godawari power & ispat ltd. - knowledge platform · 1. water complex installation of vfd 120...

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GODAWARI POWER & ISPAT LTD. welcomes

All Dignitaries & Industry Partners Energy Conserved is Energy Generated

WORKSHOP ON “BEST PRACTICES IN ENERGY EFFICIENCY

IN IRON & STEEL SECTOR” &

“OPPURTUNITIES AND CHOICES IN ENERGY CONSERVATION AT GPIL’’

Presented by:

RATNADEEP GUPTA GM SID

GPIL

3 Energy Conserved is Energy Generated

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GPIL Profile

Scope & Areas for Energy Conservation in Power Generation

Scope & Areas for Energy Conservation in Ferro Alloy Division

Scope & Areas for Energy Conservation in Sponge Iron Making

Conclusion

Walkthrough

Energy Conserved is Energy Generated

GPIL- Company Profile Godawari Power & Ispat Ltd. (GPIL) is the Flagship Company of Hira Group of

Industries; Raipur which was incorporated in 1999 to setup an integrated steel

plant with captive power generation.

GPIL is certified for adapting and implementing the following management

systems :

ISO:9001:2008 FOR Quality Management System

ISO:14001:2004 for Environment Management System

OHSAS ISO:18001:2007 for Occupational Health & Safety

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Product Portfolio

PELLET 2.1 MTPA

POWER 73 MW

HB WIRES 0.10 MTPA

SPONGE IRON 0.495 MTPA

BILLETS 0.20 MTPA

SILICO MANGANESE 0.0165 MTPA


http://www.roundwellsteel.com/images/MS HB Wires.jpg

1.Modification of fuel feeding system: Traditional Drag chain system replaced by Rotary feeding

Reduction of maintenance and power Saving cost by 8.12 Lacks per annum Additional benefits

Improvement in redundancy of AFBC Pollution control Reduced safety hazards caused by opened rotary parts.

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2.Modification of Old screw conveying system:

Dense Phase pneumatic ash handling system replaces old screw conveying system Savings of 19.35 Lacs Per annum & 56 Kilowatts of power.

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Scope & Areas for Energy Conservation in FAD

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• Changing of charge mix, size of raw material

• Optimizing the operational control system

• Periodic checking of electrode length by taking smelt down

• Installation of FES (Fumes Extraction System)

Significant Reduction of Specific Power consumption

Energy Conservation in FAD Process

4.078

4.023

3.929 3.907

3.8

3.85

3.9

3.95

4

4.05

4.1

Nov-15 Dec-15 Jan-16 Feb-16

POWER CONSUMPTION IN MWH

MWH

UPTO 25TH FEB


Scope & Areas for Energy Conservation in FAD

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S.NO. AREA ACTIVITY ENERGY SAVINGS

1. Water Complex Installation of VFD 120 Kwh/ Day

2. Fume Extraction System - ID Fan

Installation of VFD 1968 Kwh/ Day

3. Fume Extraction

System - F.D. Cooler Installation of VFD 144 Kwh/Day

4. Furnace Air Cooling

System

Reduced number of cooling fans from 6 to 3 by changing the

capacities 242 Kwh/Day



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• Coal and air can be taken as hot utility streams - process integration terminology

• Potential possible areas where energy is being lost and can form a part of heat integration, are as follows:


Combustion of Coal in the Rotary kiln in presence of air (HEAT SOURCE)

Removes moisture from feed and coal

Preheats the feed upto the desired

temperature

Metallization of Iron Ore

Compensates radiation loss from

kiln wall

Decomposition of Dolomite


Scope 1

Energy lost in the Rotary Kiln can be derived through material and energy balance.

• Streams of sponge iron, char, waste gas and volatile matter

Counter Measure

Process integration – best option to reduce:

Heat losses in the process of sponge iron making

Waste generation

Water consumption (Reduction in the highest quality heat (Coal and air) using

proper heat integration in the process automatically reduces the cold utility (water)

requirement)

Better refractory selection and Reducing Shell temperatures

Pre heating of feed material

Optimization of C/Fe ratio

F.C in Char to be optimized

L.O.I control



Scope 2

Hot sponge iron is being cooled with water in rotary cooler. For this purpose water is being sprayed

on the shell of cooler and the vapour generated from it goes directly to atmosphere. As a

consequence of it the temperature of sponge iron drops from 1020 °C to 100°C. In this process the

cold water is heated up from 30 °C to 34.7 °C

Counter Measure

Cooling efficiency can be enhanced by time to time De Scaling of Cooler shell and by

incorporating efficient cooling tower. Thus delta T can be increased and oxidation of product

can be prevented from 0.5 -1% .

Scope 3

Clean waste gas is generated in ESP from where it goes to the chimney at the temperature of 170-

180 °C and from there to the atmosphere, which is also a loss of considerably high temp. heat.

Counter Measure

Efficient heat utilization in Power plant can retain the temperature of ESP outlet to 140-150°C

through periodic soot blowing.



Scope 4

Feed material as well as air enters the process (mainly rotary kiln) at ambient temperature

and reduction reactions are taking place at 1080-1100 °C. This requires feed to be heated up

which needs the significant amount of heat generated from combustion of coal. This

preheating could be done by the waste gas. However this is not done in all Kilns .As a result of

it a large amount of coal is being utilized for preheating the feed material and air which

otherwise could have been saved.

Counter Measure

Pre heater, thus helps in feeding the material at 9000C and helps us in saving 5% of

energy.


