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Slide No. 3
Energy Mix of Tata Steel Jamshedpur FY’18
Coal & Coke Pur. Power Pur. Pellet Pur. Oxygen Pur Nitrogen Petro-Fuel Water Propane
7.517 MT 2638 GWh 105457 T 6 3
1458x10 m 919 x 10 m 6 3 5435 KL 6
40 x 10 m 3 3700 T
(50.30MGcal) (6.33 MGcal) (0.053 MGcal) (2.41 MGcal) (0.44 MGcal) (0.05 MGcal) (0.02 MGcal) (0.04 MGcal)
Steel Works
Energy Input =59.64 MGcal
Energy Sold
or to Stock Cost of Energy
2.72 MGcal Rs. 2060 per Gcal
Slide No. 4
Energy Consumption
FY 15 Target for SEC under PAT was 6.070 GCal/tcs. TSL achieved 5.960 GCal/tcs;
BEE, MOP awarded 40,188 numbers ESCerts.
BEE: Bureau of Energy Efficiency; PAT: Perform, Achieve and Trade; WSA: World Steel Association;
BM: Benchmark; SEC: Specific Energy Consumption
Slide No. 5
Energy Consumption –comparison with competitors
Source: Feedback report of POJ team of “Prime Minister’s Trophy Award for Best Integrated Steel
Plant 2015-16”, CHAPTER 2 15-16.pdf
Slide No. 6
Benchmark Study – Gap Analysis
WSA data is derived taking various factors related to all the global steel plants.
A few of the factors are not applicable to Indian steel plants. Hence, to arrive at most
authentic BM figure a like to like comparison was done as shown below:
WSA data is derived taking various factors related to all the global steel plants. A few
of the factors are not applicable to Indian Steel Plants. Hence, to arrive at most
authentic BM figure a like to like comparison was done as shown below:
Slide No. 8
Roadmap to achieved Benchmark (unit in Gcal/tcs)
A B C
Thermal Energy Input vs Waste Waste Energy Available vs Opportunity for Waste Heat
Heat Recovery Recovery
A B C D B E F G G H I J
Slide No. 10
Energy Saving Projects Implemented (2015-16) – selected few
Slide No. 11
Energy Saving Projects Implemented (2016-17) – selected few
Project Description Electricity Coal Gas Savings Investment
(Lakhs Kwh) (tons) (Lakhs Nm3) (Rs. L) (Rs. Lakhs)
Auxiliary power reduction at LD#3
27 102 191
installing VFD.
Elimination of WP Booster house by 92,400
572 248
modifying coke oven gas n/w (Steam)
Optimizing charging system & suction
70 268 Nil
at SP3 to reduce power
Logic modification to reduce O2 vent 7,920
158 Nil
loss at LD shops (O2)
Increase power generation at PH3 by
144 549 14
reducing COG vent loss.
Exhaust steam heat recovery for pre- 21,900
382 77
heating of Ammonia Still. (Steam)
Optimization of damper opening of
9.87 38 Nil
fume extraction system at Bl. Fce
Reduction in coal tar consumption at 6698
1,138 5.0
Pellet plant. (Coal Tar)
TOTAL 3,208 535
Slide No. 12
Energy Saving Projects Implemented (2017-18) – selected few
Project Title Increase in LD gas recovery at LD1 & LD3 Savings Rs 16 crores/yr
Problem There is potential to increase LD gas recovery at LD1 & LD3 from 40,000Nm3/hr
Statement to 60,000 Nm3/hr, which can be utilized to increase power generation
Action Taken
• Logic modification to recovery of gas during
Dump Tank
parallel blow. LD#1
Flare Stack
Water Seal
To Consumers
• TBM & DM to reduce analyzer fault
ESP
4
Booster 4
Slide No. 14
Innovative Projects implemented in the 3 years
Project Title Increase Coke Oven gas utilization at Pellet Plant Savings Rs 11 crores/yr
Problem Coke Oven gas & Coal Tar is used as fuel in Induration machine of Pellet Plant.
Statement While both are by-product fuel, Coal Tar can stored & sold.
Action Taken Incoming COG Line DN 800
DN 400
A new gas line was laid to increase supply of CO DN 300
gas to Pellet Plant boosters there by reducing
the use of Coal Tar and utilizing the excess CO B1 B2
gas that used to be flared.
