energy efficiency tata steel ltd.(i) · energy efficiency tata steel ltd.(i) rajeev kumar chittrey...
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CS&P (Cost Research and Standard Costing)
Energy Efficiency
Tata Steel Ltd.(I)
Rajeev Kumar Chittrey
Tata Steel Ltd. 04-03-2016
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Tata Steel group is among the top global steel companies
with an annual crude steel capacity of nearly 30 mtpa
World’s second most geographically diversified steel
producer, with operation in 26 countries and a commercial
presence in over 50 countries.
Tata Steel Group recorded a turnover of
US$ 22.32 billion in FY15.
Tata Steel group has over 80000 employees across
five continents.
Ranked amongst the Fortune 500 companies
Established in 1907- India’s first integrated steel plant -
100 years old.
The Jamshedpur Works currently comprises a 9.7 MTPA
Crude steel production facility and a variety of
Finishing Mills.
Currently setting up a 6.0 MTPA green field Steel plant
in Odisha.
Own raw material
Amongst one of the most profitable steel companies in
the world
One of the Key customer - Indian Auto sector
Profile - Tata Steel Ltd.
Odisha
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Energy Policy
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6.1256.006
6.088 6.0836.017 6.012
5.780
5.280
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5.5
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6.5
FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20
Specific Energy Consumption - Gcal/tcs
6.566.86
7.13
8.13
9.15 9.339.90
11.00
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7
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FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20
Crude Steel Production - mt
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Implementation of
best practices
(FY’04 – FY’07)
Adopting best available
technologies
(FY’08- FY’12)
New and emerging
technologies
(FY’13- FY’16)
• Utilization of by product gases for Steam & Power generation,
• Phasing out old and energy inefficient Units,
• Enhancing by product gas recovery and optimization of operating practices.
• Regular Energy Audit & implementation of its recommendations.
• Coal injection at Blast Furnaces
• Adoption of 100% continuous casting
• Waste heat recovery from waste gas of Blast Furnace stoves.
• Installation of Top Recovery Turbine,
• Use of Regenerative Burners at Hot Strip Mill for maximizing fuel efficiency
• Coke Dry Quenching
• Application of V/F drives.
• Upgraded Centralized Energy Management Centre.
• Large size Bl. Fces ( H& I) with higher energy efficiency.
• Thin Slab Caster and Rolling,
• Use of Pellets and shift to alternate fuel for utilizing lean by-product gases.
• Use of Solar Energy + LED lights for the street –To promote use of renewable energy in our operations
• Coal injection @ 200 kg/thm at Blast Furnaces.
During the decade Tata Steel has implemented a number of measures to improve energy
efficiency to sustain reduction in specific energy consumption which are depicted below :
Energy saving Measures taken at Tata Steel Ltd.(I)
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Energy Input to Steel (FY15)
Energy Sold
or Stock
3.664 MGCal
Steel Works
Total Energy Input
59.582 MGCal
Net Energy Usage = 55.918 MGCal
Petro-Fuel
(6688 kL)
Purchase Power
(2753 M kWh) Oxygen
(1255 MCum)
Water
(49.6 Mcum)
50.30 MGCal 6.607 MGCal 2.021 MGCal 0.025MGCal 0.061 MGCal 0.061 MGCal
Propane
(5297 T)
0.003 MGCal
HP Nitrogen
(941 MCum)
Purchase Pellet
(445 kT)
0.223 MGCal 0.282MGCal
Steam
(3972 T) Coal and Coke
(7.650 MT)
MGCal: Million Gega Calorie
Energy Bill
Approx. 8300 Rs Cr
Ore based integrated Iron and Steel
making processes are highly energy
intensive.
It contributes to approximately 40% of
the works saleable steel cost.
85% energy consumption is in the
form of coal/coke. Coal + Coke
85.39%
Power 10.09%
Ind. Gases 4.32%
Petroleum 0.20%
Energy Input-%
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Stage-wise Sp. Energy Consumption - % (FY15)
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571
584 589
578
569
FY'11 FY'12 FY'13 FY'14 FY'15
Combined Blast Furnace Fuel Rate (kg/thm)
356 351
416 408 406
FY'11 FY'12 FY'13 FY'14 FY'15
Plant Sp. Power Consumption (KWh/tss)
Performance (FY15)
16.01
11.98 14.75
23.45 25.34
FY'11 FY'12 FY'13 FY'14 FY'15
Power generation through TRT ( MW)
6.006
6.088 6.083
6.017 6.012
FY'11 FY'12 FY'13 FY'14 FY'15
Plant Sp. Energy Consumption (Gcal/tcs)
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5.915 5.780 5.700 5.650 5.410 5.280 5.200 5.200
0.000
1.000
2.000
3.000
4.000
5.000
6.000
7.000
FY16 ABP FY16 (E ) FY17 FY18 FY19 FY20 FY21 BM( Norm)TSL
Projects in
progress
Reduction in
SEC 0.550
Gcal/tcs
1 Power generation from CDQ (Batt 10 & 11)
2 TRT at F Blast Furnaces
3 Waste heat recovery from Sinter Plant 3 & 4
4 Duel Fuel Burner system in Pellet Plant
5 New LD Gas Holder for recovery from LD-2
6 Methane from By product gases
7 Additional power generation from 25 MW at Power House # 4
8 Waste to energy (Plasma Gasification)
9 Power generation from additional BF gas
Long Term Plan-Specific Energy Consumption-Gcal/tcs
Power gen from CDQ ( Batt# 10& 11)
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Thank You
Category Title of Technology
Sintering
1 Sinter Plant Heat Recovery(Steam Recovery from Sinter Cooler Waste Heat)
2 Sinter Plant Heat Recovery(Power Generation from Sinter Cooler Waste Heat)
3 High Efficient (COG) Burner in Ignition Furnace for Sinter Plant
Coke Making 4 Coke Dry Quenching ( CDQ)
5 Coal Moisture Control ( CMC)
Iron Making
6 Top Pressure Recovery Turbine ( TRT)
7 Pulverized Coal Injection (PCI) System
8 Hot Stove Waste Heat Recovery
Steel Making
9 Converter Gas Recovery Device
10 Converter Gas Sensible Heat Recovery Device
11 Ecological and Economical Arc Furnace
12 Waste Heat Recovery from EAF
Recycling and
Waste Reduction 13 Rotary Hearth Furnace Dust Recycling System
Common
Systems
14 Inverter (VVVF; Variable Voltage Variable Frequency)Drive for Motors
15 Regenerative Burner Total System for reheating furnace
General Energy
Savings and
Environmental
Measures
16 Energy Monitoring and Management Systems
17 Cogeneration (include Gas Turbine Combined Cycle (GTCC)
18 Management of Compressed Air Delivery Pressure Optimization
19 Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line
Recommended Customized List of Energy Saving Technologies
in Indian Steel Industries
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Thank You
End
of
Presentation