ENERGY EFFFICIENCY OPPORTUNITIES

IN
STEEL RE-ROLLING INDUSTRY

By : Nitendra Dewangan
Mail : devangann@pcra.org
Mobile : 9406122508

AN INTEGRATED ENERGY SOLUTION PROVIDER

www.pcra.org
Thermal Energy Saving Opportunities
In
Steel Rerolling Industries

AN INTEGRATED ENERGY SOLUTION PROVIDER

www.pcra.org
 COST BREAK UP FOR REROLLING
INDUSTRIES – OIL UNIT
BURNING LOSS
19% OIL
LABOUR 43%
10%

SALARY
5%
CONSUMABLES
5% ELECT
18%
 COST BREAK UP FOR REROLLING
INDUSTRIES – COAL UNIT

BURNING
LOSS COAL
21% 38%
LABOUR
11%

SALARY
CONSUMABLES ELECT
5%
5% 20%
 FURNACES

What is a Furnace?

A furnace is an equipment to melt

metals for casting or heat materials for
change of shape ( rolling, forging etc)
or change of properties (heat
treatment).
 Types and classification of furnaces
Based on the method of generating heat: combustion type
(using fuels) and electric type
According Open fire place furnace
to mode of
heat transfer Heated through liquid medium

Forging

Re-rolling
Furnace According Periodical (Batch / continuous
classification to mode of pusher)
charging Continuous Pot

Glass tank
melting
(regenerative /
Mode of heat Recuperative recuperative)
recovery
Regenerative
 Characteristics of an Efficient Furnace

Furnace should be designed so that in a

given time, as much of material as
possible can be heated to an uniform
temperature as possible with the least
possible fuel and labour.
 Furnace Energy Supply

• The products of flue gases directly contact the stock,

so type of fuel chosen is of importance.
For example, some materials will not tolerate sulphur
in the fuel. Also use of solid fuels will generate
particulate matter, which will interfere the stock place
inside the furnace.
Hence, majority of the furnaces use liquid fuel,
gaseous fuel or electricity as energy input.

• Melting furnaces for steel, cast iron use electricity in

induction and arc furnaces. Non-ferrous melting
utilizes oil as fuel.
 Reheating Furnace

• Furnace oil and Coal is the major fuel used in

reheating Furnace .
• LDO is used in furnaces where presence of sulphur is
undesirable
• Furnaces operate with efficiencies as low as 7% as
against up to 90% achievable in other combustion
equipment such as boiler.
• This is because of the high temperature at which the
furnaces have to operate to meet the required demand.
For example, a furnace heating the stock to 1200oC
will have its exhaust gases leaving at least at 1200oC
resulting in a huge heat loss through the stack.
 Rerolling Mill Furnace
Batch type furnace:
•Used for heating up scrap, small
ingots and billets weighing 2 to
20 kg. for batch type rerolling.
•Charging and discharging of the
‘material’ is done manually and
the final product is in the form of
rods, strips etc.
•Operating temperature is1200
oC.
•Total cycle time can be
categorized into heat-up time and
rerolling time.
Continuous Pusher Type:
•The process flow and operating
cycles of a continuous pusher
type is the same as that of the
batch furnace.
•Operating temperature
is1250oC.
•The material or stock recovers a
part of the heat in flue gases as it
moves down the length of the
furnace.
•Heat absorption by the material
in the furnace is slow, steady and
uniform throughout the cross-
section compared with batch
type.
Continuous Steel Reheating Furnace feature
 MAJOR AREAS OF CONCERN
1. FUEL STORAGE, HANDLING AND PREPARATION
2. COMBUSTION OF FUEL AT OPTIMUM LEVEL AND CONTROL
OF EXCESS AIR
3. TEMPERATURE CONTROL AND MAINTAINING UNIFORM
TEMPERATURE.
4. EFFICIENCT WASTE HEAT RECOVERY
5. AUTOMATION OF MILL TO SPEED UP ROLLING
6. PROPER INSTRUMENTATION FOR EFFICIENT MONITORING
7. BURNING LOSS ESTIMATION AND CONTROL
8. CONTROL ON OPENING
9. TRAINING AND EDUCATION OF PERSONNEL ON BASIC
ASPECT OF ENERGY CONSERVATION.
10. ELECTRICAL ENERGY CONSERVATION
11. MORE MONITORING IN DESIGN AND INSTALLATION STAGE
12. QUALITY AND TYPE OF RAW MATERIAL AND FINISHED
PRODUCT.
13. NOS OF AVOIDABLE BREAK DURING THE DAY’S WORK
 FUEL STROAGE AND HANDLING -OIL
1. Checks on receiving for water, sludge, and
density use water finding paste and regular
sample check.
2. Water drainage facility in MST and DST
3. Arrangement of stand by tank.
4. Filtration at different stage
5. Heating in DST and Heating Pumping Unit with
temp. control system .
6. Insulation of DST and Piping after DST to
burner and return line.
7. Desired temp at burner for FO is 100 to 105 C.
GENERAL LAYOUT
STORAGE
Viscosity Temperature Relationship of
Fuels

Outflow Heating
Viscosity of furnace Temp. below Temp. at which easy Temp. for proper
oil in Redwood no. 1 which oil is not pumpability can be atomization
@ 37.8oC pumpable achieved
(100 oF)

