Ali Naji – PMO Manager, Sangan-Khorasan Steel Mining Industries Company (SSMIC)

Green Steel: A Sustainable Approach to Steelmaking
Green steel refers to technologies that minimize CO₂ and other emissions in the steel production process. One of the main strategies in green steel production involves using renewable energy sources and optimizing energy consumption to reduce fossil fuel use and environmental impact. As global demand for steel rises, the need for sustainable production methods becomes increasingly critical.

New technologies such as solar and wind energy, along with innovative steelmaking processes, are being deployed to reduce carbon emissions. Steel production remains one of the most polluting industries worldwide, contributing significantly to CO₂ emissions and environmental degradation through water and soil contamination. High water consumption and extensive mineral extraction further exacerbate environmental damage.

Green technologies in the steel industry include renewable energy use and replacing traditional carbon-based direct reduction methods with hydrogen-based processes. In these approaches, hydrogen is used instead of coal to reduce iron ore—producing only water as a byproduct instead of CO₂.

The Spreader Project and Its Role at SSMIC
The Spreader Project at SSMIC involves the design and implementation of modern equipment for optimal management of dry tailings produced during the steelmaking process. This semi-automated system transports dry waste materials—without using water—to designated storage areas and stacks them efficiently. The project aligns with efforts to reduce the environmental impact of the steel industry and enhance sustainability. Given Iran’s need to lower energy use and emissions, SSMIC’s Spreader Project is considered a green and sustainable initiative in the sector.

The system comprises several core components:

• Conveyor Belts: Designed for flexible and energy-efficient transportation of dry tailings, these conveyors reduce reliance on traditional hauling equipment.
• Mobile Stacker Bridge: This advanced stacking arm ensures precise placement of materials, minimizes dust generation, and lowers energy use. It can stack materials in multiple layers with high density.
• Control and Monitoring Systems: Equipped with sensors and advanced software, these systems provide accurate oversight of stacking operations. They generate real-time data on pile conditions and operational requirements, minimizing errors and improving process efficiency.

Dry Tailings Management and Water Conservation
Dry tailings are generated from water-free processes. In the Spreader Project, these materials are handled and stored using dry methods, significantly reducing water consumption.

Proper tailings management also prevents dust emissions. Additionally, the mobile stacker bridge allows for organized and space-efficient stacking, minimizing waste and resource loss.

Dry Tailings Management: A Sustainable Alternative
In many steel plants, tailings are traditionally managed through water-based systems, which lead to high water consumption and groundwater contamination. The Spreader Project replaces this with a dry stacking approach, eliminating water usage and preventing pollutants from entering the environment.

Elimination of Contaminated Runoff
Wet stacking systems often generate polluted runoff that carries chemicals into soil and water sources. The dry stacking method used in the Spreader Project eliminates this issue, preserving water quality and protecting soil layers from contamination. This is especially vital in regions near agricultural land and groundwater reserves.

Long-Term Environmental Impact Reduction
Sustainable tailings management at SSMIC helps reduce the project’s long-term environmental footprint. Through intelligent and optimized systems like the Spreader, the mining and steel industries can implement strategies to lower carbon footprints and improve environmental sustainability.

Alignment with Global Green Steel Goals
The Spreader Project at SSMIC directly supports global strategies for reducing emissions and increasing energy efficiency. It serves not only as a successful model for resource conservation but also as a benchmark for other companies in the steel and mining sectors.

Importantly, the project contributes to greenhouse gas reduction. Traditional material handling processes rely heavily on fossil fuels and electricity, major contributors to CO₂ emissions. The new system minimizes transportation needs and uses energy-efficient equipment, reducing greenhouse gas output.

Environmental Benefits and the Green Steel Concept

• Soil and Water Pollution Reduction:
  Dry stacking eliminates the need for water-based processes, preventing contaminants from leaching into groundwater and soil. Additionally, organized tailings storage reduces the environmental hazards of waste accumulation.
• Lower Greenhouse Gas Emissions and Optimized Energy Use:
  The project significantly cuts emissions and enhances energy efficiency by replacing conventional, resource-intensive processes with smart, sustainable alternatives.

Conclusion and Future Outlook

Summary of Achievements and Benefits:
SSMIC’s Spreader Project has introduced innovative solutions for sustainable steel production. From reducing water and energy use to cutting pollutants and greenhouse gases, the project exemplifies the successful application of green and sustainable technologies in the steel industry. Its positive outcomes open the door for wider adoption across other parts of the sector. With the advancement of IoT and AI technologies, the potential for more precise monitoring and automated operations will only increase.

By incorporating cutting-edge technologies in tailings handling and storage, SSMIC’s Spreader Project has effectively minimized water usage, optimized energy efficiency, and curbed pollutant emissions. It demonstrates how smart technologies can support sustainable strategies in large-scale industries and contribute to environmental protection.