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

Energy Efficiency Tata Steel Ltd.(I) Rajeev Kumar Chittrey 04-03-2016 Tata Steel Ltd. CS&P (Cost Research and Standard Costing)

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Profile - Tata Steel Ltd.  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 Odisha 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 3

Energy Policy 4

Crude Steel Production - mt 11.00 11 9.90 9.33 9.15 9 8.13 7.13 6.86 7 6.56 5 FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20 6.5 Specific Energy Consumption - Gcal/tcs 6.125 6.088 6.083 6.017 6.012 6.006 6 5.780 5.5 5.280 5 FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20 5

Energy saving Measures taken at Tata Steel Ltd.(I) 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 : Implementation of Adopting best available New and emerging best practices technologies technologies (FY’04 – FY’07) (FY’08 - FY’12) ( FY’13 - FY’16) • Waste heat recovery from waste • Utilization of by product gases for • Thin Slab Caster and Rolling, Steam & Power generation, gas of Blast Furnace stoves. • Use of Pellets and shift to alternate • Installation of Top Recovery • Phasing out old and energy fuel for utilizing lean by-product Turbine, inefficient Units, gases. • Use of Regenerative Burners at • Enhancing by product gas recovery Hot Strip Mill for maximizing fuel • Use of Solar Energy + LED lights for and optimization of operating efficiency the street – To promote use of practices. renewable energy in our operations • Coke Dry Quenching • Regular Energy Audit & • Application of V/F drives. • Coal injection @ 200 kg/thm at Blast implementation of its Furnaces. • Upgraded Centralized Energy recommendations. Management Centre. • Coal injection at Blast Furnaces • Large size Bl. Fces ( H& I) with • Adoption of 100% continuous higher energy efficiency. casting 6

Energy Input to Steel (FY15) Propane Purchase Power Steam Coal and Coke Purchase Pellet Water Oxygen HP Nitrogen Petro-Fuel (5297 T) (2753 M kWh) (49.6 Mcum) (3972 T) ( 7.650 MT ) (445 kT) (6688 kL) (1255 MCum) (941 MCum) 6.607 MGCal 50.30 MGCal 0.223 MGCal 2.021 MGCal 0.282MGCal 0.061 MGCal 0.061 MGCal 0.025MGCal 0.003 MGCal Steel Works Energy Sold Total Energy Input or Stock Energy Bill 3.664 MGCal 59.582 MGCal Approx. 8300 Rs Cr Net Energy Usage = 55.918 MGCal Energy Input-%  Ore based integrated Iron and Steel Ind. Gases Petroleum 4.32% 0.20% making processes are highly energy intensive. Power 10.09%  It contributes to approximately 40% of the works saleable steel cost.  85% energy consumption is in the Coal + form of coal/coke. Coke 85.39% MGCal: Million Gega Calorie 7 7

Stage-wise Sp. Energy Consumption - % (FY15) 8

Performance (FY15) Combined Blast Furnace Fuel Rate (kg/thm) Plant Sp. Energy Consumption (Gcal/tcs) 6.088 6.083 589 584 578 6.017 6.012 571 6.006 569 FY'11 FY'12 FY'13 FY'14 FY'15 FY'11 FY'12 FY'13 FY'14 FY'15 Plant Sp. Power Consumption (KWh/tss) Power generation through TRT ( MW) 416 25.34 408 406 23.45 16.01 14.75 356 11.98 351 FY'11 FY'12 FY'13 FY'14 FY'15 FY'11 FY'12 FY'13 FY'14 FY'15 9

Long Term Plan-Specific Energy Consumption-Gcal/tcs 7.000 5.915 5.780 5.700 5.650 5.410 5.200 6.000 5.280 5.200 5.000 4.000 3.000 2.000 1.000 0.000 FY16 ABP FY16 (E ) FY17 FY18 FY19 FY20 FY21 BM( Norm) TSL 1 Power generation from CDQ (Batt 10 & 11) 2 TRT at F Blast Furnaces 3 Waste heat recovery from Sinter Plant 3 & 4 Reduction 4 Duel Fuel Burner system in Pellet Plant Projects in 5 New LD Gas Holder for recovery from LD-2 in SEC Power gen from CDQ ( Batt# 10& 11) progress 0.550 6 Methane from By product gases Gcal/tcs 7 Additional power generation from 25 MW at Power House # 4 8 Waste to energy (Plasma Gasification) 9 Power generation from additional BF gas 10

Recommended Customized List of Energy Saving Technologies in Indian Steel Industries Category Title of Technology 1 Sinter Plant Heat Recovery(Steam Recovery from Sinter Cooler Waste Heat) 2 Sinter Plant Heat Recovery(Power Generation from Sinter Cooler Waste Heat) Sintering 3 High Efficient (COG) Burner in Ignition Furnace for Sinter Plant 4 Coke Dry Quenching ( CDQ) Coke Making 5 Coal Moisture Control ( CMC) 6 Top Pressure Recovery Turbine ( TRT) Iron Making 7 Pulverized Coal Injection (PCI) System 8 Hot Stove Waste Heat Recovery 9 Converter Gas Recovery Device 10 Converter Gas Sensible Heat Recovery Device Steel Making 11 Ecological and Economical Arc Furnace 12 Waste Heat Recovery from EAF Recycling and Waste Reduction 13 Rotary Hearth Furnace Dust Recycling System Thank You Common 14 Inverter (VVVF; Variable Voltage Variable Frequency)Drive for Motors Systems 15 Regenerative Burner Total System for reheating furnace 16 Energy Monitoring and Management Systems General Energy 17 Cogeneration (include Gas Turbine Combined Cycle (GTCC) Savings and Environmental 18 Management of Compressed Air Delivery Pressure Optimization Measures 19 Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line 11

End of Presentation Thank You 12