600 SEC 4.5°C 11°C-22°C 71°C-87°C

1500 SEC 15.5°C 25°C-37°C 88°C-87°C
3000 SEC 26°C 34°C-46°C 99°C-115°C

LSHS/RFO/HPS 60°C 70°C-80°C 120°C-130°C

Service Tank
 SAVING POTENTIAL BY INSULATION OF FO LINES AND DAY TANK

SAVING POTENTIAL BY INSULATION OF FURNACE OIL LINES

SIZE OF THE FO LINE AND RETRUN LINE = 2.5 CM OR 1 INCH

TOTAL LENGTH OF THE BARE FO PIPELINE = 35 M

AVERAGE SURFACE TEMP. OF THE PIPELINE = 85 C

RUNNING HRS OF THE FURNACE PER ANNUM = 4620 HRS
TOTAL SURFACE AREA AT 85 C = 2.8 SQ M

HEAT LOSS FROM THE SURFACE AT 85 C = 550 KACL/SQ M/HR

HEAT LOSS FROM THE SURFACE AT 45 C = 200 KACL/SQ M/HR

SAVING POTENTIAL BY INSULATION = 350 KACL/SQ M/HR

TOTAL HEAT SAVING POTENTIAL = 977 KCAL/HR

EQUIVALENT ELECTRICITY SAVING POTENTIAL = 1.1 KW/HR

TOTAL KWH SAVING POTENTIAL PER ANNUM = 5,249 KWH PER ANNUM

COST OF PUCHASED POWER CONSIDERED = 5 RS/KWH

OVERALL SAVING POTENTIAL = 0.26 LACS/ANNUM

 Check List
Description Checks

Oil temperature at the burner Daily

Oil/steam leakages Daily

Cleaning of all filters Weekly

Draining of water from all tanks Weekly

Cleaning of all tanks Yearly

 FUEL STROAGE AND HANDLING –COAL
1. Proper Shed for coal storage to reduce carpet loss
and to avoid unnecessary moisture .
2. Sizing of coal - desired is 1.5” to 2”.
3. Addition of moisture only for powdered coal that
to the limited amount.1% for each 10 % of fines
of below 4mm size
4. About 5% unburned coal observed in the ash
removed from furnace due to bigger size coal and
improper bed height.
5. Firing of coal at desired frequency and quantity to
utilize the combustion air all the time
6. Avoid the stoppage of mill for ash removal by
proper bed maintenance and by additional
manpower and by better design of fire pit.
 COAL SIZES FOR DIFFERENT
FIRING
S. No. Types of Firing System Size (in mm)
1. Hand Firing
(a) Natural draft 25-75
(b) Forced draft 25-40
2. Stoker Firing
(a) Chain grate
i) Natural draft 25-40
ii) Forced draft 15-25
(b) Spreader Stoker 15-25
3. Pulverized Fuel Fired 75% below 75
micron*
4 Fluidized bed boiler < 10 mm
 FLOW OF HEAT IN FURNACE
• 1. STOCK
• 2. CRACKS AND OPENING
• 3. GROUND AND SURROUNDINGS
• 4. HEARTH
• 5. DOORS
• 6.PORTION OF STOCK PROTRUDING OUTSIDE
• 7. STACK
• 8. TO COOLING MEDIUM
 Heat Transfer in Furnaces
•Radiation from the
flame,hot combustion
products and the
furnace walls and
roof;
•Convection due to
the movement of hot
gases over the stock
surface.
Figure 4.3 : Heat Transfer in furnace
 ENERGY CONSERVATION IN FURNACES
Radiation
(Flame radiation is function of :
• Composition of fuel
• Fuel to air ratio
• Temp. of fuel and air
• Rate of mixing of fuel & air
• Thickness of flame
• Distance from burner

Variation of Heat Transfer by Radiation &

Convection
% Heat Transfer 1250 C 900 C 400 C
By radiation 70 24.7 3.6
By Convection 30 75.3 96.4
 HEAT FLOW IN REHEATING FURNACE
ACHIEVABLE – 40 %

IN PRACTICE – 20 TO 25%
42 TO 45 %

IN FLUE GAS
FLUE GAS

MOISTURE
9.28 %
DRY

HEAT INPUT HEAT OUT PUT

100% 20 TO 25 %

UNACCOUN
RADIATION
OPOENING

TABLE
LOSSES
LOSSES

10 %
2.7%
9%
Performance Evaluation of a
Typical Furnace

Figure 4.10 Heat losses in industrial heating Furnaces

 What are the furnace losses ?
Material handling loss
Cooling media losses

Wall Loss:
Radiation (opening) loss

Wall losses:

Figure 4.12. Radiation loss

Stack loss (Waste-gas loss)

Air infiltration
Stored Heat Loss:
Figure 4.11 wall losses

Figure 4.13. Air infiltration from furnace opening.

Furnace Efficiency (Direct Method)
Furnace Efficiency (Direct Method)

Fuel input = 400 litres / hr

= 368 kg/hr
Heat Input =368x10,000=3680000 kCal
Heat output = m x Cp x Δ T
= 6000 kg x 0.12 x (1340 – 40)
= 936000 kCal
Efficiency = Output x 100
Input
Efficiency = 936000 x 100
3680000
= 25.43 % = 25% (app)
Losses = 75% (app)
 Furnace Efficiency (Indirect Method)

1. Sensible heat loss in flue gas = 57.29%

2. Loss due to evaporation of moisture in fuel = 1.36 %
3. Loss due to evaporation of water
formed from H2 in fuel = 9.13 %
4. Heat loss due to openings = 5.56 %
5. Heat loss through skin = 2.64%

Total losses = 75.98 %

Furnace Efficiency = 100 - 75.98

= 24.02 %

Specific Energy Consumption = 400 litre /hour (fuel consumption)

6Tonnes/hour (Wt of stock)

= 66.6 Litre of fuel /tonne of Material (stock)

General Fuel Economy Measures in
Furnaces

1) Complete combustion with minimum excess air

2) Correct heat distribution
3) Operating at the desired temperature
4) Reducing heat losses from furnace openings
5) Maintaining correct amount of furnace draught
6) Optimum capacity utilization
7) Waste heat recovery from the flue gases
8) Minimum refractory losses
9) Use of Ceramic Coatings
1) Complete Combustion with Minimum Excess Air
The amount of heat lost in the flue gases depends upon
amount of excess air. In the case of a furnace carrying
away flue gases at 900oC, % heat lost is shown in table :
Table Heat Loss in Flue Gas Based on Excess Air Level
Excess Air % of total heat in the fuel carried away
by waste gases (flue gas temp. 900oC)
25 48

