PRESENTATION For CII GBC NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT. Rashtriya Ispat Nigam Limited VISAKHAPATNAM STEEL PLANT

Transcription

1 PRESENTATION For CII GBC NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT By Rashtriya Ispat Nigam Limited VISAKHAPATNAM STEEL PLANT

2 TEAM MEMBERS T K DEY DGM(EMD) I/c & Energy Manager K Sudhakar DGM(O) & Certified Energy Auditor S Kumar Mgr.(EMD)

3 CONTENTS COMPANY PROFILE PROCESS FLOW LIST OF PROJECTS WITH COST BENIFITS REDUCTION OF SPECIFIC ENERGY CONSUMPTION BENCH MARKING(GLOBAL AND NATIONAL BENCH MARKING) ENCON PROJECTS TO REDUCE GAP INNOVATIVE PROJECTS ENVIRONMENTAL PROJECTS & PROJECTS LINKING WITH CARBON EMISSION REDUCTION EMPLOYEE INVOLVEMENT & TEAM WORK ENCON PROJECTS FOR NEXT THREE YEARS IMPLEMENTATION OF CORRECTIVE AND PREVENTIVE ACTIONS RENEWABLE ENERGY SOURCES,UTILISATION OF WASTE BEST PRACTICES IMPLEMENTED AMONG VENDORS,ASSOCIATES CONCLUSION 1

4 RINL Corporate Structure Rashtriya Ispat Nigam Limited Operating Units Visakhapatnam Steel Plant Subsidiary company (51% stake) Eastern Investment Limited Madharam mines Dolomite Jaggyyapeta mines Limestone Garbham Manganes e Orissa Mineral Development Corp. (OMDC) Bisra Stone Lime Co. Ltd. (BSLC) Units on Anvil Transmission Line Towers Plant Wheel Plant 2

5 RINL Snapshot Unit: Rs. Crs Turnover ( ) 12,707 Net worth as on 31/03/ * 100% owned by Govt. of India 3

6 RINL - Snapshot The 1 st ISP to be certified for Quality, Health & Safety and Environment 1st steel Plant to get ISO certification for Energy Management CMMI Level 3 certification for IT Systems 1 st ISP to be 5S Certified for the whole plant 1. 46

7 Production Process flow at RINL TRT LD gas recovery BPTS 100% Continuous Casting Evaporative Cooling CO Battery with Coke Dry Quenching and Back Pressure Turbine Station 3200 cum BF with Top Recovery Turbine and BF gas recovery Rolling Mills with Stelmor & Tempcore (TMT) processes equipped with evaporative cooling for waste heat utilization 5

8 RINL s Growth Plan RINL s growth strategy for enhancement of capacity through a combination of brown field expansion and modernization in phases: 6.3 Mtpa expansion Completed in 2015 and under stabilization Invested Rs. 12,291 Cr ( 80% met through internal accruals) Upgradation & Modernization Underway to enhance capacity to 7.3 Mt by With an investment of Rs. 4,000 Crs. Vision envisages growth to 20 Mtpa by in phases 6

9 Power Generation capacity from Waste Energy (MW) 7

10 ENCON Projects with Investment ( ) S.No. 1 Title of Project Improvement in Pulverized coal injection from 5.1 to 23.4 Kg/tHM at Blast Furnace Energy Savings in Gcal/MKwh Rs Millions Investment (Rs Million) Energy saving through Billet Caster Improvement in Power Generation from CPB4 turbine station of Battery Improvement in Power Generation at Top Pressure Recovery Turbine station of BF-3 Improvement in Power generation from SHRPP of SP

11 ENCON Projects with NO/Little Investment ( ) S.No Title of Project Improvement in benzol yield at coke oven from 0.44% to 0.47% Reduction of Sp. power Consumption at coke oven from 59.97to 49.28Kwh/tDC Reduction of Sp. Power Consumption at SP-1 from 61.87to 58.88Kwh/tGS Reduction of Sp. heat Consumption at SP-2 from 15to 10Mcal/tGS Reduction of Sp. Power Consumption at SP-2 from 61.89to 58.59Kwh/tGS Reduction in fuel rate at Blast Furnace from to Kg/tHM Energy Savings in Gcal/MKwh Rs Millions

