12 integrated steel

8/6/2019 12 Integrated Steel

http://slidepdf.com/reader/full/12-integrated-steel 1/16

205

First Prize Integrated Steel Plants

JINDAL STEEL AND POWER LIMITEDRaigarh (Chhattisgarh)

Unit Prole

Jindal Steel & Power Limited (JSPL) is the youngest eet under the agship of JINDAL Organisation.

With the vision to cater the needs of nation & meeting the challenges of global markets, JSPL management

embarked on the ambitious mission to establish an Integrated steel plant with perfect blend of in-house

& state of art technology. Today JSPL has the largest coal-based sponge iron manufacturing capability

in the world, Rails of 120-meter length, the longest produced anywhere in the world & Parallel ange

universal beams in larger sizes, manufactured for the rst time in India. The unit has a obsession for

excellence shaping business in synchronized with the market dynamics, boldly venturing into newterritories and the future. Present manufacturing facilities are:

Current Capacities:

Product Name Capacity (Million

tonnes/annum)

Remarks

At Raigarh:

Sponge Iron (DRI-1) 0.65 • World’s largest coal-based sponge iron production

capability

• One of the lowest cost producers of Sponge Iron,

with in-house availability of the three Key rawmaterials, coal, iron ore and power.

Sponge Iron (DRI-2) 0.72

Mild Steel 2.40 -

Hot metal (BF-1) 0.25 -

Hot metal (BF-2) 1.25 • New projects completed

Ferro Alloys (SAF) 0.036 • 24 MVA furnace



206

Rolled product (RUBM) 0.75 • Facility to produce 120 meter, Worlds longest

Rail & 240/480-meter Flash butt-welded rails.

• Increase in production/product mix through

upgrading conventional mill with Tandem

Universal (First in the Country) for rolling high quality structurals & rails (Fig-1).

Coke 0.80 Non-recovery type, Environmental friendly and power

generation from COG is a CDM project.

Plate mill 1.00 • New projects completed

• Mill can offer both plate and coils from the

same facility (Fig-2).

Sinter 2.50 • New projects completed

Producer gas 129.6 Lakh m3 -

Oxygen 1915.2 Lakh m3 -

Power plant 333 MW • 75 MW new projects completedCoal washery 6.0 -

At Raipur:

Machinery & castings 0.0115 -

Ingots 0.030 -

CF Castings 0.003 -

(Fig-1) Technological up-gradation at RUBM (Tandem Universal mill)



207

Company is certied to ISO 9001:2000 and ISO 14001: 1996. Company is recognized by DSIR, Govt. of

India as “in-house R & D Center” and by Central Boiler Board, Govt. of India as “ well known steel maker”

for Boiler quality steels.

Energy Consumption

Product Production * CAGR

(Million TPA) 2004-05 2005-06 2006-07 (%)

Sponge Iron 692682 1017746 1196330 31.4

Hot metal 220022 269711 577494 62.0Steel 378853 522334 803303 45.6

Rolled products 215542 287389 209418 - 1.45

Ferrochrome 35656 32452 31070 - 4.82

Power (MWH) 1898244 2225232 2668358 18.5

Sales turn over

(Rs. Lakhs)

243923.63 287800.00 394876.00 27.2

* Compounded annual growth rate achieved

Energy & Cost: 2004-05 2005-06 2006-07

Net Electrical Energy consumption (purchased

+generated-sold) (Lakh kWh)

7735.85 10571.41 22332.11

Coal purchased for process (Ton)

(Coking coal +Washed coal +Steam coal)

952218.0 1652153 2321784

Coke purchased for process (Ton) 178601.8 210994.0 76457.0



208

F.O. consumption in process (KL) 9557.50 7835.55 6199.32

Diesel consumption in the process (KL) 16967.0 19401.0 24852.0

Total Thermal Energy used in process (Gcal) 6003233.9 9020049.2 11849495.2

Total Energy cost (Rs. Lakhs) 35181.65 34397.65 54230.78Total Manufacturing cost (Rs. Lakhs)