50 55

75 63

100 71
 EXCESS AIR – AFFECTS AND CONTROL
1. Air – O2 – 23 % Useful , N2 – 77 % Not useful
2. All gases and extra Air ( O2 + N2 ) leaving athigh
temp .
3. 10 % extra air – 1 % fuel loss – Observed values –
300 % in coal and 110 % in Oil .
4 Other effect-
a. Reduction in flame temp.
b. Increase the burning losses.
c. Cost due to extra mass handling .
d. Increase in initial heating time .
e. Reducing the overall furnace temperature .
f. Results in non uniform heating of material .
 AIR FUEL RATIO
FUEL O2 % IN FLUE GAS

• GASEOUS FUELS 2.0

• FUEL OIL 3.5

• PULVERISED COAL 5.0

• SOLID FUEL IN BED 5.0 – 8.0

USE OF SECONDARY AIR
 CLINKER FORMATION AND AFFECTS

• Clinker is a mass of rough, hard, slag-like material formed

during combustion of coal due to low fusion temperature
of ash present in coal.
• Presence of silica, calcium oxide, magnesium oxides etc.
in ash lead to a low fusion temperature.
• Typically Indian coals contain ash fusion temperature as
low as 1100oC.
• Once clinker is formed, it has a tendency to grow. Clinker
will stick to a hot surface rather than a cold one and to a
rough surface rather than a smooth one.
SAVING POTENTIAL BY CONTROLLING THE EXCESS AIR
IN THE FURNACE DURING LOW FIRING
ANNUAL FUEL OIL CONSUMPTION = 2500 KL

% OF TOTAL FURNACE RUNNING AT LOW FIRING =

WHEN EXCESS AIR IS HIGH 25 %

AV. % OF TOTAL FUEL OIL CON. AT LOW FIRING

WHEN EXCESS AIR IS HIGH = 625 KL
* PERCENTAGE OF EXCESS AIR % DURING LOW FIRING = 50 %

* TEMP OF EXIT FLUE GAS = 450 DEG C

* AMBIENT AIR TEMP. = 40 DEG C

* AVG FUEL CONSUMPTION/HR = 411 LIT/HR

THEROTICAL AIR REQT.KG/KG OF OIL = 14.1 KG
ACTUAL AIR SUPPLIED KG/KG OF OIL = 21.15 KG

DESIRED LEVEL OF THE EXCESS AIR FOR

OPTIMUM COMBUSTION 20 %

DESIRED LEVEL OF OPTIMUM AIR = 16.92 KG/KG OF OIL

REDUCTION IN AIR SUPPLIED = 4.23 KG/KG OF OIL

SPECIFIC HEAT OF AIR = 0.24 KCAL-KG-C

REDUCTION IN HEAT LOSS DUE TO REDUCTION

IN EXCESS AIR = 416.23 KCAL / KG OF OIL
% SAVING POTENTIAL = 4.4 %

AVERAGE FUEL OIL CONSUMPTION DURING

LOW FIRING WHEN EXCESS AIR IS HIGH = 625 KL

ANNUAL FUEL OIL SAVING POTENTIAL = 27 KL

ANNUAL SAVINGS 5.13 LACS

BURNING LOSS AND CONTROL & MONITORING
1. Contribute about 20 % of total cost.
2. Factors for more burning loss
A. Extra Air than desired in side furnace
B. Over heating of material
C. Extra halt of material in furnace and in oxidizing
medium.
D. Non uniform heating of material .
E. Furnace running at negative pressure .
F. Unnecessary openings of doors .
G. Improper damper setting.
3. Control by regular estimation at site and controlling
all the factor responsible as mentioned above .
MAT. AND OIL SAVING POTENTIAL BY REDUCTION OF BURNING LOSSES

Details of Mass Balance of 8 Sample Billets

S. No. Item
1 Weight of 8 Billets before charging 481.5

4 Weigh of Finished +losses 469.8

5 Burning Losses 11.7

6 % of raw material heated 2.43

1 Average Production of the plant = 14850 Ton/year

2 Average Raw Material Charged in the furnace = 16335 Ton/year

3 Average Burning Loss = 2.43 %

4 Desired Lvel of Burning Loss = 1.8 %

5 Reduction in Burning Losses = 0.63 %

6 Saving of steel by reduction of burning losses

= 102.90 Ton/year

7 Cost of the steel ( Billets) = 19000 Rs/ton

8 Total Saving in Material = 19.55 Lacs

9 Fuel oil consumption per ton = 50 Liter/ton

10 Saving in fuel oil Consumption = 5 KL/year

11 Cost of FO = 14000 Rs/KL

12 Saving in oil = 1 Lacs

13 Total Saving Potential 20 Lacs

 2)Correct Heat Distribution
Prevent flame
impingement.
To avoid high flame
temperature,damage of
refractory and for
better atomization

Heat distribution in furnace

Align burner
properly to avoid
touching the
material
To reduce scale
loss

Alignment of burners in furnace

 3)Operating at Desired Temperature

Temperature for Different Furnaces

CORRECT
Slab Reheating furnaces 1200oC TEMPERATURE
ENSURES GOOD
Rolling Mill furnaces 1200oC QUALITY
PRODUCTS.
Bar furnace for Sheet Mill 800oC
TEMPERATURE
Bogey type annealing furnaces- 650oC -750oC HIGHER THAN
REQUIRED
WOULD ONLY
USE UP MORE
FUEL
 LOSSES DUE TO EXTRA HEATING OF THE MATERIAL
1 Average Raw Material Charged in the furnace
= 16335 Ton/year

2 Average Nos of Days Running 300 Days/Year

3 Average Raw Material Heating per Day = 54.45 Ton per Day

4 Desired temperature for the rolling = 1200 C

5 Actual temperature Maintained = 1250 C

6 Additional Heating of Material = 50 C

7 Specific heat of Steel = 0.12 Kcal/Kg/C

8 Extra Heat for extra heating per day = 326700.00 Kcal /day

9 Furnace Efficiency = 25 %

10 Additional heat supplied = 1306800 Kcal/day

11 Calorific Value of FO = 10200 Kcal/kg

12 Saving in oil = 128 kg/day

13 Saving in Oil = 119 liters/day

15 Cost of Oil 19 Rs/lit

16 Saving per day 2264 Rs per Day

17 Annual Saving 36 KL/year

7 lacs /year
 LOW TEMPERATURE OF MATERIAL
1. It’s most of the time is non uniform temp. instead low
temp.( Extreme Range observed in the same mat. From
1180 C to 1300 C )
2. Major Factors for this problem
A. Furnace Design and mismatch between capacity and actual
production.
B. Changing in production speed during the day’s operation.
C. Slow movement of hot material between stands.
D. Improper material feeding in the furnace .
E. Improper combustion
F. Use of unnecessary measures like putting extra material
layer, coating of lime solution etc
G. Improper burner alignment and operation .
H. Changing the fuel setting very frequently.
I. No temperature measuring device .
 4) Reducing Heat Loss from Furnace
Openings
Heat loss through openings consists of direct radiation and
combustion gas that leaks through openings.

