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CII – EXIM BANK CONCLAVE ON INDIA – AFRICA PROJECT PARTNERSHIP

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CII EXIM BANK CONCLAVE ON INDIA AFRICA PROJECT PARTNERSHIP ENERGY EFFICIENT TECHNOLOGIES IN MANUFACTURING UNITS Role of Energy Efficiency in small scale ... – PowerPoint PPT presentation

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Title: CII – EXIM BANK CONCLAVE ON INDIA – AFRICA PROJECT PARTNERSHIP


1
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

A.C.R.
DAS Industrial Advisor , Ministry of Steel
Government of India
UNDP/GEF- Project (Steel)
2
introduction
  • 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)
3
SME Steel SECTOR IN INDIA
  • 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

4
Project Goals Objectives
  • 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)
5
Energy Efficient Technologies for Steel
Re-Rolling Mill Sector
High-end Technologies -Energy Saving 30-40 Low-end Technologies - Energy Saving 20-25
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)
6
Benefits to Model Units
Technical Benefits
.
Implementation of 5 S-Lean Manufacturing
Identification of existing problems
Electrical Energy Audit
Development of SOP SMP
Performance Improvement Training
UNIT
Implementation of ISO 9001 and ISO 14001
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)
7
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 lt30
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
Scale Loss 2.5-3.5 lt1
Power consumption kWh/T 90-120 60-80
Yield 89-93 94-95
Utilization of mill 65-70 80-85
UNDP/GEF- Project (Steel)
8
Major Achievements
  • 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.
  • With the Post-Commissioning data available,
    following reduction has been achieving
  • Furnace Oil 20-25
  • Pulverized Coal 15-45
  • CO2 emission 4000 10,000 t/annum. in each
    unit.
  • 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.
  • Class Room training program were held in various
    clusters, in which more than 2500 people were
    trained.
  • 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.

UNDP/GEF- Project (Steel)
9
  • 25 National Awareness Workshops are held so far,
    in different parts of the country.
  • 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.
  • SOP SMP Base documents were prepared and
    implemented in 5 Model Units. 1000 CD has been
    sent to SRRM units.
  • Electrical Energy audit was conducted in 20 Model
    Units and the reports submitted by the
    consultant.
  • Feasibility Study was carried out in 20 Pipeline
    units and reports submitted by the consultant.
  • 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)
10
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
  • CONCLUSION

UNDP/GEF- Project (Steel)
11
THANK YOU
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