Energy cost

101166.0 100580.0 160135.0

(As % of manufacturing cost) 34.78 34.20 33.87

Specic Energy Consumption

DRI Plant

Blast Furnace



209

SAF Plant

RUBM

SMS



210

Power Plant

Energy Conservation Commitment, Policy and Set up

All the above gures clearly indicate the culture of energy conservation imbibed right from initiation of the

company in 1991. When the plant started, to utilize the waste heat of rotary kilns, producing Sponge iron,

waste heat recovery boilers (WHRB) were installed on-line and the steam used for generation of electrical

power. Thus all the six kilns are tted with WHRB. Continuing the commitment for Energy conservation,

all new kilns ( 4 Nos.) are also tted with WHRB. Boilers generating steam utilize the in-house waste of

washery reject and rotary kiln char. In fact, commitment for energy conservation and waste utilization is

so high in the plant that the Power Plant unit-II & now power plant unit-3 was planned for utilization of

waste basically. Towards this end, energy policy has been formulated and Executive Director takes

structure monthly meeting on energy conservation.



211

ORGANISATION STRUCTURE

OF

ENERGY MANAGEMENT CELL



212

Installation of 1651 m3 capacity new blast

furnace of make DANIELI CORUS incorporatingall latest technology with TOTEM top charging

resulting proper and desired charge distribution,

overall coke consumption of the blast furnace

has been reduced & electrical power

consumption of EAF has reduced due to

enhancement of hot metal use.

Electrical power saving: 1809.7 kWh/annumThermal energy saving: 221856.0 Gcal/annumInvestment: Rs. 35000.00 Lakhs

Monetary Saving: Rs. 8121.1 Lakhs/annum

Power plant-1 consists of 6 nos. of waste heat

boiler. The boilers were supplied initially

without secondary air. So far in 4 nos. of waste

heat boilers; air preheater (APH) was already

installed after internal study & investigation to

improve combustion efciency of the boiler.

APH was installed for WHRB-5. This results

reduction in un-burnt carbon from 11.45% to

3.07%. Overall impact was 0.85 MW/hr extra

power generations.

Electrical power saving: 73.44 Lakhs kWh/annumInvestment: Rs. 35.00 LakhsMonetary Saving: Rs. 170.4 Lakhs/annum

The combustion efciency in the AFBC boiler

increased due to increase in the retention time

of fuel by introducing swirl type coal cap. (1)

This modication in the coal cap can handle

high moisture coal. (2) Bed temperature isuniform through the furnace. (3) Combustion

efciency improved by 0.7% in 2×100 TPH

Thermal energy saving: 14281.4 Gcal/annumInvestment: Rs. 9.0 LakhsMonetary Saving: Rs. 34.1 Lakhs/annum

Energy Conservation Achievements

Major achievements are:



213

Dual red boiler is installed for utilization of the

blast furnace gas. Dual red AFBC boiler is

unique of its type and reduced coal consumption

by 200 Tons/day. It is consuming BF gas and

playing the role in controlling pollution

Thermal energy saving: 151800.0 Gcal/annumInvestment: Rs. 90.0 LakhsMonetary Saving: Rs. 363.4 Lakhs/annum

3 X 25 MW power plant is installed to fully

utilize the coke oven gas generate from coke

oven plant. As coke oven plant is a non-

recovery type, sensible heat of the gas is

utilized to generate steam from waste heat

recovery boiler, which is ultimately used in

steam turbine to generate electrical power. On

account of these 3242 Lakhs units extra power

generation was achieved

Extra Electrical power generated: 3242.0Lakhs kWh/annumInvestment: Rs. 27500.0 LakhsMonetary Saving: Rs. 7521.0 Lakhs/annum

As experimental basis, forced air draft fans

underneath the cooling bed were introduced

by installing forced air fan. This reduced the

process delay to almost negligible from 3hrs/

day during rolling of heavy sections and there

by increase in production and cost saving was

achieved.

Investment: Rs. 46.48 Lakhs

Monetary Saving: Rs. 1598.0 Lakhs/annum



214

Furnace power consumption in ‘Sub merged

Arc furnace (SAF) plant reduced to 3572 kWh/

ton from 3719.0 kWh/ton by improving metal

recoveries, due to process control and power

factor improvement’ and taking innovative

actions.


Installation of variable voltage and frequency

drives (VVFD) in cooler drives of kiln no.# 3 &

5 of DRI-1


Roots blower (5000m3/hr, 8000 mmWC) was

replaced with new proper size roots blower

(3500 m3/hr, 8000 mmWC) in DRI-2.