Keeping the doors unnecessarily open leads to wastage of fuel

Inspection doors should not kept open during operation
Broken and damaged doors should be repaired

The heat loss from an opening can be calculated using the formula:
Q=4.88 x T 4 x a x A x H … k.Cal/hr
100
T: absolute temperature (K),
a: factor for total radiation
A: area of opening,
H: time (Hr)
 5)Maintaining correct amount of
furnace draught

Negative pressures : air infiltration- affecting air-fuel ratio control,

problems of cold metal and non-uniform metal temperatures,
Positive Pressure: Ex-filtration -Problems of leaping out of flames,
overheating of refractories,burning out of ducts etc.
 6) Optimum capacity utilization
There is a particular loading at which the furnace will operate at
maximum thermal efficiency.
Best method of loading is generally obtained by trial-noting the weight
of material put in at each charge, the time it takes to reach temperature
and the amount of fuel used.

Mismatching of furnace dimension with respect to charge and production

schedule.

Coordination between the furnace operator, production and planning

personnel is needed.
 ENERGY CONSERVATIONIN FURNACES
Loading in Furnaces

16
Consumption
14
FUEL GALLON/HR.

GALLON PER TON

12 60

10 50
S.F.C.
8
40

6
30

4
20

2
10

250 500 750 1000

STEEL THROUGHPUT (PONDS/HR.)

The ‘No Load’ consumption to maintain a simple

batch type furnace at 1300°C when empty is about
70% of that required to operate at optimum
loading rate.
WASTE HEAT RECOVERY AND MONITORING
1. Install sufficient temp. indicator to asses
the working of WHR system.
2. Insulation of recuperator and hot air line
to burner ( more than 100 C temp. drop
observed)
3. Installed well designed recuperator instead
of locally made.
4. Regular cleaning and inspection for the
puncture of tubings to be done.
7) Waste heat recovery from the flue gases

• Charge (stock) preheating,

•Preheating of combustion air,

•Utilizing waste heat for other process

WHR POTENTIAL AVAILABLE IN DIFFERENT
FURNACE OPERATION

FURNACE TYPE TEMPERATURE IN eg.C

FORGE AND BILLET HEATING 800 – 1100

ANNEALING 600 – 1100
OPEN HEARTH STEEL FURNACE 550 – 700
GLASS MELTING FURNCAE 1000 – 1300
CEREMIC KILN 700 – 1100
SOLID WASTE INCINERATORS 650-1000
ROTARY KILNS 650 -700

WASTE HEAT RECOVERY EQUIPMENT PLAYS IMPORTANT ROLE

IN WASTE HEAT RECOVERY BUT ALSO THE OPERATING
PARAMETRS OF THE FURNACE
THE HIGHER THE QUANTEM OF EXCESS AIR AND FLUE GAS
TEMPERATUR THE HIGHER WOULD BE THE WASTE HEAT
AVAILABILTY
 ENERGY CONSERVATION IN FURNACES
Waste Heat Recovery
Air pre-
heating
Flue
Gas temp

Comb. Air
temp

Sankey diagram for a furnace with recuperator

 ADVANTAGE OF HOT AIR

1. SAVING IN FUEL CONSUMPTION

2. INCREASE IN FLAME TEMPERATURE

3. IMPROVEMENT IN COMBUSTION

4. REDUCTION IN INITIAL HEATING TIME.

5. REDUCTION IN SCALE LOSSES

 CONVECTIVE TYPE
DOUBLE STAGE CROSS FLOW TYPE

COLD
HOT FLUE
FLUE
GASES
GASES

COLD HOT
COMB. COMB.
AIR AIR
 RECUPERATOR EFFICIENCY AND
SAVING POTENTIAL BY INSULATION OF HOT COMBUSTION AIR LINE

RECUPERATOR EFFICIENCY

TEMP. OF FLUE GASES AFTER FURNACE = 650 DEG C

* TEMP OF FLUE GAS AFTER RECUPERATOR = 450 DEG C

COMBUSTION AIR TEMP.AFTER RECUPERATOR = 340 DEG C

COMBUSTION AIR TEMP.BEFORE RECUPERATOR 40 DEG C

OVERALL O2 LEVEL FOR THE FURNACE = 4.4 %

* AVG FUEL CONSUMPTION/HR = 411 LIT/HR

ATMOSPHERIC AIR TEMP. 40 C

THEROTICAL AIR REQT.KG/KG OF OIL = 14.1 KG

* PERCENTAGE OF EXCESS AIR % = 26.5 %

ACTUAL AIR SUPPLIED KG/KG OF OIL = 17.8 KG PER KG OF OIL
SPECIFIC HEAT OF FLUE GASAIR = 0.25 KCAL-KG-C

TOTAL HEAT OF FLUE GAS AT ENTRY = 3061 KCAL / KG

HEAT TAKEN BY THE COMBUSTION AIR = 1284 KCAL / KG

EFFICIENCY OF THE RECUPERATOR = 42.0 %

SAVING BY INSULATION OF HOT AIR LINE

AVERAGE TEMPERATURE OF HOT AIR AT BURNER = 210 C

TEMP. DROP BETWEENRECU. AND BURNER = 130 C

ALLOWABLE DROP . MAXIMUM) 30 C

TEMP. OF COMBUSTION AIR CAN BE RAISED BY 100 C
HEAT SAVED BY RISING THE AIR TEMP 428 KCAL / KG OF OIL
% HEAT FUEL OIL SAVING 4.5 %
ANNUAL FUEL OIL CONSUMPTION 2500 KL

