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PRESENTATIONFor

CII GBC NATIONAL AWARD FOR

EXCELLENCE IN ENERGY MANAGEMENT

Rashtriya Ispat Nigam LimitedVISAKHAPATNAM STEEL PLANT

TEAM MEMBERS

S K SWAIN, GM(EMD) I/cDesignated Energy Manager

K SUDHAKAR, GM(O) –EMDCertified Energy Auditor

K V SUBBA RAO, GM(O)-TPP

CONTENTS

Company Profile Process FlowSp. Energy Consumption in last three yearsBench marking(Global and National Bench Marking)Energy Saving projects implemented in FY 2017-18Energy Saving projects implemented in FY 2018-19Energy Saving projects implemented in FY 2019-20Innovative ProjectsUtilization of Renewable Energy Sources Utilization of Waste as a fuelGHG InventorisationGreen Supply ChainTeam Work , Employee Involvement & MonitoringEnergy Management System (ISO:50001) Conclusion

1

Rashtriya Ispat Nigam Limited

Eastern Investment Limited

BisraStone Lime Co.

Ltd. (BSLC)

Visakhapatnam Steel Plant

Orissa Mineral Development Corp. (OMDC)

Operating Units

Madharammines

Dolomite

Jaggyyapetamines

Limestone

GarbhamManganes

e

Subsidiary company(51% stake)

RINL Corporate Structure

Units on Anvil

Wheel PlantTransmission Line Towers Plant

2

Turnover (2019-20)-INR Cr 15826

RINL – Growth Plan

3

RINL’s completed Upgradation &Modernization for 7.3 MTPA of CrudeSteel.

Products includes bars,rods, wirerod and structural's and ValueAdded Products

Vision envisages growth to 20 Mtpaby 2032-33 in phases

The 1st ISP to be certified for Quality, Health & Safety and Environment

1st Steel Plant to get ISO 50001 certification for Energy Management

1st Steel PSE to sign Integrity Pact of Transparency International

CMMI Level 3 certification for IT Systems and ISO 27001 for ISMS

1st ISP to be 5S Certified for the whole plant

Major Accreditations

BPTs & COB-4&5

NEDO

GETs & TRT

LD gas recovery

Billet Caster

Bloom Caster

Sinter Plant with NEDOCO Battery with Coke Dry Quenching and Back Pressure Turbine Station.BFs with Gas Expansion Turbine &Top Recovery Turbine station.SMS-1 & 2 with LD gas recovery plant.Continuous Bloom & Billet caster.

Power Generation capacity from Waste Energy (MW)Power Generation capacity from Waste Energy (MW)

7

Energy Consumption Overview

13

686

673

708

2017-18 2018-19 2019-20

Electrical Energy Consumption (Kwh/tCS)

Thermal Energy Consumption (GJ/tCS)33.2

30.8

31.6

2017-18 2018-19 2019-20

8.122

7.631

7.3597.512

2016-17 2017-18 2018-19 2019-20

SEC as PAT Scheme (Gcal/tCS)

Covid-19

Sp. Energy Consumption-Gcal/tCS

14

6.39

6.055.98 6.02

2016-17 2017-18 2018-19 2019-20

International Bench Marking of SEC(Gcal/tCS)

16

Gap: 0.55 Gcal/tCS6.02

5.47

5.15.25.35.45.55.65.75.85.9

66.1

RINL Nippon Steel

Bench Marking with Nippon Steel(2019-20)

Energy(2019-20) GHG Emission Gap :0.55 Gcal/tCSRINL NSC RINL NSC 1) Scrap usage : 200 kg/thm( As per Japanese

Industry)-RINL:80 kg/tCS2) All Energy Conservation technologies Coke Dry Quenching,Top Pressure Recovery Turbine,BOF Gas Recovery,Sinter Cooler waste heat recoveryPulverized Coal Injection,BF stoves Heat Recovery, Billet Caster, Hot Charging, Regenerative Burners, Coal Moisture Control Sensible Heat recovery from BOF gas3) Waste Plastics Injection and tires(0.2 million tons-6 kg/tCS)4) Petro fuel 16 lts/Tcs

