CII – EXIM BANK CONCLAVE ON INDIA – AFRICA
PROJECT PARTNERSHIP
ENERGY EFFICIENT TECHNOLOGIES IN MANUFACTURING UNITS
“Role of Energy Efficiency in small scale
steel industrial units in India”
UNDP/GEF- Project (Steel)
A.C.R. DAS
Industrial Advisor , Ministry of Steel
Government of India
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INTRODUCTION
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World steel production in 2011 was 1,527 million tonne and India produced
72 mt. 4th from the top of the list (China, Japan, USA)
Decadal growth rate in India varies in the range of 8-10%
India will reach to 2nd position ie; next to China in steel production in the
terminal year of 12th plan and expected to produce 200 mt by 2020.
Production (finished steel) from private sector is 80% in 2010-2011. Out of
which, the SME sector contributes 46%
The above indicates a tremendous growth potential of steel sector in India.
With the increase in production. energy consumptions and GHG emissions
will also increase correspondingly. As per available information, global carbon
emission at present is around 25.2 billion tonne /year, out of which Indias
contribution is around 1.0 billion tonnes / year (4%). The steel sector
contributes 150 million tonnes / year (15%), out of which SRRM sector
contributes 16 million tonnes / year (11%).
UNDP/GEF- Project (Steel)
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SME STEEL SECTOR IN INDIA
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Direct Reduction Iron Units (DRI) – 420 Units
Induction Furnace – 1174 Units
Electric Arc Furnace (EAF) – 48 Units
Re-rolling Mills- 1794 Units
The Energy Efficiency of Indian Steel Industry is improving with adoption of
energy efficient technologies and practices.
Ministry of Steel in collaboration with UNDP/GEF took up an initiative to
implement Energy Efficiency Improvement Project in the Steel Re-rolling Mill
Sector by intervention of Energy Efficient Technology and removal of barriers
in 2004
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PROJECT GOALS & OBJECTIVES
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The global objective is to reduce GHG emissions by improving end-use energy
efficiency levels in SRRM sector. The immediate objective is to accelerate
penetration of environmentally sustainable energy efficient technologies.
Remove key-barriers to energy efficiency measures in the sector.
Enabling environment for the industry to adopt energy efficient, economically
viable & environmentally sound technologies.
Setting up Model units and implement technology packages in major
geographic clusters of SRRM.
Emphasis on Technical Assistance for sustaining “Best Practices”
Success of Model units along with removal of barriers is
expected to promote large scale replication of technology
package in SRRM sector and induce policy changes.
UNDP/GEF- Project (Steel)
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Energy Efficient Technologies for
Steel Re-Rolling Mill Sector
High-end Technologies -Energy Saving:
30-40%
Low-end Technologies - Energy Saving : 2025%
Regenerative burner system
High Efficiency Recuperator with improved
furnace design
Hot charging of Continuous Cast Billet
Change of lump coal to coal producer gas as fuel
Top-and-Bottom firing system in reheating
furnace
Technology for use of pulverized coal as fuel
Oxy-fuel combustion system in reheating
furnace
Use of Bio-mass gas as fuel
Walking hearth/Beam furnace
Coal Bed Methane
UNDP/GEF- Project (Steel)
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Benefits to Model Units
Technical Benefits
Identification of existing
problems
Electrical Energy
Audit
Development of
SOP & SMP
Implementation of ISO
9001 and ISO 14001
.
Implementation of 5
S-Lean Manufacturing
Performance
Improvement Training
UNIT
Evaluation of Roll
Pass Design
Electrics
Capital Subsidy of
25% investment
subject to max of
30.0 /75.0 lakhs
Reimbursement of the
cost of consultancy upto a
maximum of Rs. 5,00,000
Financial Benefits
UNDP/GEF- Project (Steel)
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PROJECT TARGETS
Consumption of energy &
other important performance
parameters of re-rolling mills
(Model Units)
Unit
Status in the
beginning of
the Project
Target /
Expected
Outcome after
project
completion
Oil consumption in the
reheating furnace
Lit/T
42-45
<30
Coal consumption
(Pulverized)
Kg/T
80-120
45-65
Gas consumption
Nm3/T
48
30
Productivity of furnace
Kg/m2/h
120-220
300-350
%
2.5-3.5
<1
kWh/T
90-120
60-80
Yield
%
89-93
94-95
Utilization of mill
%
65-70
80-85
Scale Loss
Power consumption
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MAJOR ACHIEVEMENTS
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Almost 50 Model units have been selected in all over the country out of which
25 units have been commissioned with Energy Efficient Technology & Design
Suggested by our project team.
2.
With the Post-Commissioning data available, following reduction has been
achieving
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Furnace Oil : 20-25%
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Pulverized Coal : 15-45%
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CO2 emission : 4000 – 10,000 t/annum. in each unit.
3.
68,000 Training Manuals were prepared in association with SAIL(MTI) and all
these manuals have been distributed to 1000, SRRM units in the country.
4.
Class Room training program were held in various clusters, in which more
than 2500 people were trained.
5.
On-job training programs have been conducted in 22 Model units covering all
clusters, almost 20 persons in each program participated.
Awareness CD has been prepared on 1o Technology Packages & 19 Eco-tech
options for Rolling mills. 1200 copies were made and distributed.
6.
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UNDP/GEF- Project (Steel)
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25 National Awareness Workshops are held so far, in different parts of the
country.
9.
5S lean manufacturing system in 10 Model units have been implemented
and 10 more units will be taken up this year. This activity is a part of
Best Practice Programme.
10.
SOP & SMP Base documents were prepared and implemented in 5 Model
Units. 1000 CD has been sent to SRRM units.
11.
Electrical Energy audit was conducted in 20 Model Units and the reports
submitted by the consultant.
12.
Feasibility Study was carried out in 20 Pipeline units and reports
submitted by the consultant.
13.
The M/s Pulkit Steel, Pondichery a Model unit is the first steel Rolling
mill in India who installed a gasifier based on Biomass and has
successfully commissioned on 9th July, 2009. It is noted that about 8,000t
CO2 emissions will be reduced annually from his unit. Subsequently,
several SRRM units are replicating this technology.
UNDP/GEF- Project (Steel)
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CONCLUSION
BASED ON THE DATA AVAILABLE, IT IS FOUND THAT THE PROJECT IS
MOVING IN THE RIGHT DIRECTION AND WILL ACHIEVE THE TARGET
OF CO2 REDUCTION AS ENVISAGED IN THE PROJECT DOCUMENT
AMOUNTING TO ABOUT 36 MILLION TONNES OVER THE PROJECT
LIFE CYCLE OF 20 YEARS WITH 40% REPLICATION
UNDP/GEF- Project (Steel)
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THANK YOU
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