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Essar Steel's stint with Waste Heat Recovery
The global producer of steel has commissioned a 19MW power plant in Hazira to utilize waste heat for generating electricity...
|July 30, 2012 | PowerWatch India
In a fresh case of utilizing heat waste recovery system for achieving energy
efficiency, Essar Steel India Limited has recently commisioned a 19MW power
plant at Hazira. The heat recovery power plant uses waste heat as fuel to generate
electricity that ensures zero wastage at the plant site. This initiative by
the global producer of steel, is a positive move towards decreasing the overall
carbon footprint and reducing the cost of power for the company.
According to the company, the Hazira plant will utilize heat generated during
the manufacturing process of hot briquetted iron waste heat recovery boiler
(HBI-WHR) and surplus steam form blast furnace boilers, for electricity generation,
from four modules. These four modules form part of the HBI plant, each generating
flue gas of about 2,00,000 Nm/hr. The power generated by the plant will be used
for internal consumption. In the words of Mr Dilip Oommen, MD and CEO, Essar
Steel India, the company's focus is to have facilities which are both cost
efficient and environmentally friendly.
Furthermore, the new plant is helping the company save the cost of generating
19MW of power, which is equivalent to the power required for almost 10,000 homes.
This, calculated in accordance with current electricity prices, provides extensive
savings. "This allows us to help addressing the national power deficit by
not drawing this power from the grid or using scarce natural resources,"
Mr. Oommen states.
The Essar Group also has a similar facility at its Canadian operations at Essar
Steel Algoma Inc, where the company has a co-generation facility. The company
is using the skills acquired in Canada for replicating the success in India.
Essar Steel Algoma has installed a 70MW co-generation facility providing a sustainable,
highly efficient, clean energy solution meeting the standards of the Canadian
authorities. It employs low-NOx burner technology and eliminates the need to
flare byproduct fuel. The facility reduces nitrous oxide emissions and converts
by-product fuels from the coke-making and iron making processes into electricity
and steam for the steelworks. Essar has set a precedent as the first integrated
steel manufacturer in Canada to construct a co-generation facility fueled with
by-product gas from the operation. The company is sure to benefit with the availability
of carbon credits due to the reduction in emission of greenhouse gases. The
company can utilize the power more effectively without any transmission losses
or leakages of power due to the proximity of the plant in Hazira. As Mr. Oommen
rightfully says, "In order to achieve maximum carbon credits, the plant
has to ensure taking up more CDM projects in the future." He adds that
basically there are 3 categories of CDM projects, which includes energy improvement
projects, waste heat recovery projects and renewable energy projects.
The company claims to have a well defined strategy to further reduce the specific
energy consumptions, which also helps in curbing specific CO2 emissions. In
its recently commissioned expansion projects, the company has incorporated the following
- Installing top pressure recovery turbine (TRT) in blast furnace (BF) -
60,662 tons of CO2 emission redcution annually.
- Waste Heat Recovery system of hot stove in BF - 1,42,541 tons of CO2 emission
- Stem generation using BF gas in boilers - 2,35,384 tons of CO2 emission
- Installation of bell-less top (BLT) charging system in BF - 67,380 tons
of CO2 emission reduction annually.
- Corex gas to replace natural gas consumption in DRI, plate mill, CSP, lime
plant etc - 16,43,000 tons of CO2 emission reduction annually.
Interview with Mr Dilip Oommen
MD and CEO, Essar Steel India Ltd., spoke about the newly commissioned
Hazira plant that generates electricity from waste heat...
What is the technology that is being used at the Hazira plant
that utilizes waste heat as fuel?
In order to reduce the thermal emission and with a view to utilize the
heat content from flue gas, a waste heat recovery power plant is installed
by Essar Steel India Ltd. at Hazira. The plant will use heat generated
during the manufacturing process from Hot Briquetted Iron Waste Heat Recovery
Boiler (HBI-WHR) and surplus steam from blast furnace boilers for electricity
generation from four of our modules. These modules form part of our HBI
plant, each generating flue gas of about 2,00,000 NM/hr. The temperature
of flue gas is about 400 degrees celsius. With the utilization of the
steam (heat from flue gas), we will substantially save the wastage of
unutilized blast furnace gas being flared. With this one-of-its-kind power
plant, we are aiming to become a zero waste plant at Hazira.
How much power will be generated at the plan through waste heat
and how much savings do you expect to achieve?
This plant forms part of our zero-waste plant strategy. The methods incorporate
by-products from other processes to ensure we are not wasting any of the
earth's natural resources. The commissioning of the 19MW power plant at
Hazira forms part of this and further advances our sustainability credentials.
With this plant we are moving towards being a zero-waste plant at Hazira.
In the instance of the 19MW power plant, we would not require to purchase
this power at all as we are now producing it on site. Therefore, the saving
in this case would be the equivalent of purchasing 19MW of power which
at today's high natural gas prices is equivalent of over Rs100 crore annually,
which is equivalent to powering 10,000 urban homes.
What is the strategy to ensure that the plant meets the energy
efficiency criteria to achieve carbon credits?
In order to achieve maximum carbon credits, the plant has to ensure taking
up more CDM projects in the future. Basically there are 3 categories of
- Energy Improvement projects
- Waste heat recovery projects
- Renewable energy projects
For our upcoming expansion projects, following are the facilities we
have planned to reduce CO2 emissions:
- Odisha Slurry pipeline from Dabuna to Paradeep to transport iron
ore fines for pelletisation — 1,13,229 tons of CO2 emission reduction
- Coke over gas uage for power generation at Hazira — 3,05,000 tons
of CO2 emission reduction annually
- Railway siding facility at Hazira — 2,149 tons of CO2 emission reduction
- Electric Arc Furnace (EAF) flue gas waste heat recovery — 1,52,064
tons of CO2 emission reduction annually
Any plans of expanding power generating capacity of the Hazira
plant in the near term?
Our power requirements are ully met with the power plants commissioned
at Hazira and long term agreements in place with power producers. Later
this year, a dedicated 270MW multi fuel power plant is scheduled to be
commissioned in Hazira, Gujarat. This plant along with by-products like
corex coal fines and corex gas will satisfy most of the energy needs.
We have no need for further power generation at any of our locations across
Comment on the current situation of fuel shortage in the country.
Any suggestions for dealing with the electricity crunch?
There has been an enormous increase in the global demand for energy in
recent years as a result of industrial development and population growth.
Fuel such as coal, natural gas, etc play a significant role in power generation
process. Hence, shortage of these fuels creates a direct impact on electricity
production. Today, in India, steep rise in fuel prices have compelled
companies to switch to imports. Rising import cost and fall in rupee are
affecting supply of fuel in India. Also, pending proposals with government
to develop mines, ports, roads, bridges and factories have a significant
impact on supply of raw materials / fuel in the country.