sustainability through lesser energy intensive indian...

Your Reliable Partner Thermax Limited

Sustainability through lesser energy intensive Indian Steel Industry

- Vivek Taneja

Disclaimer : This presentation is for information purpose only and Thermax reserves the right to alter or change specifications

without prior notice. All photos in this presentation are representative in purpose and to be used for reference only.


Sources of useful Waste Heat & Gases

Why waste recovery

Options of steam utilization

Need for carbon reduction PAT scheme

A word about us

Contents


Sources of waste heat and gas

• Waste Heat

– Sponge Iron Kilns

– Non recovery Coke oven batteries

• Gas

– Blast furnace

– Recovery based Coke Ovens

– Corex Gas + dust


Why Waste Heat Recovery ?

• Steam thereby Power / heating Cooling is incidental!!

• Environmentally – Clean and Green option.

• Cost of Power can be as Low as Rs 0.80 per Unit!!

• 100 TPD (DRI) Kiln can generate 1.6 MW of usable power i.e. 11 million units/year. Saving

per annum (Grid @ Rs. 2.5/kWh) is Rs. 22 Million/ Yr

• All the wastes from Sponge Iron Plant is used !!

- Waste Gases generated produce steam which generates power.

- Waste Like Coal Fines & Char - generate power in FBC Boiler.

- 100 TPD Kiln can generate another 1.5 MW of power using this waste.

- Saving another Rs. 20 -21 million/year


• Potential in Coke ovens is even larger

– 75,000 MTPA - 6 MWe

– 150,000 MTPA - 12 MWe

– 300,000 MTPA - 24 MWe

– 600,000 MTPA - 48 MWe

• Potential from Blast furnace

– 250 m3/Hr – 5-6 MWe

– 500 m3/ Hr - 10-12 MWe

• Potential from recovery based coke ovens

– 1MTPA – 120MWe

Why Waste Heat Recovery ?


Options for steam usage

LP Steam for Deaerator LP Steam for Boiler water pre heating



Condenser

Cooling

chamber

Generator

Elevator

Heat recovery boiler

Cokes transfer car

Conveyor

Fan

Dust collector

Steam produced

Cokes basket

Steam turbine

Extracted

steam

Cokes

Hot coke

Condenser

Cooling

chamber

Generator

Elevator

Heat recovery boiler

Cokes transfer car

Conveyor

Fan

Dust collector

Steam produced

Cokes basket

Steam turbine

Extracted

steam

Cokes

Hot coke

WHR

Boiler

STG Gen

From Existing Coal

Based Boiler

Steam

Injection



Application: To reduce the Coke Oven Gas Temperature


Cogeneration

Trigeneration

ABSORPTION

CHILLER

CHILLING

UPTO 5 0C / (-)

30 0C

COOLING WATER HEAT

REJECTION AT 35 TO 40 0C

TO

PROCESS

HEATING

HRSG

STEAM

EXHAUST

GAS FROM

GT/DG STEAM/

HOT

WATER

EXHAUST

GAS

(TO STACK)

HRSG

Heat

Generator

Components – Power/ process side

• Gas Turbine

• DRI Kiln

• Coke oven Batteries

• IC Engine

Components – Recovery side

• HRSG / EGB

• Absorption Chiller

• Rankine Cycle Power Plant



Need to reduce carbon - PAT

• India has made a commitment to global community to be a responsible

global citizen and reduce it carbon intensity.

• BEE has instituted a Perform Achieve & Trade (PAT) scheme for energy

intensive industry

• Steel is identified as a main Designated Consumer (DC) to reduce carbon &

energy intensity.

– The industry now has obligation to reduce the energy intensity


• Captive power generation is a great success in industry and makes these

plants self sufficient.

• Continuous plant availability makes these plants highly reliable and profitable.

• Surplus power can be exported / certificates traded– separate revenue stream

• Coal fines & Char can be burnt in the FBC boiler for additional power generation,

taking care of environment issues as well as bringing extra revenue.

• Environment hazard is avoided as high temp gases are not vented out and most

process waste is utilized.

•Meets PAT targets and improves bottomlines

Advantages to industry

Your Reliable Partner

• Understanding of the Process.

