Day-3, Mr. D M Chowdhary

The 14th Regulators & Policymakers Retreat1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa

Title: WASTE ENERGY RECOVERY IN AN INTEGRATED STEEL PLANT

Speaker: D M Chowdhary

The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa

WASTE ENERGY RECOVERY

• TODAY WASTE HEAT RECOVERY IS GAINING ACCEPTANCE IN CERTAIN INDUSTRIES

• DEPENDING ON THE FORM OF ENERGY THERE MAY BE DIFFERENT TYPE & APPROACH OF ENERGY RECOVERY:I. WASTE HEAT RECOVERYII. OTHER FORMS OF INDUSTRIAL WASTE

ENERGY RECOVERY


I. WASTE HEAT RECOVERY

• DIFFERENT PROCESS INDUSTRIES HAVE DIFFERENT TYPE OF WASTE HEAT AND ITS RECOVERY METHODOLOGY

• SPONGE IRON PLANT, CEMENT PLANT, STEEL PLANTS ARE MAJOR PROCESS PLANTS WITH HIGH DEGREE OF HEAT RECOVERY POTENTIALS


TECHNOLOGY MATURITY

• TECHNOLOGY TO A LARGE EXTENT IS GETTING STABLISED FOR HEAT RECOVERY FROM COMMON PROCESSES

• NEW TECNOLOGY FOR HIGHER RECOVERY UNDER DEVELOPMENT AND NEEDS ENCOURAGEMENT

• EXAMPLES: CDQ, SINTER PLANT etc.IN A STEEL PLANT


II. OTHER FORMS OF WASTE ENERGY RECOVERY

• THIS IS AN AREA NOT WIDELY COVERED IN VARIOUS INDUSTRIES

• DIFFERENT PROCESS INDUSTRIES HAVE DIFFERENT FORMS OF ENERGY. NEED TO BE IDENTIFIED AND DEVELOP/ GET TECHNOLOGY TO RECOVER THE SAME

• SUCH TECHNOLOGIES ARE STILL AT DEVELOPMENT STAGE


• PROVEN TECHNOLOGY IS VERY LIMITED FOR MANY PROCESSES

• RELIABILITY OF SUCH PROCESS IS IN DOUBT • CAPITAL COST DEPENDS ON TECHNOLOGY• POWER GENERATION TECHNOLOGY FROM SUCH

WASTE ENERGY ARE PREDOMINANT• POWER GENERATION STILL IS A BYPRODUCT /

SECONDARY EVENT AND PROCESS STABILITY IS CRITICAL


PRESSURE ENERGY RECOVERY IN AN ITEGRATED STEEL PLANT

FOR UTILISING BLAST FURNACE PRESSURE ENERGY


BLAST FURNACES OPERATION REQUIRES LARGE VOLUME OF AIR

• BLAST FURNACE IS A TALL VERTICAL FURNACE - CONVERTS IRON ORE, COKE AND FLUX INTO LIQUID METAL

• HIGH PRESSURE LARGE VOLUME OF AIR IS PUT INSIDE THE FURNACE BOTTOM FOR CONVERSION OF IRON ORE AND COKE INTO LIQUID IRON. BY PRODUCT GAS ALSO COMES OUT AT HIGH PRESSURE

• IN A CONVENTIONAL STEEL PLANT, THE GAS IS USED AS A LOW CALORIFIC VALUE FUEL OR RELEASED IN ATMOSPHERE


PRESSURE ENERGY RECOVERY IN BLAST FURNACES: TRT

• THE PRESSURE ENERGY IS NOT UTILIZED AND GOES AS A WASTE IN MOST OF THE CONVENTIONAL STEEL PLANTS.

• TOP-PRESSURE RECOVERY TURBINE, POPULARLY KNOWN AS TRT IS A TECHNOLOGY TO CONVERT THIS PRESSURE ENERGY/ KINETIC ENERGY INTO POWER

• IT IS IN A WAY AN ARTIFICIAL WIND POWER GENERATOR AND WORKS ON SIMILAR PRINCIPLE.


15-20 MWe POWER FROM A LARGE BLAST FURNACE (3 Mtpa)

• THE HIGH PRESSURE GAS COMING OUT OF BLAST FURNACE ROTATES THE TURBINE AND GENERATES POWER

• NO FUEL/ NO HEAT IS USED FOR POWER GENERATION

• BUT THE RELIABILITY OF POWER GENERATED FROM A PROCESS PLANT LIKE BLAST FURNACE TRT IS LOW, ON AN AVERAGE ANNUAL GENERATION IS APPROXIMATELY 50-60% OF INSTALLED CAPACITY

Schematic Diagram


CHALLENGES AHEAD

• HOW TO ENCOURAGE SUCH FUEL LESS ENERGY SOURCES WHICH ARE MOSTLY A WASTE IN TODAY’S INDUSTRIAL WORLD.

• TECHNOLOGY THAT IS YET TO BE FULLY STABLISED IN INDIAN CONTEXT.

• ENCOURAGE DEVELOPMENT OF NEW TECHNOLOGIES

• INCENTIVISE THE INDUSTRY AT LEAST FOR INITIAL PERIOD- TIME GRADED MANNER


ADOPTION OF NEW TECHNOLOGIES- HIGH RISK

• ENCOURAGE FIRST FEW INSTALLATIONS IN INDIA IN SIGNIFICANT MANNER.

• ONCE THE TECHNOLOGY IS FULLY STABLISED IN THE INDIA ,IT IS LIKELY TO BE ADOPTED BY OTHERS

• ECONOMICALLY UNVIABLE ENERGY RECOVERY PROJECTS NEEDS FINANCIAL SUPPORT FOR LONGER PERIOD

• ROLE OF INDUSTRIES- TO TRY NEW ENERGY RECOVERY SOURCES/ TECNOLOGY


THANK YOU

Day-3, Mr. D M Chowdhary

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