GODAWARI POWER & ISPAT LTD.

welcomes
All Dignitaries & Industry Partners 2
Energy Conserved is Energy Generated
 WORKSHOP ON
BEST PRACTICES IN ENERGY EFFICIENCY
IN IRON & STEEL SECTOR
&
OPPURTUNITIES AND CHOICES IN ENERGY CONSERVATION AT
GPIL

Presented by:

RATNADEEP GUPTA
GM SID
GPIL

Energy Conserved is Energy Generated 3

Walkthrough
GPIL Profile
Scope & Areas for Energy Conservation in Power Generation
Scope & Areas for Energy Conservation in Ferro Alloy Division
Scope & Areas for Energy Conservation in Sponge Iron Making
Conclusion

Energy Conserved is Energy Generated 4

 GPIL- Company Profile
Godawari Power & Ispat Ltd. (GPIL) is the Flagship Company of Hira Group of
Industries; Raipur which was incorporated in 1999 to setup an integrated steel
plant with captive power generation.
GPIL is certified for adapting and implementing the following management
systems :
ISO:9001:2008 FOR Quality Management System
ISO:14001:2004 for Environment Management System
OHSAS ISO:18001:2007 for Occupational Health & Safety
Product Portfolio
SPONGE IRON
PELLET
0.495 MTPA
2.1 MTPA

BILLETS
POWER
0.20 MTPA
73 MW

SILICO
HB WIRES MANGANESE
0.10 MTPA 0.0165 MTPA

Energy Conserved is Energy Generated 5

 Scope & Areas for Energy Conservation in Power Generation

1.Modification of fuel feeding system:

Traditional Drag chain system replaced by Rotary feeding

Reduction of maintenance and power

Saving cost by 8.12 Lacks per annum
Additional benefits
Improvement in redundancy of AFBC
Pollution control
Reduced safety hazards caused by opened rotary parts.

Energy Conserved is Energy Generated 6

 Scope & Areas for Energy Conservation in Power Generation

2.Modification of Old screw conveying system:

Dense Phase pneumatic ash handling system replaces old screw
conveying system

Savings of 19.35 Lacs Per annum & 56 Kilowatts of power.

Energy Conserved is Energy Generated 7

 Scope & Areas for Energy Conservation in FAD
Energy Conservation in FAD Process
Changing of charge mix, size of raw material
Optimizing the operational control system
Periodic checking of electrode length by taking smelt down
Installation of FES (Fumes Extraction System)
Significant Reduction of Specific Power consumption
POWER CONSUMPTION IN MWH
4.1 4.078
4.05 4.023
4
3.95 3.929
3.907 MWH
3.9 UPTO
25TH
3.85 FEB

3.8
Nov-15 Dec-15 Jan-16 Feb-16

Energy Conserved is Energy Generated 8

 Scope & Areas for Energy Conservation in FAD

S.NO. AREA ACTIVITY ENERGY SAVINGS

1. Water Complex Installation of VFD 120 Kwh/ Day

Fume Extraction
2. Installation of VFD 1968 Kwh/ Day
System - ID Fan

Fume Extraction
3. Installation of VFD 144 Kwh/Day
System - F.D. Cooler

Reduced number of cooling fans

Furnace Air Cooling
4. from 6 to 3 by changing the 242 Kwh/Day
System
capacities

Energy Conserved is Energy Generated 9

 Scope & Areas for Energy Conservation in Sponge Iron Making

Combustion of Coal in the Rotary kiln in

presence of air (HEAT SOURCE)

Removes Preheats the feed Compensates

moisture from Metallization of Decomposition
upto the desired radiation loss from
feed and coal Iron Ore of Dolomite
temperature kiln wall

Coal and air can be taken as hot utility streams - process integration
terminology
Potential possible areas where energy is being lost and can form a part of heat
integration, are as follows:

Energy Conserved is Energy Generated 10

 Scope & Areas for Energy Conservation in Sponge Iron Making
Scope 1
Energy lost in the Rotary Kiln can be derived through material and energy balance.

