SYSTEM AND A METHOD FOR PRODUCING GREEN STEEL WITH NEAR ZERO GHG EMISSIONS INTENSITY

Abstract

The present invention relates to a method and a system for producing green steel. The method includes the scrap which is obtained from one or more sources of scrap. The obtained scrap and ferroalloys are charged into an induction furnace and melted in an inert environment to obtain molten steel. The inert gases are introduced into the induction furnace to prevent oxidation of the scrap and different types of scrap alloys and ferroalloys during melting. The molten steel is transferred from the induction furnace either directly to a casting area or to a refining unit to refine the molten steel. The refined steel transferred to a vacuum-degassing unit to degas the refined steel. Finally, the vacuum-degassed steel is transferred to a casting area to produce the green steel.

Claims

1. A method for producing a green steel, the method comprising: obtaining a scrap from one or more sources of scrap, wherein the obtained scrap comprises different types of scrap alloys present therein; charging the obtained different types of scrap alloys into an induction furnace; melting, inside the induction furnace and in an inert environment, the charged scrap alloys to obtain molten steel, wherein the charged scrap alloys are melted in the presence of one or more inert gases obtained in the induction furnace; and transferring the molten steel from the induction furnace to a casting area coupled to the induction furnace to thereby obtain the green steel.

2. The method as claimed in claim 1, wherein the method further comprising: refining, by a refining unit coupled to the induction furnace, the molten steel before transferring to the casting area, wherein the refining unit is coupled to the induction furnace; and degassing, by a vacuum-degassing unit coupled to the induction furnace, refining unit, and the casting area, the refined steel to transfer the vacuum-degassed steel to the casting area.

3. The method as claimed in claim 1, wherein: the obtained scrap is segregated to obtain specific metal combination therefrom and thereby charge the obtained specific metal combinations in the induction furnace; and the one or more inert gases are obtained by inserting a flow of the one or more inert gases in the induction furnace to prevent oxidation of the obtained molten steel.

4. The method as claimed in claim 1, wherein: the green steel is selected from any or a combination of low carbon, medium carbon, high carbon, high-strength low-alloy (HSLA), low alloy steel, high alloy steel, stainless steel, Fe-based super alloy, tool, die steel, or valve steel; wherein the different types of scrap alloys are selected based on a required chemical composition and chemical composition of obtained scrap.

5. The method as claimed in claim 1, wherein: the charged scrap alloys are melted using a renewable energy source; and the obtained different types of scrap alloys are charged using one or more charging mechanisms provided in the induction furnace, wherein the one or more charging mechanisms are selected from any of crane, hoist, charging bucket, or vibrating feeders.

6. The method as claimed in claim 1, wherein: the scrap is obtained using an electric vehicle; and the one or more inert gases are obtained through a gas supply inlet provided on the induction furnace, wherein the one or more inert gases are selected from any or a combination of argon (Ar), helium (He), neon (Ne), xenon (Xe), or krypton (Kr).

7. The method as claimed in claim 1, wherein: the scrap is a metal waste generated from industrial processes, manufacturing processes, construction processes, or an end-of-life products; and the casting area is equipped with one or more molds to form one or more shapes from the molten steel, wherein the casting area further comprising a cooling system that facilitates the solidification of the molten steel.

8. A system to produce a green steel, the system comprising: an induction furnace adapted to charge different types of scrap alloys, wherein the different types of scrap alloys are obtained from scrap; a melting means adapted to melt the charged scrap alloys inside the induction furnace and in an inert environment, wherein the charged scrap alloys are melted in the presence of one or more inert gases obtained in induction furnace; and a transferring means adapted to transfer the molten steel from the induction furnace to a casting area coupled to the induction furnace to thereby obtain the green steel.

9. The system as claimed in the claim 8, wherein the system further comprising: a refining unit adapted to refine the molten steel before transfer to the casting area, wherein the refining unit is coupled to the induction furnace; and a vacuum-degassing unit adapted to degas the refined steel and transfer the vacuum-degassed steel to the casting area, wherein the vacuum-degassing unit is coupled to the induction furnace, the refining unit and the casting area.

10. The system as claimed in the claim 8, wherein: the scrap is generated from one or more sources of scrap; the obtained scrap is segregated to obtain metal therefrom and thereby charge the obtained metal in the induction furnace; and the one or more inert gases are obtained through a gas supply inlet provided on the induction furnace, wherein the one or more inert gases are selected from any or a combination of argon (Ar), helium (He), neon (Ne), xenon (Xe), or krypton (Kr).

Description

BRIEF DESCRIPTION OF DRAWINGS

[0037] The accompanying drawings, which are incorporated herein, and constitute a part of this invention, illustrate exemplary embodiments of the disclosed methods and systems in which reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that the invention of such drawings includes the invention of electrical components, electronic components or circuitry commonly used to implement such components.

