| Key Data Set Information | |
| Location | CL |
| Geographical representativeness description | Data collected from integrated steel plants in India |
| Reference year | 2010 |
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Hierarchy level
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| General comment on data set | ecoQuery: https://ecoquery.ecoinvent.org/3.10/cutoff/dataset/20225/documentation The following excerpts have been taken from the report by Indian Minerals Yearbook 2015 - ;;"India is an important producer of pig iron. Post-liberalisation, with setting up of several units in the Private Sector, not only imports have drastically reduced but also India has turned out to be a net exporter of pig iron. ;;The Private Sector accounted for 91% of total production for sale of pig iron in the country in 2014-15. The production for sale of pig iron has increased from 1.6 million tonnes in April 1991- March 1992 to; 9.69 million tonnes in; April 2014-March 2015. The production of hot metal for the year April 2015- March 2016 was 58,703,000 tonnes. ;Pig iron has a very high carbon content, typically 3.5–4.5%, along with silica and other constituents of dross, which makes it very brittle, and not useful directly as a material except for limited applications. Pig iron is made by smelting iron ore into a transportable ingot of impure high carbon-content iron in a blast furnace as an ingredient for further processing steps." ;;References: Indian Minerals;Yearbook 2015 This dataset contains information for pig iron production in a Blast Furnance, intermediate process in steel production. This activity starts when raw material are delivered to the blast furnace. This activity ends at the exit of the blast furnace process. |
| Copyright | Yes |
| Quantitative reference | |
| Reference flow(s) |
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| Time representativeness | |
| Data set valid until | 2023 |
| Time representativeness description | The data was collected in 2016-17. |
| Technological representativeness | |
| Technology description including background system | Blast furnace process;The blast furnace is a reactor in which materials like coke, iron ore, additives descend and react with ascending gases. In the upper part of the furnace moisture is removed and hydrates and carbonates are separated. In the lower part of the furnace, at a temperature of about 70-1000 C, iron oxides are reduced (indirect reduction) by carbon dioxide and hydrogen. At the bottom most part of the furnace, at around 1000-1600 C, direct reduction of iron oxides takes place resulting in molten iron and slag as output. Hot air blasts are sent at the bottom where coke reacts with the oxygen and steam to form carbon monoxide and hydrogen and the iron and slag melt. This is the hottest part of the blast furnace at 1850-2200 C. The two outputs – slag and molten iron are collected in a hearth. Pig iron manufacturers sell the molten iron as ingots while integrated steel plants send the molten iron or hot metal in ladle cars to steel converters. The blast furnace slag is used for cement production.;;;Excerpts from Steel.org on pig iron production by Blast Furnace ;;"The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. These liquid products are drained from the furnace at regular intervals. The hot air that was blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions. ;;Once a blast furnace is started it will continuously run for four to ten years with only short stops to perform planned maintenance.;Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. The raw ore is removed from the earth and sized into pieces that range from 0.5 to 1.5 inches. This ore is either Hematite (Fe2O3) or Magnetite (Fe3O4) and the iron content ranges from 50% to 70%. This iron rich ore can be charged directly into a blast furnace without any further processing. Iron ore that contains a lower iron content must be processed or beneficiated to increase its iron content. Pellets are produced from this lower iron content ore. This ore is crushed and ground into a powder so the waste material called gangue can be removed. The remaining iron-rich powder is rolled into balls and fired in a furnace to produce strong, marble-sized pellets that contain 60% to 65% iron. ;Sinter is produced from fine raw ore, small coke, sand-sized limestone and numerous other steel plant waste materials that contain some iron. These fine materials are proportioned to obtain a desired product chemistry then mixed together. This raw material mix is then placed on a sintering strand, which is similar to a steel conveyor belt, where it is ignited by gas fired furnace and fused by the heat from the coke fines into larger size pieces that are from 0.5 to 2.0 inches. The iron ore, pellets and sinter then become the liquid iron produced in the blast furnace with any of their remaining impurities going to the liquid slag.;;;;The coke is produced from a mixture of coals. The coal is crushed and ground into a powder and then charged into an oven. As the oven is heated the coal is cooked so most of the volatile matter such as oil and tar are removed. The cooked coal, called coke, is removed from the oven after 18 to 24 hours of reaction time. The coke is cooled and screened into pieces ranging from one inch to four inches. The coke contains 90 to 93% carbon, some ash and sulfur but compared to raw coal is very strong. The strong pieces of coke with a high energy value provide permeability, heat and gases which are required to reduce and melt the iron ore, pellets and sinter.;;;;The final raw material in the ironmaking process in limestone. The limestone