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.
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Sources of useful Waste Heat & Gases
Why waste recovery
Options of steam utilization
Need for carbon reduction PAT scheme
A word about us
Contents
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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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• 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 ?
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Options for steam usage
LP Steam for Deaerator LP Steam for Boiler water pre heating
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Options for steam usage
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
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Options for steam usage
Application: To reduce the Coke Oven Gas Temperature
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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
Options for steam usage
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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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• 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
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• 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.
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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
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Other waste - Usage
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Ash and slag Problem
Half Solution
Problem shifted
from here to…
HERE
1st link of problem
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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
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
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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
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
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Services Group - Operations and Maintenance, Steam on Hire, Renovation & Modernization,…
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• 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
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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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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
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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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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.
Profile of some of our Power Projects
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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.
Profile of some of our Power Projects
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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: [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