[0038] FIG. 1 illustrates an exemplary flow diagram that describes the step-wise illustration of the method for producing green steel, in accordance with an embodiment of the present invention.

[0039] FIG. 2 illustrates an exemplary system block diagram of a system for producing green steel, in accordance with an exemplary embodiment of the present invention.

[0040] FIG. 3 illustrates an exemplary representation of a flow chart showing the overall process of producing green steel, in accordance with an embodiment of the present invention.

[0041] FIG. 4 illustrates an exemplary representation of an induction furnace with an inert environment, in accordance with an embodiment of the present invention.

[0042] Other objects, advantages, and novel features of the invention will become apparent from the following more detailed description of the present embodiment when taken in conjunction with the accompanying drawings.

DETAILED DESCRIPTION

[0043] Various example embodiments will now be described more fully with reference to the accompanying drawings in which only some example embodiments are shown. Specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. The present invention, however, may be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.

[0044] It will be understood that when an element is referred to as being connected, or coupled, to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being directly connected, or directly coupled, to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between, versus directly between, adjacent, versus directly adjacent, etc.).

[0045] The following is a detailed description of embodiments of the invention depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the invention. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

[0046] Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings FIGS. 1-4.

[0047] The present invention provides a method and a system customised for producing green steel with near zero GHG emissions per ton of steel.

[0048] FIG. 1 illustrates an exemplary flow diagram (150) that describes the step-wise illustration of the method (150) for producing green steel (600), in accordance with an embodiment of the present invention.

[0049] As shown inf FIG. 1, the method (150) begins with obtaining scrap from various sources at step 101, which could include industrial waste, end-of-life products, or manufacturing by-products. This scrap may contain different alloys, which need to be sorted based on their chemical composition.

[0050] At step 102, the obtained scrap is charged into an induction furnace, either by using cranes, hoists, buckets, or vibrating feeders. The scrap is melted using renewable energy sources (like solar power). This initial step prepares the raw materials for melting and further processing. It may be noted that before charging, the obtained scrap may be segregated to obtain the metal content therefrom based on their chemical composition.

[0051] In the exemplary implementation of the embodiment, the term different types of scrap and ferroalloys may refer to carbon steel scrap, stainless steel scrap, tool steel scrap, alloy steel scrap, high-strength low-alloy (HSLA) steel scrap, cast iron scrap, Fe-based superalloy scrap or any other type of scrap may be useful for obtaining metal content therefrom. Ferroalloys may refer to ferrous alloy of respective metal such as silicon, manganese, chromium, titanium, vanadium, aluminum, molybdenum, tungsten, nickel, boron, etc.

[0052] In the exemplary implementation of the embodiment, the segregation of scrap to obtain the metal content may involve several steps that ensure proper separation of different types of scrap alloys based on their chemical composition and physical properties. The segregating methods include but not limited to, initial sorting manually or using machinery, magnetic separation using a magnet, density-based separation, chemical or spectrometric analysis, manual inspection, and final sorting, shredding or granulation.

[0053] In the exemplary implementation of the embodiment, the different types of scraps and ferroalloys are selected based on their chemical composition, various factors and methods can be used to choose the appropriate scrap materials. The different types of scraps and ferroalloys are selected.

[0054] In the exemplary implementation of the embodiment, the charging of the scraps and ferroalloys may be performed using one or more charging mechanisms, such as a crane, hoist, charging bucket, or vibrating feeders. The charging mechanisms allow the efficient and safe loading of the scraps and ferroalloys into the induction furnace.

[0055] At step 103, the scrap is melted inside the induction furnace. This furnace operates in an inert gas environment, meaning gases like argon (Ar), or other inert gases (He, Ne, Xe, Kr) are supplied through a gas inlet in the furnace. These inert gases (hereinafter the terms one or more inert gases or inert gases used interchangeably) prevent oxidation during the melting process, ensuring the purity of the molten steel. The inert gas atmosphere is critical for preventing contamination and reducing the likelihood of unwanted chemical reactions during melting. The choice of gas may depend on the specific alloys being melted.

[0056] At step 104, once the melting is complete, the molten steel is transferred to a casting area. This could involve coupling of the furnace to the casting section, ensuring a seamless transfer of the molten steel. At this stage, the molten steel can be formed into the desired shapes. The casting area contains molds to shape the molten steel, and a cooling system helps solidify the steel into ingots or continuous castings. This step finalizes the steel production process.

[0057] The casting area may further include a cooling system that facilitates the solidification of the molten metal, and ensures that the green steel achieves the required physical and mechanical properties. The system may also utilize cooling media such as water, air, or inert gases to control the cooling rate of the cast green steel.

