WORLD CRUDE STEEL PRODUCTION Steel Companies in Brazil LOCATION OF STEEL PRODUCTION SITES. Steel production flowchart

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Regional / Subrregional Capacity Building Workshop on Implementation of Article 5 and Practical Use of the Guidelines on Best Available Techniques and Best Environmental Practices (BAT and BEP) WORLD

1 Regional / Subrregional Capacity Building Workshop on Implementation of Article 5 and Practical Use of the Guidelines on Best Available Techniques and Best Environmental Practices (BAT and BEP) WORLD CRUDE STEEL PRODUCTION t 600,0 20 largest steel production countries Worldwide steel production = 1,307.3 million tons 500,0 502,0 400,0 300,0 Leonardo Sambaquy Maria Cristina Yuan 200,0 100,0 0,0 São Paulo, February ,7 91,5 68, ,5 45,8 37,1 33,7 30,5 26,4 20,2 19,0 17,9 17,8 15,1 13,5 10,9 9,9 9,6 China Japan USA Russia Índia South Kores Germany Ukraine Brazil Italy Turkey Taiwan Spain France Mexico Canada UK Belgium Iran Poland Steel Companies in Brazil LOCATION OF STEEL PRODUCTION SITES ROUTE PRODUCT COMPANIES PARÁ Sinobras CEARÁ Gerdau Aços Longos (Cearense) INTEGRATED PLANTS NON-INTEGRATED PLANTS FLAT LONG LONG ArcelorMittal Inox Brasil (MG), Cosipa (SP), ArcelorMittal Tubarão (ES), CSN (RJ), Usiminas (MG) ArcelorMittal Aços Longos (Monlevade)/MG, Gerdau Açominas (Ouro Branco/MG), Gerdau Aços Longos (Barão de Cocais/MG, Divinópolis/MG, Usiba/BA), Sinobrás (PA), V&M do Brasil (MG) Aços Villares (Pindamonhangaba/SP, Mogi das Cruzes/SP), Barra Mansa (RJ),ArcelorMittal Aços Longos (Piracicaba/SP, Cariacica/ES, Juiz de Fora/MG), Gerdau Aços Longos (Açonorte/PE, Cearense/CE, Cosigua/RJ, Guaíra/PR, São Paulo/SP, Riograndense/RS), Gerdau Aços Especiais (Piratini/RS), Villares Metals (SP) MINAS GERAIS ArcelorMittal Inox Brasil Gerdau Açominas (Ouro Branco) ArcelorMittal Aços Longos (Monlevade) ArcelorMittal Aços Longos (Juiz de Fora) Gerdau Aços Longos (Barão de Cocais) Gerdau Aços Longos (Divinópolis) Usiminas V&M do Brasil RIO GRANDE DO SUL Gerdau Aços Especiais (Piratini) Gerdau Aços Longos (Riograndense) PERNAMBUCO Gerdau Aços Longos (Açonorte) BAHIA Gerdau Aços Longos (Usiba) RIO DE JANEIRO Barra Mansa CSN Gerdau Aços Longos (Cosigua) SÃO PAULO Aços Villares (Pindamonhangaba) Aços Villares (Mogi das Cruzes) ArcelorMittal Aços Longos (Piracicaba) Cosipa Gerdau Aços Longos (São Paulo) Villares Metals PARANÁ Gerdau Aços Longos (Guaíra) ESPÍRITO SANTO ArcelorMittal Aços Longos (Cariacica) ArcelorMittal Tubarão Brazilian crude steel production in 2008: 33.7 million tons Steel production flowchart Pig iron Continuous casting Scrap Blast Furnace EAF Iron ore Sinter plant Rolling mill Coal Coke plant Flat products Others BOF Long products Preparation of charge Reduction Refining Continuous Casting Rolling mill 1

2 UNINTENTIONAL POP s FORMATION POPs formation in thermal processes is favoured by: Carbon, oxygen, hydrogen and chlorine presence High temperatures (> 200ºC) and/or incomplete combustion Following conditions may influence PCDD/PCDF formation: Poor combustion (inappropriate management of temperature, turbulence and time of residence) [3T]. Metal catalysts: copper, iron, aluminium, chromium, manganese. UNINTENTIONAL POP s FORMATION UNINTENTIONAL POP s FORMATION POPs formation in chemical processes is favoured by: - Carbon, oxygen, hydrogen and chlorine presence Following conditions may influence PCDD/PCDF formation: High temperatures (> 250ºC) Alkaline conditions Metal catalysts Ultraviolet radiation (UV) Other radical starters Main source categories N Main source categories Air Water Soil Products Wastes 1 Waste incinerators X X 2 Metallurgical industry X X 3 Electricity and heat generation X X X 4 Mineral production X X 5 Transportation X 6 Uncontrolled combustion processes X X X X 7 Chemicals X X X X 8 Others X X X X X 9 Destruction, firing, burning X X X X UNINTENTIONAL POP s RELEASE Emission factor example Sinter Plants Class Characteristics High waste recycling rate, 1 including oily wastes Controlled waste recycling, good 2 management of the plant High level technology to achieve 3 emission reduction ND Not determined NA Not applied Emission factor μgteq/t sinter Air Water Soil Products Wastes 20 ND ND NA 0,003 5 ND ND NA 0,003 0,3 ND ND NA 0,003 2

3 Flue gas treatment techniques (air pollution control equipments) such as : Afterburners Rapid Quench System Dust separation Scrubbing process Sorption process Catalytic oxidation Afterburners Afterburners are either separate from or integrated into the main combustion chamber for destroying unburnt or partially burnt carbon compounds in the exhaust gas. Depending on the actual conditions a catalyst, additional combustion air or a (natural gas fired) burner may be required. Informações auxiliares no BAT/BEP Rapid Quench used to bring flue gas temperatures down quickly to below the formation threshold for chemicals listed in Annex C of the Stockholm Convention (e.g: 200 C). most of these systems, when well design, don t generate any liquid effluent, using the steam heat to cool the gases. when are included inside a wet system and associated a wastewater treatment systems, this should be designed to deal with the higher particulate matter loadings that will end up in the scrubber water as a consequence. Air Quench System injection of gases with temperature below combustion gases temperature, occurring condensation and sorption of dioxins and furans on dust surface. this technique is used together with Afterburner or Rapid Quench System. Guide BAT/BEP Dust separation fine dust fraction may be PCDD/PCDF enriched due to its high specific surface. fabric filters are often more efficient for PCDD/PCDF emission reduction. Addition of sorbents may enhance the removal efficiency. BAT Best Available Techniques Available techniques means those techniques that are accessible to the operator and that are developed on a scale that allows implementation in the relevant industrial sector under economically and technically viable conditions, taking into consideration the costs and advantages. Best means most effective in achieving a high general level of protection of the environment as a whole. 3

4 Guide BAT/BEP Guide BAT/BEP Status of development of technologies Only technologies consolidated at industrial scale, with proven performance to prevent POP s formation/release should be recommended as BAT. Regional / Local conditions Adoption of BAT shall take into account availability of raw materials and other inputs, benefit x cost effectiveness, specific characteristics of the plant and environmental impacts of BAT techniques. Scale and production capacity of the plant Adoption of BAT shall consider scale and production capacity of the plant. Emission performance Emission performance levels associated to BAT can not be achievable by some plants, since there are several particular conditions and factors influencing such performance. 4

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