Streams of sponge iron, char, waste gas and volatile matter

Counter Measure
Process integration best option to reduce:

Heat losses in the process of sponge iron making

Waste generation

Water consumption (Reduction in the highest quality heat (Coal and air) using
proper heat integration in the process automatically reduces the cold utility (water)
requirement)

Better refractory selection and Reducing Shell temperatures

Pre heating of feed material

Optimization of C/Fe ratio

F.C in Char to be optimized

L.O.I control

Energy Conserved is Energy Generated 11

 Scope & Areas for Energy Conservation in Sponge Iron Making
Scope 2
Hot sponge iron is being cooled with water in rotary cooler. For this purpose water is being sprayed
on the shell of cooler and the vapour generated from it goes directly to atmosphere. As a
consequence of it the temperature of sponge iron drops from 1020 C to 100C. In this process the
cold water is heated up from 30 C to 34.7 C
Counter Measure
Cooling efficiency can be enhanced by time to time De Scaling of Cooler shell and by
incorporating efficient cooling tower. Thus delta T can be increased and oxidation of product
can be prevented from 0.5 -1% .

Scope 3
Clean waste gas is generated in ESP from where it goes to the chimney at the temperature of 170-
180 C and from there to the atmosphere, which is also a loss of considerably high temp. heat.
Counter Measure
Efficient heat utilization in Power plant can retain the temperature of ESP outlet to 140-150C
through periodic soot blowing.

Energy Conserved is Energy Generated 12

 Scope & Areas for Energy Conservation in Sponge Iron Making

Scope 4
Feed material as well as air enters the process (mainly rotary kiln) at ambient temperature
and reduction reactions are taking place at 1080-1100 C. This requires feed to be heated up
which needs the significant amount of heat generated from combustion of coal. This
preheating could be done by the waste gas. However this is not done in all Kilns .As a result of
it a large amount of coal is being utilized for preheating the feed material and air which
otherwise could have been saved.

Counter Measure
Pre heater, thus helps in feeding the material at 9000C and helps us in saving 5% of
energy.

Energy Conserved is Energy Generated 13

 Areas of Energy Conservation in Sponge Iron Plant
We have also identified following areas where we can effectively
adopt initiatives to conserve energy

Challenges:

1. Kiln Availability
2. Campaign Life
3. Production Rate
4. Operational Losses
5. Specific Coal Consumption
6. Optimum Utilization of pre-heater
7. Utilization of Solid Wastes

Energy Conserved is Energy Generated 14

1. Kiln Availability
Frequent kiln breakdown due to mechanical, electrical and operational interruptions
have a significant effect on Kiln availability which also leads to poor efficiency.
At GPIL, we had overcome this by implementing best maintenance planning and
Robust Preventive and Predictive Maintenance.
2. Campaign Life
Frequent kiln shutdown due to accretion formation, DSC clinker formation and
refractory damage affects its capacity utilization and also consume more energy in
reviving the kiln.
At GPIL, we had overcome this by Better Process Control and monitoring,
Selection and Application of quality refractory material and Restriction of
Undersize in feed material. Today the average campaign life is around 250-300
days.
3. Production Rate
Reasons for Low Production rate identified leading to low capacity utilization are Low
Yield, Process Interruptions at Central Burner , Feeding and Injection systems which
can lead to increase energy consumptions.
At GPIL, we had over come this by:
Proper blending of Imported & Domestic coal to maintain required F.C.
Utilization of high TI Pellet .
Conducted Fe Balancing to analyze yield losses.
Fabrication of CB & Coal Injector Trolley for fast operation.
Restriction of Undersize in material.

Energy Conserved is Energy Generated 15

4. Operational Losses
There are various operational losses which needs to be saved for efficient energy
conservation
Major Losses
Emission of flue gas from slip seal, Cooler Discharge and stack cap
Radiation losses
Spillages from feed and injection area
Yield Losses
Initiatives taken:
Better sealing done in stack cap to capture fugitive emission
For Better sealing, pneumatic cylinders installed at slip seal to maintain gaps in
seals
Thorough inspection of old and worn out refractory and application of best
quality refractory which reduced in radiation losses
Inspection of spillages if any and arresting
We have done analysis of Yield losses by conducting Fe Balancing where it is
evidenced that under sized ore is poison for kiln
Using minimum coal during Shut down & Light up and following Ramp up plans
D.P. Valve Installation at Cooler Discharge