[0058] At step 105, in cases where high purity engineering quality steel is required to be produced, after melting, the molten steel is sent to a refining unit where additional purification takes place. This is to adjust the final chemical composition of the steel, ensuring that it meets required quality as per specifications.

[0059] Following refining, the molten steel undergoes vacuum degassing to remove dissolved gases like hydrogen, nitrogen, or oxygen. This step ensures high-quality steel by preventing gas porosity in the final product, and improvement in overall soundness of steel.

[0060] The refined steel is degassed using vacuum-degassing unit (204-2) in step 106. The refinement is done through a refining unit (204-1). The refining unit (204-1) refers to any equipment or system used for refining molten steel. In the refining unit (204-1), additional ferroalloys are introduced into the molten steel to achieve the desired chemical composition. The process is known as the trimming addition of ferroalloys. The additional ferroalloys may include but not limited to elements such as manganese, chromium, nickel, or molybdenum, which enhance the properties of the steel based on the required end application, whether for strength, hardness, or corrosion resistance. For example, if high-strength low-alloy steel is required, specific quantities of ferroalloys are added to obtain the correct alloying elements.

[0061] Furthermore, after the refining process of the molten steel through the refining unit, the refined steel undergoes vacuum degassing in step 106. The purpose of vacuum degassing is to remove dissolved gases, particularly hydrogen, nitrogen, and oxygen, from the refined steel. The gases, if not eliminated, can cause defects in the final steel product, such as porosity or hydrogen embrittlement.

[0062] During vacuum degassing, the refined steel is subjected to a vacuum environment, where the pressure is significantly reduced. Under low pressure, the dissolved gases in the refined steel are released and removed through a vacuum pump. The removal of gases is crucial for improving the steel's mechanical properties, such as its toughness and fatigue resistance.

[0063] In an exemplary implementation of the embodiment, the refining unit may include but not limited to, ladle furnace, RH (Ruhrstahl Heraeus) degassing.

[0064] Once vacuum degassing is completed, the vacuum-degassed steel is ready for casting, where it can either be cast into ingots casting or undergo continuous casting. The combination of ladle furnace i.e., refining unit for refining and vacuum-degassing unit ensures the quality and integrity of the green steel produced using the disclosed method.

[0065] In an exemplary implementation of the embodiment, the green steel (600) is produced through the described method may include various types of steel, including low carbon, medium carbon, high carbon, high-strength low-alloy (HSLA), low alloy steel, high alloy steel, stainless steel, Fe-based super alloys, tool steel, die steel, and valve steel. The selection of the type of green steel is dependent on the specific composition of the scrap and ferroalloys used in the induction furnace.

[0066] The resulting green steel can be available in a range of types, such as low-carbon, medium-carbon, high-carbon steel, stainless steel, or even Fe-based superalloys.

[0067] During the melting process, ferroalloys may be added to fine-tune the chemistry of the steel. These adjustments ensure that the molten steel meets the desired mechanical and chemical properties.

[0068] It may be appreciated that, the process is designed to be energy-efficient, utilizing renewable energy sources like solar or wind power to power entire steelmaking process. This contributes to the overall goal of producing green steel with near-zero greenhouse gas (GHG) emissions.

[0069] It may be appreciated that, the scrap transportation using electric vehicles further reduces the carbon footprint of the process, supporting the sustainability goals of green steel production.

[0070] It may be appreciated that, the molten steel is cast into various shapes, with molds in the casting area designed for specific products. The cooling system ensures rapid solidification, improving the quality of the final product and making it ready for subsequent processing or fabrication.

[0071] It may be further appreciated that, the entire method is structured to minimize the environmental impact by using recycled materials (scrap) and renewable energy, and avoiding the release of harmful gases during production. The use of inert gases and vacuum degassing helps maintain the quality of steel without relying on traditional high-emission processes.

[0072] Thus, the method/process as shown in FIG. 1 provides a green steel production technique by focusing on energy efficiency, emission reduction, and recycling, while maintaining the flexibility to produce various steel types for different industrial applications.

[0073] The method further includes refinement of the molten steel (204) before transferring the molten steel (204) into the casting area (206).

[0074] FIG. 2 illustrates an exemplary system block diagram (250) of a system (200) for producing green steel (600), in accordance with an exemplary embodiment of the present invention.

[0075] In a second embodiment of the present invention, the system (200) for producing green steel (600) using scraps and ferroalloys (202) and an induction furnace (203) is disclosed. The system (200) is implemented to melt and process scrap (201) into molten steel (204) under controlled inert environment, followed by transferring the molten steel (204) to a casting area (206) for shaping and solidification.

