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Energy Efficiency & New Technology Deployment in Indian Iron & Steel Sector PowerPoint PPT Presentation

Energy Efficiency & New Technology Deployment in Indian Iron & Steel Sector S. K. Jain General Manager STEEL AUTHORITY OF INDIA LIMITED INTERNATIONAL WORKSHOP ON INDUSTRIAL ENERGY EFFICIENCY – NEW DELHI SAIL Today A listed company, 86% owned by GoI; one of the “Navratna” PSUs

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Energy Efficiency & New Technology Deployment in Indian Iron & Steel Sector

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Energy Efficiency

&

New Technology Deployment

in

Indian Iron & Steel Sector

S. K. Jain

General Manager

STEEL AUTHORITY OF INDIA LIMITED

INTERNATIONAL WORKSHOP ON INDUSTRIAL ENERGY EFFICIENCY – NEW DELHI


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SAIL Today

A listed company, 86% owned by GoI; one of the “Navratna” PSUs

Authorized Capital: Rs. 5000 Crore, Paid up capital: Rs 4130 Crore.

Largest Steel producer in India and 21st largest in the world (2008)

Highest ever turnover of Rs. 48,681 Crore in 2008-09 (equivalent to over $10 billion), 7% higher on YOY. (Rs. 20,481 Cr. in April-Sept. 09-10)

SAIL’s PBT was Rs 9,404 Crore and PAT of Rs.6,175 Crore in 2008-09 inspite of the economic downturn and higher input costs. (PBT Rs. 4529 Cr. & PAT Rs. 2994 Cr. in April- Sept. 09-10)

Highest PAT among all steel companies of the world in 1st half of January –June’09 (Rs. 2627 Crore)


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Energy Scenario in Indian Iron and Steel Industry

Is the largest consumer of energy among all industrial sectors.

Consumes about 10% of total electricity and 27% of coal used by Indian industry.

Energy cost contributes nearly 30 – 35% of this sector’s production cost.

Coking coal accounts for 65 – 85% of primary source of energy.


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Energy Scenario in Indian Iron and Steel Industry

  • Iron making through BF route accounts nearly 70% of the total energy consumed by the industry.

  • Energy is essential for economic growth and to achieve the target growth in GDP.


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Indian Steel Industry

Crude Steel Production 2004-05

Major steel plants & Energy Cons. level

Source: Joint Plant Committee, Govt. of India


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Energy Consumption in Indian Steel Industry

...Contd.

  • Specific energy consumption declined by >15% in last 10 years.

  • However, it is still more than World level of 4.5 Gcal/tcs


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High Energy Consumption in India – Why ?

Out dated technology in older plants set up in 60s and 70s

Inferior raw material quality

High alumina and high alumina & silica ratio in iron ore

High ash content in coking coal even after blending

Low rate of recycling


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Domestic installed capacity of crude steel (62.6 MT)- 2009

Other Integrated

Main Producers:

36.6%

SAIL is the largest domestic steel player


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Top 5 countries in Crude Steel Production

India has emerged 3rd largest steel producer in the world in 9M ’09

Source: WSA


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Production sites will move to regions with both RM source and demand.

Excess

CIS

Latin America

Raw Material basin

Growth basin

India

Avail-ability of Iron Ore

USA / Canada

Eastern Europe

EU

China

Other emerging Asian countries

Deficit

Mature basin

Japan

High

Low

Forecasted Growth rate 2005-15


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Indian Potential for Steel

Huge Potential for Demand

  • High GDP growth rate of 8%

  • 1 billion population

  • Low per capita steel consumption of 34kg (World av. 170 kg)

Growth factors for India

Abundant Iron Ore

Skilled Human Resources

Reserves 23 billion tonnes

Government Policy

  • Encouraging trade relations with ASEAN and other countries

  • Infrastructure building

  • Exploring new Energy resources

  • Stable currency

  • Easing of regulations

  • Strong Banking & judicial system


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Future Direction : National Steel Policy - 2005

  • Enhance indigenous production of steel to 110 MT by 2020 from a level of 38 MT in 2005 with a CAGR of 7.3 %

  • Exports 26 MT by 2020, from level of 4 MT in 2004-05 with a CAGR of 13.3 %

  • Iron ore requirement to increase to 190 MTPA by 2020 from about 54 MTPA in 2004.

  • Technology/ productivity in line with global standards

  • Demand Side

    • Strengthening of delivery chain linking the producers to the users, especially rural areas

    • Interface between producers, designers of steel intensive products, fabricators and ultimate user

    • Creating awareness about steel as a cost-effective and technically efficient end-use material


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Future Direction : National Steel Policy - 2005

  • Supply side

    • Enhanced and easy access to critical inputs – iron ore & coking coal

    • Expansion and improvement in quality of infrastructure – Energy, railways, ports and other means of transport

    • Well developed financial market with efficient financial instruments

    • Increased focus on R&D, training of manpower and integrated information services


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Future Demand of Steel in India

Different projections for proposed capacity:

(In million tons)


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Projected per Capita consumption of Finished Steel in India (kg)

India’s current population is - 1160 million

It is assumed that till 2051, population would be about : 1.4 bn.


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GROWTH SCENARIOS

Estimated Steel Production by 2020 = +200 MT

* - Also projected by National Steel Policy


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Energy Saving Potential in India

Specific Energy Consumption for Steel Industry :

India: 6.9 GCal / tcs (07-08)

World: 4.5 GCal / tcs (2008)

2.4

Energy saving potential : 200x(6.9-4.5)

= + 484 million GCal / yr


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Energy Saving Potential in India

To achieve this potential, Asia-Pacific partnership for clean development and climate has suggested adoption of Energy efficient “Best Available Technologies (BAT)” in

Coke Making

Sintering

Iron Making

BOF/EAF Steel Making

Finishing


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Barriers in implementing Energy Efficiency Technologies

Focus on reducing capital cost rather than being concerned about energy input

Difficulty in acquisition of energy-efficient technologies

Space constraints/retrofit ability problem in adoption of clean technologies in existing set up


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Barriers in implementing Energy Efficiency Technologies

  • Focus on reducing capital cost rather than being concerned about energy input

  • Difficulty in acquisition of energy-efficient technologies

  • Space constraints/retrofit ability problem in adoption of clean technologies in existing set up

  • Low rate of recycling.


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Energy-efficient Technologies for Iron and Steel Making


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To Conclude..

  • Indian steel industry has a bright future

RESOURCES

  • Abundant Iron Ore reserves

  • Strong Managerial skills in Iron and Steel making

  • Large pool of skilled Man-power

  • Established steel players with strong skills in steel making

OPPORTUNITIES

  • High economic growth driven increasingly by industry

  • Faster Urbanisation

  • Increased Fixed Asset Building

  • Automobiles and component industry growth

POLICY

  • Pro-active stance of Govt.

  • Encouragement for overseas investments


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To Conclude…

  • At this juncture, when demand for steel in India is fast growing to meet domestic and global demand, energy efficiency is the only option to counteract the associated maladies.

  • However lack of financing capabilities as well as lack of incentives impede the implementation of such measures.

  • Sectoral policies to be developed to promote such incentives

  • Policy strategy would consists of mix of regulatory and price based incentives


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Thank You

There’s a little bit of SAIL in everybody’s life


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