6.02 5.47 2.619 1.98

17

Benchmarking of Energy Consumption-Gcal/tCS

15

Gap: 0.39 Gcal/tCS

Energy(2019-20) GHG Emission Gap :0.39 Gcal/tCS

RINLTata Steel RINL

Tata Steel

1)Coal Injection of >180 kg/tHM(0.250Gcal/tCS) Vs 97 kg/tCS

2) Plant Production: 10 Mt Crude Steel.6.02 5.63 2.619 2.29

6.75

6.08 6.02

5.63

55.25.45.65.8

66.26.46.66.8

7

SAIL BHILAI JSW VIJAYANAGAR RINL TATA STEEL

Energy Saving projects implemented in for last three years-(2017-18)

9

S.No. Title of ProjectEnergy Savings in

Gcal/MKwh Rs Millions

1 Reduction of Sp. power Consumption at cokeoven from 49.29 to 46.51 Kwh/tDC 11 70

2 Reduction of Coke Breeze Consumption at SP-1from 64.3 to 60.4 Kg/tGS 100892 129

3 Reduction of Sp. heat Consumption at SP-1 from33 to 30 Mcal/tGS 11503 15

4 Reduction of Sp. heat Consumption at SP-2 from10 to 9 Mcal/tGS 3025 4

5 Reduction in Sp. Power Consumption at BF-3from 38.56 to 36.57 Kwh/tHM 5 31

ENCON Projects with Investment (2018-19)

8

S.No. Title of Project Energy Savings in Investment (Rs Million)

Gcal/MKwh Rs Millions1 Commissioning of COB-5 Turbine 21812 145 800

ENCON Projects with NO/Little Investment -2018-19S.No. Title of Project Energy Savings in


1 Improvement in Gross coke yield at coke ovenfrom 72.34% to 72.88% 206997 261

2Reduction of heat consumption at Blast Furnace-3 from 432 Mcal/tHM to 403 Mcal/tHM

73035 92

3 Improvement in Pulverized coal injection atBF-2 from 3.8 to 27.8 Kg/tHM at Blast Furnace 54115 68

4Improvement in Pulverized coal injection atBF-3 from 75.9 to 95.4 Kg/tHM at BlastFurnace

69073 87

ENCON Projects with no Investment (2019-20)

S.No. Title of ProjectEnergy Savings in


1Improvement in Pulverized coal injectionat BF-2 from 27.8 to 107.2 Kg/tHM atBlast Furnace 223830

308

2 Improvement in LD gas yield at SMS-1from 104 to 109 Ncum/tCS 22457

31

3 Reduction in Coke Breeze consumptionat SP-1 from 54.8 kg/tGS to 53.5 Kg/tGS 38888

54

4 Reduction in BF Fuel rate from 541.6kg/tHM to 538.9 kg/tHM 95237

131

5Enhanced argon production by increasing argon recovery from Air Seperation Unit-5

0.16 70

ENCON Projects with Investment (2019-20)

S.No. Title of ProjectEnergy Savings in Investment

(Rs Million)Gcal/MKwh Rs

Millions

1 Improvement in Power Generation at GETS from 1.07 MW to 3.37 MW 20 142 5

2 Improvement in Power Generation at TRT from 5.39 MW to 6.80 MW 12 87 10

3

Increasing Hot Blast Temperature of BF 1 &2 by Inter Connection of Turbo Blowers-4 to BF-1&2 cold blast line at Captive Power Plant-1

67752 188 147

4 Modified Pass Design for Round 75 Rolling at MMSM 0.10 0.71 0.02

YEAR No of Projects

Thermal Savings(Gcals)

Electrical Savings

(Million KWH)

Savings in

Rs.Cr

Investment

In Rs Cr

Savings(GcaltCS)

2017-18 17 677781 48.6 110.1 767 0.172018-19 26 745719 57.14 132 80 0.17

2019-20 25 621918 75.64 155.3 16.2 0.17

Summary of the Projects identified & Implemented

12

200.3

110.1 132

155

1405591

794421 882855803464

0

200000

400000

600000

800000

1000000

1200000

1400000

1600000

0

50

100

150

200

250

2016-17 2017-18 2018-19 2019-20

Ener

gy S

avin

g (G

cals

)

Cos

t Sav

ing

(Rs.

