Energy Efficiency in the Thai Steel Sector : ISIT S Efficiency Action Plan. By Mr. Hin Navawongse Advisor Iron and Steel Institute of Thailand

Transcription

1 Energy Efficiency in the Thai Steel Sector : S Efficiency Action Plan By Mr. Hin Navawongse Advisor Iron and Steel Institute of Thailand

2 Content Part 1 Energy conservation in the Past of Iron and Steel Industry Thailand (1997 to 2010) Part 2 Energy conservation in the Future ( ) 1

3 Part1 Energy conservation in the Past of Iron and Steel Industry Thailand (1997 to 2010) 1. Awareness of energy Conservation of Iron and Steel Industry in Thailand since Survey of Specific Energy Consumption (SEC) of Steel Sector during and Reduction of SEC of interval 12 years 2

4 1. Awareness of energy Conservation of Iron and Steel Industry in Thailand since 1997 Energy Conservation in Iron and Steel Industry in Thailand has been implemented after the financial Crisis in Many energy conservation measures and research work have been done by the Iron and Steel Institute of Thailand () and Iron and Steel Club, Federation of Thai Industry. has carried out the survey of the energy consumption of the Steel Sector in 2 intervals of 6 years each, from 1999 to 2004 and 2005 to

5 2.Survey of Specific Energy Consumption (SEC) of Steel Sector during and Reduction of SEC of interval 12 years The survey covers 15 processes. Average value of SEC each internal shows that most processes have decreased (MJ/ton-product). Table below shows the SEC (MJ/t) of each interval and percentage decrease item Process SEC (MJ/t) Av. For Av. For Reduction % decrease 1 Re bar with EAF Re bar without EAF Wire-rod with EAF Wire-rod without EAF Section with EAF Section without EAF hot formed 2886 NA - - 4

6 Part 1 item Process SEC (MJ/t) Av. For Av. For Reduction % decrease 7 Hot-Rolled Coil with EAF Hot-Rolled Coil without EAF Cold-Rolled Coil Hot-Dip Galvanized steel sheet Electro-Galvanized steel sheet Tin-Plate, Tin-Free Cold-formed section 21 NA ERW Pipe Galvanized Pipe

7 Part2 Energy Conservation in the Future ( ) Thailand steel industry structure Energy consumption in Thai Steel Industry Plan for energy conservation Energy management in steel industries in Thailand 6

8 Thailand steel production Thailand production route today Source : World Steel Association 7

9 Thailand steel industry structure Iron making Steelmaking Long Product Finishing & Coating Forming End Users Scrap Hot-Rolling Cold-Drawing 1,000 Mills recycle 1 Mill TATA (Mini- Blast Furnace No-operation 16 Mills TATA G Steel GJS SYS TRIUMP Etc. Production:4.2 m T Import:3.7 m T Export:0.2 mt Demand:7.7 m T Import Russia, Ukraine, Turkey, Brazil Export Vietnam, Philippines, India, Taiwan Source: Iron and Steel Institute of Thailand ~ 50 Mills TATA Sahaviriya Tycoon Etc. Production: 3.7 m T Import: 1.7 m T Export: 0.8 m T Demand: 4.7 m T Flat Products Hot-Rolling Cold-Rolling Coating 3 Mills SUS TCRSS Bluescope 5 Mills G Steel GJ Steel Sahaviriya LPN Production: 3.9 m T Import: 3 m T Export :0.3m T Demand : 4.2 m T Import Japan, S. Korea, Australia, China Export Vietnam, Malaysia, Laos ~ 100 Mills Production: 1.7 m T Import:0.7 m T Export: 0.1 m T Demand: 1.6 m T Import Japan, S. Korea, Taiwan, China Export China, India, Italy, Indonesia ~ 15 Mills Bluescope Thai Tin Plate Production: 0.8 m T Import: 2.2 m T Export: 0.1m T Demand: 2.9 m T Import Japan, S. Korea, Taiwan, China Export Vietnam, Laos, Myanmar, Hong Kong Machining Bending Cutting Welding Forging Heat Treatment Etc. Construction 54% Automobiles and parts 16% Machinery and Industrial Products 13% Electrical Appliances Packaging 12% 5% 8

10 Content Thailand steel industry structure Energy consumption in Thai Steel Industry Potential for energy conservation Energy management in steel industries in Thailand 9