[0076] The system (200) further includes a refining unit (204-1) and a vacuum-degassing unit (204-2), both are used for refining and preparing the molten steel (204) for casting. The refining unit (204-1) is adapted to receive the molten steel (204) after initial production in the induction furnace (203). The refining unit (204-1) allows for further metallurgical refinement of the molten steel (204) by adjusting its chemical composition and removing any undesirable impurities. The refining process may include the addition of ferroalloys to adjust the composition, the removal of non-metallic inclusions, or the control of temperature. The refining unit (204-1) is coupled to the induction furnace (203), ensures a flow of molten steel between the two stages of the production process.

[0077] Further, once the refining process is done, the refined steel is transferred to the vacuum-degassing unit (204-2). The vacuum-degassing unit (204-2) is used to remove dissolved gases, such as hydrogen, nitrogen, and oxygen, from the refined steel for further refinement. The degassing process occurs under a vacuum environment, significantly reducing the gas content in the refined steel and improves quality of the refined steel. The vacuum-degassed steel is then transferred to the casting area (206) for further processing. The vacuum-degassing unit (204-2) is coupled to both the refining unit (204-1) and the casting area (206), ensures an uninterrupted flow of steel through the different stages of production of the green steel (600).

[0078] In the exemplary implementation of the second embodiment, the system (200) includes the induction furnace (203) that is adapted to charge the different types of scrap and ferroalloys (202). The scrap alloys (202) are obtained from scrap (201), which may originate from various sources (700), including industrial processes, manufacturing, construction, or end-of-life products. The scrap (201) may include metal waste that is recyclable, contributing to the sustainability and environmental responsibility of the system (200).

[0079] In the exemplary implementation of the second embodiment, the one or more sources of scrap (700) refer to various origins or supply points from which the scrap (201) is collected for use in the disclosed system (200). The sources of scrap provide the raw material for the process of producing green steel (600). The one or more sources of scrap (700) include but not limited to, industrial Processes such as offcuts, shavings, defective parts, forging scraps and other leftover materials from industrial production lines, construction, and demolition such as steel beams, pipes, rebar, and other metallic components, end-of-life products such as old vehicles, household appliances, electronic devices, or machinery, scrap yards or recycling centers, metalworking Facilities, shipbreaking Yards, or municipal waste collection such as discarded metal items from residential or commercial waste, including old furniture, metal containers, or fixtures.

[0080] In the exemplary implementation of the second embodiment, once the scrap (201) is obtained, it is segregated to extract the metal content. The segregated metal is then charged into the induction furnace (203). The induction furnace (203) is configured to melt the charged scraps and ferroalloys (202) in an inert environment to prevent oxidation during the melting process.

[0081] In the exemplary implementation of the second embodiment, a melting means (207) is provided within the induction furnace (203) to melt the different types of scraps and ferroalloys (202) and convert them into molten steel (204). The melting means (207) are selected from any of induction coils, power supply, temperature sensors and control systems, or furnace lining. The melting means (207) ensures efficient melting of the scraps and ferroalloys (202) in an induction furnace (203).

[0082] In the exemplary implementation of the second embodiment, one or more inert gases (205) are introduced into the induction furnace (203) to create an inert environment during the melting process. The inert gases (205) are introduced through a gas supply inlet (205-1) that is in fluid connection with the induction furnace (203). One or more inert gases (205) may include but not limited to, argon (Ar), helium (He), neon (Ne), xenon (Xe), or krypton (Kr). The selection of these inert gases (205) ensures that the molten steel (204) does not oxidize or degrade in quality during the melting process. The flow of inert gases (205) is carefully controlled based on the type of scrap and ferroalloys (202) and the desired characteristics of the molten steel (204).

[0083] In the exemplary implementation of the second embodiment, the scrap and ferroalloys (202) have been fully melted and converted into molten steel (204). The system (200) further includes a transferring means (208) to transfer the molten steel (204) from the induction furnace (203) to a casting area (206). The transferring means (208) may include but not be limited to, ladle or ladle car, tapping system, conveyor or track system, tilting mechanism, or pouring mechanism. The transferring means (208) ensures safe and controlled transfer of the molten steel (204) from the induction furnace (203) to the casting area (206) for producing green steel (600).

[0084] In the exemplary implementation of the second embodiment, the casting area (206) is coupled to the induction furnace (203) and serves as the section where the molten steel (204) is shaped and solidified into the desired form of green steel (600). The casting area (206) is equipped with molds that facilitate the formation of the molten steel (204) into various shapes. Additionally, the casting area (206) may include a cooling system (206-1) which helps to accelerate the solidification process, ensuring that the molten steel (204) solidifies into high-quality green steel (600).