Cr.)

Energy Saving & Cost savings

INNOVATIVE PROJECTS IMPLEMENTED

12

Name of the Project Replicability Impact on SEC (Kcal/tCS)

Annual Savings

Investment

( Rs. In lakhs)

( Rs. In lakhs)

Enhanced argon production by increasing argon recovery from Air Seperation Unit-5 Yes 80 700 0

Increasing Hot Blast Temperature of BF 1 &2 by Inter Connection of Turbo Blowers-4 to BF-1&2 cold blast line at Captive Power Plant-1

Yes 14237 1880 1470

Modified Pass Design for Round 75 Rolling at MMSM Yes 51 7 0.2

INNOVATIVE PROJECT-1

12

Enhanced argon production by increasing argon recovery from Air Separation Unit-5

Air separation is done by cryogenic distillationof liquid air into its constituents like nitrogen,oxygen and argon based on the difference intheir boiling points

In Typical ASU, the recovery of Oxygen,Nitrogen and Argon shall be 18%, 35% and0.58% respectively.

Oxygen is used in Hot metal refining in LDConverter, Oxygen enrichment of Blast air andNitrogen is used for CDCP Chamber Cooling ofHot coke and Paulwarth Gear box cooling inIntegrated Steel Plants.

Argon is used in Steel Melting Shop forhomogenization of liquid Steel before castingand is essential to produce defect free steel.


Problem:In an ASU of 650 TPD, Argon production of580 Cum/hr or 24.85 tPD is produced andused for Steel Making.

However, it is observed that Consumption ofArgon in Steel Melt shop increased due to1) Production of value added steel2) Disturbances in argon production / argonunit trip3) Damage to insulation/vacuum insulation ipipelines etc.

Due to above, Plant is forced to operateBackup pump which is resulting distributionlosses and required to purchase Argonfrom Outside.

This is resulting in loss of Argon by 1725T per year causing financial loss of Rs3.45 Crores and Energy loss of 151.3MWH

Solutions:Increase Argon recovery without disturbing purity and minimizing losses.

Modification done:By Studying various factors effecting distillation of these gases, followingmodifications done•by increasing condensation in crude argon column•Changing the refluxes(Decrease LL reflux in stages from 19,000 Nm3/hr to16,000 Nm3/hr)•Increased Argon extraction by decreasing belly point(from 89% to 87-88%.)

Argon productionBefore Modification

Argon productionAfter Modification

Energy Saving Annual Savings( Rs. In lakhs)

Investment( Rs. In lakhs)

580 Ncum/hr (24.85 TPD) 700 Ncum/hr (30 TPD) 157814 kWH 700 0

Results:Argon production increased from 580 Ncum/hr to 700 Ncum/hr Increase in Argon yield from 0.58% to 0.71%Reduction of distribution losses due to stoppage of Backup Argon Liquid Pum

Benefits



12

Inter Connection of Turbo Blowers-4 to BF-1&2 cold blast line at Captive Power Plant-1

1) RINL has five No. of blowers to meetBlast Air requirement.

2) Blower-1 to Blower-3 are havingcooler with Cold blast airtemperature of 140 deg C at coldblast outlet. These are connected tosupply blast air to Blast Furnace-1 &2.

3) Blower-4 & 5 are envisaged withoutafter cooler resulting in cold blast airtemperature of more than 200 degC. These are connected to supplyBlast air to BF-3 only.