Air curtain to entrap heat loss



215

Energy Conservation Plans and Targets

ENERGY CONSERVATION

PLANS

Anticipated Savings

in Lakhs Rs.

Approx. Investment

in Lakhs Rs.

Project

commencement &

completion year 1. Utilization of blast furnace

gas of new blast furnace, BF-2

to generate extra power from

Unit-3 power plant.

3674.0 30.0 2007-08

2. Pulverized coal injection in

the new blast furnace (BF-2) to

reduce coke consumption in

the blast furnace.

3095.0 15.0 2007-08

3. Replacement of higher head

pumps of 20 nos. to smaller

head pumps in SMS-2.

250.0 70.0 2007-08

4. Installation of PRDS in power

plant-2, phase-3, to utilize extra

steam from waste gas in plate

mill and power plant-3 of turbo

generator.

1312.0 15.0 2007-08

5. Use of mill scale in SMS-2. N.A. N.A 2007-08

Environment and Safety

Environmental ManagementFollowing steps have been taken for Environmental Management at JSPL :

Installation of Waste Heat Recovery Boilers (WHRB) to use waste heat of sponge iron unit for generating

electrical energy. Installation of AFBC boilers to reuse solid wastes (middlings) of coal washery. Installation

of ESPs and Bag Filters in all dust generating sources. Waste gas from blast furnace is used as fuel in

our Rolling mill (reheating furnace) DRI (rotary kiln & Coal dryer) and 63 TPH boiler. Installation of two

Nos. of Sewage Treatment Plants to treat the domestic waste generated from the colonies and ofces.

This treated wastewater is 100 % reused for plantation and garden development purpose.

Ø Waste Management for reduction of the waste generation and exploring the use of the waste.

Ø Construction of the pucca road inside the plant

Ø Implementation of the concept of Green Productivity.

Ø Waste water recycling and zero discharge.

Ø Rain Water Harvesting

Ø Bio-gas plant established

Ø Vermiculture composting plant has been established.



216

Ø Use of Fly Ash for Brick Manufacturing.

Ø Use of y Ash for various construction works.

AIR QUALITY

Regular monitoring of Stacks is carried out to maintain emission level within the stipulated limits. OpacityMeters have been installed in all the stacks.

Water Management :

Water consumption has been optimised by taking various conservation measures. Flow meters have

been installed in all fresh water make up pipelines in all units, which helped a lot in water monitoring and

optimising specic water consumption for long steel products in coming about 5.3 m3/T of product.

Safety Control

Safety is the prime concern of the plant and its target is zero accident. To keep employees aware about

safety and maintain zero accident targets several activities and program are being conducted in the plant.



218

the coveted ISO 14001:2004 Environment Management System (EMS) certication. Considerable

advances have been made for EMS implementation in ERW and SW Pipe Plants as well as Town

Engineering and Services. This is a beginning of the objective of RSP to improve the Environment

Management as a service towards the employees, stakeholders and the society at large.

Moreover, Quality Improvement Process Management (QIPM) was initiated and implemented in

Department like OBBP, CO, Blast Furnace, CPP-1 , SMS-II , Hot Strip Mill, Cold Rolling Mill and Power

Distribution where 44 Quality Improvement projects were taken out of which 35 projects have culminated

not only in signicant cost reduction, but also in overall process development. As a part of this project, a

Quality Improvement Team ( QIT) is formed which selects various projects with an objective to achieve

targets by doing, analyzing and taking corrective and preventive actions.

Human resource initiatives at RSP have gone a long way in creating congenial industrial relations and

work atmosphere. Mass contact exercises where the chief Executive of the Plant interacts directly with

the work force is a unique initiative, which has been continuing for the past many years. These initiatives

have ushered in the atmosphere of satisfaction and growth for both the employees and the Company.

In RSP safety is an integral part of main business activity. The organization is continuously striving to

achieve new heights of excellence by inculcating a voluntary & sustainable Culture of safety through well

planned pro-motive & pro-active activity.

The organization has a well established Safety Department reporting directly to the Executive Director

(Works). The visible commitment of top Management in implementing its Safety policy has truly been

inspiring to its employees and to integrate safety culture into the working process.

Safety Engg Department of the Plant translates safety policies into realities by monitoring safety efforts

in all the units. It undertakes regular routine activities of preventive safety using all the known techniques

of Safety Management like inspection, investigation, system audit, safety training, emergency preparedness

planning etc.