12 ENCON Projects with NO/Little Investment ( ) S.No Title of Project Reduction in Sp. Heat Consumption at Blast Furnace from 526 to 475Mcal/tHM Reduction in Sp. Power Consumption at BF-3 from 51.24to 45.74Kwh/tHM Reduction in Sp. Power Consumption at SMS-1 from 51.41to 47.68Kwh/tCS Improvement in LD gas yield at SMS-1 from 94 to 95 Ncum/tCS Reduction in Sp. Power Consumption at SMS-2 from to Kwh/tCS Improvement in LD gas yield at SMS-1 from 44 to 80 Ncum/tCS Reduction in Sp. Heat Consumption at LMMM from 449to 422Mcal/tBI Reduction in Sp. Power Consumption at Bar Mill from 70.52to 70.21Kwh/tBI Energy Savings in Gcal/MKwh Rs Millions

13 ENCON Projects with NO/Little Investment ( ) S.No Title of Project Reduction in Sp. Heat Consumption at WRM from 250 to 249 Mcal/tBl Reduction in Sp. Power Consumption at WRM from to Kwh/tBI Reduction in Sp. Heat Consumption at WRM-2 from 289 to 270 Mcal/tBl Reduction in Sp. Power Consumption at WRM-2 from to Kwh/tBI Reduction in Sp. Power Consumption at MMSM from to Kwh/tBI Reduction in Sp. Power Consumption at CRMP from to Kwh/tBI Energy Savings in Gcal/MKwh Rs Millions

14 Summary of the Projects identified & Implemented YEAR No of Projects Thermal Savings (Gcals) Electrical Savings (Million KWH) Saving s in Rs.Cr Investm ent In Rs Cr

15 Energy Consumption Thermal Energy Consumption(GJ/tCS) 38.8 Electrical Energy Consumption(Kwh/tcS) SEC as PAT scheme(gcal/tcs)

16 Sp. Energy Consumption-Gcal/tCS

17 Benchmarking of Energy Consumption-Gcal/tCS RINL SAIL-BSP TATA Steel SAIL-DSP 14

18 International Bench Marking of SEC(Gcal/tCS) RINL Nippon Steel Unit 15

19 Bench Marking with Nippon Steel( ) Energy( ) GHG Emission Gap :0.661 Gcal/tCS RINL NSC RINL NSC 1) Scrap usage : 200 kg/thm( As per Japanese Industry)-RINL:80 kg/tcs 2) All Energy Conservation technologies Coke Dry Quenching, Top Pressure Recovery Turbine, BOF Gas Recovery, Sinter Cooler waste heat recovery Pulverized Coal Injection, BF stoves Heat Recovery, Billet Caster, Hot Charging, Regenerative Burners, Coal Moisture Control Sensible Heat recovery from BOF gas 3) Waste Plastics Injection and tires(0.2 million tons- 6 kg/tcs) 4) Petro fuel 16 lts/tcs 16

20 Energy Conservation Technologies in Expansion and Modernization NAME OF THE PROJECT ENERGY SAVINGS (GCALS) GHG EMISSION REDUCTION (tco2) PCI IN BLAST FURNACES POWER GEN FROM COOLING OF COKE in Batt ENERGY EFFICIENT BURNERS AND WHR IN SP MW WHR ON SINTER STRAIGHT-LINE COOLER BF-3 STOVES WASTE HEAT RECOVERY BILLET CASTER IN SMS ENERGY EFFICIENT VERTICAL SHAFT KILN ENERGY EFFICIENT AIR SEPARATION UNIT SINTER PLANT 1&2 CAPACITY ENHANCEMENT BF-1 &2 MODERNISATION & UPGRADATION

21 Energy Conservation Projects identified for next three years Sl No Name of Energy Conservation Activity Year Power Generation from Gas Expansion Turbine station of BF-1 Pulverized Coal Injection in Blast Furnace-3(upto 100 kg/thm) Capacity Utilization of 120 MW BF gas captive power plant Revamping of Sinter Machines 1& Revamping of Billet Mill Reheating furnaces (Two Furnaces)