Problem Faced Cold Blast flow to BF-1/2 is not sufficient Hot Blast temperature to BF-2 is low Low PCI injection in BF-2SolutionInterconnection of TB-4 & 5 to cold blast headers

of TB-1,2 &3Challenges Discharge temperature of TB-4&5 will be around

230oC whereas cold blast headers 1&2 weredesigned for 160oC

Expansion of the header which is around 1.8KMlength

Modification DoneI. Installation of expansion loops in cold blast

headers – 1 & 2II. Changing of Expansion bellows for TB-1,2,3.III. Changing of Spring Supports for TB-1,2,3.IV. Interconnection.V. Modification of PLC.


Benefits

1) Cold blast supply improved.2) Blast Air temperature improved from 90 deg C to 140 deg C.3) Increase in Blast air temperature increased hot blast temperature and reduced BF-2 coke rate.4) Energy savings.

Cold Blast Temp. Before

Modification

Cold Blast Temp. AfterModification

EnergySaving

Annual Savings( Rs. In lakhs)


90 Deg C 140 Deg C 67752 Gcals 1880 1470


12

Modified Pass Design for Round 75 Rolling at MMSM

MMSM Producesangles, channels and structuralby rolling Blooms/Billets as perdemand.

The Mill Contains RoughingMill Train, IMT and FMT to rollin to various sizes. In additionto above, there is centralVentilation System fans tocool motors of Mill drives

Problem:I. It is observed that while Rolling Round 75, Stand #14V (12RO75) delivery pipe

knockout.(causing Breakdown resulting in loss of production) and Twisting in finished product(Posing quality challenge).

II. Due to this problem, there is delay of 3.6 Hours of rolling and energy loss of 30715 KWH for running of CVS fans for RMT,IMT,FMT.

BEFORE MODIFICATION

8/13/2020

ROUGHING MILL TRAIN

Transfer

Trough

INTERMEDIATE MILL TRAIN

STAND 1H STAND 2V STAND 3H STAND 4V STAND 5H STAND 6V STAND 7H STAND 8V

STAND 9H

STAND 10T STAND 11T

STAND 12V STAND 13H STAND 14V

STAND 20T

STAND 18HSTAND 17V

STAND 15T

FINISHING MILL TRAIN

Transfer

Trough

Transfer

Trough

Transfer

Trough

1RO50 PBPlain Barrel

2RO50Box Pass

3RO50Box Pass

4RO50Box Pass

5RO50Box Pass

6RO50Box Pass

7RO50Box Pass

8RO50Box Pass


10RO50Box Pass

13RO75Oval Pass

12RO75Round Pass

STAND 16T15RO56

Oval Pass17RO75

Round PassSTAND19T

Transfer

Trough

Transfer

Trough

Solution:Various solutions are explored and among the alternative, " Modify thepass design and finish the product in IMT by introducing 12RO80 and13RO75 grooves" has been finalized.

Modification Done:Removing two stands in FMT i.e. #16H (15RO56) & #17V (17Ro75).Removing 13RO75 & 12RO75 from #13H & #14V.Shift 10RO50 box pass to #10V from #12VIntroducing 12RO80 oval pass at stand #12V position.Make Round75 (13RO75) finished groove in 630mm dia. rolls andplace at stand #13H position.Change the mill configuration in IMTChange the rolling program data as per the modified design in Level-2control system.


