Energy Efficiency at VSP · Conclusion 1. Rashtriya Ispat Nigam Limited Eastern Investment Limited Bisra Stone Lime Co. Ltd. (BSLC) Visakhapatnam Steel Plant Orissa Mineral Development

PRESENTATION

For

CII GBC NATIONAL AWARD

FOR EXCELLENCE IN

ENERGY MANAGEMENT

By

Rashtriya Ispat Nigam Limited

VISAKHAPATNAM STEEL PLANT

TEAM MEMBERS

T K DEYDGM(EMD) I/c & Energy Manager

VV Ramana RaoDGM(O) -MMSM

Sudhanshu KumarMgr.(EMD) & Certified Energy Auditor

CONTENTS

➢Company Profile

➢Process Flow

➢Sp. Energy Consumption in last three years

➢Bench marking(Global and National Bench Marking)

➢Energy Saving projects implemented in FY 2015-16



➢Innovative Projects

➢Utilization of Renewable Energy Sources

➢Utilization of Waste as a fuel

➢GHG Inventorisation

➢Green Supply Chain

➢Team Work , Employee Involvement & Monitoring

➢Energy Management System (ISO:50001)

➢ Conclusion

1

Rashtriya Ispat Nigam Limited

Eastern Investment Limited

Bisra

Stone Lime Co.

Ltd. (BSLC)

Visakhapatnam Steel

Plant

Orissa Mineral

Development

Corp. (OMDC)

Operating

Units

Madharam

mines

Dolomite

Jaggyyapeta

mines

Limestone

Garbham

Manganes

e

Subsidiary company

(51% stake)

RINL Corporate Structure

Units on Anvil

Wheel PlantTransmission Line

Towers Plant

2

Turnover (2017-18) 16,618

Net worth as on 31/03/18 9873

Unit: Rs. Crs

* 100% owned by Govt. of India

RINL – Snapshot

3

1. 66

RINL - Snapshot

The 1st ISP to be certified for Quality, Health & Safety and Environment

1st steel Plant to get ISO 50001 certification for Energy Management

CMMI Level 3 certification for IT Systems

1st ISP to be 5S Certified for the whole plant

4

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

✓ Invested Rs. 12,291 Cr ( 80% met through internal

accruals)

▪ Upgradation & Modernization

✓ Underway to enhance capacity to 7.3 Mt by 17-18

✓ With an investment of Rs. 4,000 Crs.

▪ Vision envisages growth to 20 Mtpa by 2032-33 in phases

RINL’s Growth Plan

6

BPTS

TRT

100%

Continuous

Casting

LD gas

recovery

Evaporative

Cooling

CO Battery with Coke Dry Quenching and Back Pressure Turbine Station

3200 cum BF with Top Recovery Turbine and BF gas recoveryRolling Mills with Stelmor & Tempcore (TMT) processes equipped with evaporative cooling

for waste heat utilization

Production Process flow at RINL

5

Power Generation capacity from Waste Energy (MW)

7

Energy Consumption

13

38.8

36.8

33.2

2015-16 2016-17 2017-18

Thermal Energy Consumption (GJ/tCS)

715

697

686

2015-16 2016-17 2017-18

Electrical Energy Consumption (Kwh/tCS)

8.17 8.12

7.63

2015-16 2016-17 2017-18

SEC as PAT Scheme (Gcal/tCS)

Sp. Energy Consumption-Gcal/tCS

14

6.40 6.39

6.05

2015-16 2016-17 2017-18

International Bench Marking of SEC(Gcal/tCS)

6.055.47

4.0004.5005.0005.5006.0006.5007.000

RINL Nippon Steel

Unit

16

Bench Marking with Nippon Steel(2017-18)

Energy(2017-18) GHG EmissionGap :0.58 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

6.05 5.47 2.618 1.98

17

Benchmarking of Energy Consumption-Gcal/tCS

15

6.05

6.58

5.7

6.36

RINL SAIL-BSP TATA Steel SAIl-DSP

National Bench Marking of SEC(Gcal/tCS)

18

6.05

5.70

RINL TATA Steel

Bench Marking with Tata Steel(2017-18)

Energy(2017-18) GHG Emission Gap :0.350 Gcal/tCS

RINL NSC RINL NSC 1)Coal Injection of 168 kg/tHM(0.180 Gcal/tCS)

2)1.5 Mt Semi finished steel Sales(0.14

Gcal/tCS)

3) Billet Caster Production(0.25 Gcal)

4) Plant Production: 11 Mt Hot Metal 10 Mt

Crude Steel.