Areas of Energy Conservation in Sponge Iron Plant

We have also identified following areas where we can effectively adopt initiatives to conserve energy

Challenges:

1. Kiln Availability

2. Campaign Life

3. Production Rate

4. Operational Losses

5. Specific Coal Consumption

6. Optimum Utilization of pre-heater

7. Utilization of Solid Wastes


1. Kiln Availability Frequent kiln breakdown due to mechanical, electrical and operational interruptions

have a significant effect on Kiln availability which also leads to poor efficiency. At GPIL, we had overcome this by implementing best maintenance planning and

Robust Preventive and Predictive Maintenance.

2. Campaign Life Frequent kiln shutdown due to accretion formation, DSC clinker formation and

refractory damage affects its capacity utilization and also consume more energy in reviving the kiln.

At GPIL, we had overcome this by Better Process Control and monitoring, Selection and Application of quality refractory material and Restriction of Undersize in feed material. Today the average campaign life is around 250-300 days.

3. Production Rate Reasons for Low Production rate identified leading to low capacity utilization are Low

Yield, Process Interruptions at Central Burner , Feeding and Injection systems which can lead to increase energy consumptions.

At GPIL, we had over come this by: Proper blending of Imported & Domestic coal to maintain required F.C. Utilization of high TI Pellet . Conducted Fe Balancing to analyze yield losses. Fabrication of CB & Coal Injector Trolley for fast operation. Restriction of Undersize in material.


4. Operational Losses

There are various operational losses which needs to be saved for efficient energy conservation

Major Losses

Emission of flue gas from slip seal, Cooler Discharge and stack cap

Radiation losses

Spillages from feed and injection area

Yield Losses

Initiatives taken:

Better sealing done in stack cap to capture fugitive emission

For Better sealing, pneumatic cylinders installed at slip seal to maintain gaps in seals

Thorough inspection of old and worn out refractory and application of best quality refractory which reduced in radiation losses

Inspection of spillages if any and arresting

We have done analysis of Yield losses by conducting Fe Balancing where it is evidenced that under sized ore is poison for kiln

Using minimum coal during Shut down & Light up and following Ramp up plans

D.P. Valve Installation at Cooler Discharge


5. Specific Coal Consumption & C/Fe High Specific Coal Consumption leads to immense waste of energy. So it is the area of

greater concern and must be addressed. Optimum utilization of coal to minimize C/Fe is a big challenge Initiatives taken: Optimum Utilization of coal by proper Screening and Blending Optimum C/Fe level for safe and better campaign Total 3-4 % of carbon is allowed in Non Mag. Product Effective use of coal fines in injection Coal

6. Optimum Utilization of Pre-Heater We have a arrangement of Pre Heater in two 500 TPD kilns which helps in higher

production rate by 10 – 15 % but we faced various challenges in running it, Process control is tough High fines generation High FeT in fly ash (30% - 40%) Yield loss of 1 %

Initiatives taken: Utilization of high TI Pellet with minimum Under sized (Max 2%) By the help of pre heater, waste gas generated in kiln increases the temperature

of pellet to 700 – 900°C, hence low coal is required to satisfy the need for reduction and thus specific consumption of coal is low in the kiln. Furthermore it enhances the production rate.


7. Solid Waste Utilization and Disposal – Green Productivity

Reduce

• Reduction of accretion by using pellet and Imported coal • Reduce Fe in Fly ash by using high Tumbler index(>94) pellet ore • Reduce LOI in flue gas by proper process control in Kiln and ABC • Reduce emission by installing bag filters • Proper sealing of all leakage prone points

Reuse

• Use of Fly Ash for making Bricks & tiles • Char & Dolochar is used AFBC boiler for power generation • Started using Bag filter dust in ABC which led to increase in steam generation by 2-

3 tph

Recycle

• Recycle the back flow material after screening • Fines generated in Iron Ore is being used in pellet plant

Recover • Recovery of waste heat in WHRB for power generation


Year on Year Analysis

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1024 1187 1177 1264*

76.7%

87.2% 88.0% 94%

0.0%

10.0%

20.0%

30.0%

40.0%

50.0%

60.0%

70.0%

80.0%

90.0%

100.0%

0

200

400

600

800

1000

1200

1400

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16

Kiln Running Days in a Year (Days)

Overall Kiln Utilization %

*Expected

as per pro

rata basis

1.62 1.56 1.56 1.505

0.5

0.7

0.9

1.1

1.3

1.5

1.7

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16(till Feb'16)

Trend for specific consumption of Ore

Specific Consumption of Ore

1.68 1.53

1.21

1.01

0.5

0.7

0.9

1.1

1.3

1.5

1.7

1.9


Coal Consumption Analysis

Specific Consumption of Coal (Total)


90 92 85

68

0

20

40

60

80

100


Specific Power Consumption Specific Power Consumption in KWH/MT

Year on Year Analysis

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*Expected

as per pro

rata basis

293887

371784 381060

495000*

59%

75% 77%

100%

0%

20%

40%

60%

80%

100%

120%

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16

Production of Sponge Iron (MT)

Capacity Utilization

260 354

403

773

0

100

200

300

400

500

600

700

800

900

2012-13 2013-14 2014-15 2015-16

Pro

du

cti

on

(M

T)

Productivity per Head

Production (MT) per Employee

7.63 6.95

6.12 5.19

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00


Gross Specific Energy Consumption in GCal per 1MT Sponge Iron Production

4.30 4.16

3.50

2.89

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00


Net Specific Energy Consumption in GCal per 1MT sponge Production


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Conclusion

It is concluded that in Iron and Steel making, the opportunities of energy conservation are significant. If adequate awareness is created and actions are

taken, then losses of energy can be brought down to a large extent.

Any spillage or leakage is not limited only to emissions rather, it is the loss of natural resources and nation’s loss.

Energy Conserved is Energy Generated.

Thank You

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