A Diversified Competitive Areas of Physics

& Allied with Job Opportunities

Praveen Mahajan
M. Tech., Environmental Engineering & Management
IIT Kanpur

Contents

Introduction
JAM
JEST
GATE

IIT JAM EXAM

The Joint Admission Test for M.sc( JAM) is conducted by IITs & IISc
to select candidates for two year M.Sc. & integrated Phd
programme. It was started from 2004-2005.
Institute Involved: IIT Kanpur, IIT Delhi, IIT Bombai, Pawai, IIT
Roorkee, IIT Kharagpur, IIT Madras, IIT Gouhati, IIT Gandhi Nagar,
IIT Hydrabad, IIT Indore, IIT Bhuveneswar, IIT Patna, IIT Jodhpur,
IIT Rooper, IISc Banglore
Programme Offered: Full Time M.Sc(Two-years), Joint (M.Sc-Phd
Programme), M.Sc- Phd Dual Degree Programme, M.Sc-Mtech
Programme, Other Post- Bachelors degree programme at different
IITs, Integrated Phds programme at IISc

IIT JAM EXAM

Contd

Exam Pattern:
The test papers of all subjects contains only objective type
questions with three different patterns
i) The Question having four objectives, and only one answer is
correct
ii) The Question having four objectives, and more than one answer is
correct
iii) Numerical answer type(NAT) in which no choice is given and put
the correct numerical value in the answer sheet

Introduction

Sponge Iron
Sponge Iron: Suitable Method

STEEL
PROSPECTS*
High domestic steel demand.
(Provides raw material for the steel industry )

Utilizes Non Coking coal (or Natural Gas)

Large scale availability of non coking coal reserves and Iron
ore reserves.
Limitations for the use of natural gas
Relatively cheaper
Produces good quality steel
*Source: Raja B.V.R. & Pal N., Indian Sponge Iron Industry-Status, Potential & Prospects,
2006 13

IIM Metal News, Vol. 9 No. 2, April

Sponge iron
Reduction of iron ore at temperature (1050-1200 C) below
melting point of Iron. (Direct Reduced Iron or DRI)a.
Main Process inside the Rotary kiln.
Process: very sensitive to chemical and physical characteristics
of raw materials used.
Iron ore with high iron content.
Natural gas or non-coking coal (High Fixed Carbon content and volatility).
Limestone/Dolomite.

Metallic product (> 90% iron content) formed due to reduction of

iron oxide in solid state.
Typical composition: b
Fe: 87% - 94% P: 0.007% - 0.05% SiO2: 2% - 4%
Al2O3: 0.60% - 2.7% C: 0.20% - 2.4% CaO + MgO: 0.2% - 3%
S: 0.01% - 0.03%.
a
b

Source: A report on sponge iron industry, March 2007, Central Pollution Control Board, Ministry of Environment and Forests, India
Source: Raja B.V.R. & Pal N., Indian Sponge Iron Industry-Status, Potential & Prospects, IIM Metal News, Vol. 9 No. 2, April 2006 13

Sponge iron units in India

India: the largest producer, produces more than 11.1 million
tones per annum*.
Chhattisgarh, Orissa, Jharkhand and West Bengal are the
key region*.
Survey by Joint Plan Committee in 2005:
147 working coal based sponge iron plants and 3 gas (confined
to the western region) based plants up to 31 August 2005.
According to Ministry of Steel, there are 321 coal based
sponge iron plants and 3 gas based sponge iron plants
(March/April 08).
Major national coal based sponge iron leaders include Tata
Sponge Iron Plant and Jindal Steel & Power Limited. Public
sector coal based sponge iron plants are also operating which
includes Sponge Iron India Limited.
*Source: Battacharjee S., Secretary WBSIMA, Sponge iron Industry: Current Scenario, Steel World, July 2007 & A report on sponge
iron industry, March 2007, Central Pollution Control Board, Ministry of Environment and Forests, India

SPONGE IRON
UNITS
OF
INDIA

Source: sponge iron industry, March

2007, Central Pollution Control Board,
Ministry of Environment and Forests, India

A SPONGE IRON UNIT AT BELLARY

Industrial classification
Updated National Industrial Classification-2004*.

