Energy Efficiency Tata Steel Ltd.(I) · Energy Efficiency Tata Steel Ltd.(I) Rajeev Kumar Chittrey Tata Steel Ltd. 04-03-2016 . 2 . 3 Tata Steel group is among the top global steel

CS&P (Cost Research and Standard Costing)

Energy Efficiency

Tata Steel Ltd.(I)

Rajeev Kumar Chittrey

Tata Steel Ltd. 04-03-2016

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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

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

Profile - Tata Steel Ltd.

Odisha

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Energy Policy

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6.1256.006

6.088 6.0836.017 6.012

5.780

5.280

5

5.5

6

6.5

FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20

Specific Energy Consumption - Gcal/tcs

6.566.86

7.13

8.13

9.15 9.339.90

11.00

5

7

9

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FY-10 FY-11 FY-12 FY-13 FY-14 FY-15 FY-16( E) FY-20

Crude Steel Production - mt

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Implementation of

best practices

(FY’04 – FY’07)

Adopting best available

technologies

(FY’08- FY’12)

New and emerging

technologies

(FY’13- FY’16)

• Utilization of by product gases for Steam & Power generation,

• Phasing out old and energy inefficient Units,

• Enhancing by product gas recovery and optimization of operating practices.

• Regular Energy Audit & implementation of its recommendations.

• Coal injection at Blast Furnaces

• Adoption of 100% continuous casting

• Waste heat recovery from waste gas of Blast Furnace stoves.

• Installation of Top Recovery Turbine,

• Use of Regenerative Burners at Hot Strip Mill for maximizing fuel efficiency

• Coke Dry Quenching

• Application of V/F drives.

• Upgraded Centralized Energy Management Centre.

• Large size Bl. Fces ( H& I) with higher energy efficiency.

• Thin Slab Caster and Rolling,

• Use of Pellets and shift to alternate fuel for utilizing lean by-product gases.

• Use of Solar Energy + LED lights for the street –To promote use of renewable energy in our operations

• Coal injection @ 200 kg/thm at Blast Furnaces.

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 :

Energy saving Measures taken at Tata Steel Ltd.(I)

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Energy Input to Steel (FY15)

Energy Sold

or Stock

3.664 MGCal

Steel Works

Total Energy Input

59.582 MGCal

Net Energy Usage = 55.918 MGCal

Petro-Fuel

(6688 kL)

Purchase Power

(2753 M kWh) Oxygen

(1255 MCum)

Water

(49.6 Mcum)

50.30 MGCal 6.607 MGCal 2.021 MGCal 0.025MGCal 0.061 MGCal 0.061 MGCal

Propane

(5297 T)

0.003 MGCal

HP Nitrogen

(941 MCum)

Purchase Pellet

(445 kT)

0.223 MGCal 0.282MGCal

Steam

(3972 T) Coal and Coke

(7.650 MT)

MGCal: Million Gega Calorie

Energy Bill

Approx. 8300 Rs Cr

Ore based integrated Iron and Steel

making processes are highly energy

intensive.

It contributes to approximately 40% of

the works saleable steel cost.

85% energy consumption is in the

form of coal/coke. Coal + Coke

85.39%

Power 10.09%

Ind. Gases 4.32%

Petroleum 0.20%

Energy Input-%

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

9

571

584 589

578

569

FY'11 FY'12 FY'13 FY'14 FY'15

Combined Blast Furnace Fuel Rate (kg/thm)

356 351

416 408 406

FY'11 FY'12 FY'13 FY'14 FY'15

Plant Sp. Power Consumption (KWh/tss)

Performance (FY15)

16.01

11.98 14.75

23.45 25.34

FY'11 FY'12 FY'13 FY'14 FY'15

Power generation through TRT ( MW)

6.006

6.088 6.083

6.017 6.012

FY'11 FY'12 FY'13 FY'14 FY'15

Plant Sp. Energy Consumption (Gcal/tcs)

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5.915 5.780 5.700 5.650 5.410 5.280 5.200 5.200

0.000

1.000

2.000

3.000

4.000

5.000

6.000

7.000

FY16 ABP FY16 (E ) FY17 FY18 FY19 FY20 FY21 BM( Norm)TSL

Projects in

progress

Reduction in

SEC 0.550

Gcal/tcs

1 Power generation from CDQ (Batt 10 & 11)

2 TRT at F Blast Furnaces

3 Waste heat recovery from Sinter Plant 3 & 4

4 Duel Fuel Burner system in Pellet Plant

5 New LD Gas Holder for recovery from LD-2

6 Methane from By product gases

7 Additional power generation from 25 MW at Power House # 4

8 Waste to energy (Plasma Gasification)

9 Power generation from additional BF gas

Long Term Plan-Specific Energy Consumption-Gcal/tcs

Power gen from CDQ ( Batt# 10& 11)

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Thank You

Category Title of Technology

Sintering

1 Sinter Plant Heat Recovery(Steam Recovery from Sinter Cooler Waste Heat)

2 Sinter Plant Heat Recovery(Power Generation from Sinter Cooler Waste Heat)

3 High Efficient (COG) Burner in Ignition Furnace for Sinter Plant

Coke Making 4 Coke Dry Quenching ( CDQ)

5 Coal Moisture Control ( CMC)

Iron Making

6 Top Pressure Recovery Turbine ( TRT)

7 Pulverized Coal Injection (PCI) System

8 Hot Stove Waste Heat Recovery

Steel Making

9 Converter Gas Recovery Device

10 Converter Gas Sensible Heat Recovery Device

11 Ecological and Economical Arc Furnace

12 Waste Heat Recovery from EAF

Recycling and

Waste Reduction 13 Rotary Hearth Furnace Dust Recycling System

Common

Systems

14 Inverter (VVVF; Variable Voltage Variable Frequency)Drive for Motors

15 Regenerative Burner Total System for reheating furnace

General Energy

Savings and

Environmental

Measures

16 Energy Monitoring and Management Systems

17 Cogeneration (include Gas Turbine Combined Cycle (GTCC)

18 Management of Compressed Air Delivery Pressure Optimization

19 Power Recovery by Installation of Steam Turbine in Steam Pressure Reducing Line

Recommended Customized List of Energy Saving Technologies

in Indian Steel Industries

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Thank You

End

of

Presentation