ANNUAL SAVING OF FURNACE OIL 113 KL

ANNUAL SAVING OF FURNACE OIL 21.47 lacs
 INSULATION AND OPENINGS
1. Use of ceramic coating on hot face except
hearth for better heat transfer and life of
refractories .
2. Use of Ceramic lining or Castable before MS
plate.
3. Use appropriate cold insulation for burner block
4. Keep all the doors except operating always
relined and closed . Have sufficient spare doors
for operating door.
5. Keep damper in good operating condition and
desired opening to be set as per the operation.
6. Monitoring the surface temperature of furnace
regularly.
 ENERGY CONSERVATION
IN FURNACES
Refractory Insulation

SALIENT POINTS
• As wall thickness increases, heat loss reduces
• As thickness of insulation increase, heat loss
reduces
• Effect of insulation is better :- (Roughly 1 cm of
insulation brick is equivalent to 5 to 8 cm of
refractory)
• In intermittent furnaces – (Thin wall of
insulations are preferred than thick wall of
refractory to reduces heat stored
5. Ceramic fiber to be used in intermittent
furnaces
 ENERGY CONSERVATION
IN FURNACES
Refractory/Insulation Thickness

Simple fire brick wall Compound refractory

wall
Heat lost to
atmosphere is high Heat lost to
atmosphere is
minimum
 8. Minimizing Wall Losses

About 30% of the fuel input to the furnace generally goes to

make up for heat losses in intermittent or continuous furnaces.
The appropriate choice of refractory and insulation materials is
needed for high fuel savings in industrial furnaces.

The extent of wall losses depend on:

Emissivity of wall
Thermal conductivity of refractories
Wall thickness
Whether furnace is operated continuously or
intermittently
Radiation Heat Loss from Surface of Furnace

The quantity (Q) of heat release from a reheating furnace is

calculated with the following formula:

4 4
5/4 t1 273 t2 273
Q a x (t1 t2 ) 4.88 E x
100 100

where
a : factor regarding direction of the surface of natural convection
ceiling = 2.8, side walls = 2.2, hearth = 1.5
tl : temperature of external wall surface of the furnace ( C)
t2 : temperature of air around the furnace ( C)
E: emissivity of external wall surface of the furnace
 Ceramic
Fibre

• Ceramic fibre is a low thermal mass insulation

material
• A recent addition is Zr O2 added alumino silicate
fibre, which helps to reduce shrinkage levels thereby
rating the fibre for higher temperatures
 Important Properties of
Ceramic Fibre
• Lower Thermal Conductivity
• Light Weight
• Lower Heat Storage
• Thermal Shock Resistant
• Chemical Resistance
• Mechanical Resilience
• Low Installation Cost
• Simple Maintenance
• Ease of Handling
• Thermal Efficiency
 9.Use of Ceramic Coatings

The benefits of applying a high-emissivity ceramic

coating:-

 Rapid heat-up
 Increased heat transfer at steady state
 Improved temperature uniformity
 Increased refractory life
 Elimination of refractory dust.
High Emissivity Coatings
 ENERGY CONSERVATION
IN FURNACES
General Observations of Furnace

1. DIFFERENT SIZE OF FURNACES FOR

SAME OUTPUT
2. MISMATCH OF COMBUSTION
EQUIPMENTS
3. IMPROPER BURNERS
4. NO CARE FOR BLOWER
5. NO PROPER SELECTION OF MATERIAL
FOR RECUPERATOR
6. NO PROPER DESIGN OF
RECUPERATOR
 ENERGY CONSERVATION
IN FURNACES
General Observations of Furnace

7. NO CONTROL ON EXCESS AIR

8. NO INSULATION ON HOT AIR LINE

FROM RECUPERATOR TO BURNER

9. NO PROPER HEATING OF FURNACE

OIL

10. INDUSTRIES ARE DEPENDENT ON

SUPERVISOR

11. NO TRAINED MANPOWER

 Electrical Energy Saving Opportunities
In
Steel Rerolling Industries

By: PCRA, SRO Raipur (C.G.)

AN INTEGRATED ENERGY SOLUTION PROVIDER

www.pcra.org
Need to Conserve Electrical Energy

AN INTEGRATED ENERGY SOLUTION PROVIDER

www.pcra.org
Electrical Energy Scene of a typical
Rerolling Mill
• Main Motor – 65-70 % Load Energy Scene of Rolling Mill - Connected Load wise

• Motors other than Fans & Main Motor 1500 HP

Blowers – 20-25% Load

1% Fans & Blowers 78 HP
• Fans & Blowers – 4-10% 26%

Load
4% Motors other than Fans
• Lighting & Airconditioning – 69% & Blowers 567.5 HP

1-2% Load Lighting & Air

Conditioning 20 HP
(Rounded Off)

AN INTEGRATED ENERGY SOLUTION PROVIDER

www.pcra.org
 Saving Opportunities
• Electricity Tariff
• Reactive Power Compensation
• Proper Maintenance of Motors

• Optimize Transmission Efficiency (belts & gears)

• FRP blades for Cooling Fans
• Lighting System

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Reactive Power Compensation
Agenda

•Reactive Energy & Power factor

•Why to improve the Power factor
•How to improve the Power Factor
•Where to install P.F.Correction capacitors

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 To the engineer……..
Power factor is the ratio between the KW and the KVA drawn by an
electrical load where the KW is the actual load power and the KVA is the
apparent load power.

KW
ø2
ø1
A

KVAR
KVA
B

As can be clearly seen KVA requirement has been reduced for the same
KW requirement in case A.

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To the rest of us……. an analogy helps

You can’t move the

wheelbarrow
(active power delivery)

unless you lift the arms!

