PRESENTATION

For

CII GBC NATIONAL AWARD

FOR EXCELLENCE IN

ENERGY MANAGEMENT

By

Rashtriya Ispat Nigam Limited

VISAKHAPATNAM STEEL PLANT

TEAM MEMBERS

T K DEYDGM(EMD) I/c & Energy Manager

K SudhakarDGM(O) &

Certified Energy Auditor

S KumarMgr.(EMD)

CONTENTS

COMPANY PROFILE PROCESS FLOWLIST OF PROJECTS WITH COST BENIFITSREDUCTION OF SPECIFIC ENERGY CONSUMPTIONBENCH MARKING(GLOBAL AND NATIONAL BENCH MARKING)ENCON PROJECTS TO REDUCE GAPINNOVATIVE PROJECTSENVIRONMENTAL PROJECTS & PROJECTS LINKING WITHCARBON EMISSION REDUCTION EMPLOYEE INVOLVEMENT & TEAM WORKENCON PROJECTS FOR NEXT THREE YEARSIMPLEMENTATION OF CORRECTIVE AND PREVENTIVE ACTIONSRENEWABLE ENERGY SOURCES,UTILISATION OF WASTEBEST PRACTICES IMPLEMENTED AMONG VENDORS,ASSOCIATESCONCLUSION

1

Rashtriya Ispat Nigam Limited

Eastern Investment Limited

Bisra

Stone Lime Co.

Ltd. (BSLC)

Visakhapatnam Steel

Plant

Orissa Mineral

Development

Corp. (OMDC)

Operating

Units

Madharam

mines

Dolomite

Jaggyyapeta

mines

Limestone

Garbham

Manganes

e

Subsidiary company

(51% stake)

RINL Corporate Structure

Units on Anvil

Wheel PlantTransmission Line

Towers Plant

2

Turnover (2016-17) 12,707

Net worth as on 31/03/16 9873

Unit: Rs. Crs

* 100% owned by Govt. of India

RINL – Snapshot

3

1. 66

RINL - Snapshot

The 1st ISP to be certified for Quality, Health & Safety and Environment

1st steel Plant to get ISO 50001 certification for Energy Management

CMMI Level 3 certification for IT Systems

1st ISP to be 5S Certified for the whole plant

4

BPTS

TRT

100%

Continuous

Casting

LD gas

recovery

Evaporative

Cooling

CO Battery with Coke Dry Quenching and Back Pressure Turbine Station

3200 cum BF with Top Recovery Turbine and BF gas recoveryRolling Mills with Stelmor & Tempcore (TMT) processes equipped with evaporative cooling

for waste heat utilization

Production Process flow at RINL

5

RINL’s growth strategy for enhancement of capacity

through a combination of brown field expansion and

modernization in phases:

6.3 Mtpa expansion

Completed in 2015 and under stabilization

Invested Rs. 12,291 Cr ( 80% met through internal

accruals)

Upgradation & Modernization

Underway to enhance capacity to 7.3 Mt by 17-18

With an investment of Rs. 4,000 Crs.

Vision envisages growth to 20 Mtpa by 2032-33 in phases

RINL’s Growth Plan

6

Power Generation capacity from Waste Energy (MW)

7

ENCON Projects with Investment (2016-17)

8

S.No. Title of ProjectEnergy Savings in

Investment (Rs Million)

Gcal/MKwh Rs Millions

1Improvement in Pulverized coal injectionfrom 5.1 to 23.4 Kg/tHM at Blast Furnace

128418 124.69 1350

2 Energy saving through Billet Caster 202280 196.41 5520

3Improvement in Power Generation from CPB4turbine station of Battery-4

5.87 38.94 850

4Improvement in Power Generation at TopPressure Recovery Turbine station of BF-3

41.17 273.16 800

5Improvement in Power generation from SHRPPof SP-1

4.99 33.11 2502

ENCON Projects with NO/Little Investment (2016-17)