5)"H"Blast Furnace capacity utilization:123%

Capacity Utilization(3.07 mt )

6.05 5.70 2.618 2.1

19

ENCON Projects with NO/Little Investment (2015-16)

9

S.No. Title of ProjectEnergy Savings in

Gcal/MKwh Rs Millions

1Substitution of Coke by Coal through Commissioning of

Pulverized coal injection in Blast Furnace 125538.016 24.80

2Substitution of Coke by Coal through Commissioning of

Pulverized coal injection in BF 34432.912 4.30

3Recovery of LD gas from Steel Melting Shop by commissioning

of LD gas export staion at SMS 230629.114 29.74

4Power generation from Top Pressure Recovery Turbine of BF

320.308 118.92

5 Energy Savings through installation of Billet Caster 768733.5 746.44

6Reduction of Specific Heat consumption at coke ovens from

634 Mcal/t to 622 Mcal/tDC by optimising air fuel ratio and

adjusting combustion paarmeters

45608.9 44.29

7Improvement in Benzol Yield at Coke ovens from 0.26% to

0.44%6841.29 6.64

8Reduction of Specific heat consumption at Sinter Machine-3

from 18 Mcal/tGS to 15 Mcal/tGS through installation of energy

efficient burners and recycling of waste heat

5328.49 5.17


9



9Reduction of Specific power consumption at Sinter

machine -3 from 73.6 Kwh/t to 61.9 kwh/tGS20.78 121.69

10Reduction of Coke Rate at Blast Furnace from 567.5

kg/tHM to 560.9 kg/tHM by optimsing loading of Blast

Furnaces

163114.05 158.38

11Reduction of Heat Consumption at BF-12&3 from 590

Mcal/t to 526 Mcal/tHM61226.31 59.45

12Reduction of Power Consumption at BF-1,2&3 from

55.1 kwh/tHM to 51.2 kwh/tHM8.97 52.50

13Reduction of Specific heat consumption at SMS-1 from

44 Mcal/tCS to 42 Mcal/tCS4512.66 4.38

14Reduction of Specfiic heat consumption at WRM-1

from 269 Mcal/t to 250 Mcal/tiP16520.58 16.04

15Reduction in Sp.heat at CRMP from 1367 Mcal/t to 1362

Mcakl/tGL1905.70 1.85

16Reduction in BF gas bleeding from 3.54% to 2.47% of

generation through optimisation of usage at Thermal

Power Plant

51929.28 50.42

Total 1445.04


9



1Improvement in benzol yield at coke oven from0.44% to 0.47%

11482 11.15

2Reduction of Sp. power Consumption at cokeoven from 59.97 to 49.28 Kwh/tDC

10.26 68.05

3Reduction of Sp. Power Consumption at SP-1from 61.87 to 58.88 Kwh/tGS

10.46 69.42

4Reduction of Sp. heat Consumption at SP-2 from15 to 10 Mcal/tGS

12582 12.22

5Reduction of Sp. Power Consumption at SP-2from 61.89 to 58.59 Kwh/tGS

8.30 55.10

6Reduction in fuel rate at Blast Furnace from560.9 to 537.2 Kg/tHM

380415 369.38


10



7Reduction in Sp. Heat Consumption at BlastFurnace from 526 to 475 Mcal/tHM

60079.14 58.34

8Reduction in Sp. Power Consumption at BF-3from 51.24 to 45.74 Kwh/tHM

24.12 160.05

9Reduction in Sp. Power Consumption at SMS-1from 51.41 to 47.68 Kwh/tCS

8.12 53.88

10Improvement in LD gas yield at SMS-1 from 94 to95 Ncum/tCS

3505.14 3.40


8.80 58.37


189649 184.15