22 Environmental Projects & Projects linking with Carbon Emission Reduction Projects Revamping of Burden handling & Cast House FE system of Blast Furnace-1. Balacheruvu, Waste Water Treatment Plant - Commissioned in July Commissioning of Appikonda Waste Water Treatment Plant The Digital display board at Main Gate was inaugurated by CMD on 5th June 2014 for displaying the CAAQM and Stack analyzers. Dry Fog Dust Suppression System (DSS) in Expansion area of Raw Material Handling Plant, Sinter Plant & Blast Furnace. Rain water harvesting scheme near 18 MLD plant Benefits Reduce Dust emissions 253 Million Gallons 220 Million Gallons Awareness Reduced fugitive emissions Ground water recharging 18

23 Environmental Projects & Projects linking with Carbon Emission Reduction No of Projects Registered(BF3 TRT,COB4, BF3 WHR, BF gas based CPP-2) Verification completed (COB4)* 1 4 * UNFCCC issued 70,516 CER to RINL 19

24 Environmental Projects & Projects linking with Carbon Emission Reduction Name of Projects Registration Number Expected CERS BF3 Top Pressure Recovery Project COB-4 Turbine at Battery Waste Heat Recovery from Stoves of BF MW Waste Gas Based Captive Power Plant Under Registration

25 As per ISO:14064:- GHG Inventorisation Emission Details Scope 1 Direct emissions from site chimneys determined from straight carbon balance Scope 1.1 Direct emissions of exported byproduct gas Scope 2 Upstream emissions of electricity and steam from site. Scope 3 Other upstream emissions byproducts from site Scope 1 Scope1.1 Scope2 Scope 3 Total CO2(t CO2/TCS) GHG Emission-tCO2/tCS

26 Involvement of employees,team Work and Monitoring Employee Involvement Through Quality Circles, Suggestion Schemes, Department Energy Teams, Participation in Energy Conservation Campaigns, Cost Control Campaigns, Water Saving Campaigns Implementation Methods Low Cost/No Cost Ideas (Process Improvements, House Keeping Measures, etc) will be Implemented by Frontline officers Medium Investment Projects through AMR Schemes High Investment Schemes through Board Approval/COM Special Task Forces for Implementing Important Energy Conservation Projects for Sinter Cooler, Steam Utilization and By product gases usage. 21

27 Monitoring Format Energy Conservation Cell DET DGM(EMD)I/c Daily GM (E&U) Weekly ED (W) Monthly D (O) Bi-Monthly 22

28 Energy Management System ISO:50001 Features: Identification aspects of significant energy Developing Energy programmes. Management Operational control energy aspects of identified Monitoring and Measurement Internal Audit Management Review RINL implemented BS EN: Energy Management systems at VSP work division and certified in Dec, First PSU & Integrated Steel Plant to be certified for BS EN: management system energy Certified for ISO: in Aug 12 Completed 2 nd recertification in Dec 16 25

29 Implementation of Corrective/Preventive actions 24

30 Energy Management System ISO:50001 Plant has taken up Energy Objectives and Energy Management Action plans(360 Nos ) to reduce energy consumption. DEPARTMENTAL ENERGY TEAMS were constituted in various departments. The teams identified specific projects Departments conducted energy audits at various equipment through Departmental Energy Audit Teams

31 Green Purchasing Policy Procurement of Circulation fan(3000kw) for Sinter Heat Recovery Plant Star labeled Energy Efficient Air Conditioners Energy Efficient Motors Year % ENCON Investement as % of Turnover

32 Energy Monitoring Format Energy Savings are quantified with respect to displacement of Boiler Coal Electrical Savings are quantified by pegging with Electricity imported. Savings are certified by Energy Auditors

33 Renewable Energy Utilization RINL commissioned 5 MW Solar Power Plant Investment: Rs 36 cr Installing 1MW Roof Top Solar Power Plant at various Building 26

34 Utilization of Waste Type of Waste Material used Quantity of Equivalent of waste Conventional material energy used (kwh used (Tons of electricity or or any other Tons of Coking eqvt Unit) Coal) Gcal Coke Dust LD Slag Met Waste Tar sludge Benzol muck ASP sludge BF gas LD gas Coke dust(sold) Granulated Slag Waste fuel as % of total energy 23.32% 25

