International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 08 | Aug 2025
p-ISSN: 2395-0072
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Sustainable Utilization of Solid Wastes from Integrated Steel Plants through Cold Briquetting: A Case Study from Tata Steel, Jamshedpur 1Mohadeb Dutta, 2*Sindhu J. Nair, 3Manish Kumar 1MTech. Scholar, Department of Civil Engineering, Bhilai Institute of Technology, Durg G.E. Road, Bhilai, Durg, 491001. 2*Department of Civil Engineering, Bhilai Institute of Technology, Durg G.E. Road, Bhilai, Durg, 491001.
3Department of Mechanical Engineering, Bhilai Institute of Technology, Durg G.E. Road, Bhilai, Durg, 491001. -----------------------------------------------------------------------***------------------------------------------------------------------------Abstract: The steel industry, pivotal to global economic development, faces critical challenges in managing massive by-
product and waste generation. In India, steel plants generate approximately 600 kg of solid waste per tonne of crude steel, contributing significantly to environmental concerns (Ministry of Steel, 2023). This study examines the valorization of key steelmaking by-products, specifically those from Tata Steel's Jamshedpur facility, through cold briquetting technology. Experimental evaluation revealed that briquettes formulated from LD sludge, blast furnace dust, mill scale, and other fines achieved robust mechanical performance, with a tumbler index of 48% and an abrasion index of 3.63%, indicating excellent resistance to impact and wear. Chemically, these briquettes maintained Fe content above 40%, with controlled levels of CaO, SiO₂, and other minor oxides. Thermal reduction tests between 1000°C and 1400°C confirmed a clear trend of decreasing swelling index, from 18% at 1000°C to 4% at 1400°C, ensuring dimensional stability within blast furnace conditions. Notably, the integration of these briquettes into the blast furnace burden (at substitution levels of 3% and 5%) demonstrated enhanced reduction efficiency and minimized operational swelling. These results underscore the potential for waste-derived briquettes to reduce landfill demand, close resource loops, and improve operational efficiency, thereby supporting the steel sector’s sustainability and India’s ambitious steel production targets.
Keywords: Steel industry, cold briquetting, solid waste utilization, resource recovery, metallurgical properties, sustainability, Tata Steel
1. Introduction The iron and steel industry remains a cornerstone of industrial growth and economic progress worldwide, despite a steady proliferation of advanced materials (World Steel Association, 2021). Since the mid-20th century, global steel output has risen dramatically, from 200 million tonnes in 1950 to over 1.8 billion tonnes by 2020, with Asia, led by China, dominating production landscapes (Sengupta et al., 2019; World Steel Association, 2021). However, alongside this growth, the steel sector is facing mounting challenges posed by resource depletion, escalating energy costs, and, critically, the management of vast solid waste streams (Singh & Prakash, 2020). Sustainable steel production necessitates not only process improvements but also comprehensive strategies for the valorization of by-products and waste, as integrated steel plants generate an array of solid, liquid, and gaseous residues (Das et al., 2007). Of these, solid residues including blast furnace (BF) and basic oxygen furnace (BOF) slags, sludges, mill scales, flue dust, and spent refractories, represent both a significant challenge and a unique opportunity. While traditional disposal practices have historically dominated the sector, stricter regulations and land scarcity are propelling industries toward zerowaste objectives (Kumar et al., 2018). Environmental data suggests that iron and steel production is responsible for 5–7% of global anthropogenic greenhouse gas emissions (IEA, 2022), urging the sector to adopt innovative waste reduction, recycling, and utilization techniques. Recent advancements in beneficiation, agglomeration, and resource recovery have allowed some plants to approach 95–97% waste recycling rates, in line with best practices observed in Europe and Japan (Yuan et al., 2017; Dutta et al., 2019). India's steel industry, the world's second largest, is similarly evolving. Major steel plants produce upwards of 100 million tonnes of crude steel per year, accompanied by an estimated 60 million tonnes of solid waste annually. The National Steel Policy (2017) has set ambitious production and sustainability targets, including the aim for 100% by-product utilization
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