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This presentation provides detailed information about energy saving opportunties in Steel and Metal industries in Nepal. It focusses on energy management issues in Steel Rolling Mills. Case studies are presentated to show how energy audit can lead to enormous cost savings. The findings are based on a GIZ baseline study conducted in 200 industries in 2012.
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Bhishma PanditEnergy Efficiency expert/ GIZ/Integration/FNCCI/EEC
Energy Efficiency in Steel Rolling Sector: Overview/Concern
Contents
Sector overviewElectricity & Fuel costPotential area of saving in rolling
mill sectorNepalese best practiceCases
Overview as per baseline
14 rolling mill units are operating.Average installed capacity of iron
and steel plant is 113 TPD and average production is 63.7 TPD
All units have their captive plant (DG sets) .- Total capacity is 12976 kVA
Out of total turnover energy cost is 3.24%
Overview as per baseline
Thermal Energy consumption = 1470 GJ = 41 liter/ton
(ESPS – 41-55 liter/ton)As per base line specific Electricity
consumption per MT- 149.17 kWh
Out of which 120.7 kWh from GRID and 28.47 from DG
6.17%- saving in electricity and 22.97% thermal saving
Overview
Billets are importing from IndiaSome plants have scarab melting
induction furnaceCoal, Furnace oil and Diesel are using as
thermal energyNEA, Grid Connected with 66 kV ,33 kV
and 11 kV with TOD metering and captive plants are source of electricity
NEA TARIFF RATES
Consumer Category & Supply Level
Monthly Demand Charge (Rs./kVA )
Energy Charge (Rs./unit)
Peak Time O -Peak ff Normal
18:00-23:00 23:00-6:00 6:00 - 18:00
High Voltage (66 kV and Above)
Industrial 175.00 Rs. 5.20 3.15 4.55
Medium Voltage (33 kV)
Industrial 190.00 6.55 4.00 5.75
Medium Voltage (11 kV)
Industrial 190.00 6.70 4.10 5.85
Fuel cost
Diesel cost – Rs.89/literFO- Rs.55/literCoal – Rs. 22000/ton
Potential Areas of Energy Saving
Furnace – Waste heat recovery system(installing metallic recuperator), Furnace design, insulation, Burner – air fuel ratio, tips LAP, pusher length, Zone optimization, temperature optimization, thermostat calibration
Pulverize Coal fired furnace- Ball mill and roller mill
Electrical – load management, maintenance scheduling
VFD application, Coupling, Reactive power compensation
Potential Area of saving
Variable Frequency drive for combustion air blower
Producer gas based reheating furnace
Efficient oil burnersRegenerative burnersComplete change of furnace lineAntifriction bearing for rollers
Case
1.Gate opening
Minimization of gate opening fuel consumption has been decreased from 50 liter/Ton – 48 liter/ton
Ambient Air Being Sucked in at the Blower and Sent to the Burner
45 oC Air Being Supplied to the Burner for Combustion
2.APH with waste heat from furnace
Furnace
Cold Air Inlet
Heated Air to BurnerBillets
Billet Discharge Door
Burner
Chimney
Hot Gas to Recuperator
ENERGY AND COST SAVINGS
Project Implementation Cost (NRs.)
330,000
Annual FO Savings (Liters) 34,853
Annual Fuel Cost Savings (NRs.)
760,826
Simple Payback period (Years) 0.6
ENVIROMENTAL BENIFITS
CO2 emission reduction 100.6 Tons
SO2 emission reduction 0.856 Tons
Motor Replacement
Parameter STD EE STD EERated kW 11 9.3 15 15Measured kW 6.5 6.5 12 12opearing efficiency 85 92 88 92Operating losses kW 1.1 0.63 1.54 1.03Difference in losses kW 0.47 0.51Annual Operating hours 6000 6000Saving in kWh 2820 3060Unit cost Rs/kWh 5.5 5.5Cost Saving 15510 16830Payback 2 years 2 Years
Thank you