(reactive power)

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To the engineer……..
A poor power factor can be the result of either a significant
phase difference between the voltage and current at the load
terminals, or it can be due to a high harmonic content or
distorted/discontinuous current waveform.

Poor load current phase angle is generally the result of an

inductive load such as an induction motor, power
transformer, lighting ballasts, welder or induction furnace.

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Why to improve the P.F

•Reduction in the cost of electricity

-Through reduced MD & Rebate from SEB
•Technical / Economic optimization
-Reduction in distribution losses
-Smaller Transformers, Switchgear & Cables
-Exact voltage at the motor terminals adding to the
life of the same.

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How to improve the P.F

Improving the power factor of an installation

requires a bank of capacitors which acts as a
source of reactive energy .
The compensation is provided by:
•Fixed value capacitors
•Equipment providing automatic regulation or
banks which allow continuous adjustment as the
loading of the installation changes.

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Where to install P.F. correction capacitors
•Global Compensation – The capacitor bank is
connected to the busbars of the main LT distribution
board of the installation.
•Compensation by sector – The capacitor banks
are connected to busbars of each local distribution
boards.
•Individual Compensation – The capacitors are
connected directly to the terminals of the inductive
circuit.

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How to decide the optimum level of
compensation

KVAR required = KW (tan (cos-1 (p.f.1)) - tan (cos-1 (p.f.2))

Where
KW = Average KW required
p.f.1 = Existing power factor
p.f.2 = Desired power factor

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Compensation at the terminals of the
transformers
•To compensate for the reactive energy absorbed
by the transformer which can amount to about 5%
of the rating of the transformer rating when
supplying its full load.
•In transformers reactive power is being absorbed
by both shunt (Magnatizing) and series(Leakage
flux) reactances.
•Complete compensation can be provided by a
shunt connected LT capacitors.
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Reactive Power consumption of
distribution Transformers
Rated Reactive Power to be compensated
Power (KVAR)
(KVA) No Load Full Load
100 3.5 7.1
160 4.7 10.6
250 6.3 15.7
315 7.3 19.4
400 8.6 23.9
500 10.5 29.7
630 12.3 36.7

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Reactive Power consumption of
distribution Transformers
Rated Reactive Power to be compensated
Power (KVAR)
(KVA) No Load Full Load
800 21 55.5
1000 24.9 73.4
1250 28.4 95.5
1600 32.9 127
2000 38.8 177

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The effects of harmonics
Harmonics are caused by the nonlinear magnetizing impedances of
transformers, reactors, fluorescent lamp ballasts & all the equipments
which uses power electronic components (VSD,Thyrystor controllrd
rectifiers, etc.)
Harmonics on a symmetrical 3-phase power sysytems are generally odd
numbered & the magnitude decreases as the order increases.
Capacitors are especially sensitive to the harmonic components of the
power supply due to the fact that capacitive reactance decreases as the
frequency increases.In practice this means, that a relatively small
percentage of harmonic voltage can cause a significant current to flow
in a capacitor circuit.
These can be reduced to a minimum by harmonic filters.

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3 phase Induction Motors
Agenda

• Motor Lifetime
• Size Motors for Efficiency
• Proper Maintenance
• Energy Efficient Motors
• Reactive Power Compensation
• Issue of Motor Rewinding

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 Motor Lifetime

•The typical lifetime of small motors in the field is not well

determined. Studies at one manufacturer show that small
motors have an “L10” life (defined as the point where 10
percent of test population has failed) under typical operating
conditions of around 25,000 hours .

•("typical“ assumes no start/stop or excessive vibration, 75 C

bearing temperatures, normal, mineral-oil-based,bearing
lubricants, and regular-sized lubricant reservoirs).

•For an average utilization of 2500 hours per year, that would

yield a ten-year L10 life.
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Motor Lifetime

•The life of a motor depends on a variety of factors in the

service conditions of the application.These include
environment (largely temperature), loading of the motor,
and speed of rotation.

•The studies cited above have shown that bearing failure

is by far the most critical factor in motor failure. In turn,
the main reason for bearing failure is failure of the
lubricant, mainly due to heat generation.

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 Energy Efficient Motors

Why ?
Energy-efficient
motors, are 2 to 8%
more efficient than
standard motors.

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Energy Efficient Motors
Design Improvement
•Lengthening the core
•using lower-electrical-
loss steel, thinner stator
laminations.
•more copper in the
windings reduce electrical
losses.
•Improved bearings and a
smaller, more
aerodynamic cooling fan
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Energy Efficient Motors

• Energy-efficient motors, also called premium or

high- efficiency motors, are 2 to 8% more efficient
than standard motors.

• Motors qualify as" energy-efficient " if they meet or

exceed the efficiency levels listed in the National
Electric Manufacturers Association's (NEMA's)
MG1-1993 publication.

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Reactive Compensation in motors
• Individual motor compensation is recommended where the
motor power (KVA) is significant with respect to the declared
power of the installation.
• The Reactive Compensation at any individual motor shall
not be in any case more than the No-load magnetizing KVAR
of the motor, above which self excitation can occur.
• In order to avoid self excitation ,the kVAR rating of the
capacitor bank must be limited to the following maximum
value:
• Qc ≤ 0.9 Io Un 1.732
Where Io = no load Current
Un = Phase to phase voltage in KV
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Maximum KVAR applicable to 3 phase motor
terminals without the risk of self excitation
Rating KVAR to be installed
For Speed of rotation (RPM)
KW HP 3000 1500 1000 750
22 30 6 8 9 10
30 40 7.5 10 11 12.5
37 50 9 11 12.5 16
45 60 11 13 14 17
55 75 13 17 18 21
75 100 17 22 25 28
90 125 20 25 27 30

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Maximum KVAR applicable to 3 phase motor
terminals without the risk of self excitation
Rating KVAR to be installed
For Speed of rotation (RPM)
KW HP 3000 1500 1000 750

110 150 24 29 33 37
132 180 31 36 38 43
160 218 35 41 44 52
200 274 43 47 53 61
250 340 52 57 63 71
280 380 57 63 70 79
355 482 67 76 86 96
400 544 78 82 97 106
450 610 87 93 107 117

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Proper Sizing & Loading of Motors
Why ?

