore use has been eliminated partially; (2)
Reduction in oxygen consumption is envisaged; (3)
Reduction in lime consumption; (4) Good coating of
converter vessel was seen; (5) Land filling is reduced;
(6) This has helped in controlling final temperature by
reducing desired tapping temperature; and (7) Longer
life and thus less frequent repairs of the BOF lining.
Conclusions
Converter sludge briquette/mix (LSB, DSM) are
low cost, in-house produced by-products, which have
been found to be valuable recyclable material. Their
use is an eco-friendly solution to the problem of
landfill disposal of huge quantity of BOF sludge,
which is becoming increasingly unaffordable. This
study will result in a net return to any integrated steel
plant by the recovery of iron, reduced landfill cost and
substantial reduction in steel making cost. Through
this work, a viable industrial process has been
developed for treating steel making sludge to produce
useful by-product having improved flow rate
properties in a recycling system. LSB and DSM are
environment friendly and portend substantial cost
savings.
Acknowledgments
Authors sincerely acknowledge the support
provided by the Management of Bhilai Steel Plant,
Bhilai. RKA acknowledges the support of Bhilai
Institute of Technology.
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