[0085] In the exemplary implementation of the second embodiment, the green steel (600) produced by the system (200) can include various types of steel, such as low carbon, medium carbon, high carbon, high-strength low-alloy (HSLA) steel, low alloy steel, high alloy steel, stainless steel, Fe-based super alloys, tool steel, die steel, and valve steel. The flexibility of the system (200) allows for the production of different types of green steel (600) depending on the scrap and ferroalloys (202) charged into the induction furnace (203).

[0086] In the exemplary implementation of the second embodiment, the system (200) is implemented using electricity generated from renewable energy sources to power entire steelmaking process system (200). Renewable energy sources, such as solar, wind, or hydropower, can be used to reduce the environmental impact of the system (200).

[0087] To summarise, the system (200) provides a sustainable and efficient solution for recycling scraps (202) and converting it into high-quality steel products. The process is environmentally responsible, and the inclusion of inert gases (205) ensures the purity and quality of the molten steel (204) throughout the production process in two ways. The first way produces green steel by coupling the induction furnace (203) with a dedicated casting area (206) and cooling system (206-1), the system (200) enables a seamless and controlled process for producing green steel (600) in various forms and compositions. Another way to produce the green steel by coupling Induction furnace (203) to refining unit (204-1) and vacuum degassing (204-2), and finally to casting area (206) and cooling system (206-1).

[0088] FIG. 3 illustrates an exemplary representation of a flow chart (350) showing the overall process of producing green steel (600), in accordance with an embodiment of the present invention. A green steel production process aimed at achieving near-zero greenhouse gas (GHG) emissions is disclosed. It begins with scrap metal transportation via electric vehicles, followed by scrap charging into an induction furnace powered by renewable energy (solar power). The melting occurs in an argon-inert gas environment to minimize oxidation. Adjustments to the chemical composition are made using ferroalloy additions. The melted steel then passes through a ladle furnace and vacuum degassing to remove impurities. The final product is formed through either ingot or continuous casting, maintaining near zero GHG emissions.

[0089] In an exemplary embodiment, each step in the green steel production process from the FIG. 3 is briefly elaborated below:

[0090] Scrap Transported through electric vehicle (301): Scrap metal is moved to the plant using electric vehicles, minimizing emissions from transportation by avoiding fossil fuels.

[0091] Scrap charging (302): The collected scrap metal is loaded into the induction furnace for charging. The charging process prepares the metal for recycling into steel.

[0092] Induction furnace melting (306): The scrap metal is melted in an induction furnace, powered by renewable energy (solar power). The use of solar energy ensures that the process is carbon-neutral.

[0093] Argon Inert Gas Environment (303): The melting process is conducted in an argon inert gas atmosphere. Argon prevents oxidation of the metal, maintaining its purity and avoiding unwanted chemical reactions.

[0094] Trimming Addition of Ferroalloys for Chemistry Adjustment (305): Ferroalloys are added to the molten metal to adjust the chemical composition, ensuring the steel meets required quality standards for various applications. This step allows for precise control over the properties of the final product.

[0095] Ladle Furnace (307): After melting, the molten steel is transferred to a ladle furnace, where further refining and temperature control are carried out. This helps in maintaining the desired steel quality and removing impurities.

[0096] Vacuum Degassing (308): The molten refined steel undergoes vacuum degassing to remove dissolved gases like hydrogen, oxygen, and nitrogen. This step improves the steel's quality by preventing gas-related defects, such as bubbles or cracks.

[0097] Trimming Addition of Ferroalloys for Chemistry Adjustment (309): After vacuum degassing the molten refined steel again undergoes for the process of the trimming addition of ferroalloys for chemistry adjustment.

[0098] Ingot Casting (310-1) or Continuous Casting (310-2): The molten steel is then shaped into solid forms through one of two methods:

[0099] Ingot Casting (310-1): Steel is poured into molds to form ingots, which are later processed into various shapes.

[0100] Continuous Casting (310-2): The molten steel is continuously poured into a casting machine, forming long sheets or billets that are cut to size.

[0101] Near Zero GHG Emissions (311): By using renewable energy sources, electric vehicles, usage of recycled scrap, bio-fuels and advanced melting and refining processes, the overall emissions of greenhouse gases are kept near zero, making this a sustainable process for steel production.

[0102] In these embodiments, the green steel production process involves the step of casting (307-1) immediately after the indication furnace melting (step 306) step. Further, molten steel goes into the casting area for either ingot casting (308-1) or continuous casting (308-2) process.

[0103] The method significantly reduces the carbon footprint of traditional steel manufacturing while maintaining high-quality steel production.

[0104] Referring to FIG. 3, a process for producing green steel (600) using an induction furnace summarized below.

