Evaluation of the integration of recycling unit in an iron manufacturing plant

Abstract

Manufacturing of new steel from virgin iron ore is not only an energy intensive process but also generates a considerable amount of annual carbon footprint with respect to the world’s total carbon generation. It is actually considered as the highest carbon footprint generated among the heavy industries. Considering these characteristics of steel making, recycling technologies from scrap metal had been an area of interest in the circular economy framework. Production of new steel from scrap metals only requires as little as 10% of the energy used in the production of steel from virgin materials. This study aims to integrate a scrap metal recycling unit in an existing iron manufacturing plant using an optimization model that evaluates the carbon footprint. LINGO is used for the optimization model. The results have shown that carbon emission was reduced by 10.35% and significantly reduced one of the raw materials, coal, by 35.44%. The total power consumption was also reduced by 15.42%.