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04. sms siemag tsl sustainability expo
1.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Commercial &
Ecological Competitiveness in Steelmaking Process Helmuth Ester / Surinder Baluja Tata Sustainability Expo 2016 , 17th June 2016 1
2.
Confidential·Allrightsreserved·©2014SMSGmbH Development in Germany
(Ruhr) 209.06.2016 Developments of Emissions in Germany In the past ….Today Up to 20 kg of dust per ton of steel are generated within each melting process Cleaning of exhaust air is governed by numerous regulations Stress on energy recovery (Most Steel making Plants in Germany are with energy recovery. In India none of the steel making plant is presently running with energy recovery) ECO plants by SMS Group : Saving Energy & Protecting Environment
3.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Introduction Gas Cleaning Assistance
for secondary dedusting systems Hydro-hybrid system for existing BOF shops Energy recovery for existing BOF shops TATA Sustainability Expo 2016 3
4.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Gas Cleaning
Assistance for secondary dedusting systems 4TATA Sustainability Expo 2016
5.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Herkömmliches Verfahren Conventional method Gas Cleaning
Assistance COMPARISON P Mixer Filter ID fan Gas Cleaning Assistance Manual setting - Always optimal flap position operation due to continous network analysis + No network analysis High negative pressure for all process steps resulting into high power consumption Constant network analysis resulting into high efficiency due to consideration of network resistances for actual operating conditiones Always optimal negative pressure operation resulting into low power consumption 5TATA Sustainability Expo 2016
6.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Scope of
Supply for Existing Plant ECO-DUST PCsystemDedusting-PLC Field P NewExisting HMI HMI Model Flexibly extendable IBN functions Emergency functions 6 Gas Cleaning Assistance TATA Sustainability Expo 2016
7.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Gas Cleaning
Assistance Summary Highlights: ■ Optimal flap positions ■ Maximum suction power with minimum energy consumption ■ Reacts flexible to every process step ■ Usable for all possible aopplications of Secondary Dedusting Systems such as BOF, BF, EAF etc Features: ■ Gas Duct Auto-Cleaning-Mode ■ IBN function ■ Damper functionality monitored on HMI ( a Secondary Ventilation System functions only if all dampers are functioning) 7TATA Sustainability Expo 2016
8.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Gas Cleaning
Assistance Case Study kWh Energy Saving 8 JSW, Toronagalu SMS 3: After implementation of GCA 1 out of 3 fans is switched off. Power savings up to 35% TATA Sustainability Expo 2016
9.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 9 Gas
Cleaning Assistance TATA Sustainability Expo 2016 BENEFIT TO TATA STEEL EXAMPLE: Possible Approx. Power Savings in LD # 3 Secondary Dedusting System per annum : 6000 MWh * * / annum ** Has to be checked with a study Substantial power savings can be done in Secondary Dedusting Systems throughout the plant like for LD # 1, LD # 2, Blast Furnaces etc. With very minimal investment. With installation of GCA approx. 20-40 % power savings can be done but it depends upon the type and operation of plant.