Section D (manufacturing).
Division 27 (manufacture of basic metals)
Group 271 (manufacture of basic iron and steel)
Class 2712
Subclass 27120 (i.e. manufacture of direct reduced
iron (DRI)/ sponge iron and other spongy ferrous
products.)

*Source: Updated National Industrial Classification-2004, Ministry of Statistics and Programme Implementation, Government of India

Indian economy & Sponge iron Production

Indian Economy after 1991
Introduction of LPG
Delicensing & Decontolling
of Steel Sector in 1991 &
1992.
Growth in Production of
Sponge Iron.

Increasing production of Sponge iron

in India from 1991-92

* Source: Policies and facts 2007-08, Iron and steel sector, Website of Ministry of Steel

Steel Sector and Sponge iron industry

The growth of sponge iron
industry and growth in the
production of steel in India are
taking place at a faster rate after
the economic reforms of 1991.

Production and Apparent

Consumption of the Finished Steel
since 1991

The growth is also influenced by

the increase in the apparent
consumption (i.e. Production +
Imports Exports +/- Variation in
Stocks) of the steel, as more is
the Demand more will be supply.

* Source: Policies and facts 2007-08, Iron and steel sector, Website of Ministry of Steel

Net Export/Import of Steel

The increase in the
production of steel also
influences the Net
Export/Import of steel

Exports, Imports and Net

Exports/Imports of Total Steel in India
since 1991
* Source: Policies and facts 2007-08, Iron and steel sector, Website of Ministry of Steel

Period of
1997-98
After 2000

Introduction of
L,P,G

Sponge Iron & Sectoral

Trends

*Source: International Iron & Steel Institute (DRI Statistics)

Production of Sponge Iron:

Current Trends
If the same trends
continues then the
annual production
capacity will be about 37
million tones / year by
2014-15

Production of Sponge Iron in India

from 2001-02 till now: Showing an
exponential growth in past few years.
* Source: Policies and facts 2007-08, Iron and steel sector, Website of Ministry of Steel

Benefits of the Sponge iron industry

Raw material for making the Steel.
Benefits through eco-friendly practices.
Ash generated in Cement manufacturing and Brick making.
Waste hot gases may be used to produce steam in Waste
heat recovery boilers, which can be used to produce Power.
Generate a large scale employment for the local people.
Infrastructure development is also enhanced with the growth of
such plants. Few important benefits may include FDI, large
scale technology transfer and development.
Indirect Benefits includes literacy, life style improvement and
Better transportation facilities with the development of railways,
roads and ports. The industry may help in developing the socioeconomic status of the local people and the area by an efficient
Corporate Social Responsibility Plan.

Socio Environmental problems

associated with the sponge iron industry
Many industries do not uses proper pollution control devices.
The emission of Dust and the Fly ash is the major problem. It
is generated at different stages
Carrying and processing raw materials
Discharge of product
Crushing and sizing
Wagon tripping, wagon loading and unloading etc.
Problems due to fly ash:
Water gets polluted when comes in contact with it.
Emissions contain heavy metals like Iron, Nickel, Cadmium,
Hexavalent Chromium, Arsenic and Copper etc.
Adverse effect on the green leaves & pollination of plants.
Source: Gupta S. et.al, Assessment of heavy metal accumulation in macrophyte, agricultural
zone of sponge iron factory, Environmental Geology, August 2007

Soil, and crop plants adjacent to discharge

Contd
Pollution Problem:
Water gets polluted by the disposed water of the slurry from
settler.
Thermal Pollution caused by the Waste water from the coolant
system.
Air gets polluted due to the gaseous emissions, which along
with fly ash, also consists of gaseous products of reduction
and mainly it contains dust of raw materials like iron ore, coal,
limestone/dolomite and gases like CO2, CO, NOX, unburnt
hydrocarbons, SOX etc.
The hot gases coming out of rotary kilns at higher may
generate thermal pollution also.
These gases are also contributing to Climate change.