– Gas flow fluctuations

– Temperature variations

• Maximum & Minimum temperatures for corresponding gas flows

• Super heater design

• Attemperator selection

• Optimum point of operation for Boiler

– Start up procedures

– Batch process or continuous process

• Exhaust Gas composition

• Exhaust gas characteristics

• Nature of Dust

– Properties of Dust, Erosive/Corrosive

– Sticky/Free Flow

– Particle size distribution

Critical issues to be addressed for Waste Heat Boiler design

• Boiler Operating Parameters

- Optimum operating point for

boiler design

- Superheater design

- Type of attemperator

- Water quality

• Past experience of operation

- Field proven Calculation

programs

- Experience on Similar

applications

- Experience on the same

application

- Leanings in the past.

- Improvement done on the

process side.

Thermax Limited


Boiler- Salient Features

• WHRB on CDQ key parameters to look for:

Experience in waste heat recovery in

coke oven plant

Water wall panel construction in 1st/2nd

pass for optimized heat X’fer

Gas tight membrane panel construction

Wide pitched in-line geometry to prevent

choking

On-line soot blowing system

Welded steel gill design of the

economizer for making the unit compact

• WHRB on Flue gas from Non-Recovery Type

Natural circulation design.

Gas tight membrane panel

construction

Wide pitched in-line geometry to

prevent choking.

On-line soot blowing system.

Two pass design

Radiation cavity to take care of

temperature excursions.

Optional blast furnace firing capability

Thermax Limited


Other waste - Usage

Thermax Limited


Ash and slag Problem

Half Solution

Problem shifted

from here to…

HERE

1st link of problem

Thermax Limited


Options…

Potential uses :-

Fly Ash Bricks Classified Ash for Concrete Concrete blocks & Pavers AAC Blocks Pre-Stressed Concrete Ready Mix Mortar Rendering Material Special Cement Admixture

Thermax Limited


Fully Automatic Vibro Compacting Technology for Concrete Product


Details

Brick / hr 1,000 1,500 2,000 7,000

Working hr/day 10 10 10 21

Brick / day 10,000 15,000 20,000 147,000

Working Day/year 200 200 200 350

Brick / Year 2,000,000 3,000,000 4,000,000 51,450,000

Model Neptune Plus

1000HEY Neptune Plus

1500HEY Neptune Plus

2000HEY NHF1100C

Hyd.Press - Ton 60 75 100 1100

No. of Bricks/mould

No. of Strokes/ min 4.5 5 5.5 5

Tonnage per Brick 15 15 17 42

Specific compacting pressure(kg/cm²)

230 X 110 X 70 59 59 66 167

Raw Materials Storage - - - ~ 200 cu.m

Auto Batch Weighing, Feeding - - - Batching

Basic Plant Advance Powder Compacting Technology, Hyd.Brick Press

Thermax Limited


Outsourcing a possibility EPC + O&M = EPCOM

• Outsourcing of setting up as well as

operations and maintenance

• EPC contractor bound with the

performance of the plant

• O&M guarantee on all vital parameters

like:

– Efficiency – heat rate

– Availability

– Gross Power

– Aux Consumption


A word about us

Cooling

• Steam fired chillers

• Hot water fired

chillers

• Direct fired chillers

Heating

• Packaged solid fuel

fired boilers

• Packaged oil/gas

fired boilers

• Fired thermic fluid

heaters

• Exhaust waste heat

recovery boilers

B&H

• Package boilers

• Large capacity

Power boilers

• Thermal oil /

Water heaters

• Energy recovery

systems

Turnkey Power Plants

• Solid fuel based

• Gas - combined cycle

• Waste heat recovery

based

• RE based incl. Biomass,

Bagasse, solar, etc.

• O&M of power plants

• BOP of Large power

plants

Chemicals

• Ion exchange resins

• Cooling water chemicals

• Fireside chemicals

• Polyelectrolyte

Water and wastewater

• Wastewater & Effluent

treatment systems

• Water recycling

• Waste management

Enviro

•ESP & Bag filters

• Scrubbers

• Air purification

• Retrofit & Revamp

Boilers & Heaters Cooling & Heating Power Generation Chemicals & Water Air Pollution Control

THERMAX

Services Group - Operations and Maintenance, Steam on Hire, Renovation & Modernization,…

Thermax Limited


• Contracted over 100 Power Projects in India and Abroad on turnkey basis including total BOP

• Over 3000 MW Projects already commissioned. Another 1050 MW under commissioning.

• Series of Bullet bonus for early completion of turnkey projects.

• O&M contracts for Power Projects representing over 1000MW

• Over 850,000 Hours of operational & maintenance experience.

• Boilers supplied produce steam equivalent to over 10,000 MW worldwide.

• Over 6000 Environment abatement systems working

• Can undertake complete mechanical , electrical BOP for utility Power plants on EPC basis

A word about us


Conclusion

Sponge iron industry/ Steel facing tough challenges due to -

• Increased cost of Iron Ore And Coal.

