This document provides an overview of energy efficiency opportunities in the steel rolling sector in Nepal. It discusses the current state of 14 rolling mill units in Nepal, including their electricity and fuel costs which account for around 3.24% of total costs. Potential areas for energy savings are identified, such as waste heat recovery systems, improving furnace designs and insulation, installing variable frequency drives, and replacing motors. The document presents two case studies of mills that implemented energy efficiency measures, such as minimizing gate opening times to reduce fuel consumption and installing an air pre-heater to capture waste heat, resulting in annual fuel savings of over Rs. 760,000 with a payback period of just 0.6 years. Motor replacement projects also achieved
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
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
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