10RO50Box Pass12RO80

Oval Pass

AFTER MODIFICATION

8/13/2020

ROUGHING MILL TRAIN

INTERMEDIATE MILL TRAIN

STAND 1H STAND 2V STAND 3H STAND 4V STAND 5H STAND 6V STAND 7H STAND 8V

Transfer

Trough

STAND 10T

STAND 20TSTAND 15T

FINISHING MILL TRAINSTAND 11T

Transfer

Trough

Transfer

Trough


2RO50Box Pass

3RO50Box Pass

4RO50Box Pass

5RO50Box Pass

6RO50Box Pass

7RO50Box Pass

8RO50Box Pass

STAND 9H


15RO56Oval Pass

17RO75Round Pass

STAND19T

10RO50Box Pass

STAND 17T

Transfer

Trough

STAND 18T

Transfer

Trough

13RO75Oval Pass13RO75

Round pass12RO75

Round Pass

STAND 13H STAND 14VSTAND 12VSTAND 10V STAND 11H

STAND 18HSTAND 17VSTAND 14T

Transfer

Trough

STAND 18T

Transfer

Trough

Transfer

Trough

Transfer

Trough

MMSMProduction

Before Modification

MMSMProduction

AfterModification

EnergySaving

Annual Savings( Rs. In lakhs)


1875 TPD 2460 TPD 101350 Kwh

7.15 0.2

Benefits:1) Breakdown reduced2) Production Improved from 1875 Tons to 2460Tons/day.3)Energy Savings of 101250 KWH and financialsavings


Utilisation of renewable energy sources-Solar Energy Utilization

RINL commissioned 5 MW Solar Power PlantInvestment: Rs 36 crInstalling 0.16 MW Roof TopSolar Power Plant at variousBuilding

33

Planning to install 5 MW Solar Power Plant under RESCO model

Utilization of Waste Material as fuel

Type of Waste Material used

Quantity of waste material used (Tons or any other eqvt

Unit)

Equivalent of Conventional energy used

(kWh of electricity or

Tons of Coking Coal)

Gcal

Coke Dust 898 6755 6066LD Slag 124970 1000 124970Met Waste 365573 500 182787Tar sludge 3119 7100 22145Benzol muck 190 7100 1349ASP sludge 350 7100 2485BF gas 8274030 814 6735060LD gas 375360 1767 663261Coke dust(sold) 68347 775 52969

Granulated Slag 1507272 1070 1612781

34

26.71

29.24

26.15

24252627282930

2017-18 2018-19 2019-20

Waste Fuel utilisation as % of total energy

GHG Inventorisation

25

Emission Details

Scope 1 Direct emissions from site chimneysdetermined from straight carbonbalance

Scope 2 Upstream emissions of electricity andsteam from site.

Scope 3 Other upstream emissions by-products from site

Scope 1 Scope2 Scope 3Total CO2(t CO2/TCS)

92,47,927 16,26,155 15,89,390 2.619

As per ISO:14064:-

2.618

2.59

2.62

2017-18 2018-19 2019-20

GHG Emissions-tCO2/tCS

Best Practices implemented in Green Supply chain

35

Name of Activity BenefitsDisposal of fly ash 70709 tons and 14849 tCo2

Disposal of BF Slag 1507272 tons & 0.83 Million Tons Co2

Receiving Raw Material (Coking coal) from Ganagavaram Port instead of Vizag Port

Reduced Co2 Emissions

Dispatch of Steel Products by Rail 60% of Dispatches by Rail. Reduced Co2 emissions 128332 tCO2

Imparting Training on EMS, OHSAS and QMS to contract employees

Increased Awareness

Procurement of Raw materials on GCV Basis

Penalty clauses for ash and CV

Adoption of E-Office Reduced Manual movements

Adoption of Green Technologies Increased dissemination in Steel Industry

Energy Efficient Procurement Air Conditioners, Circulation fan, Motors

Green Purchasing Policy

31

Procurement of Circulation fan(3000KW) for Sinter Heat Recovery Plant

Star labeled Energy Efficient Air Conditioners Energy Efficient Motors

Year ENCON Investment as % of Turnover

2019-20 0.5%

Involvement of employees, Team Work and Monitoring

• Employee Involvement Through– Quality Circles, Suggestion Schemes, Department Energy

Teams, Participation in Energy Conservation Campaigns, CostControl Campaigns, Water Saving Campaigns

• Implementation Methods– Low Cost/No Cost Ideas (Process Improvements, House

Keeping Measures, etc) will be Implemented by Frontlineofficers

– Medium Investment Projects through AMR Schemes– High Investment Schemes through Board Approval/COM– Special Task Forces for Implementing Important Energy

Conservation Projects for Sinter Cooler, Steam Utilization andBy product gases usage.

