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Doing more with Less Coal Efficiency and GHG Intensity enhancement potential for the Steel Sector in India. Institutional Mentor / Partner. Lead Researchers: Dr. Amit Garg, Vivek Gilani Co-Researchers: Gyan Prakash, Saumya Aggarwal, Bhaskar Govindrajan, Udit Bansal. - PowerPoint PPT Presentation
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Doing more with LessCoal Efficiency and GHG Intensity enhancement
potential for the Steel Sector in India
Institutional Mentor / Partner
Lead Researchers: Dr. Amit Garg, Vivek GilaniCo-Researchers: Gyan Prakash, Saumya Aggarwal, Bhaskar Govindrajan, Udit Bansal
Facts from India Coal Market Watch – August 2011
Domestic coal production target for 2011-12 is 554 mt
India adds 1660 MW generation capacity in July (all Thermal Power)
Indian plants exceed power generation target in July 2011
Coal India Ltd (CIL) reported a 64.06% rise in profit after tax (PAT) during the first quarter (April-June) of 2011-12
So far so good……………..
Facts from India Coal Market Watch Out! – August 2011
India’s coal import in 2011-12 likely at 137.03 mt
The import of coking coal through Paradip port on the eastern coast of India surged by almost 4,10,095 tons in July 2011 to 6,68,574 tons as compared to 2,58,479 tons in June 2011
Imports of PCI coal through Vizag port in July 2011 stood at 1,13,467 tons, which was higher by 86,764 tons than 26,703 tons imported in June 2011
The imports of Low Ash Metallurgical (LAM) coke through Paradip port in the month of July 2011 rose sharply to 60,590 tons compared with 6000 tons in June 2011
171 coal mining proposals involving 28,862 hectares of forest land are awaiting forestry clearance as on June 30, 2011
44 projects of Coal India Ltd (CIL) stuck under Comprehensive Environment Pollution India (CEPI) norms introduced by MoEF
Question?
Can the most efficient users of coal in India’s
Steel Sector help -
increase India’s Energy Self-Sufficiency,
meet it’s Climate Change Commitments,
and also save some Forests in the bargain?
Trends - GHG Intensity of Production in Sample Steel Companies
Coking Coal40%
Coal26%
Steam Turbines12%
Coke3%
Non-Coking Coal2%
Grid Electricity12%
Combined Others5%
Indian Steel Sector - GHG Emissions Sources (2010)
Trends - GHG Intensity of Production in Sample Steel Companies
Company NameProduction GHG Intensity 2008
Production GHG Intensity 2009
Production GHG Intensity 2010
tonnes CO2e/tonne product
tonnes CO2e/tonne product
tonnes CO2e/tonne
J S W Steel Ltd. 1.275 1.528 1.432Steel Authority of India ltd. 1.554 1.619 1.537Jindal Steel & Power Ltd. 2.943 2.971 2.666Tata Steel Ltd. 1.875 2.269 2.100
Essar Steel Ltd. 0.541 1.334
J S W Ispat Steel Ltd. 0.319 0.368 0.292Bhusan Steel Ltd. 0.367 0.641 0.695J S L Stainless Ltd. 0.616 0.601
Monnet Ispat & Energy Ltd. 2.675 4.060 4.578M S P Steel & Power Ltd. 3.838 3.636 2.583Mukund Ltd. 0.911 2.790 0.966Jai Balaji Industries Ltd. 0.377 0.445 0.441Kalyani Steels Ltd. 0.776 0.837 0.647Electrotherm (India) Ltd. 0.838 0.965 1.591Lloyds Steel Industries Ltd. 0.651 0.746 0.693I S M T Ltd. 0.670 0.743 0.963Ankit Metal & Power Ltd. 1.265 1.431 0.942Shah Alloys Ltd. 0.799 1.414 1.542Tulsyan N E C Ltd. 0.363 0.377 0.313
Mittal Corp. Ltd. 0.288 0.454 0.534Narbada Steels Ltd. 0.636 0.760 0.813Anil Special Steel Industries Ltd. 0.716 0.816 0.713Facor Steel Ltd. 1.014 1.150 1.459Gallant Metal Ltd 1.713 1.841 1.772
Sr. No. Parameter 2008 2009 2010
SAMPLE Companies
1 Total Production - SAMPLE Companies (mt Steel) 68.4 66.1 77.5
2 Sample: Universe Ratio 81% 82% 82%
3 Coal Use (Direct + Indirect) - SAMPLE Companies (mt Coal) 34.7 42.4 43.7
