Energy Efficiency Tata Steel Ltd.(I) Rajeev Kumar Chittrey - - PowerPoint PPT Presentation

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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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6.125 6.006 6.088 6.083 6.017 6.012 5.780 5.280 5 5.5 6 6.5 FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20

Specific Energy Consumption - Gcal/tcs

6.56 6.86 7.13 8.13 9.15 9.33 9.90 11.00 5 7 9 11 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

• r 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)

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TRT at F Blast Furnaces

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Waste heat recovery from Sinter Plant 3 & 4

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Duel Fuel Burner system in Pellet Plant

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New LD Gas Holder for recovery from LD-2

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Methane from By product gases

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Additional power generation from 25 MW at Power House # 4

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Waste to energy (Plasma Gasification)

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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

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