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.

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 Contents

Sources of useful Waste Heat & Gases

Why waste recovery

Options of steam utilization

Need for carbon reduction PAT scheme

A word about us

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 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

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 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

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 Why Waste Heat Recovery ?

• 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

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 Options for steam usage

LP Steam for Boiler water pre heating LP Steam for Deaerator

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 Options for steam usage

From Existing Coal

Based Boiler

Elevator STG Gen

WHR
Hot coke Heat recovery boiler Boiler
Steam
Cokes basket Injection

Dust collector
Steam produced

Steam turbine
Cooling
chamber
Generator

Fan

Condenser
Extracted
steam

Cokes transfer car Cokes

Conveyor

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 Options for steam usage

Application: To reduce the Coke Oven Gas Temperature

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 Options for steam usage

COOLING WATER HEAT

REJECTION AT 35 TO 40 0C

Cogeneration
EXHAUST STEAM
GAS
CHILLING
(TO STACK) ABSORPTION UPTO 5 0C / (-)
30 0C
HRSG CHILLER

EXHAUST
GAS FROM
GT/DG STEAM/
Heat TO
Generator HRSG
HOT
WATER
PROCESS Trigeneration
HEATING

Components – Power/ process side

Components – Recovery side
• Gas Turbine
• HRSG / EGB
• DRI Kiln
• Absorption Chiller
• Coke oven Batteries
• Rankine Cycle Power Plant
• IC Engine

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 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

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 Advantages to industry

• 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

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 Critical issues to be addressed for Waste
Heat Boiler design
• 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
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• 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.
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 Boiler- Salient Features
• WHRB on CDQ key parameters to look for:
• WHRB on Flue gas from Non-Recovery Type
 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
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 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
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 Other waste - Usage

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 Ash and slag Problem

Half Solution
Problem
1st link of problem shifted
from here
to…

HERE

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 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

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Fully Automatic Vibro Compacting Technology
for Concrete Product

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 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
Neptune Plus Neptune Plus Neptune Plus
Model 1000HEY 1500HEY 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) 59 59 66 167
230 X 110 X 70
Raw Materials Storage - - - ~ 200 cu.m
Auto Batch Weighing, Feeding - - - Batching

Basic Plant Advance Powder Compacting Technology, Hyd.Brick Press

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 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

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 A word about us
THERMAX

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

B&H Cooling Turnkey Power Plants Chemicals Enviro

• Steam fired chillers
• Package boilers • Hot water fired • Solid fuel based • Ion exchange resins •ESP & Bag filters
• Large capacity chillers • Gas - combined cycle • Cooling water chemicals • Scrubbers
Power boilers • Direct fired chillers • Waste heat recovery • Fireside chemicals • Air purification
• Thermal oil / based • Polyelectrolyte • Retrofit & Revamp
Water heaters Heating • RE based incl. Biomass,
• Energy recovery • Packaged solid fuel Bagasse, solar, etc. Water and wastewater
systems fired boilers • O&M of power plants
• Packaged oil/gas • BOP of Large power
fired boilers • Wastewater & Effluent
plants treatment systems
• Fired thermic fluid
heaters • Water recycling
• Exhaust waste heat • Waste management
recovery boilers

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

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 A word about us

• 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

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 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

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 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

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 Profile of some of our Power Projects

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

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 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

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 Profile of some of our Power Projects
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.

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 Profile of some of our Power Projects
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.

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 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

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 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)

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 Thank You
For further details:
Vivek Taneja
Head of Business Development
Ph: +91 20 66414814 (D) ; 66414000 (B)
Email: vivek.taneja@thermaxglobal.com
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.

Thermax Limited Your Reliable Partner

Set 2015