Escolar Documentos
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Cultura Documentos
K. Shanmuganathan
Project Assistant (Technical)
UNDP
06/09/2014
Key parameters
[energy use, production/ productivity]
Energy Cost
1
2
3
4
5
Unit
Carbon
DIE
Status in the
beginning of the
project, 2004
Target/expected due
to project intervention
in model units
Oxide
l/t
kg/t
Nm3/t
42 to 45
80 to 120
48
<30
45 to 65
30
Productivity of furnace
Scale loss
kg/m2/h
%
120 to 220
2.5 to 3.5
300 to 350
<1
Power consumption
kWh/t
90 to 120
60 to 80
7
8
Yield
Utilization of mill
89 to 93
65 to 70
94 to 95
80 to 85
%
%
30%
Thermal
Energy share
70%
Electrical
2
3
4
6
7
8
9
10
11
Technology package
Rolling mill
Estimated
energy
saving in
%
25
10
10
35
25
30
40
20
20
20
Over 50
SN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Estimate
d power
saving in
%
5
4
5
4
3
2
3
Nil
2
20
30
5
2
10
10
20
4
4
4
Unit
1 Production
tph
8.33
10.47
F.O.
l/t
48.97
37.43
Coal
kg/t
105.15
62.59
SFC
(The
2
rmal
)
Baseline
70.24
Biomass
kg/t
104.1
Natural gas
Nm3/t
40.75
31.12
kWh/t
110.91
89.19
3 SPC (electrical)
Modified
pulverized
coal fired
system
13
Post
implemen
tation
Producer gas
based plant
5
Direct rolling
3
Oxy fuel
combustion
1
Biomass
3
Best achieved:
Unit
code
Energy
source
Savings
18.2 l/t
(692 MJ/t)
M1
Furnace oil
M12
Coal
92.32 kg/t
(2,382 MJ/t)
M6
Electrical
43.85 kWh/t
(515 MJ/t )
3
4
5
6
7
8
9
10
11
12
13
Parameter
Average
Specific
consumption [baseline]
Interventions
Reheating furnace
Rolling section Total
energy
2,150 MJ/t
1,302 MJ/t
3,452 MJ/t
[56 liters of furnace oil]
[110 kWh/t]
One of the options from A set of options
identified technology from identified
EE tech options
Investments by units
Rs 1,42,76,594
Rs 24,25,203
Investment by GEF and MoS
Total investments
Rs 1,67,01,798
Specific energy consumption [post
2,354 MJ/t of
1,307 MJ/t
1,047 MJ/t
commissioning interventions]
steel
Average reduction per tonne of
1,098 MJ/t of
843 MJ/t
255 MJ/t
steel
[22.2 liters of furnace oil]
[21.7 kWh/t]
steel
Average
reduction
of
GHG
0.065 tCO2/t
0.020 tCO2/t
0.085 tCO2/t
emissions per tonne of steel
Average steel production per year
29,987 t/y
Average energy reduction per year
20.9 TJ/y
7.29 TJ/y
28.19 TJ/y
[5,50,347 liters of furnace [6,19,897 kWh]
oil]
Average reduction in energy cost
Rs 117 lakhs
Rs 31 lakhs
Rs 148 lakhs
per year
Average payback on investment
Average GHG reduction per year
14 months
2,041 tCO2/y
559 tCO2/y
2,600 tCO2/y
3 units:
M/s Shri Bajrang Power & Ispat Ltd.
M/s Real Ispat & Power Ltd. and
M/s Indus Smelters Pvt. Ltd.
Now, many units have started to replicate
direct rolling
Pros:
Eliminates the usage of reheating furnace
Fuel savings and GHG emission reduction
Cons:
Can be employed only in composite mills
All 34 units were awarded by MoS(GoI), GEF & UNDP with energy efficiency certificate.
M/s MPK Steel Pvt. Ltd received Rajasthan Energy Conservation Award (RECA) by the
Department of Energy, Government of Rajasthan for year 2010.
M/s Pulkit Steel Rolling Mills received Energy Conservation Award from Government of
Puducherry for adopting bio-mass technology.
M/s Shree Prithvi Steel Rolling Mill has received the following awards:
Partners
Budget
Ministry of Steel,
(GoI)
$ 2,000,000
Australian aid
program
$ 675,000
UNDP
$ 950,000
Total
$ 3,625,000
Cluster details
No
Cluster
Total
number of
units
Target
units
250
120
200
100
60
90
20
60
30
20
60
20
150
45
Jalna, Aurangabad
40
10
60
20
10
11
Guwahati, Shillong
60
25
20
10
12
50
35
1,175
380
Mandi Gobindgarh
Raipur
Coimbatore, Palakkad
Total
Project design
Submission of EoI & Affidavit
Approval of committee
Conduction of baseline study
Implementation of EE tech option/package
Financial assistance
Financial incentive of Rs 2 lakhs for group 1
[very low cost] and group 2 [low to
moderate cost] interventions for replication
category
Upto Rs 5 lakhs for interventions of direct
rolling
Upto Rs 40 lakhs for piloting EE in Induction
furnaces
Upto Rs 20 lakhs for piloting EE as second
generation interventions in SRRM
Developments so far
THANK YOU
No
.
Categor
y
EE Technology
Investm
Implem
ent
Saving
entatio
estimat potential
n
e
period
Direct rolling
Savings in
specific
fuel
consumpti
on by 5 15%
Financial
incentive
Maxi
mum
per
unit
2 3
months
20% of
capital cost
INR 2
lakhs
4 8
months
20% of
capital cost
or
consultancy
fee or both
INR 2
lakhs
Less
than 6
months
20% of
capital cost
or
consultancy
fee or both
INR 2
lakhs
6 8
months
20% of
capital cost
or
consultancy
fee or both
INR 5
lakhs
Savings in
specific
power
consumpti
on by 2 10%
Savings in
specific
fuel
consumpti
on by 20 35%
Savings in
specific
power
consumpti
on by 10 15%
Savings in
specific
INR upto
energy
15 lakhs consumpti
on by 5
15%
Savings in
specific
INR 1.5- 3
fuel
crores
consumpti
on by 80 100%
No.
Parameter
1.
Reheating furnace
2.
Rolling mill
3.
Total
Unit
kgCO2/t
Baseline
Post implementation
Reduction
166
101
65
(39.21 %)
100
80
20
(19.58%)
266
181
85
( 31.85%)
SAVE ENERGY
FOR A GREEN FUTURE