Eşleştirme Projesi TR 08 IB EN 03 IPPC – Entegre Kirlilik Önleme ve Kontrol T.C. Çevre ve Şehircilik Bakanlığı BAT Guide for electric arc furnace iron & steel installations Project TR-2008-IB-EN-03 Mission no: 2.1.4.c.3 Prepared by: Jesús Ángel Ocio Hipólito Bilbao José Luis Gayo Nikolás García Cesar Seoánez Iron & Steel Producers Association Serhat Karadayı (Asil Çelik Sanayi ve Ticaret A.Ş.) Muzaffer Demir Mehmet Yayla Yavuz Yücekutlu Dinçer Karadavut Betül Keskin Çatal Zerrin Leblebici Ece Tok Şaziye Savaş Özlem Gülay Önder Gürpınar October 2012 1 Eşleştirme Projesi TR 08 IB EN 03 IPPC – Entegre Kirlilik Önleme ve Kontrol T.C. Çevre ve Şehircilik Bakanlığı Contents 0 FOREWORD ............................................................................................................................ 12 1 INTRODUCTION. ..................................................................................................................... 14 1.1 IMPLEMENTATION OF THE DIRECTIVE ON INDUSTRIAL EMISSIONS IN THE SECTOR OF STEEL PRODUCTION IN ELECTRIC ARC FURNACE ................................................................................. 14 1.2 OVERVIEW OF THE SITUATION OF THE SECTOR IN TURKEY ...................................................... 14 1.2.1 Current Situation ............................................................................................................ 14 1.2.2 Iron and Steel Production Processes............................................................................... 17 1.2.3 The Role Of Steel Sector in Turkish Economy .............................................................. 18 1.3 RELEVANT ENVIRONMENTAL IMPACTS OF THE SECTOR. .......................................................... 18 2 PRODUCTION PROCESSES AND TECHNIQUES ........................................................................ 21 2.1 STORAGE AND HANDLING OF RAW MATERIALS ....................................................................... 21 2.2 SCRAP CHARGING ...................................................................................................................... 23 2.3 ARC FURNACE MELTING AND REFINING. .................................................................................. 23 2.4 SECONDARY STEEL MAKING ...................................................................................................... 24 2.5 CASTING ..................................................................................................................................... 26 2.6 SLAG TREATMENT, LANDFILLS ................................................................................................... 30 2.7 HOT ROLLING MILLS .................................................................................................................. 31 2.7.1 Process Overview ........................................................................................................... 31 2.7.2 Surface Rectification and Conditioning of Input ............................................................ 42 2.7.3 Reheating- and Heat Treatment Furnaces ...................................................................... 43 2.7.4 Descaling ........................................................................................................................ 45 2.7.5 Edging ............................................................................................................................ 46 2.7.6 Roughing ........................................................................................................................ 46 2.7.7 Strip Rolling/Finishing Train ......................................................................................... 47 2.7.8 Rod Rolling/Finishing Train .......................................................................................... 47 2.7.9 Plate Rolling ................................................................................................................... 48 2.7.10 Transport of Roll Stock between Rolling Stands ........................................................... 48 2.7.11 Cooling Lines ................................................................................................................. 48 2.7.12 Sheet and Plate Production ............................................................................................. 49 2.7.13 Plate Heat Treatment ...................................................................................................... 49 2.7.14 Roll Shop ........................................................................................................................ 49 2.8 Cold Rolling Mills ....................................................................................................................... 50 2.8.1 Process Overview ........................................................................................................... 50 2.8.2 Pickling of Low Alloy and Alloy HR Steel .................................................................... 52 2.8.3 Initial Annealing and Pickling of High Alloy HR Steel ................................................. 53 2.8.4 Cold Rolling of the Pickled Hot Rolled Strip ................................................................. 54 2.8.5 Annealing of Low Alloy and Alloy Steel ....................................................................... 57 2.8.6 Final annealing and Pickling of High Alloy Steel .......................................................... 59 2.8.7 Tempering of Cold Rolled Strip ..................................................................................... 60 2 Eşleştirme Projesi TR 08 IB EN 03 IPPC – Entegre Kirlilik Önleme ve Kontrol T.C. Çevre ve Şehircilik Bakanlığı 2.8.8 Finishing ......................................................................................................................... 61 2.8.9 Roll Shop ........................................................................................................................ 62 2.8.10 Wire drawing plants ....................................................................................................... 63 2.9 Continuous Hot Dip Coating Process ......................................................................................... 70 2.9.1 Galvanizing of Sheet (Zinc and Zinc Alloy Coating) ..................................................... 71 3 PRESENT EMISSION LEVELS AND RAW MATERIALS AND ENERGY CONSUMPTION ............... 82 3.1 Present consumption and emission levels ................................................................................ 82 3.1.1 Mass stream overview and input/output data ................................................................. 82 3.1.2 Environmental issues for electric arc furnace steelmaking process ............................... 86 3.2 Emissions to air .......................................................................................................................... 86 3.2.1 Primary and secondary emissions and treatment ............................................................ 86 3.2.2 Emissions from secondary metallurgy processes and continuous casting ...................... 91 3.2.3 Emissions from scrap preheating.................................................................................... 92 3.2.4 Emissions from slag processing ..................................................................................... 92 3.3 Emissions to water .................................................................................................................... 92 3.3.1 Waste water .................................................................................................................... 92 3.4 Solid waste and by-products. Landfills ...................................................................................... 95 3.4.1 Process residues such as wastes and by-products ........................................................... 95 3.4.2 Slags from production of carbon steel/low alloyed steel/high alloyed steel ................... 95 3.4.3 Dusts from off-gas treatment .......................................................................................... 97 3.4.4 Refractory bricks ............................................................................................................ 99 3.5 Noise emissions ......................................................................................................................... 99 3.5.1 Techniques concerning noise aspects ............................................................................. 99 3.5.2 Aspects of relevant noise sources ................................................................................. 100 3.5.3 Main noise sources ....................................................................................................... 101 3.6 Soil contamination ................................................................................................................... 103 3.6.1 Storage and handling of input materials ....................................................................... 103 3.6.2 Drainage water from the scrapyard .............................................................................. 104 3.7 Raw materials consumption .................................................................................................... 104 3.8 Energy consumption ................................................................................................................ 105 4 BATs FOR THE PRODUCTION PROCESSES