BEST PRACTICES ON ENERGY EFFICIENCY << Energy Management >> JSW Steel Limited, Dolvi Works
Key Themes: Lowest Energy Consuming unit amongst Integrated Steel Plant in India Continuously Improving Energy Efficiency for each of the production units Usage of Innovative process & equipment technologies for the manufacturing Continuous endeavor to utilize energy waste: either in form of process waste and /or hidden chemical & thermal energy Energy sources optimization for Input cost efficiency Energy Management center for proper monitoring & control
Coke BF Gas Sinter Steel Scrap DR I Calcined lime Oxygen Oxygen Jetty Iron ore Iron Ore fines Fluxes Coke/ Coal Lime Stone Pallet LCP SIP Oxygen Oxygen Plant Oxygen Pallet RMHS Iron ore Blast furnace Hot Metal SMS Liquid Steel Hot Strip Mill Caster Slab Rolling Mill Power Plant Iron ore fines COG Gas Sinter Oxygen Scrap Yard Coil Yard HR Coil Railway Siding Coke Oven Coal Pellet Plant Iron ore Steel Scrap 4
Specific Energy Consumption Summary for FY2012-13 and 2013-14 Sr. No Plants GCal/TP (2011-12) GCal/TP (2012-13) GCal/TP (2013-14) Diff between last two years (%) 1 Sponge Iron 2.724 2.710 2.990 10.33 2 Sinter Plant 0.607 0.567 0.689 21.16 3 Blast Furnace 3.745 3.760 3.502-6.91 4 SMS 1.001 0.914 0.831-8.75 5 Caster 0.014 0.015 0.016 0 6 Mill 0.301 0.305 0.289-6.55 7 Aux & Losses 0.482 0.506 0.21-59.2 Upstream Plants 1 Coke Making unit 0.351 0.326 0.334 3.06 2 Pellet Making unit 0.170 0.283 0.235-17.66 Total Gcal 9.395 9.385 9.096-3.09
Sr no. PLANT 1 Sponge Iron 2 Sinter Plant 3 Blast Furnace 4 SMS Source Optimization Operation Discipline High productivity Process/System Change Increasing the DRI metallization from 94% to 94.5% to reduce the melting Power in EAF by 2 kwh/mt of DRI used. At Sinter plant- Installation of VVVF drives- 2nos. at pump motors has saved 1.73 lacs kwh per year 1.At Blast furnace -Reduced usage of lump ore at Blast furnace and usage of pellet and sinter only reduced the fuel rate by 5 kg/thm. 1.At SMS- Exploration of suitable technology to recover waste heat from EAF off gases has been initiated in steel melting area. Waste Utilization Natural gas Cons reduced by 10% using COG(Gcal/tcs reduced by 0.002) BFG Flaring reduced from 47% to 18%. Overall change in energy consumption(%) 5 Caster 0 6 Mill 7 Aux & Losses UPSTREAM At Hot Rolling Mill- Optimization of the logic of run speed for coiler -1 & Coiler-2 drives when running at no load has resulted in energy saving of 2.16 Lacs kwh per annum Oxygen venting reduced by 34% BF Gas flaring reduced by 56% NG Cons reduced by 3.5%(Gcal/tcs reduced by 0.012) 10.33 21.16-6.91-8.75-6.55-59.28 1 Coke Oven 2 Pellet Plant 0.012 Gcal/tcs 0.048 Gcal/tcs
BF Gas MNm3 Percentage Potential waste utilization and innovation BF Gas: BF Gas Flare Financial Year Flare Value Saved Gcal Remarks 2012-13 47 % - 2013-14 18 % 0.32 By installing power plant 2014-15 14% 0.027 By efficient round the clock Gas Monitoring 2015-16 3% 0.076 Will install Gas Holder 3500 BF Gas Generation Vs Flaring Trend 60.00% 3000 2500 50% 2651 49% 2313 44% 2396 47% 2682 3126 50.00% 40.00% 2000 30.00% 1500 1325 1272 1000 1132 1055 18% 20.00% 500 549 10.00% 0 2009-10 2010-11 2011-12 2012-13 2013-14 FINANCIAL YEAR 0.00% Gas Generated Gas Flared % of BFG Flare
Major Investment - 55 MW Power Plant Project start date : 09.09.2011 Commissioning date : 19.03.2013 Project Cost Technology (BTG) : Rs.182 Cr : DF Power System Boiler Main features Blast Furnace Gas fired Single drum boiler with capacity of 204 TPH steam at 540 deg C (SH) & 114 kg/cm2. Steam Turbine (1no.)- HP turbine (104 Kg/cm2), 3000 RPM & Single Casting with condenser. Generator (1no.)- 53.4 MW, 66.87 MVA, 3510A. Turbine 8
In plant Initiatives Sr. No Initiatives Location User Benefits 1. 53.5 MW Power Plant Power Plant Grid Saving energy upto 0.32GCal/tcs 2. Coal Injection Usage (PCI) Blast Furnace Blast Furnace Cost reduction per ton of hot metal 3. Gas expansion turbine Blast Furnace Grid 5 MW power 4 Auto ON/OFF control to torpedo tilting suction motor Steel melting Shop Steel melting Shop Net Power saving of 989 KW per day 5 Auto ON/OFF control to Air cooling fan using PLC logic Steel melting Shop (GCP) Steel melting Shop (GCP) Net Power saving of 906 KW per day