35 Best Practices implemented in Green Supply chain Implementation of Green Technologies Implementation of ISO :50001 Energy Management System( SAIL/DSP implemented. SAIL BSP is replicating EnMS based on RINL experience) Procuring Energy Efficient Equipment(Life Cycle Criteria for Procuring Energy Efficient equipment) Production of Green Steel( Steel Consumption reduces by 15% due to high yield strength of 550 N/m2 on Fe 550 grade) 28

36 Adoption of Green Technologies Name of Technology Features Energy Savings(TOE) GHG redn(tco2) Coke Dry Quenching Plant Top Pressure Recovery Turbine LD Gas Recovery System Evaporative Cooling System Power gen: 2X7.5MW Power gen; 2x12 MW Cum ata steam: 19 t/hr Preheating of combustion air at CRMP Gas and air recuperators in ROLLING MILLS Air preheating: 250degc Air : 450 degc Gas:250 degc Reducing GHG emission by about 13 lakh tons annually 29

37 Adoption of Energy Efficient Technologies-Unique Features of RINL Name of Technology Coke Dry Quenching Plant Top Pressure Recovery Turbine First Time in India(1990) First Time In India(1993) LD Gas Recovery System First Time in India( ) Evaporative Cooling System Sinter Cooler Waste Heat Recovery(Power Gen) First Time in India(1993) First Time in India(2014) Level of Diffusion 13.5% 13.9% 50% 25% 5% 30

38 Innovative Project: 1x120MW Blast Furnace gas power plant RINL has three blast furnaces having annual production capacity of 7.5 MTPA of Hot metal (Iron) after adding 1no. Blast Furnace (2.5MTPA) and revamping of 2 nos. existing blast furnace from 1.7MTPA to 2.5MTPA each. During the process of iron making blast furnace gas is generated as by product gas and used in various metallurgical units. Blast Furnace gas is a lean gas having heat value 750 Kcal/Ncum. There is surplus BF gas to the extent of 4,50,000 Nucm/hr after expansion BF Gas Gen&Distribution Value Shop/Unit (Ncum/hr) Generation 14,84,000 Consumption (Ncum/hr) BF-1&2 3,34,000 BF-3 1,79,000 CO&CCP,SP, Rolling Mills 2,01,000 CPP-1 3,18,000 Surplus 4,52,000 31

39 Innovative Project: 1x120MW Blast Furnace gas power plant Present Scenario: Burning of blast furnace gas generates huge volume of flue gases and results in high flue gas temperature due to high furnace pressure. Innovative Design of Boilers Improved burner design in boilers. The boilers are designed in such a way that low volumetric heat release rate with larger boiler furnace results in higher residence time & higher heat surface area. The boilers are envisaged with Scroll type burner which provides spin to the BFG at the point of air fuel mixing and adequate refractory lining on water wall tubes of furnace heat surface which will reradiate Flue gas generation in Ncum/Gcal Co Gas 1200 BF gas 2000 Boiler Coal 1300 Parameters Flue Gas temp(deg.c) Boiler Efficiency Existing Boilers New Boilers < heat into the flame. 34

40 Innovative Project: 1x120MW Blast Furnace gas power plant The Boilers are also designed with low flue gas temperature (155 Deg.c and lesser NOx emissions of 320 mg/ncum). 35

41 Innovative Project: 1x120MW Blast Furnace gas power plant Technical Details: Parameter Unit Value No of Boilers Nos 2 No of Steam Turbine Nos 1 Steam flow t/hr 223 Steam pressure ATA 115 Steam Temperature Deg.c 540+/-5 BF gas flow to Boiler Ncum/hr *2 Calorific Value Kcal/Ncum 700 Steam Turbine Capacity MW 120 MW Steam flow to turbine t/hr 443 Condenser pressure ATA 0.1 Auxiliary Power Consumption MW Flue Gas Temp. at inlet of ID Deg.c 155 fan Boiler efficiency % 89.5 Turbine Heat rate Kcal/Kw 2137 Investment Rs Cr

42 Innovative Project: 1x120MW Blast Furnace gas power plant Estimated Benefits: Reduction of BF gas bleeding Reduction of GHG emission by 12,00,000 tons 37

43 Thank you र ष ट र य इस प त न गम लऱलमट ड RASHTRIYA ISPAT NIGAM LIMITED