Day-3, Mr. D M Chowdhary
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The document discusses waste energy recovery technologies in integrated steel plants. It describes how blast furnaces produce high pressure gas that can be used to power turbines for electricity generation without using additional fuel. This pressure recovery turbine (TRT) technology converts kinetic energy from blast furnace gas into electricity, generating 15-20 MW from a large blast furnace. However, the reliability of power from such process-dependent systems is low at around 50-60% of capacity on average annually. The document calls for incentives to encourage adoption of new waste energy recovery technologies in India, as initial installations carry high risks but can stabilize technologies for broader adoption over time.
Day-3, Mr. D M Chowdhary
- 1. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa Title: WASTE ENERGY RECOVERY IN AN INTEGRATED STEEL PLANT Speaker: D M Chowdhary
- 2. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa WASTE ENERGY RECOVERY • TODAY WASTE HEAT RECOVERY IS GAINING ACCEPTANCE IN CERTAIN INDUSTRIES • DEPENDING ON THE FORM OF ENERGY THERE MAY BE DIFFERENT TYPE & APPROACH OF ENERGY RECOVERY: I. WASTE HEAT RECOVERY II. OTHER FORMS OF INDUSTRIAL WASTE ENERGY RECOVERY
- 3. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa I. WASTE HEAT RECOVERY • DIFFERENT PROCESS INDUSTRIES HAVE DIFFERENT TYPE OF WASTE HEAT AND ITS RECOVERY METHODOLOGY • SPONGE IRON PLANT, CEMENT PLANT, STEEL PLANTS ARE MAJOR PROCESS PLANTS WITH HIGH DEGREE OF HEAT RECOVERY POTENTIALS
- 4. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa TECHNOLOGY MATURITY • TECHNOLOGY TO A LARGE EXTENT IS GETTING STABLISED FOR HEAT RECOVERY FROM COMMON PROCESSES • NEW TECNOLOGY FOR HIGHER RECOVERY UNDER DEVELOPMENT AND NEEDS ENCOURAGEMENT • EXAMPLES: CDQ, SINTER PLANT etc.IN A STEEL PLANT
- 5. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa II. OTHER FORMS OF WASTE ENERGY RECOVERY • THIS IS AN AREA NOT WIDELY COVERED IN VARIOUS INDUSTRIES • DIFFERENT PROCESS INDUSTRIES HAVE DIFFERENT FORMS OF ENERGY. NEED TO BE IDENTIFIED AND DEVELOP/ GET TECHNOLOGY TO RECOVER THE SAME • SUCH TECHNOLOGIES ARE STILL AT DEVELOPMENT STAGE
- 6. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa • PROVEN TECHNOLOGY IS VERY LIMITED FOR MANY PROCESSES • RELIABILITY OF SUCH PROCESS IS IN DOUBT • CAPITAL COST DEPENDS ON TECHNOLOGY • POWER GENERATION TECHNOLOGY FROM SUCH WASTE ENERGY ARE PREDOMINANT • POWER GENERATION STILL IS A BYPRODUCT / SECONDARY EVENT AND PROCESS STABILITY IS CRITICAL
- 7. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa PRESSURE ENERGY RECOVERY IN AN ITEGRATED STEEL PLANT FOR UTILISING BLAST FURNACE PRESSURE ENERGY
- 8. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa BLAST FURNACES OPERATION REQUIRES LARGE VOLUME OF AIR • BLAST FURNACE IS A TALL VERTICAL FURNACE - CONVERTS IRON ORE, COKE AND FLUX INTO LIQUID METAL • HIGH PRESSURE LARGE VOLUME OF AIR IS PUT INSIDE THE FURNACE BOTTOM FOR CONVERSION OF IRON ORE AND COKE INTO LIQUID IRON. BY PRODUCT GAS ALSO COMES OUT AT HIGH PRESSURE • IN A CONVENTIONAL STEEL PLANT, THE GAS IS USED AS A LOW CALORIFIC VALUE FUEL OR RELEASED IN ATMOSPHERE
- 9. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa PRESSURE ENERGY RECOVERY IN BLAST FURNACES: TRT • THE PRESSURE ENERGY IS NOT UTILIZED AND GOES AS A WASTE IN MOST OF THE CONVENTIONAL STEEL PLANTS. • TOP-PRESSURE RECOVERY TURBINE, POPULARLY KNOWN AS TRT IS A TECHNOLOGY TO CONVERT THIS PRESSURE ENERGY/ KINETIC ENERGY INTO POWER • IT IS IN A WAY AN ARTIFICIAL WIND POWER GENERATOR AND WORKS ON SIMILAR PRINCIPLE.
- 10. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa 15-20 MWe POWER FROM A LARGE BLAST FURNACE (3 Mtpa) • THE HIGH PRESSURE GAS COMING OUT OF BLAST FURNACE ROTATES THE TURBINE AND GENERATES POWER • NO FUEL/ NO HEAT IS USED FOR POWER GENERATION • BUT THE RELIABILITY OF POWER GENERATED FROM A PROCESS PLANT LIKE BLAST FURNACE TRT IS LOW, ON AN AVERAGE ANNUAL GENERATION IS APPROXIMATELY 50-60% OF INSTALLED CAPACITY Schematic Diagram
- 11. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa CHALLENGES AHEAD • HOW TO ENCOURAGE SUCH FUEL LESS ENERGY SOURCES WHICH ARE MOSTLY A WASTE IN TODAY’S INDUSTRIAL WORLD. • TECHNOLOGY THAT IS YET TO BE FULLY STABLISED IN INDIAN CONTEXT. • ENCOURAGE DEVELOPMENT OF NEW TECHNOLOGIES • INCENTIVISE THE INDUSTRY AT LEAST FOR INITIAL PERIOD- TIME GRADED MANNER
- 12. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa ADOPTION OF NEW TECHNOLOGIES - HIGH RISK • ENCOURAGE FIRST FEW INSTALLATIONS IN INDIA IN SIGNIFICANT MANNER. • ONCE THE TECHNOLOGY IS FULLY STABLISED IN THE INDIA ,IT IS LIKELY TO BE ADOPTED BY OTHERS • ECONOMICALLY UNVIABLE ENERGY RECOVERY PROJECTS NEEDS FINANCIAL SUPPORT FOR LONGER PERIOD • ROLE OF INDUSTRIES- TO TRY NEW ENERGY RECOVERY SOURCES/ TECNOLOGY
- 13. The 14th Regulators & Policymakers Retreat 1st – 4th August, 2013, Goa Marriott Resort & Spa, Goa THANK YOU