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 1/3rd of manufacturing cost of steel making and RINL focussing 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 2,22,842 tonne of oil equivalent (toe) and GHG emissions by 13.32 lakh tons annually. Read More

Expansion and Modernization of existing facilities

 New Energy and Industrial Technology Development Organization (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)

Read More

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 Million ton to 6.3 Million ton per annum. With this, the share of power generation from waste energy 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 3^rd 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

58871

2

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

9988

70516

3

Waste Heat recovery from stoves of Blast Furnace-3

10024

42573*

* Verification under progress

Renewable Energy

Installed 5 MW Solar Power Plant. This project was commissioned on 20th Dec'2016.

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).

GHG Emissions Reductions from 5MW Solar Power Plant (tCO2e);

2017-18 2018-19 2019-20

9192 9868 9603

Awards

RINL has been awarded "National Energy Conservation Award-2019" first prize for the year 2018-19 by Bureau of Energy Efficiency, Ministry of Power.

RINL has been awarded "National Energy Leader" Award for consecutively winning" Excellent Energy Efficient unit award" for the year 2017,2018 & 2019 at Hyderabad during 20th National Competition for Excellence in Energy Management-2019.