TATA Steel, therefore, faces a significant and necessary sustainability challenge. Not only in terms of CO₂ emissions and other substances but also the environment and nuisance to the (immediate) surroundings. Introducing a dedusting installation is a significant step towards cleaner production and limiting nuisance for local residents and the environment. In addition, it will also positively affect flora and fauna in the area.
Rick de Jong is the Programme Director on behalf of Iv-Industrie & Consult. Rick is responsible for finding a solution with, among others, Project Manager Don de Jong and Paul van der Werf (Senior Lead Engineer - Piping & Mechanical). In the PEFA, iron ore is pre-processed into round balls (pellets), which are then introduced into the production process in the Blast Furnace. The pellets form an important raw material for the production of pig iron.
In addition to carbon dioxide (CO₂), the entire production process also releases a considerable amount of nitrogen (N2). Therefore, nitrogen emissions (NOx) must also be significantly reduced. The solution: a cleaning installation connected to the PEFA. “It’s a kind of dust & gas scrubber”, explains Rick de Jong. “In the preliminary phase, we examined workable solutions. This is one of them. There needs to be a ‘system’ in the middle that removes the pollution. This can be achieved in various ways. This new cleaning installation is a filter and a washing installation in one. A washer, also known as a scrubber, is like a water shower.”
The ‘cleaning installation’, a so-called DeNOx installation, delivers a considerable impact. Until now, substances such as sulphur, metals and lead were directly expelled via the chimney, causing elevated pollution levels. A filter and a scrubber will now be placed between the chimney and the PEFA to capture much of these emissions.
It works as follows: the first step is installing the dedusting installation, for which Iv provided the engineering and design, including the preparatory studies. This installation is connected directly to the PEFA and must do exactly what the name suggests: dust removal, thus reducing emissions of heavy metals, dust and lead. The flue gases are transported to the dedusting installation via a special pipe. The dedusting installation will be operational in 2023, and TATA expects the emissions of all these substances to be reduced by no less than 80 percent.
The size of the installation is impressive, both inside and out. It is 80 metres long and 35 metres tall and contains no fewer than 6,000 filter bags that filter all substances. The pipeline from the PEFA to the dedusting installation is 140 metres long with a diameter of 6 metres: comparable to a tunnel tube of the North-South metro line in Amsterdam.
This is followed by the DeNOx installation, which should reduce nitrogen dioxide emissions by the same amount and is linked to the dedusting installation. Here the flue gases are washed from the PEFA by the aforementioned ‘water shower’. The water from the DeNOx installation is then forwarded to a water treatment system. The interventions surrounding the PEFA are an essential part of TATA’s Roadmap Plus. If all goes according to plan, the DeNOx installation will be ready by the end of 2024 or early 2025.