26

Monitoring Format

Energy Conservation

CellDET

GM(EMD)I/c Daily

CGM (Energy,Utilities & Power)

Weekly

ED (W) Monthly

D (O) Bi-Monthly

27

Energy Savings are quantified with respect to displacement of Boiler CoalElectrical Savings are quantified by pegging with Electricity imported.Savings are certified by Energy Auditors

DAILY ENERGY REPORT

Production 30-Apr-20Monthly ACTUAL For the Shop PARAMETER UNIT NORM ON DATE CUM

Plan On date Month3167 192 210 COCCP GROSS COKE YIELD : 0 73.0 73.1 73.1

Plan/day 48 1581 Bat-1 Met.Coke Yld . % 68.2 68.8 68.8 48 1578 Bat-2 C. O .GAS YIELD : NCUM/TDC 335 325 331 48 1573 Bat-3 SP. HEAT. CONS : MCAL/TDC 623 649 657 48 1580 Bat-4 C.O. GAS .C.V. : K.CAL/N.CU.M 4150 4303 4260

380000 6737 395531 SP SP. HEAT. CONS : MCAL/TSP 21 33 22 0 225575 SP-1(M/c-1) SP. HEAT. CONS : MCAL/TSP 28 #DIV/0! 23

6737 56831 SP-1(M/c-2) SP. HEAT. CONS : MCAL/TSP 28 33 42 0 113125 SP-2 SP. HEAT. CONS : MCAL/TSP 9 #DIV/0! 11

6950 186900 BF-1 SP. HEAT. CONS-1: MCAL/THM 558 453 494 0 0 BF-2 SP. HEAT. CONS-2: MCAL/THM 558 0 0 0 75500 BF-3 SP. HEAT. CONS-3: MCAL/THM 400 0 470

260000 6950 262400 BF(All) SP. HEAT. CONS (All): MCAL/THM 495 471 4950 0 Pellets/tHM(BF) B. F. GAS.YIELD : NCUM/TC(D) 3007 2957 2946 0 0 Pellets/tHM(BF1) COKE RATE BF1 : KG/THM 525 423 426

0 Pellets/tHM(BF2) COKE RATE BF2 : KG/THM 435 0 0 0 Pellets/tHM(BF3) COKE RATE BF3 : KG/THM 420 0 439

1342 1301 Sinter/tHM(BF) COKE RATE (All) : KG/THM 453 423 430 1342 1301 Sinter/tHM(BF1) Pul Coal: BF-1 KG/THM 20 134 116

Sinter/tHM(BF2) Pul Coal: BF-2 KG/THM 100 0 0 1300 Sinter/tHM(BF3) Pul Coal: BF-3 KG/THM 110 0 117

5.0 3.4 O2-BF1 Pul Coal (All): KG/THM 82 134 117 0.0 O2BF-2 B. F. GAS. C .V.: K.CAL/N.CUM 710 859 833 3.3 O2BF-3 COAL RATE : KG/THM 786 785 779

SMS-1 HOT METAL RATE(R): KG/TLS 1000 1074 995 100000 1274 96474 LS SP. HEAT. CONS MCAL/tCS 34 154 69 160000 1204 90975 CS CONV.GAS YIELD : NCUM/TLS 95 0 103

691 9 22.4 Heats SP.OXYGEN CONS : NCUM/TLS 57 -194 -194 SP.ARGON CONS : NCUM/HEAT 226 74.8 127.1 SP. LPG CONS: Kg/tCS 0.19 0.30 0.31

SMS-2 HOT METAL RATE(R): KG/TLS 1013 1010 1011160000 4248 157465 LS SP. HEAT. CONS(TOTAL) MCAL/TLS 42 53 47 154050 4108 152203 CS CONV.GAS YIELD : NCUM/TLS 88 0 0 1092 28 34.6 Heats Total Heats Nos 45 37 57.0