11 Cost Structure of Thai Steel Industries Long products Flatted products Other Source: Iron and Steel Institute of Thailand 10

12 Structure of iron industry in energy consumption in Thailand Source: Iron and Steel Institute of Thailand 11

13 Structure of iron industry in energy consumption in Thailand Terminology referring to the 15 process Semi-finished products = Product from EAF to produce Billet+Bloom+Slab HR long products = Re-bar without EAF +Wire-rod without EAF +Section HR flat products = HR-Coil without EAF CR flat products = Cold-Rolled Coil Coated sheet = Hot Dip Galvanized steel sheet +Electro Galvanized steel sheet +Tin Plate, Tin Free Galv. Pipe = Galvanized Pipe Pipe + Cold formed = ERW Pipe +Cold Formed Section Source: Iron and Steel Institute of Thailand 12

14 Demand for steel in Thailand Thailand apparent steel use ( 000 Tonnes) Steel market has increased 4.5% from year ,000 18,000 16,914 16,000 14,000 12,000 10,000 8,000 12,661 13,876 12,154 12,718 13,528 10,644 13,871 14,411 17,676 6,000 4,000 2, f Production Import Export Apparent steel use Source: Iron and Steel Institute of Thailand 13

15 Forecasting the demand for steel consumption in Thailand ( ) 30,000,000 25,000,000 24,998,627 20,000,000 15,000,000 10,000,000 14,538,239 9,793,655 16,133,592 8,865,035 5,000,000 4,744,584 0 Long product Flat product Total steel demand Source: Iron and Steel Institute of Thailand 14

16 Content Thailand steel industry structure Energy consumption in Thai Steel Industry Plan for energy conservation Energy management in steel industries in Thailand 15

17 Action to reduce energy use in the steel industry, Thailand. 1. The master plan for managing the energy consumption in the steel industry of Thailand 2. The action plan for energy conservation in Thailand steel industry in the short term of 5 years ( ) Opportunity of energy reduction Roadmap Technology catalog for energy conservation 16

18 E 2014E 2015E 2016E 2017E 2018E 2019E 2020E 2021E 2022E 2023E 2024E 2025E 2026E 2027E 2028E 2029E 2030E 2031E Energy Consumption (ktoe) The master plan for managing the energy consumption in the steel industry of Thailand Energy Consumption: Master Plan Forecast for 20 year 1,300 1,200 1,100 1,000 Actual Energy Consumption of Thai Iron & Steel Industry BAU, According to Master Plan 2012 Energy Consumption Target, According to Master Plan : Drawing Master Plan Nowadays ktoe Actua l 833 Master Plan Semi-finished Production Hot rolled Production Cold rolled Production Coated Production Piped Production 17

19 Opportunities to reduce energy consumption in steel industry in Thailand KTOE Energy Consumption classified by group (KTOE) Opportunity of reduced Energy Consumption by Group (KTOE) Cold Rolled 4% Hot Rolled 47% Steel Making Hot Rolled Cold Rolled Coated Other 78 Coated 1% Energy consumption (ktoe) 22 Other 0.32% Steel Making 48% 5 Group Cal. Final Energy Opportunity of reduced Energy Consumption (%) Steel Making 28.78% Hot Rolled 25.93% Cold Rolled 10.99% Coated 8.00% Other 14.00% Total 25.34% First priority processes to tackle with are EAF-melting and Hot-rolling Ref: The survey of energy consumption in the steel industry in Thailand. 18

20 Energy Saving Opportunity for Thai Iron & Steel Industry OTHER COATED COLD ROLLING Best Practice Energy Management New & Emerging Technology HOT ROLLING STEEL MAKING Opportunity for Energy Saving (%) 19

21 Energy Consumption (ktoe) The action plan for energy conservation in Thailand steel industry in the short term of 5 years Energy Consumption of Thai iron and steel industry: BAU and Energy Saving target ,291 BAU based on MP Production Growth: ,111 1,149 1, Energy Saving Target based on MP Production Growth: 2014 Start drawing Master Plan ktoe (4.6%) 600 Start drawing 5 yearaction Plan Actual Forecast 0 Note MP : Master Plan E 2014E 2015E 2016E 2017E 2018E 2019E 20

