Since the establishement of Bureau of Energy Efficiency in 2001 India has been implementing a lot of activities in energy-intensive sector. In Steel Rolling Mills with low-end and high-end technolgies considerable energy and cost sanvings can be achieved. The presentation was prepared in the Context of GIZ NEEP programm in Nepal in 2012.

1. D. Pawan Kumar
Team Leader
D. Pawan Kumar
Team Leader
ENERGY EFFICIENCY
SHARING INDIAN EXPERIENCES
ENERGY EFFICIENCY
SHARING INDIAN EXPERIENCES
08/02/13

2. Current Major EE
initiatives/Drivers
08/02/13
 Accelerated depreciation for EETs
Energy Conservation Act implementation,
 NMEEE
MNRE initiatives
APDRP & RAPDRP programmes
MSME schemes for SME sector
CDM and other international Programmes
SDA capacity building
DC & PAT Scheme
S&L Programmes
SME Clutter programme
DSM (Agriculture, Municipal DSM)
NECA, initiatives, BLY, ECBC Scheme
ISO 50001
ESCO capacity building
Financial instruments /Bank Schemes

3. ENERGY CONSERVATION TECHNOLOGIES
ADOPTED IN INDIAN STEEL ROLLING MILLS:
• Low - end Technologies
Requires investment Rs. 1.5 to 2 Crores and
energy saving 20-25%
• High-end Technologies
• Requires investment Rs. 5 to 6 Crores and
energy saving 30-40%
08/02/13

4. Low - end Technologies
• High efficiency recuperator with improved
furnace design
• Change of lump coal to producer gas as fuel
• Technology for use of pulverized coal as fuel
• Use of Bio-mass gas as fuel
08/02/13

5. High-end Technologies
• Regenerative burner system
• Hot charging of continuous cast billet
• Top and bottom firing system in reheating
furnace
• Oxy - fuel combustion system in reheating
furnace
• Walking hearth/beam furnace
08/02/13

6. ECO TECH OPTIONS IN FURNACES
• Total replacement of the existing pusher
type with the energy efficient furnace.
• Walking beam reheating furnace
• Producer gas based reheating furnace
• Modifying of grate coal fired system to
pulverized
08/02/13

7. ECO TECH OPTIONS IN FURNACES Contd…
• Revamping /modernization of existing pusher
furnace
• Efficient oil burners
• Regenerative burners
• Complete change of furnace line
• Ceramic fibre veneering
08/02/13

8. ECO TECH OPTIONS IN FURNACES Contd…
• Microprocessor based furnace zone
temperature/pressure control
• Metallic Recuperator
• Hot Charging in composite mills
• Variable voltage variable frequency drive
(VVVF)
08/02/13

9. ECO Tech options in Rolling Mills
• Crop length optimization
• Rollers guide
• Spindle and coupling
• Antifriction bearing
• Installation of Y-roller table
• Installation of drop tilter
• Installation of tilting table
08/02/13

10. ECO Tech options in Rolling Mills Contd…
• Quenching and self-tempering of re-bars
• Oval repeaters
• No - Twist Block
• Slit rolling
• Computerized roll pass design
• Lubrication technology
08/02/13

11. ECO Tech options in Rolling Mills Contd…
• Cast in carbide rolls in conventional stands
• Endless welding roll
• Reactive power compensation
• Energy efficient drives for rolling mills
• Pre-stressed housing less stands
• High voltage (HT) AC motor for rolling mills
etc
08/02/13

12. Recommendatio
n
Key Technical
elements of
proposed
design
Major
Specificatio
n
Standard
Equipmen
t
Suppliers
Productivity/Yiel
d
Improvements,
Power
consumption
reduction, Fuel
Consumption
Reduction etc.
Investmen
t in Rs.
Lakh
Reheating
Furnace
Proper Coal
storage
House keeping
measure which
reduces carpet
loss
Furnace
Instrumentation
1.Pressure
gauge,
2.Thermocoupl
e for flue gas,
3.O2 Analyser
for flue gas
4. Automation
of air and fuel
ratio
+0.1mm W.G
800
(max)degC
Electronic
gas analyser
Amsat
EDC Pune
Maharastra
Better operation
control and
efficiency
improvement
2 lakhs
TECHNOLOGY PACKAGES /ECO-TECH OPTIONS
& SPECIFICATION OF MAJOR FACILITIES
08/02/13

13. Recommendatio
n
Key Technical
elements of
proposed
design
Major
Specificatio
n
Standard
Equipment
Suppliers
Productivity/Yiel
d
Improvements,
Power
consumption
reduction, Fuel
Consumption
Reduction etc.
Investmen
t in Rs.
Lakh
Variable
Frequency drive
for combustion air
blower
Variable
Frequency
Drive (VFD)
ABB Power savings 0. 8 lakhs
Waste heat
recovery by
installing metallic
recuperator
Metallic
recuperator
Indaid
Engineers
(P) Ltd.,
Chennai
Waste heat
recovery,fuel
saving and
efficiency
improvement
7 lakhs
Energy efficient
burner
Energy
efficient burner
Webster
Engineers
&
manufactur
ing
Company
Better turbulence
and excess air
reduction
1.5 lakh
Contd…
08/02/13

