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PREFACE



United Nations Development Programme (UNDP) in collaborat ion wit h
Ministry of Steel (MoS), Government of India (GoI) with funding support
from Global Environmental Facil ity (GEF) implement ed a project t itled
Removal of Barri ers to Energy Efficiency Improvement in the Steel Re -
Rolli ng Mill Sector in India between 2004 and 2013. The project identif ied
energy eff icient technology packages for reheating furnace and roll ing mil ls.
The proj ect provi ded technical assistance and f inanci al i ncent ive to the
SRRM units to adopt energy ef ficiency measures. 34 steel rerol li ng mill s
have successf ully adopted energy efficient technologies and accomplish ed a
substanti al savings in specif ic energy consumption and reduction i n GHG
emissions. Energy savings were approximately 25% in f urnace oil using unit s
and exceeded 40% in coal using units.

UNDP along with MoS and supported by AusAID, has l aunched a new project
to upscal e the energy eff ici ency measures i n steel reroll ing and other
subsectors. The project titl ed Upscal i ng Energy Efficient Production in
Small Scale St eel Industry in India aims at
Up-scal ing Energy Efficiency int ervent ions in about 300 SRRM
Piloti ng EE measures i n other steel subsectors such as Induction
furnaces
Trialing second generation of technology packages in SRRM

This publ icat ion provides descri ption of dif ferent technology packages,
salient feat ures and economic benefits. Most of these are successf ull y
demonstrated i n the earl ier project . The aim of this publ icat ion is to
dissemi nate detai ls of various technology packages among the SRRMs sector
and to help to them to suitably choose the appropriate technology to improve
their present energy consumpt ions and reduce associat ed GHG emissions. We
hope the units wil l fi nd this publ ication f or them to make informed choice.





S N Srinivas
Programme Analyst [Energy for Development]
United Nat ions Development Programme


No. Category EE Technol ogy
Investment
estimate
Saving
potential
Impl emen
tation
period
Financial
incentive
Maximum
per unit
1
GROUP 1A
Low-end EE
tech
equipment

Shel l i n shel l t ype recuperat or f or pul veri zed coal
f i ri ng syst em
INR 3 15
l akhs
Savi ngs i n
speci f i c f uel
consumpt ion
by 5 - 15%.
2 3
months
Capi t al subsi dy
of 20% on
i nst al l at i on of
i ndi vidual
equi pment

INR 2 l akhs
Modi f i ed pul veri zed coal f i ri ng syst em
Energy ef f i ci ent pul veri zor
Inst al l at i on of automat i on & cont rol syst em
(Proport i onal Int egrat ed Deri vat i ve [PID] based f or
reheat i ng furnace ai r-f uel rat i o cont rol syst em)
Hi gh ef f i ci ent U-tube cross f l ow t ype met al l i c
recuperat or (f or furnace oi l / gas f i red reheat i ng
f urnaces)
Vari abl e Vol t age Vari abl e Frequency (VVVF) dri ve
Savi ngs i n
speci f i c power
consumpt ion
by 2 -10%
Uni versal spi ndl es & coupl i ngs
Ant i f ri ct ion rol l er beari ngs
Inst al l at i on of Y-rol l er t abl e i n 3-Hi mi l l st ands of
rol l i ng mi l l s
Inst al l at i on of t i l t ing t abl e f or 3-Hi mi l l st and
Energy ef f i ci ent dri ves f or rol l i ng mi l l s
2

GROUP 1B
Low-end EE
technol ogy
package
Repl acement of exi st i ng furnace wit h new energy
ef f i ci ent furnace
INR 1 2
crores
Savi ngs i n
speci f i c f uel
consumpt ion
by 20 - 35%.
4 8
months
Consul t ancy
f ees
rei mbursement
on successf ul
commi ssi oning
of i ndi vi dual
packages
INR 2 l akhs
Conversi on of f ossi l fuel t o CBM based reheat i ng
f urnace
Conversi on of f ossi l fuel t o biomass based producer
gas reheat i ng f urnace
Revampi ng / moderni sat i on of pul veri sed coal f i red
re-heat i ng furnace
Revampi ng exi st i ng furnace wi th energy ef f i ci ent
t op f i red re-heat ing furnace
3
GROUP 3
High-end
technol ogy-
Direct
rol l ing
Di rect rol l i ng
INR 1.5- 3
crores
Savi ngs i n
speci f i c f uel
consumpt ion
by 80 -100%.
6 8
months
Consul t ancy
f ees
rei mbursement
on successf ul
commi ssi oning
INR 5 l akhs
4
GROUP 5
New
generation
EE
technol ogies
Regenerat i ve burners
INR 1. 5 6
crores
Savi ngs i n
speci f i c f uel
consumpt ion
by above 40%
6 8
months
Capi t al subsi dy
of 20% on
i nst al l at i on of
i ndi vidual
equi pment

INR 20
l akhs
Oxy-fuel combust ion syst em
## - EE technol ogy packages under group 2 & 4 and additional technol ogies under group 5 are under f inal ization.