9

S.No. Title of ProjectEnergy Savings in

Gcal/MKwh Rs Millions

1Improvement in benzol yield at coke oven from0.44% to 0.47%

11482 11.15

2Reduction of Sp. power Consumption at cokeoven from 59.97 to 49.28 Kwh/tDC

10.26 68.05

3Reduction of Sp. Power Consumption at SP-1from 61.87 to 58.88 Kwh/tGS

10.46 69.42

4Reduction of Sp. heat Consumption at SP-2 from15 to 10 Mcal/tGS

12582 12.22

5Reduction of Sp. Power Consumption at SP-2from 61.89 to 58.59 Kwh/tGS

8.30 55.10

6Reduction in fuel rate at Blast Furnace from560.9 to 537.2 Kg/tHM

380415 369.38

ENCON Projects with NO/Little Investment (2016-17)

10

S.No. Title of ProjectEnergy Savings in

Gcal/MKwh Rs Millions

7Reduction in Sp. Heat Consumption at BlastFurnace from 526 to 475 Mcal/tHM

60079.14 58.34

8Reduction in Sp. Power Consumption at BF-3from 51.24 to 45.74 Kwh/tHM

24.12 160.05

9Reduction in Sp. Power Consumption at SMS-1from 51.41 to 47.68 Kwh/tCS

8.12 53.88

10Improvement in LD gas yield at SMS-1 from 94 to95 Ncum/tCS

3505.14 3.40

11Reduction in Sp. Power Consumption at SMS-2from 117.71 to 112.78 Kwh/tCS

8.80 58.37

12Improvement in LD gas yield at SMS-1 from 44 to80 Ncum/tCS

189649 184.15

13Reduction in Sp. Heat Consumption at LMMMfrom 449 to 422 Mcal/tBI

52500 50.98

14Reduction in Sp. Power Consumption at Bar Millfrom 70.52 to 70.21 Kwh/tBI

0.26 1.76

ENCON Projects with NO/Little Investment (2016-17)

11

S.No. Title of ProjectEnergy Savings in

Gcal/MKwh Rs Millions

15Reduction in Sp. Heat Consumption at WRM from 250to 249 Mcal/tBl

1018 0.99

16Reduction in Sp. Power Consumption at WRM from124.8 to 122.54 Kwh/tBI

2.30 15.26

17Reduction in Sp. Heat Consumption at WRM-2 from289 to 270 Mcal/tBl

7739.61 7.52

18Reduction in Sp. Power Consumption at WRM-2 from340.9 to 287.5 Kwh/tBI

21.75 144.31

19Reduction in Sp. Power Consumption at MMSM from83.37 to 81.42 Kwh/tBI

1.53 10.15

20Reduction in Sp. Power Consumption at CRMP from67.34 to 66.36 Kwh/tBI

0.41 2.71

YEARNo of

Projects

Thermal

Savings

(Gcals)

Electrical

Savings

(Million KWH)

Saving

s in

Rs.Cr

Investm

ent

In Rs Cr

2013-14 10 145710 15.3 19.1 25

2014-15 10 54172 176.6 59.4 332

2015-16 16 1186320 50.1 144.5 410

2016-17 33 1049671 148.3 200.3 687

Summary of the Projects identified & Implemented

12

Energy Consumption

39.4538.8

36.83

2014-15 2015-16 2016-17

Thermal Energy Consumption(GJ/tCS)

719

715

697

2014-15 2015-16 2016-17

Electrical Energy Consumption(Kwh/tcS)

8.24

8.17

8.122

2014-15 2015-16 2016-17

SEC as PAT scheme(Gcal/tCS)

Sp. Energy Consumption-Gcal/tCS

6.376.40 6.39

2014-15 2015-16 2016-17

13

Benchmarking of Energy Consumption-Gcal/tCS

6.396.58

5.70

6.36

RINL SAIL-BSP TATA Steel SAIL-DSP

14

International Bench Marking of SEC(Gcal/tCS)

6.060

5.439

4.000

4.500

5.000

5.500

6.000

6.500

7.000

RINL Nippon Steel

Unit

15

Bench Marking with Nippon Steel(2009-10)