10.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Hydro-hybrid system for
existing BOF shops 10TATA Sustainability Expo 2016
11.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Conventional wet
type gas cleaning system Hydro Hybrid System 11 TATA Sustainability Expo 2016
12.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Typical
clean gas dust content: 50 mg/m³ Wet scrubber (e.g. Baumco system) Water treament plant Electro Static precipitator (final cleaning) after gasholder Wet scrubbing tower Conventional Technology 12 Hydro Hybrid System TATA Sustainability Expo 2016
13.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 13 From
conventional system to Hydro Hybrid System TATA Sustainability Expo 2016 Hydro Hybrid System
14.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 14
Typical clean gas dust content: 10 mg/m³ Hydro Hybrid Filter System Wet scrubbing tower Water treament plant (hidden) Wet-type ESP Water treament plant A new concept for wet-type BOF primary off-gas cleaning Hydro Hybrid System TATA Sustainability Expo 2016
15.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 15
Summary and advantages of the Hydro Hybrid System Much lower dust contents at system outlet. Less dust loads at the ID fans and therefore maintenance for the fans. Reduction of operation costs is possible by optimal tuning of wet scrubber and ESP. Existing water treatment facilities of scrubber do not need to be extended and can be normally used for the wet-type ESP. Suction capacity of existing ID fan can be increased as system permits lower pressure drop. Low investment cost in case of a revamp. Short down time required for hooking up. 300 200 100 2.0001.5001.000 TATA Sustainability Expo 2016 Hydro Hybrid System
16.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 16
Advantages of the new process - Hydro Hybrid Filter system Upgrade of almost every existing wet scrubber is possible Meeting existing and future authority requirements No further ESP for fine cleaning necessary (downstream of the gas holder) Especially for TATA Steel it is beneficial since in LD # 1 & 2 where high dust emission problems is there, it can be solved. ≤10 mg/m³ Hydro Hybrid System TATA Sustainability Expo 2016
17.
Confidential·Allrightsreserved·©2014SMSSiemagAG SMS Group Energy recovery
for existing BOF shops 17TATA Sustainability Expo 2016
18.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 18 Energy
Recovery – BOF shop TATA Sustainability Expo 2016
19.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Recovery
of sensible heat energy from BOF Off Gas 19 Off-gas (2000° – 800°C) has to be cooled down BOF converter Energy Recovery – BOF shop TATA Sustainability Expo 2016
20.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group SMS SIEMAG
HOT WATER UTILIZATION SYSTEM (HWU SYSTEM) Hot Water Users (Absorption Chillers) 20TATA Sustainability Expo 2016 Energy Recovery – BOF shop
21.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group up to
2000°C 180 TNm³/h Cooling Stack: 56 m Hot Water Cooling up to 2000°C 180 TNm³/h Cooling Stack: 56 m Modified Hot Water Cooling Offgas Water 850ºC 130°C Offgas Water 850ºC 130°C Energy Wasted to Atmosphere Chilling 4800 TR ( i.e 3.5 MWh Power Savings ) 15,5 MWh Example 250 Ton Converter TTT : 45 mins 22 MWh 22 MWh Comparison : Conventional Hot Water Cooling Vs Modified Hot Water Cooling with Energy Recovery Energy Recovered to generate free chilling 21 Energy Recovery – BOF shop TATA Sustainability Expo 2016
22.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group SMS Siemag
Steam Generation during BOF Gas Cooling 22 80 kg steam / tls Energy Recovery – BOF shop TATA Sustainability Expo 2016
23.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS GroupE Options for
steam utilisation 23 Power generation Power generation Cooling by absorption chilling Cooling by absorption chilling Steam injector pumps for VD / RH process Steam injector pumps for VD / RH process Steam netSteam net Other Applications Other Applications TATA Sustainability Expo 2016 Energy Recovery – BOF shop
24.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 24 Energy
Recovery – BOF shop TATA Sustainability Expo 2016 BENEFIT TO TATA STEEL EXAMPLE: 1. Possible Approx. TR generation from LD # 3 Primary Gas cooling System per annum : 5000 TR * * / annum ** Has to be checked with a study 2. Possible Approx. Steam generation from LD # 3 Primary Gas cooling System per annum : 200 X 103 tonnes* * / annum ** Has to be checked with a study
25.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group Summary 25 • All
three solutions will reduce the power consumption and reduce the CO2 footprints for the present facilities in TATA Steel. • Also TATA Steel will have environmental benefits with reduction in dust emissions and efficient fume collection. • Case wise Pay back solutions can be worked out • Apart from the tangible benefits, the described solution is one of our contributions for environmental protection & make the World - A better place to live “ in our own small way. “ TATA Sustainability Expo 2016
26.
Confidential·Allrightsreserved·©2016SMSSiemagAG SMS Group 26 We
thank you for your attention TATA Sustainability Expo 2016
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