Joint participation is ensured through functioning of Apex Central Safety Committee and Zonal Safety

Committees. Issues on safety are discussed in these joints forums. There is a system of following written

down operating practices for regular jobs. For special jobs protocols are prepared where Safety aspects

are considered. At Departmental level HOD Communication meetings and at functional head level GMs

Communication Meetings are held every fortnight to discuss issues relating to safety and productivity with

workmen.

Video graphic recording of unsafe condition are done and shown in different meetings for better

understanding of issues. There is system of internal safety audit teams who are engaged in Safety audit

of 59 Departments and audit points are taken care.

The Plant has bagged National Safety Award-2005, runner up under scheme VII & VIII in 2006, Ispat

Suraksha Puraskar for maximum reduction in Accident rate for maintenance, Service and projects Zone

in 2004.



219

Over the past few years the Company has registered signicant improvement in production performance,

technological parameters and nancial indices. During 2006-07, RSP exceeded rated production levels

in a number of units, which was unthinkable on earlier days. On nancial front also the plant has been

achieving substantial net prot for the past three years.

Presently RSP has embarked upon a massive expansion plan to increase the Hot Metal Production

capacity to 4.5 mtpa from the present level of 2.0 mtpa and crude steel capacity to 4.2 mtpa from the

present level of 1.9 mtpa. The expansion plan envisages addition of a number of units with state of art

technology and upgradation of existing units like a tall Coke Oven battery with coke dry quenching, a new

big blast furnace with high top pressure and top recovery turbine, coal dust injection in all the blast

furnaces, combined blowing and RHOB degassing in Steel Melting Shop, a new high capacity Plate Mill

to produce wide plates and new HCl pull push pickling line in Cold Rolling Mills besides a number of

logistics and support facilities. After the completion of these expansion schemes which is likely to by Nov-

2010 the Sp. energy consumption will be brought down to 5.4 Giga calories per ton of crude Steel ( Gcal/

TCS) from the present level of 7.5 Gcal/TCS.

Energy Consumption

Like in any other integrated Steel Plant, Coking Coal (for producing coke to be used as a reducing and

heating agent in Blast Furnaces) boiler coal (for generating Steam & power) furnace oil (to be used as a

supplementary fuel in Power Plant and reheating furnaces of Hot Strip Mill) and purchased electricity (to

supplement in house generation) are the major external energy inputs to the Plant . For the past years

some amount of Blast Furnace grade Coke is also being purchased to meet the total coke demand in

blast furnaces.

Besides purchased fuels, by product fuel gases (Coke Oven gas, Blast Furnace Gas & LD gas generated

during the process of Steel Making at various stages are used for process heating.

Energy Conservation Commitment, Policy and Set up

Energy Conservation has always been an important Management objective in Rourkela Steel Plant. We

are aware that conserving energy is desirable not only to reduce costs but also for conserving precious

& fast depleting fossil fuel reserves and protecting the environment.

Continuous and sustained efforts towards energy conservation have been continuing in RSP for the past

many years. Energy policy has been issued by the Chief Executives of RSP(copy provided page-17) to

provide direction to set performance goals, integrate energy management into the organization culture

and operational practices and to ensure the commitment of the highest authority of the Plant towards

energy conservation and environmental protection. Through the energy policy, the Plant is committed to

reduce Sp. energy conservation by 2 % every year up to 2012.

Energy Management Department monitors the availability and distribution of fuel gases and utilities

around the clock basis for optimization, monitors major energy parameters on daily basis and generates

MIS reports on unit wise overall energy parameters for variance analysis and corrective actions. It also



220

monitors condition of energy generating and consuming equipments/process on a regular basis and

carries out periodic inspections to detect leakages and wastages of energy bearing materials for corrective

actions. The department also conducts energy audits in each of the major shops at least once a year

along with the concerned personnel from the department. The audit covers mainly analysis of energy

consumption, combustion status, heat balances, physical condition of heat/energy consuming facilities,condition of gas / utility grid including leakages, efciency of fans, blowers and cooling towers and

electrical energy consuming units etc. The ndings and recommendations of audits are discussed with

the head of the auditee department for formulating action plans for implementation. The salient points are

also discussed with the Head of works of the Plant.

12 integrated steel

Documents