Energy(2009-10) GHG EmissionGap :0.661 Gcal/tCS

RINL NSC RINL NSC 1) Scrap usage : 200 kg/thm( As per Japanese

Industry)-RINL:80 kg/tcS

2) All Energy Conservation technologies

Coke Dry Quenching,

Top Pressure Recovery Turbine,

BOF Gas Recovery,

Sinter Cooler waste heat recovery

Pulverized Coal Injection,

BF stoves Heat Recovery,

Billet Caster,

Hot Charging,

Regenerative Burners,

Coal Moisture Control

Sensible Heat recovery from BOF gas

3) Waste Plastics Injection and tires(0.2 million tons-

6 kg/tCS)

4) Petro fuel 16 lts/Tcs

6.06 5.439 2.615 1.943

16

Energy Conservation Technologies in Expansion and

Modernization

NAME OF THE PROJECT ENERGY

SAVINGS

(GCALS)

GHG

EMISSION

REDUCTION

(tCo2)

PCI IN BLAST FURNACES 1518750 910164

POWER GEN FROM COOLING OF COKE in Batt-4 207384 124282

ENERGY EFFICIENT BURNERS AND WHR IN SP-2. 73349 89294

20.6 MW WHR ON SINTER STRAIGHT-LINE COOLER 368130 220612

BF-3 STOVES WASTE HEAT RECOVERY. 149008 43958

BILLET CASTER IN SMS-2 1807185 1083030

ENERGY EFFICIENT VERTICAL SHAFT KILN 141000 51912

ENERGY EFFICIENT AIR SEPARATION UNIT 61939 23227

SINTER PLANT 1&2 CAPACITY ENHANCEMENT 279125 167475

BF-1 &2 MODERNISATION & UPGRADATION 652800 391200

5196731 3081927

17

Sl No Name of Energy Conservation Activity Year

1Power Generation from Gas Expansion Turbine station of BF-1

2017-18

2Pulverized Coal Injection in Blast Furnace-3(upto 100 kg/tHM)

2017-18

3Capacity Utilization of 120 MW BF gas captive power plant

2017-18

4 Revamping of Sinter Machines 1&2 2017-18

5Revamping of Billet Mill Reheating furnaces (Two

Furnaces)2018-19

Energy Conservation Projects identified for next three

years

23

Environmental Projects & Projects linking with Carbon

Emission Reduction

Projects Benefits

Revamping of Burden handling & Cast House FE

system of Blast Furnace-1.

Reduce Dust emissions

Balacheruvu, Waste Water Treatment Plant -

Commissioned in July 2014.

253 Million Gallons

Commissioning of Appikonda Waste Water Treatment

Plant

220 Million Gallons

The Digital display board at Main Gate was

inaugurated by CMD on 5th June 2014 for displaying

the CAAQM and Stack analyzers.

Awareness

Dry Fog Dust Suppression System (DSS) in

Expansion area of Raw Material Handling Plant, Sinter

Plant & Blast Furnace.

Reduced fugitive emissions

Rain water harvesting scheme near 18 MLD plant Ground water recharging

18

No of Projects Registered(BF3 TRT,COB4 , BF3 WHR, BF gas based CPP-2)

4

Verification completed (COB4)* 1

* UNFCCC issued 70,516 CER to RINL

Environmental Projects & Projects linking with Carbon

Emission Reduction

19

Name of ProjectsRegistration

NumberExpected

CERS

BF3 Top Pressure Recovery Project 9613 60410

COB-4 Turbine at Battery-4 9988 68540

Waste Heat Recovery from Stoves of BF-3

10024 44932

120 MW Waste Gas Based Captive Power Plant

Under Registration

602433

Environmental Projects & Projects linking with Carbon

Emission Reduction

20

GHG Inventorisation

25

Emission Details

Scope 1 Direct emissions from site

chimneys determined from straight

carbon balance

Scope

1.1

Direct emissions of exported by-

product gas

Scope

2

Upstream emissions of electricity

and steam from site.