GAS DISRIBUTION NETWORK NG CPP BF CO SIP TF GMS PELLET SINTER GMS: Gas mixing station ; CPP-Captive Power Plant ; NG-Natural Gas BF-Blast furnace; CO-coke oven ; SIP-Sponge iron Plant ; TF- Tunnel furnace
Waste Gas utilization CO Gas Utilization Plants 2013-14 2014-15 Remarks Cost Benefits Pellet NIL 12000 Nm3/Hr Replacing NG 2,40,000 Rs/hr SIP NIL 12000 Nm3/Hr Replacing NG 2,40,000 Rs/hr Tunnel Furnace NIL 8000 Nm3/Hr Replacing NG 1,60,000 Rs/hr Total NIL 32000 Nm3/Hr 6,40,000 Rs/hr
Substitution of Natural Gas by COG at Tunnel Furnace Waste minimization : Utilization of Coke Oven Gas for Process Heating Impact
10% Substitution of Natural Gas by COG at SIP Waste minimization : Utilization of Coke Oven Gas for Process Heating
MAJOR ACHIEVMENTS 1. At Hot Rolling Mill- Optimization of the logic of run speed for coiler -1 & Coiler-2 drives when running at no load has resulted in energy saving of 2.16 Lacs kwh per annum. 2. At Blast furnace -Reduced usage of lump ore at Blast furnace and usage of pellet and sinter only reduced the fuel rate by 5 kg/thm. 3. At Sinter plant- Installation of VVVF drives- 2nos. at pump motors has saved 1.73 lacs kwh per year. 4. At Coke Oven- Utilization of Coke oven gas from 1.0 mtpa coke oven plant for process heating in place of conventional fossil fuels. 5. At Mill- RLNG (Reliquified Natural Gas) has been replaced by COG in Tunnel Furnace at Mill, Ladle heating at steel making, Tundish heating at caster and boilers at HSM, Pellet Plant, Blast Furnace & Sinter plant. 6. At SIP- Utilization of coke oven gas to reduce/ substitute approximately 20% of the natural gas in the DRI production. 7. At SMS- Exploration of suitable technology to recover waste heat from EAF off gases has been initiated in steel melting area.
MAJOR ACHIEVEMENTS (continued) 8. DRI plant Enhancing the Reducing gas temperature to 970-980 Deg.C to optimized the reducing gas flow thereby reducing energy consumption by 0.008 GCal/Mt Increasing the DRI metallization from 94% to 94.5% to reduce the melting Power in EAF by 2 kwh/mt of DRI used. Stopping the CO-5 dust collection system water supply pump (PU-E78) by meeting the requirement from existing Hot water pump PU-E66. (Power savings by (288 kwh /Day) Stopping additional pump Pu-E12 used for diverting SIP Process blow down water to SMS slag cooling by using available head from PU-E97 pump, thereby reducing the Power consumption by 120 kwh/day Fixing the transparent sheets in Instrument air compressor house & Fire pump station, thereby reducing the Power consumption by 45 kwh/day.
Trends of Specific Energy Consumption and CO2 emission 6.6 2.22 6.5 2.2 2.2 6.4 6.3 2.18 2.18 6.2 2.16 6.1 6 6.547 6.516 2.128 2.14 5.9 2.12 5.8 5.7 5.919 2.1 5.6 FY 11-12 FY 12-13 FY 13-14 Specific Energy Consumption (SEC) CO2-(carbon dioxide) 2.08
Dolvi Railway Siding Railway Siding at Dolvi Project start date : Oct 2012 Commissioning date : 24.06.2013 Project Cost : Rs.50 Cr. Dolvi Railway Siding Facility - Railway siding at Dolvi works Main features 1.0 MTPA Handling Capacity 3.5 km broad gauge track length. 2500 MT rake capacity Rake size is 43 nos. of wagons. Wagon loading is three coils/wagon Benefits No interruption in dispatch during Ganapti festival Reduction in road traffic congestion Reduction of 24016 tons/year of CO2 emmission. 17
BF Gas Iron Ore Phase -1 Expansion Coal Coke Iron Ore & Fluxes Scenario- 2015 Pellet Plant 4 MTPA Coke Oven 1 MTPA Sinter Plant 2.8 MTPA Sinter Plant 2.24 MTPA NG Sponge Iron Plant 1.6 MTPA Blast Furnace 3.5 2 MTPA LCP 1200 TPD Cal. Lime DRI SMS (Con-Arc) 4.0 5.0 MTPA Hot Metal Billet Caster 1.5 MTPA Liquid Steel Thin Slab Caster 3.3 MTPA 55 MW Power Plant Billet Bar Mill 1.5 MTPA Hot Strip Mill 3.3 MTPA Slab Bars 1 MTPA Railway Siding HRC 18 18
Pradeep Agarwal DY. GENERAL MANAGER-Energy Management JSW Steel Limited, Dolvi Works Maharashtra, India - 402107 Mobile: +91 8108162672 Agarwal.Pradeep@jsw.in