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Iron and Steel

Production of iron and steel is an energy intensive processes. At present, the specific energy consumption of large integrated Indian steel plants is 6.5–7.0 Gcal/ ton of crude steel as against the international norm of 4.5–5.5 Gcal/ton.
Specific energy consumption varies from 0.0527 to 1.907 toe/t for the 67 designated consumers. By the end of the first PAT cycle, the energy savings of 1.486 million ton of oil equivalent /year is expected to be achieved, which is around 22% of total national energy saving targets assessed under PAT.

This section contains best practice in energy efficiency adopted by some progressive and proactive Iron and Steel industry in India. The case studies from KEP launch workshop, National Energy Conservation Awards, NECA, 2012-2013 are presented here.

Resource Name: Best Practices adopted by TATA Sponge Iron Limited

Abstract: The resource presents benefits achieved by replacing of impeller of Kiln #2 ID fan motor (3.3 KV, 260 kW motor), replacing of under loaded LT motors with correct size motors of DE system of Kiln-1 & Kiln-3, VFDs for pump motors running in throttled condition, different VFD panels for odd & event set of SAB motors of Kiln-1, delta to star connection for cooling tower motors ( 2x 15 kW) of Kiln #1 and lighting control through timers.

Published by: Presented by Sh. Bijay Kumar Agrawal, Head – Electrical Maintenance  in the Sector level workshop for Iron & Steel sector

Resource: Best practices presentation by TATA Sponge

 

Resource Name: Best Practices adopted by Jindal Steel and Power Limited, Angul

Abstract: The resource presents benefits achieved by modifications in DMCW pump at the power plant facility, raw water pumps, and makeup water pumps, which led to an annual monetary savings of Rs. 40.78 lakhs, Rs. 30.72 lakhs and Rs. 39.85 lakhs respectively.

Published by: Presented by Sh. Jay Prakash Choudhary, Energy Manager , in the Sector level workshop for Iron & Steel sector

Resource: Best practices presentation by JSPL, Angul

 

Resource Name: Best Practices adopted by Tata Steel Works, Jamshedpur

Abstract: The resource presents benefits achieved by installing thin slab caster and rolling, use of pellets and shift to alternate fuel for utilizing lean by-product gases, using solar energy & LED lights for the street and coal injection @ 200 kg/thm at blast furnaces.

Published by: Presented by Sh. Rajiv K. Chittrey, Senior Manager, Fuel Management Department, in the Sector level workshop for Iron & Steel sector

Resource: Best practices presentation by Tata Steel Works

 

Resource Name: Best Practices adopted by Nalwa Steel and Power Limited

Abstract: The resource presents benefits achieved by installing Iron Ore wet screening plant, installing Deshelar system, use of pellet, segregation of injection coal size, use of imported coal in DRI, and implementation of effective techniques in DRI.

Published by: Presented by Sh. Vishal Vashishtha, Energy Manager and Sh. Debasis Roy, Manager-DRI, in the Sector level workshop for Iron & Steel sector

Resource: Best practices presentation by Nalwa Steel and Power Limited

 

Resource Name: Best Practices adopted by SMC POWER Generation Limited

Abstract: The resource presents benefits achieved by installing online Hot Billet Charging through high speed conveyor, HMI PLC automation for Hot billet shifter to reduce reject of Billets, installing Hot Billet counter and installing water flow meter for accurate water measurement in rolling mill.

Published by: Presented by Sh. S. K. Singh, Manager-Instruments, in the Sector level workshop for Iron & Steel sector

Resource: Best practices presentation by SMC POWER Generation Limited

 

Resource Name: Best Practices adopted by Usha Martin Limited (Usha Alloys & Steels Division)

Abstract: The resource presents benefits achieved in electrical arc furnace by introducing innovation which led to monetary saving of Rs. 746/MT.