13Reduction in Sp. Heat Consumption at LMMMfrom 449 to 422 Mcal/tBI

52500 50.98

14Reduction in Sp. Power Consumption at Bar Millfrom 70.52 to 70.21 Kwh/tBI

0.26 1.76


11



15Reduction in Sp. Heat Consumption at WRM from 250to 249 Mcal/tBl

1018 0.99

16Reduction in Sp. Power Consumption at WRM from124.8 to 122.54 Kwh/tBI

2.30 15.26

17Reduction in Sp. Heat Consumption at WRM-2 from289 to 270 Mcal/tBl

7739.61 7.52

18Reduction in Sp. Power Consumption at WRM-2 from340.9 to 287.5 Kwh/tBI

21.75 144.31

19Reduction in Sp. Power Consumption at MMSM from83.37 to 81.42 Kwh/tBI

1.53 10.15

20Reduction in Sp. Power Consumption at CRMP from67.34 to 66.36 Kwh/tBI

0.41 2.71

Total 2003.2

ENCON Projects with Investment (2017-18)

8


Investment (Rs Million)


1Improvement in Pulverized coal injectionfrom 23.4 to 53.6Kg/tHM at Blast Furnace

240524 308 1350

2 Energy saving through Billet Caster 187995 241 5520

3Improvement in Power Generation at TopPressure Recovery Turbine station of BF-3

13 84 800


9



1Improvement in benzol yield at coke oven from0.47% to 0.51%

15746 20

2Reduction of Sp. power Consumption at cokeoven from 49.29 to 46.51 Kwh/tDC

11 70

3Reduction of Coke Breeze Consumption at SP-1from 64.3 to 60.4 Kg/tGS

100892 129


11503 15


3025 4

6Reduction in Sp. Power Consumption at BF-3from 38.56 to 36.57 Kwh/tHM

5 31


10



7Reduction in Sp. Heat Consumption at SMS-1from 43 to 38 Kwh/tCS

12855 16

8Reduction in Sp. Heat Consumption at SMS-2from 46 to 41 Kwh/tCS

10798 14


13 82


33605 43

11Replacement of Air Recuperartors in F/C-2 ofLMMM

4800 6

12Replacement of Gas Recuperartors in F/C ofWRM-1

1200 2


11



13Reduction in Sp. Power Consumption at MMSMfrom 81.42 to 72.65 Kwh/tBI

8 50

14Reduction in Sp. Heat Consumption at CRMP-2from 1210 to 941 Mcal/tGL

54839 70

Total 1101

YEARNo of

Projects

Thermal

Savings

(Gcals)

Electrical

Savings

(Million KWH)

Saving

s in

Rs.Cr

Investm

ent

In Rs Cr

2015-16 16 1186320 50.1 144.5 410

2016-17 33 1049671 148.3 200.3 687

2017-18 17 677781 48.6 110.1 767

Summary of the Projects identified & Implemented

12

INNOVATIVE PROJECT

12

Modified Pass Schedule for Rolling of

Billet-75 at MMSM

CAPACITY : 8,50,000 TONS/YEAR

FURNACE MILL TRAIN

COOLING BED & BATCHING COLD SAW

PRODUCT MIX

ANGLES CHANNELS

SQUARESROUNDS

BEAMS

FLATS

8/31/2018

http://www.vspsite.org:86/hr/

Before Modifications

12

1. To Produce 75mm billet from 250x250 mm, as per

manufacturer we need to operate

RMT(8),IMT(4),FMT(2).

2. To ensure trouble free operation closed CVS is

envisaged for cooling of main drives in all three

train resulting in energy consumption for cooling.

3. There is need for relocation of strands with a view

to operate at full capacity in each mill train and

minimize wastage of energy.

4. This resulting in energy loss of 480KW for running

of CVS fans.

