Energy efficiency campaign

Tata Steel, Jamshedpur

National Workshop

Industrial Energy Efficiency

8th November‘2016

India Habitat Center, New Delhi

Energy Efficiency Improvement Journey (Gcal/tcs)

6.088 6.083

6.017 6.012

5.767 5.750

5.200

5.000

5.100

5.200

5.300

5.400

5.500

5.600

5.700

5.800

5.900

6.000

6.100

6.200

FY'12 FY'13 FY'14 FY'15 FY'16 ABP FY'17 FY'20

Good -4%

By-product gas

firing facility in

Boilers, New

Power plants

132 kV Power

transmission,

Energy efficient

motor / equpt

CDQ boiler,

BF TRT, VFD

Gas holders

Focused

Energy

efficiency

campaign

Journey – Power Generation

180 200

218

220 236

238 239

298

127

95 99

108

65 70

42

0

0

20

40

60

80

100

120

140

120

170

220

270

FY'10 FY'11 FY'12 FY'13 FY'14 FY'15 FY'16 FY'20

Co

al C

on

su

mp

tio

n (

To

ns

X 1

03 )

Po

we

r G

en

era

tio

n (

MW

)

By-product gas based In-House Generation

Power Generation (MW) Coal Consumption (Thousand Tons)

Long Term CAPEX Projects under implementation

Scope of project : Jamshedpur works

Overall lighting load is expected to come down by ~50%

3MW installed at Noamundi. 6 (six) more locations have been identified at Jamshedpur Works.

Site survey for Solar plant at Jamshedpur Completed

Increased usage of by-product gas

Revenue generation from sale of coal tar

Expected reduction in annual Liquid fuel consumption at few identified areas by ~ 4%

LED lighting

Duel fuel burner for Pellet plant

CO

GAS Duel fuel

burner

Solar Power

Magnetic resonator to improve fuel efficiency

Long Term CAPEX Projects being pursued

Low heat recovery using ORC technology

Ability to recover energy from low temperature source

Adaptive control system and sophisticated diagnostic

Plasma gasification to generate syngas from steel plant waste

Steel Plant

waste Syngas

generation

Plasma

Gasifier

Injection in Gas

Network

Conversion of waste into syngas

Improved waste management (Waste generation- 10 TPD)

Recovery of energy at low pressure

Compact design with higher efficiency

Shorter installation period

2,10,000 Nm3/hr 320-360◦ C

300 kg/Nm3

SP#3 SP#4 DUST 2 gm/Nm3

2 X 18.7 TPH 275◦C

165◦C

Bag Filter

ID Fan

Recovery of Waste Heat from SP3 & SP4 Sinter Cooler @ 4.5 MT production.

Package TRT

2.73 MW F-BF

Top gas

GCP

Gas

Network

Blower

Packaged TRT installation at F-BF Power generation

Sinter Cooler Heat recovery

Quick Gain – Low / No CAPEX Initiative

Reduction In

idle or speed

Loss

Optimization

of

Equipment

& Process

Efficient

Use or

Right

Selection

Arresting

Leakage loss

/ waste

minimization

Run time optimisation of coal circuit

conveyor at Coke plant

Installation of Closed type Goggle

valve at ‘H’ Blast Furnace TRT to

increase its availability

Use of hydraulic control valve with

auto control facility for fuel supply in

reheating furnace of HSM

Optimization of heating system for HP

CO injection through modification in

gas pipe network

Increase in COG utilization reducing

coal tar consumption at Pellet plant

through modified COG network

Reduction on Oxygen venting loss at

LD1

Reduction in compressed air loss at

CRM by sizing and connecting to

compressed air network

Reducing power consumption at LD1

Vessel ID Fan by running at 1000 rpm

instead of 1550 rpm

Quick Gain – Low / No CAPEX Initiative

Reduction In

idle or speed

Loss

Optimization

of

Equipment

& Process

Efficient

Use or

Right

Selection

Arresting

Leakage loss

/ waste

minimization

Reduction in idle running of auxiliaries

of D&G machine at Pellet Plant

Reducing waiting time at LF1 by

shifting LC grade from CC1 to CC3 at

LD1

Modification of Blowing strategy to

optimize coal blast supply at F- BF

Compressed air network pressure

optimization

LP steam line network repairing /

modification to reduce steam loss

Use of waste wash oil in place of LDO

for Boiler operation

Supply of MP oxygen in place of HP

oxygen to Blast Furnaces

Speed reduction of ID Fan of LD1

Vessel from 1550 to 1000 rpm

11/15/2016 TATA INNOVISTA 2016

Spent wash oil: an alternative source

of energy

11/15/2016 TATA INNOVISTA 2016

Energy efficiency improvement

program launched in April 15

Genesis of idea

Steel Plant

Energy use

Coal

Fuel oil

Power

Industrial

Gases

Raw

Material

Coke

oven Coal Coke

Coke oven gas

Blast

furnace

Concerns in Current practices Generation of spent wash oil

Current practice in Industry

Direct selling as low value waste

for disposal

Distillation inside plant to recover

by products

Current practice in Tata Steel

Direct selling as low value waste

for disposal as distillation require

capital investment

Considerable amount

Environmental concern: Storage,

handling & disposal

Social obligation Accountability for the

entire life cycle from cradle to grave:

Dependency on external agencies, might

affect the brand image.