Scope 3 Other upstream emissions by-

products from site

Scope 1 Scope1.1 Scope2 Scope 3

Total

CO2(t

CO2/TCS)

8591761 2803255 534435 -895786 2.785

2.793

2.7872.785

2014-15 2015-16 2016-17

GHG Emission-tCO2/tCS

As per ISO:14064:-

Involvement of employees,Team Work and

Monitoring

• Employee Involvement Through

– Quality Circles, Suggestion Schemes, Department Energy

Teams, Participation in Energy Conservation Campaigns, Cost

Control Campaigns, Water Saving Campaigns

• Implementation Methods

– Low Cost/No Cost Ideas (Process Improvements, House

Keeping Measures, etc) will be Implemented by Frontline

officers

– Medium Investment Projects through AMR Schemes

– High Investment Schemes through Board Approval/COM

– Special Task Forces for Implementing Important Energy

Conservation Projects for Sinter Cooler, Steam Utilization and

By product gases usage.

21

Monitoring Format

Energy

Conservation

CellDET

DGM(EMD)I/c Daily

GM (E&U) Weekly

ED (W) Monthly

D (O) Bi-Monthly

22

Energy Management System ISO:50001

25

• Features:

Identification of significant energyaspects

Developing Energy Managementprogrammes.

Operational control of identifiedenergy aspects

Monitoring and Measurement

Internal Audit

Management Review

RINL implemented BS EN: 16001Energy Management systems at VSPwork division and certified in Dec,2010.

First PSU & Integrated Steel Plant to becertified for BS EN: 16001 energymanagement system

Certified for ISO: 50001 in Aug’12

Completed 2nd recertification in Dec’16

Implementation of Corrective/Preventive actions

24

Energy Management System ISO:50001

25

• Plant has taken up Energy Objectives and Energy Management Action

plans(360 Nos ) to reduce energy consumption.

• DEPARTMENTAL ENERGY TEAMS were constituted in various

departments. The teams identified specific projects

• Departments conducted energy audits at various equipment through

Departmental Energy Audit Teams

2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

94 89 90 89 89 85 85

Green Purchasing Policy

• Procurement of Circulation fan(3000KW) for

Sinter Heat Recovery Plant

• Star labeled Energy Efficient Air Conditioners

• Energy Efficient Motors

Year ENCON Investement as % of

Turnover

2016-17 0.8%

Energy Monitoring Format

• Energy Savings are quantified with respect to

displacement of Boiler Coal

• Electrical Savings are quantified by pegging

with Electricity imported.

• Savings are certified by Energy Auditors

Renewable Energy Utilization

RINL commissioned

5 MW Solar Power

Plant

Investment: Rs 36 cr

Installing 1MW Roof Top

Solar Power Plant at

various Building

26

Utilization of Waste

Type of Waste

Material used

Quantity of

waste

material

used (Tons

or any other

eqvt Unit)

Equivalent of

Conventional

energy used (kWh

of electricity or

Tons of Coking

Coal)

Gcal

Waste fuel

as % of

total

energy

Coke Dust 460 440 3125

23.32%

LD Slag 36202 5099 36202

Met Waste 416333 29319 208167

Tar sludge 3289 3289 23352

Benzol muck 785 785 5574

ASP sludge 276 276 1960

BF gas 7106270 774684 5500253

LD gas 348360 80515 571659

Coke dust(sold) 68291 7454 52926

Granulated Slag 1434882 216243 1535324

25

Best Practices implemented in Green Supply chain

• Implementation of Green Technologies

• Implementation of ISO :50001 Energy Management

System( SAIL/DSP implemented . SAIL BSP is

replicating EnMS based on RINL experience)

• Procuring Energy Efficient Equipment(Life Cycle Criteria

for Procuring Energy Efficient equipment)

• Production of Green Steel( Steel Consumption reduces by

15% due to high yield strength of 550 N/m2 on Fe 550

grade)

28

Adoption of Green Technologies

Name of Technology FeaturesEnergy

Savings(TOE)

GHG

redn(tCo2)