Existing Pass Design of SQUARE 75

Stand No. Pass Code Pass TypeHeight

(mm)

Width

(mm)

Draft

(%)

Motor

(KW)

Current

(%)

1H 1RO50 PB 209 259 16.5 600 30

2V 2RO50 220 212 18.0 600 45

3H 3RO50 175 220 20.5 600 50

4V 4RO50 185 175 20.5 600 55

5H 5RO50 143 190 23.0 1000 40

6V 6RO50 150 150 21.0 1000 40

7H 7RO50 113 160 25.0 1000 40

8V 8RO50 120 119 26.0 1700 35

9H 9RO50 PB 82 136 32.0 1700 45

10T - - - - - 1700 -

11T - - - - - 1700 -

12V 10RO50 93 97 31.0 1700 40

13H 11RO50 78 100 22.0 1700 40

14V 12SQ75 80 84 21.0 1700 40

15T - - - - - 1700 -

16H 16SQ65 PB 73 84 13.5 1700 20

17V 17SQ65 PB 76 76 14.0 1000 25

18H - - - - - 1700 -

19V - - - - - 1000 -

- - - - - - 1700 -

8/31/2018

Table 1.1 :

R

M

T

I

M

T

F

M

T


EXISTING MILL CONFIGURATION FOR ROLLING SQ75

8/31/2018

ROUGHING MILL TRAIN

Transfe

r

Trough

INTERMEDIATE MILL TRAIN

STAND 1 STAND 2 STAND 3 STAND 4 STAND 5 STAND 6 STAND 7 STAND 8

STAND 9

STAND 10 STAND 11

STAND 12 STAND 13 STAND 14

STAND 19 STAND 20STAND 18

STAND 17STAND 16

STAND 15

FINISHING MILL TRAIN

Transfe

r

Trough

Transfe

r

Trough

Transfe

r

Trough

1RO50 PBPlain Barrel

2RO50Box Pass

3RO50Box Pass

4RO50Box Pass

5RO50Box Pass

6RO50Box Pass

7RO50Box Pass

8RO50Box Pass


10RO50Box Pass

11RO50Box Pass

12SQ75Box Pass

16SQ65 PBPlain Barrel

17SQ65 PBPlain Barrel

Transfe

r

Trough

Transfe

r

Trough


MEDIUM MERCHANT & STRUCTURAL MILL

CV1 CV2 CV3

M1 M2

M3 M4

M1 M2

M3 M4

M1 M2

M3 M4

2/2

LUBE OIL

STATION

2/3

LUBE OIL

STATION

1 3

H H

5

H

7

H

2

V

4

V

8

C

6

C

ROUGHING MILL TRAIN

2500KNS9

1

1

H H

1

3

H

1

0

C

1

2

C C

1

4


800KNS1

51

6

H H

1

8

H

1

7

C C

1

9


500KN S2

0

H

160KW160KW 160KW 160KW 160KW160KW160KW 160KW 160KW 160KW 160KW 160KW

55KW55KW55KW

- LEVEL

ZERO LEVELFC1 FC2

95KW

MILL

HYDRAULIC

STATION

2/1

LUBE OIL

STATION



Modification

12

1. Based on the study and finding out various

alternatives, the team decided to shift 2 nos of FMT

strands to IMT with suitable selection of roll, beam

and guides along with casette selection.

2. A trail run was conducted after relocation and it

was running successfully and rolling rate remains

same.

3. CVS fan in FMT are stopped.

Modified Pass Schedule of SQUARE 75

Stand No. Pass Code Pass TypeHeight

(mm)

Width

(mm)

Draft

(%)

Motor

(KW)

Current

(%)