is removed from the earth by blasting with explosives. It is then crushed and screened to a size that ranges from 0.5 inch to 1.5 inch to become blast furnace flux . This flux can be pure high calcium limestone, dolomitic limestone containing magnesia or a blend of the two types of limestone.;;Since the limestone is melted to become the slag which removes sulfur and other impurities, the blast furnace operator may blend the different stones to produce the desired slag chemistry and create optimum slag properties such as a low melting point and a high fluidity.;;All of the raw materials are stored in an ore field and transferred to the stockhouse before charging. ;;Once these materials are charged into the furnace top, they go through numerous chemical and physical reactions while descending to the bottom of the furnace.;;The iron ore, pellets and sinter are reduced which simply means the oxygen in the iron oxides is removed by a series of chemical reactions. These reactions occur as follows:;;1) 3 Fe2O3 + CO = CO2 + 2 Fe3O4 Begins at 850° F;2) Fe3O4 + CO = CO2 + 3 FeO Begins at 1100° F;3) FeO + CO = CO2 + Fe; or; FeO + C = CO + Fe Begins at 1300° F;At the same time the iron oxides are going through these purifying reactions, they are also beginning to soften then melt and finally trickle as liquid iron through the coke to the bottom of the furnace.;;The coke descends to the bottom of the furnace to the level where the preheated air or hot blast enters the blast furnace. The coke is ignited by this hot blast and immediately reacts to generate heat as follows:;;C + O2 = CO2 + Heat;;Since the reaction takes place in the presence of excess carbon at a high temperature the carbon dioxide is reduced to carbon monoxide as follows:;;CO2+ C = 2CO;;The product of this reaction, carbon monoxide, is necessary to reduce the iron ore as seen in the previous iron oxide reactions.;;The limestone descends in the blast furnace and remains a solid while going through its first reaction as follows:;;CaCO3 = CaO + CO2;;This reaction requires energy and starts at about 1600°F. The CaO formed from this reaction is used to remove sulfur from the iron which is necessary before the hot metal becomes steel. This sulfur removing reaction is:;;FeS + CaO + C = CaS + FeO + CO;;The CaS becomes part of the slag. The slag is also formed from any remaining Silica (SiO2), Alumina (Al2O3), Magnesia (MgO) or Calcia (CaO) that entered with the iron ore, pellets, sinter or coke. The liquid slag then trickles through the coke bed to the bottom of the furnace where it floats on top of the liquid iron since it is less dense.;;Another product of the ironmaking process, in addition to molten iron and slag, is hot dirty gases. These gases exit the top of the blast furnace and proceed through gas cleaning equipment where particulate matter is removed from the gas and the gas is cooled. This gas has a considerable energy value so it is burned as a fuel in the "hot blast stoves" which are used to preheat the air entering the blast furnace to become "hot blast". Any of the gas not burned in the stoves is sent to the boiler house and is used to generate steam which turns a turbo blower that generates the compressed air known as "cold blast" that comes to the stoves. In summary, the blast furnace is a counter-current realtor where solids descend and gases ascend. In this reactor there are numerous chemical and physical reactions that produce the desired final product which is hot metal.";References: http://www.steel.org/making-steel/how-its-made/processes/how-a-blast-furnace-works.aspx |
| LCI method and allocation | |
| Type of data set | Unit process, black box |
| LCI Method Principle | Other |
| Data sources, treatment and representativeness | |
| Data treatment and extrapolations principles | This dataset is extrapolated for some emissions to air from the dataset "pig iron production, GLO". |
| Data source(s) used for this data set | |
| Sampling procedure | The data has been collected from two integrated steel plants in India. The data collected represents approximately 34% of hot metal manufactured in the country. Total Hot Metal Manufactured in India from April 2015- March 2016: 58,703,000 tonnes Data collected for LCI: 19,721,978 tonnes |
| Completeness | |
| Completeness of product model | No statement |
| Data generator | |
| Data set generator / modeller | |
| Data entry by | |
| Time stamp (last saved) | 2024-10-18T12:53:31.368000-03:00 |
| Data set format(s) | |
| Data entry by | |
| Publication and ownership | |
| UUID | 5eb46f05-f832-4578-a44c-c7086f6c925a |
| Date of last revision | 2024-10-17T19:33:45.514000-03:00 |
| Data set version | 00.00.009 |
| Unchanged re-publication of | |
| Copyright | Yes |
Inputs
| Type of flow | Classification | Flow | Location | Mean amount | Resulting amount | Minimum amount | Maximum amount | ||
|---|---|---|---|---|---|---|---|---|---|
| Product flow | C:Manufacturing / 28:Manufacture of machinery and equipment n.e.c. / 281:Manufacture of general-purpose machinery / 2815:Manufacture of ovens, furnaces and furnace burners | GLO | 1.3333E-11 Item(s) | 1.3333E-11 Item(s) | |||||
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| Product flow | Recycled content cut-off | GLO | -4.34 MJ | -4.34 MJ | |||||
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| Product flow | Recycled content cut-off | GLO | -0.403 kg | -0.403 kg | |||||
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| Product flow | C:Manufacturing / 19:Manufacture of coke and refined petroleum products / 191:Manufacture of coke oven products / 1910:Manufacture of coke oven products | RoW | 13.025 MJ | 13.025 MJ | |||||