Induration
Machine
Results
Slide No. 15
Innovative Projects implemented in the 3 years
Project Title Utilize cold blast loss through snort valve Savings Rs 4 crores/yr
Problem Due to cold blast O2 enrichment, cold blast demand at Bl Fce. has reduced
Statement resulting in air at 5 bar vented @ 40,000 Nm3/hr through the snort valve.
Action Taken Utilize the extra cold blast at Blast Furnace to reduce the moisture of the coke.
Surge Line
Pressure
Operating Line
Flow
Slide No. 16
Utilization of Renewable Energy Source
Naphth. Scrubber
Naphthalene is 0C preheated up
Naphthalene Still
to 150 0C
separated
absorbed in wash oil
Lean Oil
Rich Oil
30-350C
Rich Oil
Increased
Coke oven
Preheater up to 170 -
gas
175 0C
Wash oil
Storage
Makeup wash
oil
Spent wash Cooler
oil Regenerator
Storage Temperature is
tank for maintained at 160
spent 0C (range 150-180
Polymerized
Oil
Slide No. 19
Utilization of waste material as fuel – project 2
We failed to get the desired result; trying to
Plasma Gasification – waste to energy explore in consultation with subject experts
Highlights
• Any steel plant waste (wood, plastic, rubber,
cable, electrical waste, oil soaked cotton, oil
sludge etc.) can be handled
• Plasma gasification process converts the waste
into Syngas
• Also, vitrified slag is generated which can be used
1.0 TPD Pilot plant at TSL, JSR Works
as land filling.
Slide No. 20
CO2 Emission Intensity
8.4 MW 26%
LCI Drive- Reduction
3.12 SP3
2 x 21.5 MW
over Last 13
3.11 8.4 MW LCI Drives- years
LCI Drive- Blowers I BF: TRT, Stove WHR,
SP4 E.Blower + LCI drive, INBA
2.85 H BF TRT & Granulation
Stove WHR Pellet Plant, TSCR
in H BF
2.65 CDQ in
Higher Gas
Batt.5,6 & recovery,
Conversion of 2.66
Coal Fired 2.51 7 2.53 Higher BF Coal
injection
2.47
Boilers
to Gas Firing 2.50 2.50 2.47
2 x 4 MW
VFD – SP1 2.40 2.29
TRT in G
BF
3 MTPA 2.30
RHF3/HSM Expansion
- HiTAC
BF
Optimisation
Unit in Ton of CO2 per ton of crude
FY-05FY-06FY-07FY-08FY-09FY-10FY-11FY-12FY-13FY-14FY-15FY-16FY-17FY-18
TSJ expected to continue as Indian Steel sector (BF-BOF) Benchmark in CO2
TSJ: Tata Steel, Jamshedpur BP: Best Practice WSA: World Steel Association IJM: Tata Steel,Ijmuiden
Slide No. 21
CO2 Emission–comparison with competitors
Source: Feedback report of POJ team of “Prime Minister’s Trophy Award for Best Integrated Steel
Plant 2015-16”, CHAPTER 2 15-16.pdf
Slide No. 22
CO2 Emission–reaching < 2 t/tcs
Slide No. 23
GHG Management Systems Program
Slide No. 24
GHG Management Systems Program
Process: Information Flow
Source Analysis & Reporting Stakeholders Usage
• Performance Recording
SAP • Tracking & Review
All Divisions /
i-Monitor Departments of • Process control
Environment Steel Works
Accounts Management • Planning & Target setting
FMD CS&P, BOSS (ABP & LTP – BO&S)
WS
IBMD R&D, Technology • Benchmarking & Gap
MoniCA Analysis
ET&D TQM, KM, CC
• Analysts’ input
Travels GHG Tools External
• Responsible Advocacy
Publications &
CSD Disclosures • Setting directional inputs
(Vision & Goals)
Admin: Group Environment
Server: IJmuiden, Netherland (MLE)
Slide No. 25
GREEN SUPPLY CHAIN
Governance structure
Chief
GM/EIC/CoMs
BPE-O
Implementatio Central
PMO Shikhar25 Project
n Tracking Analytics BAG
Facilitators Champion Team
Group team
3-4 Persons 1 per IMPACT Centre 4-5 people team 1 per war room Part time Part time
(Full time)
Slide No. 28
GREEN SUPPLY CHAIN
224
279
65
14
1-Aug 9-Aug
FY16 FY17 FY18 Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
Slide No. 29
GREEN SUPPLY CHAIN
↑ Recovery & ↓