Gas

cleaning

Wash Oil Spent Wash Oil

Clean Coke oven gas for process use

11/15/2016 TATA INNOVISTA 2016

Current process & Process innovation

Major concern to reuse the Spent wash oil – It contains impurities

Objective : To identify the process by which Spent wash oil can be reutilised efficiently without

any Capital investment

Naphthalene is

absorbed in wash oil

Wash oil

Storage

Spent wash oil

Ric

h O

il

Na

ph

ta. S

cru

bb

er

Coke oven gas

Clean Coke oven Gas

Storage tank

for spent

wash oil

Le

an

Oil

Makeup wash oil

Temperature

is maintained

at 160 0C

(range 150-

180 0C)

Rich oil is

preheated

up to 140 0C

Naphthalene

and wash oil is

separated

Polymerized oil

Preheater

Na

ph

tha

len

e S

till

Regenerator Cooler

Rich Oil

30-350C

11/15/2016 TATA INNOVISTA 2016

Current process & Process innovation

Temperature is

maintained at

160 0C (range

150-180 0C)

Rich oil is

preheated

up to 140 0C

Rich oil is

preheated up to

150 0C

Naphthalene

and wash oil is

separated

Increased

up to 170

- 175 0C

Polymerized oil

Preheater

Na

ph

tha

len

e S

till

Regenerator Cooler

Rich Oil

30-350C

Process Approach Lab Scale Study

Literature confirms that appreciable

difference in boiling point temperature

between impurities and wash oil

Lab scale distillation with temperature

elevation of 100C

In the range of 150-1800C distillation

gives impurities < 0.001%

Plant trial

Plant trial conducted initially 4 hours

with two modifications

Spent wash oil quality improved with

impurities < 0.003%

Modification

11/15/2016 TATA INNOVISTA 2016

Exploration for utilizations - How

Development of idea

Sampling and analysis done by

Internal team – R&D

National test house , Kolkata

Average Properties LDO Spent wash oil

Gross Calorific Value,

kcal/kg 10200-10800 10872

Flash Point (P.M.C.C.). oC 66 50

Water Content (by Xylene

distillation), % (v/v) 0.25 < 0.01

Total Sulphur as S, %, max 1.8 0.45

Pore point, oC 12-21 (-) 6

Kinematic Viscosity at 40oC,

Cst 2.5-15.7 3.6027

Ash Content, % 0.02 0.019

Sediment, % 0.1 0.017

Carbon Residue, % 1.5 0.0010

Copper strip corrosion No. 2 No. 1A

Analysis has given startling result: all

parameters are very close to LDO except the

density.

This has triggered us to use spent wash oil as a replacement of LDO

11/15/2016 TATA INNOVISTA 2016

Exploration for utilizations - Where

Potential area of utiliasation

Area of Utilization Remarks Status

Heavy vehicles / Earth

moving machineries

Insufficient requirement

× Pre-heating Furnaces Quality issue in finished product

× Diesel Generator Intermittent use and OEM declined

× Boiler After lots of technical deliberation with subject

experts and statistical analysis it has been

concluded that boiler would be the best possible

utilization safely and in an effective manner

√

11/15/2016 TATA INNOVISTA 2016

Exploration for utilizations – Trial phase

PDCA 1

PDCA 2

Experiment in boiler Result

Use of spent wash oil in boiler

as support fuel

( Not connected to the network)

Failed

Improper oil atomization and

dripping of fuel

Use of spent wash oil as support fuel after

tuning/ readjustment of atomization

pressure ( Not connected to the network)

Successful.

Stable operation as a support fuel.

11/15/2016 TATA INNOVISTA 2016

PDCA 3

Experiment in boiler Result

Use of spent wash oil in boiler with

modified logic and reaction plan

(connected to the network)

Successful.

Stable generation as a load carrying fuel

No deviation in Chimney emission

No deposits on pressure part

Challenges Risk mitigation

Combustion failure due to higher viscosity

Tuning of steam atomizer control system with redefined logic

Inspection of deposits on pressure parts

Online monitoring of flue gas temperature

Interruption in process steam supply to

Tata steel network might lead to

catastrophic failure

Revised operational control procedure and reaction plan

Alternate support fuel firing during the trial period

Kept all the stakeholders informed and alert

Higher emission beyond the permissible

Statutory limit

Online monitoring of stack emission

Kept environment management department informed

Exploration for utilizations – Implementation phase

11/15/2016 TATA INNOVISTA 2016

Results and benefits

After successful trial, boiler operation with spent wash oil has been deployed in all in-house power generating stations

Energy saving 3712 Gcal/Yr

Reduction in CO2 emission1570 Ton/Yr

11/15/2016 TATA INNOVISTA 2016