LD Gas CV K.CAL/N.CUM 1760 1870 1833 260000 Liquid Steel Ton 6426 5522 253939 314050 Crude Steel Ton 6165 5312 243178

457 15183 Sp. Heat(CRMP-2) MCAL/TGL 940 1116 967 65000 0 61637 BILLETS SP. HEAT. CONS : MCAL/TIP 421 #DIV/0! 495 30000 0 24969 BARS SP. HEAT. CONS : MCAL/TIP 20 #DIV/0! 25

0 0 17486 WRM-1 SP. HEAT. CONS : MCAL/TIP 248 #DIV/0! 287 24800 0 18381 WRM-2 SP. HEAT. CONS : MCAL/TIP 263 #DIV/0! 241 26000 0 0 MMSM SP. HEAT. CONS : MCAL/TIP 400 #DIV/0! 0

100 0 0 SBM SP. HEAT. CONS : MCAL/TIP 300 #DIV/0! #DIV/0!15000 0 0 STM SP. HEAT. CONS : MCAL/TIP 310 #DIV/0! #DIV/0!

TPP 151 182 TPP SP. HEAT. CONS : MCAL/TP 749 846 785 PP-2 73 77 PP-2 SP. HEAT. CONS : MCAL/TP 720 705 734

GETS 5.0 4.0 PP-2 Heat Rate (pp-2): Mcal/Mwh 3071 3106 3060 TRT 0.0 3.4 Steam Rate (PP-2): Ton/MWH 3.93 3.74 3.69 WHR 17.0 22.1 POWER GEN..-BPTS MW 25.9 11.1 13.4 Imp 6.0 13.3 POWER GEN..- TRT + GETS MW 13.7 5.0 7.3

Plant Load 244.8 293.5 POWER GEN.-NEDO MW 5.0 0.9 1.4

Steam (PP-1) 21302 782268 LOSSES C.O.GAS BLEEDING: % 0.2 0.00 0.08

B Coal (PP-1) 4100 158011 B.F.GAS.BLEEDING: % 2.0 0.21 0.36

Steam (PP-2) 6553 204593 OXYGEN BLEEDING : % 2.2 16.8 38.5 NITROGEN BLEEDING % 13.9 1.2 7.8

VM (C Coal) 25.89 26.11 PLANT SP. POWER. CONS : KWH/TCS 397 648 503

Ash (C Coal) 10.96 10.44 A.P.P SP. ENERGY. CONS: G.CAL/TCS 5.80 6.93 6.59 VM (Coke) 0.61 0.60 TPP OIL CONSUMPTION KL 167 0 0.0 Ash (Coke) 15.25 13.80 On and N2 Ncum/tCS 298 620 540

Energy Management System ISO:50001

28

Features: Significant Energy Use. Developing Energy Management

programmes. Operational control of identified

energy aspects Monitoring and Measurement Internal Audit Management Review Certified for ISO: 50001 in Aug’12

Completed 3rd recertificationdone in 2019.

Shall be upgraded to 2018version by Dec’2020.

Implementation of Corrective/Preventive actions

29

• Plant has taken up Energy Objectivesand Energy Management Actionplans(710 Nos ) to reduce energyconsumption.

• DEPARTMENTAL ENERGY TEAMSwere constituted in various departments.The teams identified specific projects

• Departments conducted energy audits atvarious equipment through DepartmentalEnergy Audit Teams

94

89

90

8989

8585

89

85 85

808284868890929496

No. o

f EM

APs

EMAPs

Environmental Projects & Projects linking with Carbon Emission Reduction

Projects BenefitsRevamping of Burden handling & Cast House FEsystem of Blast Furnace-1.

Reduce Dust emissions

Balacheruvu, Waste Water Treatment Plant -Commissioned in July 2014.

