Energy Management in Small and Medium sized Re-rolling mills...

Energy Management in Small and Medium sized Re-rolling mills Energy consumption in small and medium sized re-rolling mills takes place in two forms namely (i) electrical energy, and (ii) fuel or heat energy. Electrical energy is used directly in main rolling process for shaping of hot billets into rolled product (rolling mill, and shears etc.), in reheating furnace (coal pulverizer, blower, and pusher etc.) and also in auxiliary (roll turning machines, pumps, man coolers, overhead crane etc.), and shop lighting. Fuel energy is used in the reheating furnace for raising the temperature of the feed material to desired temperatures (generally 1150 deg C–1250 deg C). The division of the energy in these two forms normally varies from mill to mill based on the practices employed as well facilities installed in the re-rolling mills in SME (small and medium enterprise) sector. However, the share of electrical energy in small and medium sized mill generally varies in the range 20 % to 30 %. Consumption of fuel energy takes the major share of the energy consumption and usually constitutes 70 % to 80 %. From a theoretical perspective, the energy in hot rolling is primarily determined by the requirements of reheating of feed material. The theoretical energy for deformation is only 0.02 GJ/ton (around 5000 kcal/ton), compared to 0.83 GJ/ton (around 200,000 kcal /ton) for heating billets when charged cold in the reheating furnace. Though it is not technically feasible to achieve theoretical energy consumption figures, but the energy efficiency of the rolling mill is depends upon how close it is to the theoretical consumption. Management of electrical energy consumption Out of the total electrical energy consumed by a re-rolling mill, the share of the process of rolling is in the range of around 60 %...

Energy Conservation in a Steel Plant...

Energy Conservation in a Steel Plant Production of iron and steel is an energy intensive manufacturing process and needs natural resources (including the energy resource) in large amounts. Energy cost is one of the major costs in the operation of the steel plant. The energy efficiency and hence the energy consumption of the steel plant varies depending on production route, type of iron ore and coal used, the steel product mix, operation control technologies employed, and material efficiency of the plant. Conservation of energy is one of the most effective ways to improve the energy efficiency, to reduce the energy consumption, and to lower the costs with an added benefit of reducing the impact of the steel plant on the environment. In recent years, the need for a more rational and efficient use of energy has emerged as a strategic and urgent issue. The rational use of the energy resource is being regarded as a twofold issue, a first aspect being related to the achieved consciousness of the limited availability of energy, regarded as a source, and the second being represented by a mature appreciation of the costs incurred to procure energy. The cost of energy is not only the important motivation for the steel plant management to make efforts towards energy conservation and to increase the energy efficiency of the processes but the threat of energy shortages is leading the management to take steps for the conservation of the energy. Energy conservation also helps the steel plant towards its societal goal towards reduction of the generation of greenhouse gases. The composition and local conditions of each steel plant is different, and based on each unique situation the most favourable selection of energy conservation opportunities are required to be made to address to the...

Energy Management in a Steel Plant...

Energy Management in a Steel Plant Iron and steel industry is the largest consumer of energy among all industrial sectors. Energy conservation in steel industry is crucial for its competitiveness, sustainability and minimization of environmental impacts including green house gas emissions and better resource management. As per World Steel Association, energy costs represent around 20 % to 25 % of the total input of steel plants. Energy cost cutting and energy efficiency improvements are the most important topics of control for the steel plant management.  Energy management provides the following opportunities in a steel plant. It provides opportunities to decrease the energy intensity per ton of crude steel It provides opportunities to adopt best or good practices for utilization of energy sources more effectively It provides opportunities for using best or good practices for recovery of heat and gas energy wherever practical. It enables the plants to develop plans for reduction of plant’s energy intensity It makes plant to carry out prioritization of those investments which have biggest impact on the energy efficiency. Energy management efforts, which aim to reduce energy use, are a must as well as a key element for a steel plant’s energy management programme. Twin approach for energy management in a steel plant is desirable and necessary. Energy management programme can be system based through implementation of ISO 50001-2011 standard as well as it can be a technical approach based on real time information obtained from process monitoring and control systems and on production plans received from production planning systems. While the first approach is a management approach which streamlines all the systems connected with energy use and energy conservation, the second approach provides information on actual and planned energy indicators of production, distribution and consumption on real time basis...