energy efficiency in steel rolling mills of nepal

17
Bhishma Pandit Energy Efficiency expert/ GIZ/Integration/FNCCI/EEC

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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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Page 1: Energy Efficiency in Steel Rolling Mills of Nepal

Bhishma PanditEnergy Efficiency expert/ GIZ/Integration/FNCCI/EEC

Page 2: Energy Efficiency in Steel Rolling Mills of Nepal

Energy Efficiency in Steel Rolling Sector: Overview/Concern

Page 3: Energy Efficiency in Steel Rolling Mills of Nepal

Contents

Sector overviewElectricity & Fuel costPotential area of saving in rolling

mill sectorNepalese best practiceCases

Page 4: Energy Efficiency in Steel Rolling Mills of Nepal

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%

Page 5: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 6: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 7: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 8: Energy Efficiency in Steel Rolling Mills of Nepal

Fuel cost

Diesel cost – Rs.89/literFO- Rs.55/literCoal – Rs. 22000/ton

Page 9: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 10: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 11: Energy Efficiency in Steel Rolling Mills of Nepal

Case

Page 12: Energy Efficiency in Steel Rolling Mills of Nepal

1.Gate opening

Minimization of gate opening fuel consumption has been decreased from 50 liter/Ton – 48 liter/ton

Page 13: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 14: Energy Efficiency in Steel Rolling Mills of Nepal

Furnace

Cold Air Inlet

Heated Air to BurnerBillets

Billet Discharge Door

Burner

Chimney

Hot Gas to Recuperator

Page 15: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 16: Energy Efficiency in Steel Rolling Mills of Nepal

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

Page 17: Energy Efficiency in Steel Rolling Mills of Nepal

Thank you