Contd..
Land Acquisition Problem:
Industries require better land & location for getting better facilities.
It includes generally the forest or fertile areas which are abundant in
minerals.
Such lands are generally owned by rural and tribal people. Such lands
are fertile and are habitat to large biodiversity (wildlife).
Over mining or Over Production Problem:
The industry with its rapid growth as observed by the trend of
productivity in last few years may force to mining of mineral reserves at
alarming rate.
Road damage is also among one of the problems which may arise due
to excessive transportation by roads but under low or no maintenance.
Lack of Public Awareness about the after effects of exposure to the
polluted atmosphere.

Contd..
The employment during construction phase and initial phase
of processing may be temporary one.
(The labors (local & rural) removed once will be deprived of
their past available Opportunity cost.)
Various policies regarding industries, tribal development,
water and power related grants, some monetary benefits i.e.
charging less taxes than large scale industries, subsidy etc
are sometimes overlooked.
Pollution control devices are either not installed properly(or
not installed sometimes) within such industries to control the
air pollution in the industries.
Corporate Social Responsibility framework should be efficient.
Other problems includes lack of adequate water supply, lack
of proper transportation facilities and lack of proper law and
Order etc.

GREEN FIELDS

BARREN LANDS

LEAF BURN

Source: Internet

LEAKAGE PROBLEM

PEOPLE AT REST : EXPOSURE TO IRON

DUST AND FLY ASH

Conclusions
Steel sector has shown an increased growth in the last few
years, so as the Sponge iron sector.
Global and National level steel companies have made huge
investments in sponge iron and steel industry.
Many of the sponge iron units are small- scale industries.
Thus operates at low capital, provides large scale
employment and uses low operational instruments BUT the
environmental and social problems gets intensified.
It is generating environmental and social problems varying
from place to place and seems unsustainable.
This development with environmental and social problems
may create an imbalance between the nature and the society
in the coming future.
Need of immediate action from Private, Public and Politics.

Suggestions and Recommendations

Proper use of all required pollution control devices and
methods.
Proper Enquiry of the Location before granting No-objection
certificates to the industries.
Preservation of the interest of tribes, Forests & Biodiversity,
and Culture as a priority.
Necessary & Beneficial Plantations programs.
Proper Local level employment facility, educational facilities,
health facilities and better financial schemes.
Proper CSR (Corporate social Responsibility) plans and
Public Private partnership plans.
Socio-Environmental or Environmental problems should be
monitored and solved regularly.
Proper appraisal studies should be done using proper
methods like doing Social Cost Benefit Analysis.

RAIN WATER HARVESTING

SPRAYING WATER FOR DUST

SUPRESSION

PLANTATION PROGRAM

PUBLIC CONSULTATION

THANK YOU

THANK YOU

Reactions Involved within

Rotary Kiln
Fe2O3 + CO
Fe3O4+CO

Fe3O4 + CO2
FeO + CO2

Fe + CO2
FeO + CO
If Sulphur is present in the Coal
FeO + H2S

FeS + H2O

FeS + CaO + CO

Return

Fe + CaS + CO2

Effects Of Heavy Metals

Arsenic(As) : Organ failures, Oxidative stress
Cadmium(Cd) : Pneumonitis (Inflammation of lung
tissues), Pulmonary edema (abnormally increase of fluid
volume between body cells), Carcinogenic.
Chromium(Cr) : Irritating to eyes, Skin and mucous
membranes.
Copper(Cu): Palsy (complete or partial muscle paralysis),
and insensibility , Oxidative stress.
Nickel(Ni) : Carcinogenic, Skin damage, Birth defects,
Continuation of pathogenic infection
Iron(Fe) : Oxidative stress
Return

Per Capita Steel

Consumption
Low per capita steel consumption of
around 38 kg of Indian people (which
is less that of world avg. i.e. 189 Kg.)

Return

Source: Website of World Iron and Steel Institue, 2007 data

Foreign Direct Investment

Up to 100 % FDI is allowed which is
also influenced with the terms and
conditions of WTO.
Large scale technology transfer also
takes place.

Return

Source: FDI Manual, Govt. of India & Sponge Iron Industry 2007 report CPCB