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Bhishma Pandit
Energy Efficiency expert/ GIZ/Integration/FNCCI/EEC
Energy Efficiency in Steel Rolling
Sector: Overview/Concern
Contents
Sector overview
Electricity & Fuel cost
Potential area of saving in rolling
mill sector
Nepalese best practice
Cases
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 India
Some plants have scarab melting
induction furnace
Coal, Furnace oil and Diesel are using as
thermal energy
NEA, 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 -Peakff 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/liter
FO- Rs.55/liter
Coal – 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 burners
Regenerative burners
Complete change of furnace line
Antifriction 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 o
C 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 EE
Rated kW 11 9.3 15 15
Measured kW 6.5 6.5 12 12
opearing efficiency 85 92 88 92
Operating losses kW 1.1 0.63 1.54 1.03
Difference in losses
kW 0.47 0.51
Annual Operating
hours 6000 6000
Saving in kWh 2820 3060
Unit cost Rs/kWh 5.5 5.5
Cost Saving 15510 16830
Payback 2 years 2 Years
Thank you

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Energy Efficiency in Steel Rolling Mills of Nepal

  • 1. Bhishma Pandit Energy Efficiency expert/ GIZ/Integration/FNCCI/EEC
  • 2. Energy Efficiency in Steel Rolling Sector: Overview/Concern
  • 3. Contents Sector overview Electricity & Fuel cost Potential area of saving in rolling mill sector Nepalese best practice Cases
  • 4. 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%
  • 5. 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
  • 6. Overview Billets are importing from India Some plants have scarab melting induction furnace Coal, Furnace oil and Diesel are using as thermal energy NEA, Grid Connected with 66 kV ,33 kV and 11 kV with TOD metering and captive plants are source of electricity
  • 7. NEA TARIFF RATES Consumer Category & Supply Level Monthly Demand Charge (Rs./kVA ) Energy Charge (Rs./unit) Peak Time O -Peakff 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
  • 8. Fuel cost Diesel cost – Rs.89/liter FO- Rs.55/liter Coal – Rs. 22000/ton
  • 9. 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
  • 10. Potential Area of saving Variable Frequency drive for combustion air blower Producer gas based reheating furnace Efficient oil burners Regenerative burners Complete change of furnace line Antifriction bearing for rollers
  • 11. Case
  • 12. 1.Gate opening Minimization of gate opening fuel consumption has been decreased from 50 liter/Ton – 48 liter/ton
  • 13. Ambient Air Being Sucked in at the Blower and Sent to the Burner 45 o C Air Being Supplied to the Burner for Combustion 2.APH with waste heat from furnace
  • 14. Furnace Cold Air Inlet Heated Air to BurnerBillets Billet Discharge Door Burner Chimney Hot Gas to Recuperator
  • 15. 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
  • 16. Motor Replacement Parameter STD EE STD EE Rated kW 11 9.3 15 15 Measured kW 6.5 6.5 12 12 opearing efficiency 85 92 88 92 Operating losses kW 1.1 0.63 1.54 1.03 Difference in losses kW 0.47 0.51 Annual Operating hours 6000 6000 Saving in kWh 2820 3060 Unit cost Rs/kWh 5.5 5.5 Cost Saving 15510 16830 Payback 2 years 2 Years