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Louis Bosch AMSA VDBP

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Louis Bosch AMSA VDBP

  1. 1. Arcelor Mittal Vanderbijlpark Industrial Energy Efficiency IEE Case Study
  2. 2. ArcelorMittal South Africa (AMSA) is the largest steel producer in Africa. AMSA produces 4.8 million tonnes per year of saleable steel. The plant’s steel products are manufactured in an integrated process. Raw materials such as iron ore, coke and dolomite are charged to blast furnaces where they are converted to liquid iron. The liquid iron is refined in basic oxygen furnaces and electric arc furnaces to produce liquid steel. The liquid steel is cast into slabs, which are hot rolled into heavy plate in a plate mill, or into coils in a strip mill. The coils are either sold as hot rolled sheets in coil or processed further into cold rolled and coated products, such as hot dip galvanised, electro- galvanised and pre-painted sheet, and tinplate. Company Profile
  3. 3. • First encounter with the Industrial Energy Efficiency Project (IEEP) – Dec 2013 with UNIDO experts becoming a valuable extension of the AMSA energy efficiency team. • Energy management systems (EnMS) expert level training – May 2014. • Compressed air system optimisation (CASO) 2 day training – June 2014 • Pump system optimisation (PSO) 2 day training – Mar 2014 • PSO expert level training – Jul 2014 • Fan system optimisation (FSO) 2 day training – Sep 2014 • FSO expert level training – Oct 2014 • Steam system optimisation (SSO) 2 day training – Sep 2014 • SSO expert level training – Feb 2015 • In the process of implementing EnMS – ISO 50001, energy systems optimisation (ESO) assessments and case studies in pumps, fans, steam and compressed air. Arcelor Mittal VDBP - NCPC / IEEP Journey
  4. 4. ArcelorMittal VDBP - EnMS implementation results: Electricity and natural gas data on baseline period 2013 Actual Savings 2016 – Approx. R105 million! ESO Assessment Results - Case Study Compressed air leak detection assessment R3.6 million Pump system optimisation assessment (Ph1) R25 million Compressed air system optimisation assessment R36 million Steam system optimisation assessment (Incl. power generation) R175 million
  5. 5. Status of Energy Phase1 Pump Savings Projects with the assistance of UNIDO / NCPC Funding Plate Mill Descaler pump Ph1 Plate Mill Descaler pump Ph1&2 BF- D Furnace cooling pumps 5 Stand South Ph I Cool pump 5 Stand South Ph 2 Cool pump HSM-HP Pump (after VSD’s) Savings study mechanism funded by NCPC Run best out of 3 pumps only after pump efficiency test Refurbish pumps Run 1 pump only Run 1 less pump Reduce friction Reduce orifice size at bypass Automate main pumps on/off Analyse / optimise in PumpMonitor Savings (Rand) R253,246 R458,557 R1,498,421 R811,992 R900,113 R2,200,000 Energy savings (kWh p.a) 358,705 649,514 1,971,607 1,014,990 1,125,141 2,820,513 Total equipment investment VDB (Rand) None (completed) R457,053 (completed) R 676,640 (completed) R30,000 R300,000 R508,000 Payback time N/A 12 months 5.5 Months <1 month 4 months 3 months Project status & plant support Completed M&V Audit Completed Implemen - tation Proposal Proposal
  6. 6. How the Blast Furnace (BF-D) Pump System Works Motor Data : Rated Power 315 kW Voltage 3 300 V Full Load Amps 68 A Speed 998 RPM Pump Data : Salweir Centrifugal Split Casing Double suction Model SDA 400-500 Type 400/500 Impeller Diameter 478mm Cooling Tower Sum p Heat Exchangers BF-D Close System IN BF-D Close System OUT
  7. 7. BF-D Pump System - Root Cause Analysis Pump Station BF-D New Water Level increase NPSH
  8. 8. Pumps to Operate close to BEP
  9. 9. BF-D Pump System - Root Cause Analysis Pump operation outside BEP 2 Inlet cavitation Low NPSH available Inline strainers got blocked restricting flow Plastic cooling tower packing collapsed and contaminated water Strainers at cooling tower and pump suction were not effective 2.1 Cooling tower fill is in bad state due to ageing. End of life. 2.2 Strainers cause high ∆P even when clean Design restriction 2.3 Long rusted inlet pipes with elbows increase pipe resistance Pipes ageing 2.4 One out of two inlet valves stuck in close position restricting half of the flow Butterfly valve sleeve damaged during installation cause disk to become stuck Installation is too rigid. Valve had to be forced into position 2.5 Low level in the sump Water overflows to BF-C sump Leaking sluices 2.6 No control by operational personnel 2.7 Lack of maintenance & lubrication 1 Grease does not enter the bearings but stays in the bearing cap Bearings were not greased by supplier Bearings were not greased by maintenance personnel
  10. 10. • Recommendations (without large capital) : • Sump level increase to 100%. • Automatic level control for top-up. • Redesign suction pipe in order to reduce pressure loss o Use bigger size pipe; o Regularly clean strainers; and o Remove elbow on inlet. • Regularly clean heat exchangers. • Adjust flow based on temperature. • Confirm ΔT requirements of the ‘BF closed loop’ system and calculate the required flow rate of the ‘open’ loop system. • Compare flow requirements with cooling degree days. • Operate a single pump year round. BF-D Pump System - Root Cause Analysis Operation outside BEP 2 Outlet cavitation High back pressure Blocked heat exchangers increase system pressure Plastic cooling tower packing collapsed and contaminated water Strainers at cooling tower and pump suction were not effective 2.1 Cooling tower fill is in bad state due to ageing. End of life. 2.2Heat exchangers were not cleaned regularly No maintenance plan for heat exchangers cleaning 2.8 Not effective and unreliable system for monitoring HE pressure drop 2.9
  11. 11. BF-D Pump System - Root Cause Analysis
  12. 12. Effect of Increased Maintenance at the Right Time on Total Operational and Energy Cost
  13. 13. The Plate Mill makes use of a descaling pump system (1 out of 3 pumps in parallel) that sprays concentrated high pressure water onto the plate, after the heating and rolling process, to remove any scale that has formed on the plate. Effect of Increased Maintenance on Total Operational and Energy Cost
  14. 14. Plate Mill Descaler PSO - Worn Pump Reduce Head, Flow, Efficiency at Increase Power
  15. 15. Thank You Questions ?