Increase In-house Power Reduce Power Consumption of Liquid Renewable & non- Export Energy &
Generation Consumption Conventional Power Commercial Levers
& Gaseous Energy
Foundations
Promote energy efficiency through Collaboration with Building Capability for Energy
18
17 employee engagement by creating Internal & External 19 Integration across value chain
awareness (JDCs, organizing Stakeholders through digital initiative
Seminar, Online campaign etc)
Slide No. 30
Team Work, Employee Involvement & Energy Monitoring
Energy Efficiency Awareness Campaign thr0ugh JDC Development of energy champions across the organization
Session by Experts from Japan Energy Course in Collaboration with Tata Steel, Europe
Slide No. 31
Team work, Employee Involvement & Monitoring
Recognition by CEO & MD to top ideas of online campaign Participation of employees from all department
Slide No. 32
Team work, Employee Involvement & Monitoring
Slide No. 33
Implementation of Green Co/IGBC rating
Slide No. 34
Energy saving customized Technologies for Steel Industry
Adoption Adoption
Technology in TSL
Technology
in TSL
Sinter Cooler Waste Heat Recovery BOF Gas Recovery Device
(diffusion rate 34%) (diffusion rate 63%)
High Efficient Burner at Sinter Plant BOF gas sensible heat recovery device
(diffusion rate 45%) (diffusion rate – no data)
Coke Dry Quenching (CDQ) Ecological & Economical Arc Furnace
(diffusion rate 35%) (diffusion rate 0%)
Coal Moisture Control (CMC) Waste Heat Recovery from EAF
(diffusion rate 10%) (diffusion rate 0%)
Inverter VVVF Drive for motor Rotary Hearth Fce Dust Recycling Sys.
(diffusion rate – no data) (diffusion rate – no data)
Regenerative Burner for reheating fce Energy Monitoring &Mgt. system
(diffusion rate 0%) (diffusion rate – no data)
Top Pressure Recovery Turbine (TRT) Cogeneration (GTCC)
(diffusion rate 28%) (diffusion rate – no data)
Pulverized Coal Injection (PCI) System Compressed Air Pressure Optimization
(diffusion rate 65%) (diffusion rate – no data)
Hot Stove Waste Heat Recovery Power by Steam Turbine in PSR
(diffusion rate 255%) (diffusion rate – no data)
Implemented Under Implementation Not Implementation Not Applicable
Diffusion rate (%) - Technology adopted in 7 major Indian Steel Companies of India
Source : Published during Indo-Japan Collaboration Initiative
Slide No. 35
Way Forward – effieient & emerging technologies
Top gas
GCP
Gas
Networ
Package k
F-BF TRT
2.73 MW
Low Heat Recovery using OCR Technology Micro Turbine to reduce losses in PRDS
LP
Steam
Header 4 kg/cm2,
280 Deg
PRD @12 TPH
De-Aerator
15 S
kg/cm2
320 Deg
@12
TPH ~
Back Pressure 700 kw
Turbo
Generator
• Ability to recover energy from low • Loss thro’ PRDS can be utilized to generate
temperature source power with help of Micro Turbine.
• Adaptive control system & sophisticated • Micro Turbine will provide required quality
diagnostic of steam & will generate power
• Investment is Rs. 28 cr for 1.2 MW Power
Slide No. 37
Way Forward – effieient & emerging technologies
Vapor Absorption Machine to Recover Waste Heat from Boiler Blow Down Water
4th Boiler VAM 100
DCS TR Cooling
Building Tower
Hot Water
Tank
CHW Hot Water Pump
P
1W+1S
Chilled water inlet 12⁰C Blow Down Cooling
Ø100mm Tank Boiler # 4 Water
Pump
Hot Water Line
PRDS # 2
Methane
Generation Present
Methane To
Facility Storage
@ 1100 Nm3/hr SCM
Tank
(93% recovered)
Steam @0.72 TPH, 30 Bar-
for use in process Potential saving through propane
replacement is Rs. 15 cr/yr at an
investment of Rs. 48 cr.
Slide No. 39
Any other relevant information
Slide No. 40
Thank you