Energy Efficiency in Steel Rolling Mills of Nepal

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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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Energy Efficiency in Steel Rolling Mills of Nepal

  1. 1. Bhishma Pandit Energy Efficiency expert/ GIZ/Integration/FNCCI/EEC
  2. 2. Energy Efficiency in Steel Rolling Sector: Overview/Concern
  3. 3. Contents Sector overview Electricity & Fuel cost Potential area of saving in rolling mill sector Nepalese best practice Cases
  4. 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. 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. 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. 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. 8. Fuel cost Diesel cost – Rs.89/liter FO- Rs.55/liter Coal – Rs. 22000/ton
  9. 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. 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. 11. Case
  12. 12. 1.Gate opening Minimization of gate opening fuel consumption has been decreased from 50 liter/Ton – 48 liter/ton
  13. 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. 14. Furnace Cold Air Inlet Heated Air to BurnerBillets Billet Discharge Door Burner Chimney Hot Gas to Recuperator
  15. 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. 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
  17. 17. Thank you

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