• The Efficiency
& Power factor
depends on the
loading of the
motor.

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Proper Sizing & Loading of Motors

Why ?
• The fixed Losses remain the
same at lower loads therefore
Size motors to run primarily in the
65% to 100% load range.

• Consider replacing motors

running at less than 40% load with
properly sized motors

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Use Suitable Starters

• Direct On Line Starter

• Primary resistance or reactance

starter
• Auto transformer starter
• Star Delta Starter
• Soft Starter: A soft starter is
another form of reduced voltage
starter for A.C. induction motors.

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Motor Rewinding
• Rewinding can reduce motor efficiency and
reliability.
• Rewind-versus-replace decision is quite
complicated and depends on such variables as the
rewind cost, expected rewind loss, energy-efficient
motor purchase price, motor size and original
efficiency, load factor, annual operating hours,
electricity price, etc.
• Majority of the users would wish to rewind the
motor.

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Motor Rewinding
• During a motor failure or in the stripping of the winding
from the stator core prior to rewinding, high temperatures
can occur. These temperatures can, in many cases, affect
the electrical characteristics of the stator core steel and
result in increased iron losses and lower motor efficiency.

• Check the no load current before & after rewinding.

Maintain a history card of motor rewinding.

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Life Cycle cost of a motor

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Optimizing Transmission Efficiency
•Transmission equipment
including shafts, belts,
chains, and gears should
be properly installed and
maintained.

• When possible, use flat

belts in place of V-belts

• It is better to have a direct

drive for avoiding losses in
transmission system.

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Slip-ring motor
The advantages of a slip-ring motor

• Its susceptibility to speed control by

regulating rotor resistance.

• High starting torque of 200 - 250% of full

load torque.

• Relatively low starting current (250 to

350% of the full load current) compared to
a squirrel-cage motor, which may have a
starting current in the order of 600% of its
full load current.

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Energy savings points

• Maintain High Power Factor

• Use Variable Speed Drives (VSDs) Where Appropriate
• Minimize Phase Unbalance
• Use controls to turn off idling motors
• Match Motor Operating Speeds
• Size Motors for Efficiency
• Follow proper maintenance schedule

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FRP blades for Cooling Fans
Why ?
• The consumption in the fans supplying cooling
air to the workers vary in a wide range from 1.5
KW to 5.5 KW.

• This may be attributed to the material of the fan

blade which of MS & Aluminum and to the motor
rating which varies from 3 HP to 15 HP for the
same type of fans.

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FRP blades for Cooling Fans

•With the technological improvements

in material processing technologies,
FRP (Fiber Reinforced Plastic) has
come as an alternative to the
conventional Aluminum .

•We recommend replacing the metal

alloy blades of all the fans with FRP
blades. It has been estimated that
energy savings of minimum 20 % can
be achieved by above conversion.

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Energy savings in lighting System
• Make maximum use of natural light (North roof/translucent
sheets/more windows and openings)

• Switch off when not required

• Provide timer switches / PV controls for yard lighting

• Provide lighting Transformer to operate at reduced voltage

• Install energy efficient lamps, luminaries and controls

• Metal halide in place of Mercury and SVL lamps

• CFL in place of incandescent lamps

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Instruments Required

Electrical Measuring Instruments:

These are instruments for measuring
major electrical parameters such as
kVA, kW, PF, Hertz, kvar, Amps and
Volts. In addition some of these
instruments also measure harmonics.

• Demand Analyzer
• Digital power recorder
• Lux Meter
• Anemo meter
• Digital Manometer
• Techometer

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Maintenance of Electric Motors
• Under normal operation, motors should be checked on a
regular basis. If the environment is hostile (e.g. wet, dirty
and hot), the checks should be at least on a daily basis.

• Cleanliness of the surroundings, ensuring that cooling

vanes are clear of extraneous matter.

• Signs of grease or oil leakage from the bearings.

• The motor frame and bearing plates (if accessible) are not
unduly hot;

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Maintenance of Electric Motors
• The motor is not showing signs of abnormal vibration or noise.

• There is no evident damage to incoming cables and or

terminal boxes.

• Air intakes and filters (if applicable) are not clogged.

• Apply blower to the sealing, especially in motors situated in

dusty areas.

• Check the motors & driven equipment for proper alignment &
Inspect the condition of the belts.

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Maintenance of Electric Motors
• Contactors, Relays, Selector switches and push buttons to
be checked for proper working.

• Inspect the foundation of motors for excessive vibration.

Tighten the foundation bolts, if required.

• Physical checkup of the motors to be carried out.

- Take No load & Full load current.
-Check the starters and relay settings.
- Tighten all the connections.
- Apply blower to PCC & MCC panels, Normal checkup to be
done.

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 UNDP/GEF PROJECT (STEEL)

“REMOVAL OF BARRIERS TO ENERFY

EFFICIENCY IMPROVEMENT IN STEEL
REROLLING MILL SECTOR”

DETAILED CLUSTER MAPPING PROJECT

REPORT
(RAIPUR CLUSTER)
Overview of SRRM Sector in the Cluster
Chhattisgarh Rerolling mill industry is going through
different phase of global competition. It is being increasingly
released that technology is tool for competitiveness in the
market place. At present 148 rolling mills are running in the
region producing:-
1. CTD/TMT Bar / Round (6mm to 100mm) ,
2. Angle (25x3 to 200x10) ,
3. Beam (100x50 to 600 to 210),
4. Channel (75x40) to 400x100) ,
5. Flats (18x3 to 200x12) ,
6. Strip (upto 200mm) ,
7. window section ,
8. wire rod of all sizes.
 Distribution

Location wise
• Raipur-122 Nos
• Bhilai –Durg –Rajnandgaon -23 Nos
• Bilaspur-03 Nos
 Fuel Used
• Coal Fired - 97 nos
• Oil Fired- 43 Nos
• Producer Gas fired- 8 Nos **