1H 1RO50 PB 209 259 16.5 600 30

2V 2RO50 220 212 18.0 600 45

3H 3RO50 175 220 20.5 600 50

4V 4RO50 185 175 20.5 600 55

5H 5RO50 143 190 23.0 1000 40

6V 6RO50 150 150 21.0 1000 40

7H 7RO50 113 160 25.0 1000 40

8V 8RO50 120 119 26.0 1700 35

9H 9RO50 PB 82 146 32.0 1700 45

10T 10RO50 97 94 33.0 1700 40

11T 11RO50 78 100 16.0 1700 25

12V 12SQ75 80 84 16.0 1700 30

13H 13RO50 73 84 9.0 1700 20

14V 13RO50 76 76 10.0 1700 20

15T - - - - - 1700 -

16H - - - - - 1700 -

17V - - - - - 1000 -

18H - - - - - 1700 -

19V - - - - - 1000 -

20T - - - - - 1700 -

R

M

T

I

M

T

F

M

T

MODIFIED MILL CONFIGURATION FOR ROLLING SQ75

8/31/2018

ROUGHING MILL TRAIN


STAND 1H STAND 2V STAND 3H STAND 4V STAND 5H STAND 6V STAND 7H STAND 8V

Transfe

r

Trough

STAND 10T

STAND 20TSTAND 15T


Transfe

r

Trough

STAND 11T

Transfe

r

Trough

Transfe

r

Trough


2RO50Box Pass

3RO50Box Pass

4RO50Box Pass

5RO50Box Pass

6RO50Box Pass

7RO50Box Pass

8RO50Box Pass

STAND 9H


15SQ65Plain Barrel

15SQ65Plain Barrel

STAND19T

Transfe

r

Trough

10RO50Box Pass

STAND 17T

Transfe

r

Trough

STAND 18T

Transfe

r

Trough

STAND 16T

Transfe

r

Trough

11RO50Box pass

11 O50Box Pass

10RO50Box Pass

12SQ75Box Pass

12SQ75Box Pass

13RO50Plain Barrel

13RO50Plain Barrel

STAND 13H STAND 14VSTAND 12VSTAND 10V STAND 11H

STAND 18H STAND 17V

MEDIUM MERCHANT & STRUCTURAL MILL

CV1 CV2 CV3

M1 M2

M3 M4

M1 M2

M3 M4

M1 M2

M3 M4

2/2

LUBE OIL

STATION

2/3

LUBE OIL

STATION

1 3

H H

5

H

7

H

2

V

4

V

8

C

6

C

ROUGHING MILL TRAIN

2500KNS9

1

1

H H

1

3

H

1

0

C

1

2

C C

1

4


800KNS1

51

6

H H

1

8

H

1

7

C C

1

9


500KN S2

0

H

160KW160KW 160KW 160KW 160KW160KW160KW 160KW 160KW 160KW 160KW 160KW

55KW55KW55KW

- LEVEL

ZERO LEVELFC1 FC2

95KW

MILL

HYDRAULIC

STATION

2/1

LUBE OIL

STATION



POWER REQUIREMENT & SAVINGSCLOSED VENTILATION SYSTEM

AREA

NO. OF

MOTORS IN

USE

CAPACI

TY OF

THE

MOTOR

(KW)

TOTAL

POWER

(KW)

TOTAL

UNITS

/DAY

(KWH)

CV-1 3 160 480 11520

CV-2 3 160 480 11520

CV-3 3 160 480 11520

TATAL POWER CONSUMED BY CVS: 34560

MAKE UP BLOWER

AREA

NO.

BLOWERS

AVAILBLE

CAPCITY

OF THE

BLOWER

(KW)

TOTAL

POWER

(KW)

TOTAL

UNITS /

DAY

(KWH)

CV-1 1 4 4 96

CV-2 1 4 4 96

CV-3 1 4 4 96

TOATL POWER CONSUMED BY MAKE UP

BLOWERS (MB):288

LUBE OIL STATION

AREA

NO. OF

PUMPS IN

USE

MOTOR

CAPACITY

(KW)

TOTAL

POWER

(KW)

TOTAL

UNITS /

DAY

(KWH)

2/1 (RMT) 1 55 55 1320

2/2 (IMT) 1 55 55 1320

2/3 (FMT) 1 55 55 1320

TOATAL POWER CONSUMED BY LUBE

STATIONS (LS):3960

TOTAL POWER REQUIREMENT FOR CVS & LUBE

STATIONS PER DAY (KWH) CVS + MB + LS: 38808

ACTUAL POWER CONSUMED PER DAY (KWH)

(80% OF TOTAL CAPACITY)31050

CLOSED VENTILATION SYSTEM

AREA

NO. OF

MOTORS

IN USE

CAPACITY

OF THE

MOTOR

(KW)

TOTAL

POWER

(KW)

TOTAL

UNITS

/DAY

(KWH)

CV-1 3 160 480 11520

CV-2 3 160 480 11520

CV-3 - - - -

TATAL POWER CONSUMED BY CVS: 23040

MAKE UP BLOWER

AREA

NO.