Published by: Presented by Sh. Bidhan Mandal, Assistant Manager and Sh. Yogesh Mhatre, Assistant Manager (E & A), in the Sector level workshop for Iron & Steel sector

Resource: Best practices presentation by Usha Martin Limited (Usha Alloys & Steels Division)

 

Resource Name: Best Practices adopted by JSW Steel, Dolvi works

Abstract: The resource presents benefits achieved by  using coke oven in sponge iron plant which led to an annual savings of Rs. 98 crores.

Published by: Presented by Sh. V. V. Gokhale, Senior Manager and Sh. Yogesh Mhatre, Assistant Manager (E & A), in the Sector level workshop for Iron & Steel sector

Resource:Best Practice presentation by JSW Steel, Dolvi works

 

Resource Name: Best Practices adopted by M/s. BMM Ispat Limited

Abstract: The resource presents benefits achieved by  introducing pre-heating technology, bag-filter dust injection system into ABC and modifications in operation of ID fan.

Published by: Presented by Sh. Y. Bhaskar Rao, Deputy Manager, in the Sector level workshop for Iron & Steel sector

Resource:Best Practice presentation by BMM Ispat limited

 

Resource Name: Best Practices adopted by Jindal Steel and Power Limited, Raigarh

Abstract: The resource presents benefits achieved by modifications in steam traps & steam systems, blast furnace pressure recovery turbine and efficient lighting systems.

Published by: Presented by Sh. Kumar Rohit, Manager, in the Sector level workshop for Iron & Steel sector

Resource:Best Practice presentation by JSPL, Raigarh

 

Resource Name: Best Practices adopted by Godawari Power and Ispat Limited

Abstract: The resource presents benefits achieved by modifications in fuel feeding systems, old screw conveying systems, modifications in FAD systems, and innovative strategies adopted in sponge iron making.

Published by: Presented by Sh. Ratnadeep Gupta, AGM, in the Sector level workshop for Iron & Steel sector

Resource:Best Practice presentation by GPIL

 

Resource Name: Best Practices adopted to achieve Energy Efficiency, JSPL, Raigarh

Abstract: Best Practices Adopted to Achieve Energy Efficiency, The case study presents various energy eficincy technology interventions and processes adopted by JSPL Raigarh. The highlighting interventions are blast furnace pressure recovery turbine, waste heat recovery from blas furnace stoves, hot blast rtemperature increase by coating inner surface of the tuyers with ceramic, use of VVFD for heavy electrical loads, optimization of compressed air use, leakage arrests, use of regenrative burners, reduction in blast furnace fas flaring. The manufacturing facility is in process of ISO 50001:2011 implementation.

Published by: Presented by Sh. Kumar Rohit and Sh. Sudhanshu Rometra, JSPL, Raigarh, in the KEP launch workshop

Resource:Best Practice Case Study-IIP-Jindal_-Raigarg-KEP03-08

Resource Name: Best Practices in Energy Efficiency- JSW Steels Limited, Dolvi

Abstract: This resource highlights the specific energy consumption of different sub processes of the manufacturing unit. The major technology interventions are installation of BF gas fired captive power plant, utilization of Coke Oven Gas for process heating, increasing the DRI metallization, utilization of coke oven gas in DRI production.

Published by: Presented by Sh. Pradeep Agarwal, JSW, in KEP launch workshop

Resource: Best Practice Case Study-IIP-JSW_KEP03-09

Resource Name: Best Practice Case Study- Bhushan Steels Limited

Abstract: Energy Conservation Measures adopted by Bhushan Steels. The resource highlights major technology interventions carried out at bhushan steels in thye period 2011-2015. The major interventions are, intallation od a condensqate recovery system, use of VVFD drives, solenoid vallve for automatic compressed air blow for thr tube mill, use of solar water heating, Use of FRP blades, improvement in combustion efficiency of the gas fired boiler, energy efficient pumps, process load optimization, muli effect evaporator, power factor corrections, rain water harvesting.

Published by: Presented by Bhushan Steel Limited in KEP launch workshop.

Resource: Best-practices-case-study-Bhushan-Steels-Limited-KEP03-10