[0105] At step 301, the scrap (which may be obtained from various sources like industrial waste or end-of-life products) is transported to the production facility using electric vehicles. The electric vehicle is used to reduce carbon emissions compared to traditional transportation methods reliant on fossil fuels. At step 302, the obtained scrap is charged. At step 306, the melting process takes place in the induction furnace (203), an inert environment is created by introducing argon gas at step 303. Argon helps to prevent oxidation of the scrap during melting, which improves the quality of the steel produced and reduces harmful emissions. At step (304), the electricity required for the induction furnace is provided by renewable energy sources, (for examplesolar power). This significantly reduces the carbon footprint of the steelmaking process, making the production more sustainable. Further, to achieve the desired chemical composition of the green steel, a minimum quantity of ferroalloys is added in step (305). This step ensures that the steel meets the required mechanical properties and specifications without unnecessary additions, thereby optimizing resource use.

[0106] Furthermore, At step (306), the scrap (201) is loaded into the furnace (203) for the melting process. In step (306), the scrap (201) is melted in the induction furnace (203) under the argon inert gas environment, using energy supplied by a renewable source (for examplesolar power). The use of renewable energy and inert gas further reduces the environmental impact of the process. Further, the positive pressure of argon is maintained which ensure that very minimal GHG emissions are released into the environment after melting. At step 307, The molten steel (204) thus produced is then transferred to ladle furnace i.e. refining unit for refining the molten steel thereby obtain the refined steel. At step 308, after the refining process in the refining unit (204-1), the refined steel undergoes vacuum degassing. At step 308, the slag metal reactions occur in the refining unit (204-1) followed by the vacuum treatment through the vacuum-degassing unit (204-2) that further refines the refined steel as well as controls the level of gases such as oxygen (O), hydrogen (H), and nitrogen (N) to obtain the vacuum-degassed steel. Further, trimming addition of ferroalloys is performed on the refined steel at step 309. The GHG emissions occurs during this process is very minimal near zero GHG emissions at step (311). The refined and degassed steel then taken for either ingot casting or continuous casting process.

[0107] In a third embodiment of the present invention, the process further includes another shorten process to obtain the green steel (600) i.e. after melting of charged scrap in the induction furnace (203). The molten steel (204) directly transferred for casting into the casting area (206). The molten steel (204) is either transferred for the ingot casting process (308-1) or continuous casting (308-2) process.

[0108] In a fourth embodiment of the present invention, a method (150) to reduce the GHG emissions including scope 1direct emissions, scope 2indirect emissions due to electricity generation, and scope 3indirect emissions due to production of raw materials, transportation, etc.

[0109] In an exemplary implementation of the fourth embodiment, scope 1 includes the raw material required to produce the steel through the IF route is Approximately 100% scrap generated during hot deformation, steel casting, forging, grinding and machining, etc. Such scrap is available in the nearby area of the manufacturing location. To reduce and avoid the usage of virgin ferroalloys, scrap is carefully selected to match the chemistry required for the finished steel product. The inert environment is provided inside the induction furnace crucible to aid in minimizing the GHG emissions further to near zero level.

[0110] In the exemplary implementation of the fourth embodiment, the method (150) produces electricity through a captive renewable energy power plant. The same energy is being utilized for the melting of steel in the induction furnace.

[0111] In the exemplary implementation of the fourth embodiment, the raw material, i.e. scrap, is available in the vicinity of the various companies or residential premises which is transported to the melting facility using electric vehicles. (for exampleforklifts or trucks). Further, such end-of-life manufacturing scrap has Zero GHG emissions as per ISO 14404-2:2013 i.e. calculation method of carbon dioxide emission intensity from iron and steel production, and steel plant with electric arc furnace (EAF).

[0112] In the exemplary implementation of the fourth embodiment, the required scrap is strategically selected to have lesser to no ferroalloy additions. The induction furnace crucible is covered with a metallic hood to arrest air ingress inside the furnace crucible. Positive pressure of Argon gas is maintained inside the furnace crucible, which first replaces the air present in the furnace and then provides a neutral environment. Air ingress thus prevented at the crucible helps to maintain an oxygen-free environment in the furnace crucible hence the GHG emissions are reduced to near zero.

[0113] In the exemplary implementation of the fourth embodiment, the scrap that is used for melting is selected nearer to the alloy chemistry to be made so as to reduce the ferroalloys consumption. Inert gas (such as Argon) environment is maintained throughout the melting and helps to improve the recovery of elements from ferroalloys which further reduces the ferroalloys consumption and GHG emissions due to the melting. Since the positive pressure of argon is maintained using the disclosed method (150) it is ensured that very minimal GHG emissions are released into the environment after melting.

[0114] The disclosed method (150) helps to minimize the GHG emissions that occur during the entire process chain of steelmaking.