BLOWERS

AVAILBLE

CAPCITY

OF THE

BLOWER

(KW)

TOTAL

POWER

(KW)

TOTAL

UNITS /

DAY

(KWH)

CV-1 1 4 4 96

CV-2 1 4 4 96

CV-3 - - - -

TOATL POWER CONSUMED BY MAKE UP

BLOWERS (MB):192

LUBE OIL STATION

AREA

NO. OF

PUMPS IN

USE

MOTOR

CAPACITY

(KW)

TOTAL

POWER

(KW)

TOTAL

UNITS /

DAY

(KWH)

2/1 (RMT) 1 55 55 1320

2/2 (IMT) 1 55 55 1320

2/3 (FMT) - - - -

TOATAL POWER CONSUMED BY LUBE

STATIONS (LS):2640

TOTAL POWER REQUIREMENT FOR CVS & LUBE

STATIONS PER DAY (KWH) CVS + MB + LS:25872

ACTUAL POWER CONSUMED PER DAY (KWH)

(80% OF TOTAL CAPACITY)20700

TOTAL POWER SAVING PER YEAR = 10350 X 34 = 351900KWH

TOTAL MONITORY BENEFIT PER YEAR = 351900 X 6.80 = Rs. 23,92,920/-

BEFORE AFTERTable 9.1 :

Renewable Energy Utilization

RINL commissioned

5 MW Solar Power

Plant

Investment: Rs 36 cr

Installing 1MW Roof Top

Solar Power Plant at

various Building

33

Utilization of Waste

Type of Waste

Material used

Quantity of

waste

material used

(Tons or any

other eqvt

Unit)

Equivalent of

Conventional energy

used (kWh of

electricity or Tons of

Coking Coal)

Gcal

Waste fuel

as % of total

energy

Coke Dust 639 607 4311

24.02%

LD Slag 57851 8148 57851

Met Waste 368584 25957 184292

Tar sludge 2735 2735 19419

Benzol muck 329 329 2336

ASP sludge 254 254 1803

BF gas 8170050 910213 6462510

LD gas 436570 106314 754830

Coke dust(sold) 68673 7496 53222

Granulated Slag 2349984 354153 2514483

34

GHG Inventorisation

25

Emission Details

Scope 1 Direct emissions from site chimneys

determined from straight carbon

balance

Scope

1.1

Direct emissions of exported by-

product gas

Scope 2 Upstream emissions of electricity and

steam from site.

Scope 3 Other upstream emissions by-

products from site

Scope 1 Scope1.1 Scope2 Scope 3

Total

CO2(t

CO2/TCS)

92,80,912 33,55,388 5,44,242 -7,96,134 2.618

As per ISO:14064:-

2.787 2.785

2.618

2015-16 2016-17 2017-18

GHG Emissions-tCO2/tCS

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).

• Increasing Transportation of Steel Products and By products

through Rail (% loading by rail increased from 41% in 2016-17 to

57% in 2017-18).

• Receiving Raw Material (Coking coal) from Ganagavaram Port

instead of Vizag Port.

• 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)

35

Green Purchasing Policy

31

• Procurement of Circulation fan(3000KW) for

Sinter Heat Recovery Plant

• Star labeled Energy Efficient Air Conditioners

• Energy Efficient Motors

Year ENCON Investment as % of

Turnover

2018-19 0.8%

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.

26

Monitoring Format

Energy

Conservation

CellDET

DGM(EMD)I/c Daily

GM (E&U) Weekly

ED (W) Monthly

D (O) Bi-Monthly

27

Energy Management System ISO:50001

28

• Features:

❑ Identification of significant energyaspects

❑ Developing Energy Managementprogrammes.