• Coal Supply issues

• Campaign against illegal mining of Iron Ore In Some States.

• Many Companies have incurred losses in the past few months.

With Waste Heat Recovery and Power generation options the recovery

time on initial investments takes lesser time.

Meet PAT targets and improve profitability

Thermax Limited


Case 1 - Sree Metaliks Limited 8 MW + 20 MW Captive Power Plant

• Based on 4 x 100 TPD + 1x 350 TPD Sponge Iron Kilns 350

• Location : Barbil, Orissa

• Scope: EPC including :

Design and Engineering of the entire plant

4 x 9.6 + 1 x 38 TPH Waste Heat Boilers with ESP

1 x 8 MW Condensing Turbine of + 20 MW STG BHEL make

DM Plant with all tankages and pipings

Cooling water, Air Compressor , Ventilation Sys, Piping etc.

Complete Civil Works with STG & Control Room Building

Electrical system & PC-PLC based Control system

Erection & Commissioning of the entire plant

Thermax Limited


Sree Metaliks (P) Ltd.

Highlights:

- 28 MW of Power from Waste Heat Power Plant

- The 8 MW units was the first CPP in India to be set up in the sponge iron industry on EPC Basis. This is based on recovery of waste heat from the sponge iron kilns

Profile of some of our Power Projects

Thermax Limited


BF Gas Based Project

Steel Authority of India, 42.5 MW, Rourkela, Orissa, India

•Part of crude steel expansion project at SAIL

•Configuration : 2x18 MW + 1X6.5 MW

•3X100 TPH Thermax Blast Furnace Gas Fired Boilers (62 Kg/cm2, 485 Deg C);

• Steam Turbine make: Shin Nippon

•Thermax awarded certificate for three million accident free man hours during execution of this project

•Project execution on EPC basis

Thermax Limited


JK Lakshmi

Highlights:

- 36 MW CPP at Sirohi. Two repeat orders 18MW and 12MW Waste Heat recovery based.

- Thermax won bullet bonus of 1.5 Crores for early completion of project.

- Thermax recently awarded 1 x12.1 MW Power Plant based on waste heat recovery from cement kilns.


Thermax Limited


Madras Cement Limited

Highlights:

- 36 MW CPP for their cement plant at Alathiyur, followed by another 36 MW CPP at Jayantipuram.

- Thermax received a bonus of 1 Crore for early completion of the project.

- Thermax recently awarded another 40 MW Power Project for their upcoming cement plant at Ariyalur.


Thermax Limited


In Conclusion

Addressing the issues faced by Steel industry

• Cost and Reliability of Power

• Fuel

• Water

• Trained manpower availability

• Capacity constraints for raw material / equipment manufacturers

• Increase in Capex costs

• Increase in completion time

• Environment issues

• Carbon and Energy Intensity


Few other Projects in steel sector on EPC basis • Tata Sponge Iron Limted Joda, Orissa

• JK Cement Nimbahera, Rajasthan

• Bombay Rayon Fashion Doddaballapur, Karnataka

• Nilkanth Concast Gandhidham, Gujarat

• Sona Alloy Pune, Maharashtra

• Bhatia Energy & Steel Ltd Gummidipoondi, Tamil Nadu

• KIC Metaliks Limited Durgapur, West Bengal

• Apple sponge & Power Private Limited Kolhapur, Maharashtra

• Global Coke Limited Sindhudurg, Maharashtra

• Tata Metaliks Ltd Kharagpur, West Bengal, etc.

• KIC Metaliks Limited, Durgapur, West Bengal

• Deepak Steel & Power Ltd Dopati, Orissa

• HRG Alloys & Steel Private Limited Hospet, Karnataka

• NRI Power & Steel Pvt Ltd, Bilaspur, Chattisgarh

• HRG Alloys & Steel Private Limited, Hospet, Karnataka

• KJS Ahluwalia, Barbil,Orissa

• SAIL RSP

• Sesa Goa ( Vedanta)

Thermax Limited


Thank You For further details:

Vivek Taneja Head of Business Development

Ph: +91 20 66414814 (D) ; 66414000 (B) Email: [email protected]

www.thermaxglobal.com

Disclaimer : This presentation is for information purpose only and Thermax reserves the right to alter or change specifications

without prior notice. All photos in this presentation are representative in purpose and to be used for reference only.

Set 2015 Thermax Limited

mailto:[email protected]

http://www.thermaxindia.com/

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