[0115] In the exemplary implementation of the fourth embodiment, it may be appreciated that using the disclosed steel manufacturing method (150) produces all types of steels including low carbon, medium carbon, high carbon, HSLA, low alloy steel, high alloy steel, stainless steel, Fe-based super alloy and Tool and Die steel, Valve steel can be effectively produced. The individual elemental range is specified in the below table 1. The entire range of various chemical compositions of the steel grades that can be produced will be a subset of the elemental range. The below table 1 encompasses all the types of steel and ferrous alloys.

TABLE-US-00001 Element C Mn Si S P Cr Ni Mo Al Ti Range 0.005- 0- 0- 0- 0- 0- 0- 0- 0- 0- (Wt %) 1.5 30 5 0.9 0.9 30 45 15 10 5 Element V Nb W Cu Pb Sn Te Ca Co Ta Range 0- 0- 0- 0- 0- 0- 0- 0- 0- 0- (Wt %) 10 10 10 10 0.5 0.5 0.5 0.5 5 0.1 Element Sb Ce La Zr Zn O H N As B Range 0- 0- 0- 0- 0- 0- 0- 0- 0- 0- (Wt %) 0.1 0.1 0.1 0.1 0.1 0.05 0.01 1 0.5 0.5

[0116] To summarise, the present invention integrates the different concepts to reduce GHG emissions in each scope. For minimizing the scope 1 emissions, scrap has been used as a raw material, and an inert gas environment is provided to further reduce the GHG emissions to a level of near zero. The scrap is selected to match the chemistry of the final finished grade of steel product. To reduce scope 2 emissions, the power is generated using a renewable energy source like solar power. To reduce the scope 3 emissions, scrap is taken from nearby locations and transported through electric vehicles to the melting station.

[0117] FIG. 4 illustrates an exemplary representation (450) of an induction furnace (203) with an inert environment, in accordance with an embodiment of the present invention. FIG. 4 illustrates the induction furnace (203), its components, and the overall working of the induction furnace (203) for the green steel production method discussed earlier. Here's a component-wise explanation of the system:

[0118] Induction Furnace (203): Central to the melting process of scrap in the green steel method, using renewable or non-renewable energy.

[0119] Argon Gas Inlet (205-1): Inert gas, such as argon, is injected here to prevent oxidation during the melting process (step 103).

[0120] Hood for Arresting Air Ingress (209): Prevents air contamination, maintaining an inert environment.

[0121] Furnace Refractory Lining (216): Protects the furnace's inner structure during high-temperature operations.

[0122] Spout (215): Likely used for molten steel transfer from the furnace to the casting area (step 104).

[0123] Refractory Cover (210): Protects against high heat and corrosion during melting.

[0124] Induction Coil Plaster (218): Houses the induction coils, creating electromagnetic fields to heat the scrap.

[0125] Magnet Yoke (213): Assists in stabilizing the magnetic field for efficient induction heating.

[0126] Protection during Melting and Casting (212): It protects from heat and splashes of liquid metal during casting.

[0127] Ejector (214) and Bottom Cast Preform (220): Mechanisms likely aiding in casting operations and transfer of molten metal.

[0128] These components work together to perform the various steps (scrap charging, melting, refining, casting) described in the green steel process.

[0129] Again referring to FIG. 4, in an exemplary implementation of the fifth embodiment, the induction furnace (203) includes a gas supply inlet (205-1) for one or more inert gases (205), a hood for arresting air ingress (209), refractory cover (210), alumina cast pre-form (211), protectors (212), magnet yoke (213), ejector (214), bottom cast pre-form (220), Bakelite pillar (219), induction coil plaster (218), sliding surface lining (217), refractory lining (216), and spout (215).

[0130] In the exemplary implementation of the fifth embodiment, the argon or other inert gases are introduced into the furnace to create a controlled environment through argon Gas Inlet/gas Supply Inlet (205-1) for preventing oxidation during the melting process. The hood (209) prevents external air from entering the induction furnace (203), thereby maintaining the inert environment necessary for optimal steel melting and reducing contamination from unwanted gases like oxygen and nitrogen. The refractory cover (210) protects the furnace components from the intense heat and corrosive effects of the molten metal, prolonging the furnace's lifespan. The alumina cast preform (211) is a heat-resistant material that lines certain parts of the induction furnace (203), providing protection against high temperatures during the melting and casting process. The protectors (for exampleused during melting and casting) to the structural elements and protective materials used to safeguard both the furnace and the steel being produced from damage or contamination during melting and casting operations. The magnet yoke (213) is part of the induction furnace (203) that generates the magnetic field necessary for heating the metal. It helps in induction melting process by creating an electromagnetic field that heats the scrap (201). The spout (215) is the outlet through which molten steel (204) is poured from the induction furnace (203) into molds or other processing equipment.