Energy Conserved is Energy Generated 16

5. Specific Coal Consumption & C/Fe
High Specific Coal Consumption leads to immense waste of energy. So it is the area of
greater concern and must be addressed.
Optimum utilization of coal to minimize C/Fe is a big challenge
Initiatives taken:
Optimum Utilization of coal by proper Screening and Blending
Optimum C/Fe level for safe and better campaign
Total 3-4 % of carbon is allowed in Non Mag. Product
Effective use of coal fines in injection Coal

6. Optimum Utilization of Pre-Heater

We have a arrangement of Pre Heater in two 500 TPD kilns which helps in higher
production rate by 10 15 % but we faced various challenges in running it,
Process control is tough
High fines generation
High FeT in fly ash (30% - 40%)
Yield loss of 1 %
Initiatives taken:
Utilization of high TI Pellet with minimum Under sized (Max 2%)
By the help of pre heater, waste gas generated in kiln increases the temperature
of pellet to 700 900C, hence low coal is required to satisfy the need for
reduction and thus specific consumption of coal is low in the kiln. Furthermore it
enhances the production rate.

Energy Conserved is Energy Generated 17

7. Solid Waste Utilization and Disposal Green Productivity
Reduction of accretion by using pellet and Imported coal
Reduce Fe in Fly ash by using high Tumbler index(>94) pellet ore
Reduce LOI in flue gas by proper process control in Kiln and ABC
Reduce Reduce emission by installing bag filters
Proper sealing of all leakage prone points

Use of Fly Ash for making Bricks & tiles

Char & Dolochar is used AFBC boiler for power generation
Started using Bag filter dust in ABC which led to increase in steam generation by 2-
Reuse 3 tph

Recycle the back flow material after screening

Fines generated in Iron Ore is being used in pellet plant
Recycle

Recovery of waste heat in WHRB for power generation

Recover

Energy Conserved is Energy Generated 18

 Year on Year Analysis
Kiln Running Days in a Year (Days) *Expected Trend for specific consumption of Ore
as per pro
Overall Kiln Utilization % rata basis
Specific Consumption of Ore
1400
94% 100.0% 1.7
87.2% 88.0%
76.7% 90.0%
1200
80.0%
1.5 1.62
1.56 1.56 1.505
1000 70.0% 1.3
800 60.0%
1.1
50.0%
600 1187 1177 1264* 40.0% 0.9
1024
400 30.0%
0.7
20.0%
200
10.0% 0.5
0 0.0% FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16
FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 (till Feb'16)

Coal Consumption Analysis Specific Power Consumption

1.9 Specific Consumption of Coal (Total) Specific Power Consumption in KWH/MT

1.7 100 90 92
85
1.5 1.68
1.53
80 68
1.3
60
1.1
1.21
0.9 40
1.01
0.7 20
0.5
FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 0
(till Feb'16) FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16
(till Feb'16)

Energy Conserved is Energy Generated 19

 Year on Year Analysis
Production of Sponge Iron (MT) *Expected
as per pro
Productivity per Head
Capacity Utilization rata basis
Production (MT) per Employee
495000*
500000 120%
900 773
450000
371784 381060 100% 800
400000

Production (MT)
100% 700
350000 80%
293887 600
300000
250000 75% 77% 60% 500 403
354
200000 400
59%
40%
260
150000 300
100000 200
20%
50000 100
0 0% 0
FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 2012-13 2013-14 2014-15 2015-16

Gross Specific Energy Consumption in GCal per 1 Net Specific Energy Consumption in GCal per 1
MT Sponge Iron Production MT sponge Production
9.00 5.00
7.63 4.30 4.16
8.00 6.95 4.50
7.00 6.12 4.00 3.50
6.00 5.19 3.50 2.89
3.00
5.00
2.50
4.00
2.00
3.00 1.50
2.00 1.00
1.00 0.50
0.00 0.00
FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16
(till Feb'16) (till Feb'16)

Energy Conserved is Energy Generated 20

 Conclusion

It is concluded that in Iron and Steel making, the opportunities of energy

conservation are significant. If adequate awareness is created and actions are
taken, then losses of energy can be brought down to a large extent.

Any spillage or leakage is not limited only to emissions rather, it is the loss of
natural resources and nations loss.

Energy Conserved is Energy Generated.

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Thank You

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