22 SEC improvement goal by Group of Process Period (5 years) Group Ref SEC % [MJ/ton] [MJ/ton] reduction Semi-finished Product 3,374 3, % HR, Long Product 1,967 1, % HR, Flat Product 2,367 2, % CR, Flat Product 1,963 1, % Gal.sheet (HDG+EG) 1, % Galv.pipe 1,670 1, % Pipe % 21

23 Catalog of energy saving technologies in Thailand steel industry. 22

24 Benchmarking of SEC for World Best Practice, Thailand Item Process SEC, Final Energy (GJ/t-product) World BPT Thailand (Avg) 1 Electric Arc Furnace Continuous casting Hot rolling strip Hot rolling Bars Hot rolling Wire Hot rolling Section 7 Cold rolling Coated sheet Galvanized pipe Pipe & Cold form

25 Content Thailand steel industry structure Energy consumption in Thai Steel Industry Plan for energy conservation Energy management in steel industries in Thailand 24

26 Thailand s Existing Policy & Measures to support the Energy Efficiency Improvement Mainly focused on the Financial Support & Voluntary Program Source: The Department of Alternative Energy Development and Efficiency (DEDE) is the government agency responsible for implementing EE under the ENCON Act. 25

27 Training Information Regulation Standard Practice Tax Incentive Soft Lone ESCO Demonstration Dissemination DSM Bidding Research & Project Implement Most important Important Less important Energy management Process improvement High efficiency technology Investment Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Efficient Ladle & Tundish Preheater Scrap Preheating o o o o Using C from Plastic and Tires Scrap Management o o o o o o Neural Network o o o Slag Foaming o o o o Continuous Scrap Feeding o o Ladle EAF Synchronization o o o o 27 26

28 Training Information Regulation Standard Practice Tax Incentive Soft Lone ESCO Demonstration Dissemination DSM Bidding Research & Project Implement Most important Important Less important Energy management Process improvement High efficiency technology Investment Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Direct Rolling and Hot Charge o o o o High Efficiency recuperator o o Advance Descaling Nozzle Combustion Setting o o o o o Emulsion Fuel o o o Insulation of Furnace o o Air Compressor for Atomize air o o Oxygen Enrichment o o o Biomass Thermal gasification o o o Roller water cooling bottom furnace o o Emisspro o o Process Control o o o o 28 27

29 Training Information Regulation Standard Practice Tax Incentive Soft Lone ESCO Demonstration Dissemination DSM Bidding Research & Project Implement Energy management Process improvement High efficiency technology Investment Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Combine line (Coated & Colour coated) o o o Solid State Welding o o o Solar Water Heater o o Submerged Combustion Burner o o o Turbulent Pickling o o o Ball Blowing Type o o Most important Important Less important 29 28

30 Training Information Regulation Standard Practice Tax Incentive Soft Lone ESCO Demonstration Dissemination DSM Bidding Research & Project Implement Most important Important Less important Energy management Process improvement High efficiency technology Investment Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Cooling Tower o o o o Oxy-Fuel Burner o o o Regenerative Burner o o o Boiler o o o o Compressed Air Management o o o o Combustion Setting o o o High Efficiency Recuperator o o o VSD AC, CT, Chiller, Pump o o o o Pump Management o o Solar PV o o o o LED Light o o o o Biomass Boiler o o o o Waste Heat Recovery o o o o 30 29

31 Tech Verification Survey Analysis & Synthetic Engineering M&V Process improvement Research and development program to increase energy efficiency (The action plan for energy conservation in Thailand steel industry in the short term of 5 years) Item Project Name Budget (Million-Baht) Duration (month) Implementation Year Scope of Work 1 Scrap Management (Improve scrap quality) Neural Network for EAF CONSTEEL Optimization Slag Foaming Ladle EAF Synchronization Heat balance & Combustion setting Direct Rolling and Hot Charge BATs & Emerging for Steel Making & Hot Rolling SOP for Utility management Database & Evaluation of Energy saving (Iron and Steel) Combine line (Coated & Colour coat) Heat Recovery Submerged Combustion Burner Oxygen Enrichment Energy Conservation Expert for Steel Industry Gasified for replace of NG or HFO

32 To be Driven Continuously Working Together Towards a Common Goal 31

33 THANK YOU FOR YOUR ATTENTION