4 GHG Emissions (Total Production) - SAMPLE Companies (mt CO2e) 91.7 106.4 112.5
5 Potential Coal Savings w. BPT Replication - SAMPLE Companies (mt Coal) 25.3 29.8 29.4
6 Potential GHG Mitigation w. BPT Replication - SAMPLE Companies (mt CO2e) 72.0 82.0 84.5
7 % Coal Intensity Improvement- Steel Sec. 73% 70% 67%
8 % GHG Intensity Improvement- Steel Sec. 79% 77% 75%
ENTIRE Steel Sector (Liquid Steel Production)
9 Total Production - Steel Sec. (mt Steel) 84.6 80.6 94.4
10 Coal Use (Direct + Indirect) - Steel Sec. (mt Coal) 42.9 51.7 53.3
11 GHG Emissions (Total Production) - Steel Sec. (mt CO2e) 113.5 129.6 137.1
12 Potential Annual Coal Savings through BPT Replication (mt Coal) 31.3 36.3 35.8
13 Potential Annual GHG Mitigation through BPT Replication - mt CO2e 89.1 100.0 102.9
14 % Target of Annual GHG Emissions Mitigation (COP15 commitment) 139.3% 156.2% 160.8%
Coal Efficiency & GHG Intensity Enhancement in Steel Companies
50%
70%
90%
110%
130%
150%
170%
190%
10
30
50
70
90
110
130
150
2008 2009 2010
CO
P-1
5 C
om
mit
tme
nt
%
Co
al S
av
ing
s a
nd
GH
G M
itig
ati
on
(m
illio
n t
on
s)
Year
Steel Sector Coal Savings, GHG Intensity Reduction and COP15 Commitment Opportunities -2008-2010
Coal Savings GHG Mitigation COP-15 Committment
Source: Mckinsey – Environment and energy sustainability: An approach for India
Energy Efficiency measures
Process efficiency – sinter plant heat recovery, coal moisture control
Optimized energy use - pulverized coal injection, coke dry quenching and recovering waste heat
Fuel Shift
Substituting coke used in BF/BOF furnaces with fuel based on biomass (charcoal)
Replacing 10% of coke as the primary blast furnace tool
Technology Changes
Direct smelting remove need for coking plants Challenge – Issues with technologies need to be resolved
Scrap based steel making 1/3 energy required by standard blast furnace Challenge – if 10% of the total production moved to this system
70% of India’s steel would need to be recycled which involves a economic cost
Gas based direct reduced iron Challenge: Availability of gas to steel plants
Cogeneration – gas from the BOF/BF process is recovered, cleaned and used for power generation
Energy Self-Sufficiency and Indian Steel Sector
Coking coal prices at $225 a ton for the second quarter beginning July 2010 compared with $129 a ton level in 2009-10
Very high dependency on Australia for coking coal
Energy Self-Sufficiency: India would need 2.4 billion tonnes of steel/yr by 2030 which would assume India would need to import 40% of its coal needs
Learnings and Way Forward Best practice gap in terms of GHG Intensity of Production from Coal for
Cement Industry: increased from ratio of 13.4 to 15.7 in 3 years.
Best Practice Technology (BPT) replication achievable realistically using off-the-shelf technologies in India
BPT replication in Steel Industry alone can yield 36 million tons of coal saving and reduce India’s imports dramatically
BPT replication from merely this sector can help India achieve more than 100% of its GHG Emissions commitment to COP15 (reducing GHG intensity of the GDP by 20%-25% by 2020)
Thus, despite being a proactive environmental research and outreach body – not anti-coal as a fuel – but a rational promoter of the roadmap to do more with the lessening coal we have in India and globally.
Need of the hour – process optimisation technology sharing amongst the Steel Industry and active promotion and incentivisation of efficient users of coal and low-GHG intensity steel on platforms such as coaljunction and metaljunction.
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