14. Recommendatio
n
Key Technical
elements of
proposed
design
Major
Specificatio
n
Standard
Equipmen
t
Suppliers
Productivity/Yiel
d
Improvements,
Power
consumption
reduction, Fuel
Consumption
Reduction etc.
Investmen
t in Rs.
Lakh
Rerolling Mill
Universal spindle
and coupling
Spindle &
coupling
Armech
Engineers
(P) Ltd.,
Noida
Power savings 6 lakh
Antifriction bearing
for rollers
Antifriction
bearings
Power
savings
2 lakh
Installation of
roller table at
furnace discharge
Mill
Mechanization
Delay in rolling 1.5 lakhs
Installation of
tilting table and
drop tilter at
roughing stand,
Skew table& roller
table at all mill
stand
Mill
Mechanization
Power saving 3 lakhs
Contd…
08/02/13

15. Practice Parameters on which performance is measured
Producti
vity
(tph)
Utilization
(%)
Fuel
(kg/t)
(lt/t)
(Nm3/t)
Power
(kWh/t)
Burning
loss %
Mill
Scale
(%)
Rolling
and
cuts
(%)
Yield
(%)
Current
Practices
8TPH 70% 100
kg/t
97 1.57 0.50 1.4 96.53
%
Projected
Case
8TPH 70% 75
kg/t
85 1.5 0.50 1.4 96.60
%
Benchmark 80% 65
kg/t
80 1.3 0.5 0.5 97.7%
08/02/13

16. The energy balance sheet of unit for baseline and ecotech for
Reheating furnace
Operating Parameter Base line Projected Case
Fuel Consumption( per MT of throughput), kg 100 75
Scale loss,( per MT of throughput), kg 20.6 20
Through put rate ( tonnes per hour), tph 7.25 8
Furnace Parameter
Rolling Temperature, Hs(0C) 1280 1200
Avg Skin Temperature, ts 67 67
O2 in flue Gas (%) 12 7
CO2 in Flue Gas(%) 9 12.5
CO in Flue Gas ( PPM) 60 60
Excess air ( %) 133 50
Exhaust gas temp at furnace backend, Th in (0C) 518 600
Exhaust gas temp at Stack, Th out (0C) 518 250
Air Preheat Tf (0C) NA 300
Fuel Preheat ( 0C) NA NA
08/02/13

17. Operating Parameter Base line Projected Case
Thickness of Refractory lining , X (cm) 50 50
Calorific value of fuel 6000 6000
Energy Input ( Thermal)
Fuel ( Mcal/t) 600 450
Sensible heat of fuel (Mcal/t) NA NA
Sensible heat of air ( Mcal/t) NA 67.5
Heat of formation of scale ( Mcal/t) 20.9595 20
Total 620.9595 537.5
Energy Output (Thermal)
Steel (Mcal/t) 149.52 149.52
Scale (Mcal/t) …………..
Dry exhaust gas , (Mcal/t) 191.5262237 124.0262237
Water vapur ( Mcal/t) 37.580366 37.580366
Heat Loss due to radiation and convection(Mcal/t) 41.56015617 41.56015617
Heat Loss due to opening (Mcal/t) 42.63917863 30
Heat Loss due to non continous operation (Mcal/t) 48 40
Total 510.8259245 422.6867459
Other difference , (Mcal/t) 110.1335755 114.8132541
Contd…
08/02/13

18. Summary of Rolling Mill Parameter
Operating
Parameter Baseline Projected Case
Specific power
consumption
( KWh/t) 97 85
power Factor 0.98 0.99
Mill utilization (%) 70 70
Mill yield (%) 96.5 96.6
Miss roll (% of
furnace throuput) 1.04 1
Mill scale (%) 0.49 0.49
08/02/13

19. Summary of Rolling Mill Parameter
Operating
Parameter Baseline Projected Case
Rolling Mill Parameter
Rolling Temperature at
furnace discharge (⁰C) 1200 1150
Rolling Temperature at
roughing mill inlet (⁰C) 1125 1125
Rolling time (Seconds)
Roughing
Intermediate
Finishing 40 40
08/02/13

20. Summary of Rolling Mill Parameter
Operating
Parameter Baseline Projected Case
Rolling Temperature at
finishing mill outlet (⁰C) 850 850
Rolling Temperature at
cooling bed (⁰C) 850 850
Mill efficiency (%)
70 70
Mill delays ( Min)/day
75 50
Total roll cooling water
consumption (m3/s/t)
Total roll consumption
(kg/tonne of finished
product)
08/02/13

21. Thank you