❑ Operational control of identifiedenergy aspects

❑ Monitoring and Measurement

❑ Internal Audit

❑ Management Review

RINL implemented BS EN: 16001Energy Management systems at VSPwork division and certified in Dec,2010.

First PSU & Integrated Steel Plant to becertified for BS EN: 16001 energymanagement system

Certified for ISO: 50001 in Aug’12

Completed 2nd recertification in Dec’16

Implementation of Corrective/Preventive actions

29

Energy Management System ISO:50001

30

• Plant has taken up Energy Objectives and Energy Management Action

plans(710 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

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18

94 89 90 89 89 85 85 89

Environmental Projects & Projects linking with Carbon

Emission Reduction

Projects Benefits

Revamping of Burden handling & Cast House FE

system of Blast Furnace-1.

Reduce Dust emissions

Balacheruvu, Waste Water Treatment Plant -

Commissioned in July 2014.

253 Million Gallons

Commissioning of Appikonda Waste Water Treatment

Plant

220 Million Gallons

The Digital display board at Main Gate was

inaugurated by CMD on 5th June 2014 for displaying

the CAAQM and Stack analyzers.

Awareness

Dry Fog Dust Suppression System (DSS) in

Expansion area of Raw Material Handling Plant, Sinter

Plant & Blast Furnace.

Reduced fugitive emissions

Rain water harvesting scheme near 18 MLD plant Ground water recharging

22

Sl No Name of Energy Conservation Activity Year

1Power Generation from Gas Expansion Turbine station of BF-1

2018-19

2Pulverized Coal Injection in Blast Furnace-3(upt o 150 kg/tHM)

2018-19

3 Revamping of Sinter Machines 2 2018-19

4Revamping of Billet Mill Reheating furnaces (Two

Furnaces with Regenerative Burners)2018-19

Energy Conservation Projects identified for next three

years

21

No of Projects Registered(BF3 TRT**,COB4 , BF3 WHR, BF gas based CPP-2)

4

Verification completed (COB4)* 1

*UNFCCC issued 70,516 CER to RINL **Verification for issuance of CER has been initiated for CDM

Project “BF3 TRT”


Emission Reduction

23

Name of ProjectsRegistration

NumberExpected

CERS

BF3 Top Pressure Recovery Project 9613 60410

COB-4 Turbine at Battery-4 9988 68540

Waste Heat Recovery from Stoves of BF-3

10024 44932

120 MW Waste Gas Based Captive Power Plant

Under Registration

602433


Emission Reduction

24

Energy Monitoring Format

32

• 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

Adoption of Green Technologies

Name of Technology FeaturesEnergy

Savings(TOE)

GHG

redn(tCo2)

Coke Dry Quenching

Plant Power gen: 2X7.5MW 115285 689586

Top Pressure

Recovery Turbine Power gen; 2x12 MW 21257 127152

LD Gas Recovery

System 80000 Cum 58022 347060

Evaporative Cooling

System 13 ata steam: 19 t/hr 12173 72814

Preheating of

combustion air at

CRMP

Air preheating:

250degc3469 21062

Gas and air

recuperators in

ROLLING MILLS

Air : 450 degC

Gas:250 degC16105 57088

Reducing GHG emission by about 13 lakh tons annually

36

Adoption of Energy Efficient Technologies-Unique

Features of RINL

Name of Technology Level of

Diffusion

Coke Dry Quenching

Plant

First Time in

India(1990)

13.5%

Top Pressure Recovery

Turbine

First Time In

India(1993)

13.9%

LD Gas Recovery System First Time in

India(1991-93)

50%

Evaporative Cooling

System

First Time in

India(1993)

25%

Sinter Cooler Waste Heat

Recovery(Power Gen)

First Time in

India(2014)

5%

37

Thank you

राष्ट्र ीय इस्पात निगम निनम डे RASHTRIYA ISPAT NIGAM LIMITED

Energy Efficiency at VSP · Conclusion 1. Rashtriya Ispat Nigam Limited Eastern Investment Limited Bisra Stone Lime Co. Ltd. (BSLC) Visakhapatnam Steel Plant Orissa Mineral Development

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