[0131] Further, the furnace refractory lining (216) is made from heat-resistant materials that line the interior walls of the furnace (203), protecting the furnace shell from the extreme heat and corrosion caused by the molten metal. The sliding surface lining (217) allows for smooth movement and manipulation of furnace parts during operations, enhancing the overall functionality and reducing wear. The induction coil (218) is encased in plaster to insulate and protect it while ensuring that the electromagnetic field efficiently heats the scrap metal. This also prevents overheating or short circuits. The bakelite pillar (219) provides structural support to the furnace components and is resistant to high temperatures and electrical currents, ensuring safety during the melting process. The bottom cast preform (220) is located at the induction furnace's base, which provides support and shape the molten steel (204) in the bottom.

[0132] To illustrate the green steel making process, two examples are given in table 3.

[0133] In these embodiments, the process is applied to two more cases of different steel families such as CMn steel and Low Alloy Steel. In both cases, 99.8% of the scrap (201) (matching with the aim chemistry) is used (illustrated below table 3)

TABLE-US-00002 TABLE 3 Grade Heat No. C % Mn % Si % S % P % Cr % Ni % Mo % Al % N ppm 42CrMo4 IF-147 0.4 0.81 0.24 0.032 0.01 1.01 0.075 0.178 0.02 78 C38 IF-156 0.388 1.44 0.65 0.021 0.013 0.29 0.078 0.056 0.011 152

[0134] In these embodiments, below tables 4a and 4b give the exact quantity used for 42CrMo4 and C38 grade steels.

TABLE-US-00003 TABLE 4a Ferro alloys required for grade 42CrMo4: Ferroalloys for 42CrMo4 Scrap 998.21 (kg) Ferroalloys Qty (kg/MT) FeSi 0.18 FeCr 0.818 FeMn 0.607 FeMo 0.151 Al bar 0.022 CPC 0.212 Quick Lime 16.5 DBM 1 Electrode consumption 1.25 Ar 1.9 m3 N 1 m3 BioDiesel 7 m3

TABLE-US-00004 TABLE 4b Ferro alloys required for grade C38 Ferroalloys for C38 Scrap 998.13 (kg) Ferroalloys Qty (kg/MT) FeSi 0.489 FeCr 0.235 FeMn 1.079 Al bar 0.02 CPC 0.205 Quick Lime 16.5 DBM 1 Electrode consumption 1.25 Ar 1.9 m3 N 1 m3 Bio Diesel 7 m3

[0135] The GHG emissions that occurred during the processing of above mentioned two examples were observed to be in the range of 0.027 to 0.030 (Ton of CO.sub.2/MT steel of cast) which is very negligible. Hence, the method mentioned in the present invention helps to reduce GHG emissions and can be used for production of various steel grades from different families. It is clear from the above Tables 4a and 4b that using the disclosed system (200) and the method (150) the GHG emissions are reduced to near zero levels.

[0136] To summarise, the scrap (201) melting through the induction furnace route has the highest recovery and minimal or near-zero GHG emissions. The Alloys that may be made using the method (150) of the present invention cover all types of ferrous alloys i.e. green steel (600). The power required for melting in the induction furnace (203) and casting of the obtained scrap (201) is generated by renewable energy sources such as solar power. The present invention provides a cost-effective way of producing the green steel (600) where green hydrogen is not required to produce the same.

[0137] What are described above are merely preferred embodiments of the present invention, and are not to limit the present invention; any modification, equivalent replacement, and improvement within the principle of the present invention should be included in the protection scope of the present invention.

[0138] Since the subject matter of the dependent claims in relation to the prior art on the priority date may form separate and independent inventions, the applicant reserves the right to make them the subject matter of independent claims or divisional declarations. They may furthermore also contain independent inventions that have a configuration that is independent of the subject matters of the preceding dependent claims.

[0139] Further, elements and/or features of different example embodiments may be combined with each other and/or substituted for each other within the scope of this invention and appended claims.

Advantages of the Invention

[0140] The proposed invention provides a system and a method for producing green steel.

[0141] The proposed invention provides a system and a method that implements advanced charging mechanisms, such as cranes, hoists, charging buckets, for loading scrap alloys into the induction furnace.

[0142] The proposed invention provides a system to ensure a seamless transition of molten steel to a casting area equipped with molds and a cooling system.

[0143] The proposed invention provides a method and a system that facilitates the recycling of scrap metal from various sources, including industrial waste, construction debris, and end-of-life products, thus contributing to a circular economy model in steel production.

[0144] The proposed invention offers a comprehensive solution for producing green steel that incorporates electric vehicles for the collection and transport of scrap metal, further enhancing the sustainability aspect of steel production.