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| Product flow | B:Mining and quarrying / 08:Other mining and quarrying / 089:Mining and quarrying n.e.c. / 0891:Mining of chemical and fertilizer minerals | RoW | 0.00295772 kg | 0.00295772 kg | |||||
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| Product flow | D:Electricity, gas, steam and air conditioning supply / 35:Electricity, gas, steam and air conditioning supply / 351:Electric power generation, transmission and distribution / 3510:Electric power generation, transmission and distribution | CL | 1.584E-4 MJ | 1.584E-4 MJ | |||||
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| Product flow | B:Mining and quarrying / 05:Mining of coal and lignite / 051:Mining of hard coal / 0510:Mining of hard coal | RoW | 1.6E-9 kg | 1.6E-9 kg | |||||
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| Product flow | C:Manufacturing / 17:Manufacture of paper and paper products / 170:Manufacture of paper and paper products / 1701:Manufacture of pulp, paper and paperboard | RoW | 0.0565 MJ | 0.0565 MJ | |||||
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| Product flow | B:Mining and quarrying / 07:Mining of metal ores / 071:Mining of iron ores / 0710:Mining of iron ores | CL | 0.3039 kg | 0.3039 kg | |||||
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| Product flow | C:Manufacturing / 24:Manufacture of basic metals / 241:Manufacture of basic iron and steel / 2410:Manufacture of basic iron and steel | CL | 0.396 kg | 0.396 kg | |||||
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| Product flow | C:Manufacturing / 24:Manufacture of basic metals / 241:Manufacture of basic iron and steel / 2410:Manufacture of basic iron and steel | RoW | 0.92 kg | 0.92 kg | |||||
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| Product flow | B:Mining and quarrying / 08:Other mining and quarrying / 081:Quarrying of stone, sand and clay / 0810:Quarrying of stone, sand and clay | RoW | 0.00267 kg | 0.00267 kg | |||||
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| Product flow | C:Manufacturing / 20:Manufacture of chemicals and chemical products / 201:Manufacture of basic chemicals, fertilizers and nitrogen compounds, plastics / 2011:Manufacture of basic chemicals | RoW | 0.0313 kg | 0.0313 kg | |||||
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| Product flow | C:Manufacturing / 20:Manufacture of chemicals and chemical products / 201:Manufacture of basic chemicals, fertilizers and nitrogen compounds, plastics / 2011:Manufacture of basic chemicals | RoW | 0.0535 kg | 0.0535 kg | |||||
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| Product flow | C:Manufacturing / 24:Manufacture of basic metals / 241:Manufacture of basic iron and steel / 2410:Manufacture of basic iron and steel | RoW | 3.5E-6 kg | 3.5E-6 kg | |||||
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| Product flow | C:Manufacturing / 19:Manufacture of coke and refined petroleum products / 191:Manufacture of coke oven products / 1910:Manufacture of coke oven products | RoW | 0.145 kg | 0.145 kg | |||||
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| Elementary flow | Resources / Resources from water / Renewable material resources from water | CL | 7.3832E-4 m3 | 7.3832E-4 m3 | |||||
| Product flow | C:Manufacturing / 19:Manufacture of coke and refined petroleum products / 192:Manufacture of refined petroleum products / 1920:Manufacture of refined petroleum products | CL | 5.99283E-6 kg | 5.99283E-6 kg | |||||
Outputs
| Type of flow | Classification | Flow | Location | Mean amount | Resulting amount | Minimum amount | Maximum amount | ||
|---|---|---|---|---|---|---|---|---|---|
| Product flow | C:Manufacturing / 24:Manufacture of basic metals / 241:Manufacture of basic iron and steel / 2410:Manufacture of basic iron and steel | CL | 1.0 kg | 1.0 kg | |||||
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| Waste flow | E:Water supply; sewerage, waste management and remediation activities / 38:Waste collection, treatment and disposal activities; materials recovery / 382:Waste treatment and disposal / 3822:Treatment and disposal of hazardous waste | RoW | 0.016 kg | 0.016 kg | |||||
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| Waste flow | E:Water supply; sewerage, waste management and remediation activities / 37:Sewerage / 370:Sewerage / 3700:Sewerage | RoW | 5.90656E-4 m3 | 5.90656E-4 m3 | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 0.2025 kg | 0.2025 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 0.0013404 kg | 0.0013404 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 2.6596E-15 kg | 2.6596E-15 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 1.0745E-5 kg | 1.0745E-5 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 6.9149E-8 kg | 6.9149E-8 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 7.4468E-8 kg | 7.4468E-8 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 1.5957E-8 kg | 1.5957E-8 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 7.9787E-5 kg | 7.9787E-5 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 2.8723E-5 kg | 2.8723E-5 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 1.5957E-6 kg | 1.5957E-6 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 1.5957E-6 kg | 1.5957E-6 kg | |||||
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| Elementary flow | Emissions / Emissions to air / Emissions to air, unspecified | CL | 1.47664E-4 m3 | 1.47664E-4 m3 | |||||
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| Elementary flow | Emissions / Emissions to water / Emissions to water, unspecified | CL | 1.3298E-4 kg | 1.3298E-4 kg | |||||