Coke Dry Quenching

Plant Power gen: 2X7.5MW 115285 689586

Top Pressure

Recovery Turbine Power gen; 2x12 MW 21257 127152

LD Gas Recovery

System 80000 Cum 58022 347060

Evaporative Cooling

System 13 ata steam: 19 t/hr 12173 72814

Preheating of

combustion air at

CRMP

Air preheating:

250degc3469 21062

Gas and air

recuperators in

ROLLING MILLS

Air : 450 degC

Gas:250 degC16105 57088

Reducing GHG emission by about 13 lakh tons annually

29

Adoption of Energy Efficient Technologies-Unique

Features of RINL

Name of Technology Level of

Diffusion

Coke Dry Quenching

Plant

First Time in

India(1990)

13.5%

Top Pressure Recovery

Turbine

First Time In

India(1993)

13.9%

LD Gas Recovery System First Time in

India(1991-93)

50%

Evaporative Cooling

System

First Time in

India(1993)

25%

Sinter Cooler Waste Heat

Recovery(Power Gen)

First Time in

India(2014)

5%

30

Innovative Project:

1x120MW Blast Furnace gas power plant

RINL has three blast furnaces

having annual production capacity

of 7.5 MTPA of Hot metal (Iron) after

adding 1no. Blast Furnace

(2.5MTPA) and revamping of 2 nos.

existing blast furnace from 1.7MTPA

to 2.5MTPA each.

During the process of iron making

blast furnace gas is generated as by

product gas and used in various

metallurgical units.

Blast Furnace gas is a lean gas

having heat value 750 Kcal/Ncum.

There is surplus BF gas to the

extent of 4,50,000 Nucm/hr after

expansion

31

BF Gas Gen&Distribution

Shop/Unit

Value

(Ncum/hr)

Generation 14,84,000

Consumption (Ncum/hr)

BF-1&2 3,34,000

BF-3 1,79,000

CO&CCP,SP,

Rolling Mills 2,01,000

CPP-1 3,18,000Surplus 4,52,000

Innovative Project:

1x120MW Blast Furnace gas power plant

Innovative Design of BoilersImproved burner design in boilers.

The boilers are designed in such a way

that low volumetric heat release rate

with larger boiler furnace results in higher

residence time & higher heat surface

area.The boilers are envisaged with Scroll type

burner which provides spin to the BFG at the

point of air fuel mixing and adequate

refractory lining on water wall tubes of

furnace heat surface which will reradiate

heat into the flame. 34

Flue gas generation in

Ncum/Gcal

Co Gas 1200

BF gas 2000

Boiler Coal 1300

Present Scenario:

Burning of blast furnace gas generates

huge volume of flue gases and results in

high flue gas temperature due to high

furnace pressure.

Parameters Existing

Boilers

New

Boilers

Flue Gas

temp(deg.c)

200 155

Boiler

Efficiency

<80 89.5

Innovative Project:

1x120MW Blast Furnace gas power plant

The Boilers are also designed with low flue gas temperature (155 Deg.c and

lesser NOx emissions of 320 mg/Ncum).

35

Innovative Project:

1x120MW Blast Furnace gas power plant

Technical Details:

Parameter Unit Value

No of Boilers Nos 2

No of Steam Turbine Nos 1

Steam flow t/hr 223

Steam pressure ATA 115

Steam Temperature Deg.c 540+/-5

BF gas flow to Boiler Ncum/hr 219846*2

Calorific Value Kcal/Ncum 700

Steam Turbine Capacity MW 120 MW

Steam flow to turbine t/hr 443

Condenser pressure ATA 0.1

Auxiliary Power Consumption MW 5.392

Flue Gas Temp. at inlet of ID

fan

Deg.c 155

Boiler efficiency % 89.5 Turbine Heat rate Kcal/Kw 2137 Investment Rs Cr 677

36

Innovative Project:

1x120MW Blast Furnace gas power plant

Estimated Benefits:

• Reduction of BF gas bleeding

• Reduction of GHG emission by 12,00,000 tons

37

Thank you

राष्ट्रीय इस्पात निगम लऱलमटेडRASHTRIYA ISPAT NIGAM LIMITED