MEASURES BEING TAKEN TO MITIGATE GHG EMISSIONS AND EFFORTS REGARDING CLIMATE CHANGE BY RINL-VSP

Energy Efficiency EnMS ISO: 50001 GHG Management
Energy Efficiency

RINL adopts holistic approach towards energy management since inception as it believes that effective energy management is key to improving organisation bottom line and achieving sustainability. Energy Cost accounts for about 40% of manufacturing cost of steel making and RINL focusing on reducing energy consumption through multipronged approach of technology deployment, capacity building and systemic improvement.

 

The approach of RINL towards energy efficiency

a)    Adoption of State of Art Cleaner Technologies

b)    Continuous improvement of energy consumption through process management

c)    Energy Efficient Equipment Procurement

d)    Implementation of Energy Management System

 

 

Adoption of State of Art Cleaner Technologies

 

Design Stage

 

  •   Coke Dry Quenching Plant (4Nos) to recover waste heat energy of hot coke to generate electricity, process steam and chilled water. Back Pressure Turbine stations (2*7.5MW) and Condensing Extraction Turbine (13 MW) is installed at RINL.

  •   Top Pressure Recovery Turbine at BF1 &2 (12 MW each capacity) to convert waste pressure energy of Blast Furnace gas to electricity.

  •   LD Gas Recovery system at Steel Melt Shop-1 &2  to recover LD gas from converter blowing for use as fuel in reheating furnaces

  •   Evaporative Cooling System to generate process steam  from cooling of reheating furnace skids and posts

  •   Preheaters in Calcination plant kilns and Gas and air recuperators in Rolling Mills to recover waste heat from combustion systems.

 

These measures reducing energy consumption by 196254 tonne of oil equivalent (toe) and GHG emissions by 12.1 lakh tons annually. Read More

 

Expansion and Modernization of existing facilities

 

  •   NEDO Model Project on Sinter Cooler Waste Heat Recovery to generate 20.6 MW of electricity using heat energy of hot sinter. This project is taken up as part of  international cooperation project between India and Japan

  •   BF3 Stoves Waste Heat recovery to recover waste heat from stoves of Blast Furnace-3

  •   Energy efficient burners and waste Heat Recovery system in Sinter Plant-2

  •   Pulverised Coal Injection in  Blast Furnaces to substitute coke in Blast Furnace

  •   Billet Caster in Steel Melting Shop-2

  •   Energy efficient Vertical Shaft  Kiln

  •   Energy Efficient  Air Separation Unit

  •   120MW BF Gas based captive power plant to utilise surplus BF gases for power generation

  •   Rebuilding of BF-1 Furnace with energy efficient features and higher productivity

  •   Rebuilding of BF-2 Furnace with energy efficient features and higher productivity

  •   Capacity Enhancement of Sinter Plant 1 &2  along with  envisaging energy efficient features( energy efficient burners, variable frequency drives)

 

Completion of these projects shall reduce specific energy consumption by about 5 Lakh toe (ton of oil equivalent)

 

 

Power generation through waste energy

 

 RINL installed waste energy recovery technologies to recovery waste energy for generation of electricity. RINL is meeting about 56% of power requirements through utilization of waste energies at present. RINL fully geared to utilize waste gases generated during expansion of steel works from 3 Mt to 6.3 Mtpa. With this, the share of power generation from waste energies is to go up to 62% which is the best in Indian Steel Industry

 

 

 

Continuous improvement of energy consumption through process management

 

RINL always believe that continuous improvement through process management is possible .With the involvement of Departmental Energy Teams at grass root level and implementation of suggestion scheme and quality circles, RINL is able to reduce energy consumption significantly. Some of Process management initiatives are

 

  • Continuous monitoring of generation and distribution of by product fuels and resulted in diversion of more surplus gases to power plant and reduced bleeding losses of fuels & utilities. Due to these efforts, surplus by product gases is diverted to Thermal Power Plant and saved 12 lakh tons of boiler coal annually.

  • Reducing coke consumption in Blast Furnaces by proper blending of raw materials, Optimizing AL2O3/SiO2 ratio and Oxygen enrichment of Blast.

  • Optimizing thermal energy consumption by deep bed sintering in sinter plants,

  • Introduction of hot charging in WRM and reducing heat losses in furnaces

  • Electrical Energy management through maximizing captive plant electricity generation, demand side management during peak hours, Reducing field currents in DC motors of rolling mills, Unification of strands in MMSM and Bar Mill, up gradation of frequency converters in MMSM. Read More

Energy efficient equipment procurement

 

  • Replacing existing chillies with energy efficient one in Chilled water plant 3 &4

  • Circulation fan of  Sinter Cooler Waste Heat Recovery using life cycle costing.

  • Star Rated Air Conditioners

  • Energy efficient Motors

  • Installing variable frequency drives in electrical systems

  • Energy Efficient (T5) lamps

  • Energy Savers in lighting systems Read More

 

Green Products

 

  • Production of Green Steel such as FE500( Steel Consumption reduces by 15% due to high  yield strength of 500 N/mm2 on Fe 500 grade)

 

International Cooperation

 

RINL installed 20.6 MW Waste Heat recovery Project on Sinter Cooler of Sinter Plant-1 with technological assistance from NEDO under Green Aid Plan. The project is first of its kind in Indian Steel Industry in Sinter Plants generating electricity.  The project was commissioned and dissemination programme was conducted on 31.7.2014 .  The Project generates electricity without burning any fossil fuels and reduces GHG emissions.

 

RINL also participating in Public Private Partnership collaborative meetings between India and Japan annually as part of Bilateral Offset Credit Mechanism (BOCM). The Japanese delegation visited RINL on 3rd Mar 2015 and appreciated the efforts made by RINL towards energy conservation and GHG emission management.

 

Clean Development Mechanism Projects

 

RINL implemented CDM projects as per Kyoto protocol mechanism. Identified 15 Clean Development Mechanism projects both in expansion and existing units to claim carbon credits. Host Country approval from Ministry of Environment and forests is obtained for 13 No of Projects. These CDM projects have been developed within house efforts.  The following projects have been registered with UNFCCC

 

SL No

Name of Project

UNFCCC registration number

Expected CERs

1

Power Generation using Waste pressure Energy of BF gas from Gas Expansion Turbine Station of BF-3 of Rashtriya  Ispat Nigam Limited

9613

60410

2

Power Generation from Cooling of coke in Coke Oven Battery#4 of Rashtriya Ispat Nigam Limited

9988

68540

3

Waste Heat recovery  from stoves of Blast Furnace-3

10024

44932

 

Renewable Energy
  • Solar Water Heating system of 1500 LPD each in Ukku house and VSGH
  • Polycarbonate sheets to use natural lighting
  • Solar Energy based traffic signal lights in the Plant
  • Solar Energy Lamps under Corporate Social Responsibility to the villages in Paderu who are inaccessible to electricity.
  • Solar Energy City at SOS Village
  • Purchased Green attributes through purchase of Renewable Energy Certificates (REC).

Way Forward

  • Planning to install 5 MW Solar Energy Plant
  • Roof Top Solar System in Various Buildings (Technical Training Institute, Visakha Steel General Hospital, Town Administration)