253 Million Gallons

Commissioning of Appikonda Waste Water TreatmentPlant

220 Million Gallons

The Digital display board at Main Gate wasinaugurated by CMD on 5th June 2014 for displayingthe CAAQM and Stack analyzers.

Awareness

Dry Fog Dust Suppression System (DSS) inExpansion area of Raw Material Handling Plant, SinterPlant & Blast Furnace.

Reduced fugitive emissions

Rain water harvesting scheme near 18 MLD plant Ground water recharging

22

Sl No Name of Energy Conservation Activity Year Impact (Mcal/tCS)

1 To improve Pulverized coal injection at BF-1 from 33.4Kg/tHM to 119 kg/tHM at Blast Furnace 2020-21 70.41

2 To improve Pulverized coal injection at BF-2 from 107.2Kg/tHM to 115 Kg/tHM at Blast Furnace 2020-21 5.13

3 To improve power generation at NEDO from 0.15 MW to 5 MW. 2020-21 25.56

4 To improve Pulverized coal injection at BF-2 from 115 Kg/tHM to 150 Kg/tHM. 2021-22 24.50

5 To improve power generation at NEDO from 5 MW to 7.5 MW. 2021-22 10.51

6 To improve Pulverized coal injection at BF-1 from 119 Kg/tHM to 150 kg/tHM at Blast Furnace 2022-23 18.08

7 To improve power generation at NEDO from 7.5 MW to 10 MW. 2022-23 8.76

Total Savings 163

Energy Conservation Projects identified for next three years

21

4 No. of projects registered (TRT, COB4, BF3-WHR).UNFCCC issued 1,29,356 CER to RINL for two CDM projects. Verification for issuance of CER has been initiated for CDM Project “BF3-WHR”.

Environmental Projects & Projects linking with Carbon Emission Reduction

23

Name of Projects Registration Number

Expected CERS

BF3 Top Pressure Recovery Project 9613 60410

COB-4 Turbine at Battery-4 9988 68540

Waste Heat Recovery from Stoves of BF-3 10024 44932

Adoption of Green Technologies

Name of Technology Features Energy Savings(TOE)

GHG redn(tCo2)

Coke Dry Quenching Plant Power gen: 2X7.5MW 115285 689586

Top Pressure Recovery Turbine Power gen; 2x12 MW 21257 127152

LD Gas Recovery System 80000 Cum 58022 347060

Evaporative Cooling System 13 ata steam: 19 t/hr 12173 72814

Preheating of combustion air at CRMP

Air preheating: 250degc 3469 21062

Gas and air recuperators in ROLLING MILLS

Air : 450 degCGas:250 degC

16105 57088

Reducing GHG emission by about 13 lakh tons annually36

Adoption of Energy Efficient Technologies-Unique Features of RINL

Name of Technology Level of Diffusion

Coke Dry Quenching Plant

First Time in India(1990)

13.5%

Top Pressure Recovery Turbine

First Time In India(1993)

13.9%

LD Gas Recovery System First Time in India(1991-93)

50%

Evaporative Cooling System


25%

Sinter Cooler Waste Heat Recovery(Power Gen)


5%

37

Long Term Target/Roadmap for Energy Consumption & GHG emissions.

Beyond 5.7 Gcal/tCS, RINL explore Injection of PCI more than 150 kg/THM Increased use of Scrap based on circular economy Usage of Natural Gas in Blast Furnace. Harnessing JV with Multinational agencies for

Technology deployment in Coal Moisture control, Regenerative Burners, Sp Exhaust Gas heat recovery etc.

6.02

6.3

5.95.8

5.72.62

2.74

2.572.52

2.48

2.352.402.452.502.552.602.652.702.752.80

5.45.55.65.75.85.9

66.16.26.36.4

2019-20 2020-21 2021-22 2022-23 2023-24

Thank youThank youरा ीय इ ात िनगम िलिमटेडRASHTRIYA ISPAT NIGAM LIMITED

presentation for cii gbc national award for … · presentation for cii gbc national award for...

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