Post on 09-Mar-2018
Best Practices In Energy Efficiency in Sponge Iron
Nalwa Steel and Power Ltd.
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Nalwa Steel and Power Limited is an Integrated Steel Plant set up by great visionary Late Shri O. P. Jindal. It works under the umbrella of Jindal Steel & Power Limited.
Introduction
Date:- 04-03-2016 2 Presented By:- Vishal Vashishtha & Debashis Roy
The plant is equipped with DRI Plant, Coal washery, Power plant, Steel Melting Shop, Oxygen Plant, Rolling Mill, and P.G. Plant etc. which make it fully integrated steel plant having capacity to produce 0.25 MTPA finished product. The major product of Nalwa steel and power limited are Sponge Iron, MS Billets & TMT Rebar.
Nalwa Steel and Power Limited is committed to adopt Energy Efficient practices in all its verticals. In this regard, Company has implemented ISO 50001:2011 and aligning the same with organization's business objectives and goals
1. DRI : 198000 MT/Year
2. SMS : 160000 MT/Year
3. WRM : 250000 MT/Year
4. CPP : 3X8 MW
Introduction: Continued…
Date:- 04-03-2016 3 Presented By:- Vishal Vashishtha & Debashis Roy
Energy Management Policy
Date:- 04-03-2016 4 Presented By:- Vishal Vashishtha & Debashis Roy
Process flow diagram of NSPL
Date:- 04-03-2016 5 Presented By:- Vishal Vashishtha & Debashis Roy
Particulars UOM Base Year FY 2014-15
Production MT 161917.67 186355.00
Thermal SEC Gcal/MT 7.5 6.2
Electrical SEC KWH/MT 90.56 83.86
Utilization % 81.78 94.12
90.56
83.86
80.00
82.00
84.00
86.00
88.00
90.00
92.00
Base Year FY 2014-15
7.52
6.21
0.00
2.00
4.00
6.00
8.00
Base Year FY 2014-15
DRI Performance:
Baseline Vs. FY-2014-15
Thermal SEC Electrical SEC
Date:- 04-03-2016 6 Presented By:- Vishal Vashishtha & Debashis Roy
Productivity = Sp. Energy Consumption
1. Installation of Iron Ore Wet Screening Plant
2. Installation of Deshelar System
3. Use of Pellet
4. Segregation of Injection Coal Size
5. Use of Imported Coal
Project Implemented/Process Change Activities
Date:- 04-03-2016 7 Presented By:- Vishal Vashishtha & Debashis Roy
1. Installation of Iron Ore Wet Screening Plant
IRON ORE WET SCREENING PLANT UOM BEFORE AFTER VARIANCE
IRON ORE FACTOR REDUCES @ 62.5FeT MT 1.84 1.76 0.08
COAL FACTOR REDUCES MT 1.6 1.54 0.06
TOTAL INVESTMENT COST 5Cr.
Date:- 04-03-2016 8 Presented By:- Vishal Vashishtha & Debashis Roy
Benefits of Deshelar
System:-
•Improves Quality of Coal
•Increases Efficiency of
Washery
•Increases Production of
Washery
•Generated by-product is
used in Power Plant
After Crushing, Coal is fed in Deshelar Chamber. Magnetic Powder is used as mix in the charged water to change the density of water. As density changes, the heavier particles settle down at the base of chamber and light articles floats on the charged water due to less density. Heavier Particles are dragged out from the settling chamber with the help of drag chain making the concentration heavier for the coal. It helps to improve quality of coal and increase the efficiency of coal Washery. The shale removed is by-product.
2. Installation of Deshelar System
Date:- 04-03-2016 9 Presented By:- Vishal Vashishtha & Debashis Roy
BENEFITS UOM IRON ORE PELLET VARIANCE
YIELD IMPROVEMENT % 56.80% 67.57% 10.77%
PRODUCTION FACTOR MT 1.76 1.5 0.26
REDUCTION IN SOLID FUEL CONSUMPTION
MT 1.54MT/MT 1.4MT/MT 0.14MT/MT
3. Use of Pellet
Pellets are balls of iron ore used in the DRI Plant. They are made with technology that uses the powder that is generated during the ore extraction process, once considered waste. The process of pelletization enables converting Iron Ore Fines into “Uniformed Sized Iron Ore Pellets
Date:- 04-03-2016 10 Presented By:- Vishal Vashishtha & Debashis Roy
Benefits of Segregation:-
•Production Efficiency Improved
•Coal Consumption reduced
•Coal Utilisation Increased
•FC in Ash Char Reduced
4-10mm 0-4 mm
Date:- 04-03-2016 11 Presented By:- Vishal Vashishtha & Debashis Roy
4. Segregation of Injection Coal Size
Benefits of Imported Coal Usage:-
• Coal Factor Reduced
• Specific Air Requirement Reduced
• Approx 30% Load Reduced on FD Fan & ID Fan
• Dolachar Generation Reduced by 50%, resulting
reduction in logistic expenses
• Kiln Main Drive & Cooler Main Drive RPM Reduced by
50%, Resulting reduction in Power Consumption
5. Use of Imported Coal in DRI
Date:- 04-03-2016 12 Presented By:- Vishal Vashishtha & Debashis Roy
1. Replacement of 70 Watt HPSV Lights with 12 Watt LED
Lights
2. Use of Transparent Sheets in Shed
3. Astronomical Timer for Lighting
4. 40 % DRI Equipments are Equipped with VVVF Drives
5. Erection & Commissioning of De-dusting System
6. SAP Based Preventive Maintenance Plan for Effective &
Improved Maintenance of Equipments
7. Monthly Review of Maintenance Statistics
8. Replacement of LDO Firing with FO Firing
Implementation of Small but Effective
Techniques in DRI
Date:- 04-03-2016 13 Presented By:- Vishal Vashishtha & Debashis Roy
Date:- 04-03-2016 14 Presented By:- Vishal Vashishtha & Debashis Roy
ISO 50001:2011 Certificate
Date:- 04-03-2016 15 Presented By:- Vishal Vashishtha & Debashis Roy
Thank You
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Presented By:- Vishal Vashishtha & Debashis Roy, 04-03-2016