** Producer Gas plus Oil fired units

 Location wise Distriution of SRRM in Chhattisgarh

16% 2%

Raipur
Bhilai –Durg -Rajnandgaon
Bilaspur

82%
 Product wise distribution

Product Nos of SRRM

• Tor (TMT/CTD Bar/Rounds) 56
• Structure (Angle/Channel/Beam/Joist) 79
• Flat/ Strip 13
 Fuel wise distribution of selected 20 % Industries

14%

42%

44%
Coal
FO
Producer Gas
 Specific Energy Consumption of Rolling Mill using FO as Fuel (Lit of FO/Ton of
Production)

70
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Specific Energy Consumption (Lit of FO/Ton of Production)
 Specific Energy consumption of Rolling Mill Using Coal as Fuel
(Kg of Coal/Ton of Product)
250

200

150

100

50

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Specific Energy consumption of Rolling Mill Using Coal as
Fuel (Kg of Coal/Ton of Product)
 Variation in % Scale Loss in the Cluster

0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 % Scale loss
 Specific Energy Consumption of Rolling Mill using Producer gas (Kg
of Coal/Ton of production) and FO (Lit /Ton of production) as Fuel

90

80

70

60

50
FO consumption in Lit/Ton
40 Coal consumption in Kg/Ton

30

20

10

0
1 2 3 4 5
 Specific Power Consumption

130
125
120
KWH/Ton 115
110 Specific Power Consumption

105
100
1 4 7 10 13 16 19 22 25 28 31 34 37
Units
 Variation in Power Factor in the Cluster

0,95

0,9

0,85

0,8
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 Power Factor
 TYPICAL ENERGY CONSUMPTION PATTERN
IN ROLLING MILLS

Auxiliaries 10%

Mill Proper
20%

Reheating
Furnace 70%

Note: - AUXILIARIES INCLUDES

 Drives for Roller Tables, Fans, Pumps and Shears etc.
 Operational and Maintenance spares reclaiming facilities etc.
 Cranes
 Lighting
 TECHNOLOGY PACKAGES
• Installation of high efficiency recuperator in
conventional pusher hearth continuous oil fired
furnaces.
• Conversion of oil fired pusher hearth furnace to oil
fired walking beam furnaces.
• Conversion of oil fired pusher hearth furnaces to gas
fired walking beam furnaces with regenerative
burner.
• Conversion of lump coal fired to pulverized coal
firing with recuperator.
• Conversion of lump coal fired to producer gas fired
furnace with high efficiency recuperator.
• Adoption of hot charging in the composite mills.
 CUSTOMIZED PACKAGES
(Combustion furnace )

• Installation of improved refractory

lining.
• Adoption of ceramic fiber veneering.
• Adoption of high emissivity coating.
• Installation of high velocity / oil film
burners.
 CUSTOMIZED PACKAGES
(Rolling Mill)
• Introduction of crop-length optimization
techniques.
• Adoption of roller entry and delivery guides.
• Installation of roller bearings for roll necks in the
mill stands.
• Replacement of cotton and pin type spindles &
couplings to universal type spindles.
• Installation of tilting tables on 3-Hi stands.
• Installation of repeaters.
 FUEL SAVINGS IN REHEATING FURNACE AT A
GLANCE
EST. COST SIMPLE
ENERGY ANNUAL
APPROX. OF PAYBACK
SAVING ENERGY
ECOTECH INVESTMENT ENERGY PERIOD
(GJ/T OF SAVING
(RS. LAKHS) SAVING (MONTHS)
PRODUCT) (RS. LACS)
(RS/MT)

Solid pusher hearth, single row long 0.18

120 129 95 15
furnace-combustion air heated to 350C (50 kwh)

Solid pusher hearth, double row, high 0.28

performance furnace-combustion air 145 200 144 12
heated to 550C (77.84 kwh)

Walking hearth furnace/e-combustion 0.41

190 293 214 10.6
air heated to 650C (114 kwh)
Walking hearth furnace designed to
work on coal producer gas with 0.59
500 423 510 12
regenerative burners-combustion air (164 kwh)
heated to 10000C
As above plus hot charging - 75% 1.12
550 802 613 11
billets are hot charged at 650C (311 kwh)

(Base Case: Solid pusher hearth, oil fired and 15tph continuous reheating furnace
with conventional features with 20 hours/day operation, 250 days working in a
year)
 PROJECT BENEFITS
I. Direct Benefits
Consumption of energy & other Unit Status in the Target / Expected
important performance beginning of Outcome after
parameters of re-rolling mills the Project project
(Model Units) completion

Oil consumption in the reheating Lit/T 42-45 <32

furnace
Coal consumption Kg/T 70-80 45-55
Gas consumption Nm3/T 48 30
Productivity of furnace Kg/m2/h 120-220 300-350
Scale Loss % 2.5-3.5 <1
Power consumption kWh/T 90-120 85-100
Yield % 89-93 94-95
Utilization of mill % 65-70 80-85
 PROJECT BENEFITS…Contd.
II. Indirect Benefits
Sl. Support Current During / After Project
No. Status Completion

1 Institutional / expert support NIL TIRFAC

2 Design support NIL Software Centre (TIRFAC)

3 Software support NIL -Do-

4 HRD NIL -Do-
5 Data/Information/Knowledge support NIL -Do-
6 Consultancy support Local level -Do-
7 Standardization / Benchmarking NIL -Do-
8 Standard operating & maintenance practice (SOP & SMP), NIL -Do-
ISO 9002, 14002 accreditation, etc
9 Capacity building to other stakeholders like consultants, NIL -Do-
equipment manufacturer, Banks/FIs, etc.

10 Market analysis / research (data on sales / price, etc.) NIL -Do-

11 Technology development, R&D Demonstration, etc NIL Hardware Center

(TIRFAC)
 BENEFITS TO INDUSTRY
• Reduced energy bills.
• Reduction in scale loss.
• Improvement in yield.
• Improvement in product quality.
• Improvement in productivity.
• Technology up gradation of the unit.
• Reduction in manpower Overall increase in
bottom line.
Get your Industry Energy Audited

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