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