1A-1 Shell in shell type recuperator for pulverized coal firing
system
Descript ion
Recuperators are generally heat exchangers
that use the energy in hot waste flue gases to
preheat combustion air. In recuperators heat flows
steadily through the wall from the heat source (hot
flue gas) to the heat receiver (cold combustion air).
Increase in air pre-heat temperature can
significantly reduce specific fuel consumption.
Salient features, Investment & Benefi ts
The following table describes the salient features, application, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Waste heat recovery upto 350
0
C with a flue gas temperature of
700
0
C can be achieved.
Recuperator designed with optimum surface area
Inner shell is made of stainless steel to withstand high
temperature.
Application
All pulverized coal fired reheating furnace, which is not
equipped with recuperator.
Technological
advantages
This type of recuperator is ideal for pulverized coal fire re-
heating furnace as conjunction due to coal deposits in the
recuperator line is avoided.
Technological
limitations
Combustion air temperature to be maintained below 400
0
C for
pulverised coal as the same may get ignited.
To avoid heat losses in line, combustion air pipes should be
insulated.
Estimated investment INR 3 6 lakhs (depending on the furnace capacity)
Estimated
implementation
period
2 3 months.
Expected benefits
Savings in specific fuel consumption by 10 - 15%
Reduction in CO2 emission by 10 -15 %.
Estimated payback on
investment
Less than 6 months.




1A-2 Modified pulverized coal firing system
Descript ion
The steel rerolling units to a large
extent uses coal as fuel for the reheating
furnaces. However the obsolete design of
the pulverized coal firing system leads to
incomplete combustion, thereby leading to
higher specific thermal energy consumption
and burning loss.
The modified pulverized coal system provides a solution towards eradicating un-
burnt coal particles, there by leading to lower specific fuel consumption.
Salient features, Investment & Benefi ts
The following table describes the salient features, application, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Separate hoppers with silo and air filter system placed above
burners.
Specially designed burners allow use of hot preheated
combustion air and also proper mixing of fuel and air.
Air fuel flow controlled through automatic control system.
Application
All pulverized coal fired reheating furnace, which is not
equipped with recuperator.
Technological
advantages
The system provides solution for using 100 % hot combustion
air.
Control flow air & fuel leads to lesser fuel consumption.
Technological
limitations
Preheated combustion air above 400
0
C may lead to ignition of
the pulverized coal.
Moisture content in coal may lead to coal deposits in hoper.
Estimated investment INR 5 15 lakhs (excluding recuperator)
Estimated
implementation
period
2 3 months.
Expected benefits
Savings in specific fuel consumption by 10 - 15%.
Reduction in CO2 emission by 10 -15 %.
Estimated payback on
investment
Less than 6 months.




1A-3 Energy efficient pulverizor
Descript ion
In order to achieve maximum
combustion efficiency (-) 200 mesh fines of coal
is recommended. The same can be achieved
through a modified and energy efficient
pulverizor design.

Salient features, Investment & Benefi ts
The following table describes the salient features, application, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
High manganese alloy, high carbon and high chromium
hammer with approximately 2000 2200 gms weight.
EN31 steel machine grooved liner hardened with nitriding.
Stainless steel classifier blades.
Stainless steel fan blades
RPM of approximately 2200.
Application
All pulverized coal fired reheating furnace, which is not
equipped with recuperator.
Technological
advantages
Fines of -200 mesh coal size can be achieved.
Better life of pulverizor.
Technological
limitations
Maintenance of critical part to be more frequent.
Estimated investment INR 10 -15 lakhs.
Estimated
implementation
period
2 3 months.
Expected benefits
Savings in specific fuel consumption by 5 10%.
Reduction in CO2 emission by 5 - 10 %.
Estimated payback on
investment
6 9 months.




1A-4 Installation of automation & control system (Proportional
Integrated Derivative [PID] based for reheating furnace air-fuel
ratio control system)
Description
Control systems with microprocessor based PID controllers
are used in reheating furnace for controlling and regulating air-
fuel flow which has direct impact on the specific fuel
consumption.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Control of desired temperature regimes and air-fuel ratio are
possible.
Operator interaction for maintaining temperature is minimal.
Application
All types of re-heating furnace irrespective of type of fuel.
The installation of automation & control system is to monitor
flow of combustion air & gases, temperature, air fuel ratio and
pressure.
Complete interlocking and sequential control of the furnace
with respect to the charging and discharging shall be done
through relay logic to be provided in the instrumentation
panel.
Technological
advantages
Optimum fuel flow, air flow and excess air % are maintained.
Automatic control based on operating scenario.
Human errors are minimized.
Technological
limitations
Skilled manpower requirement.
Maintenance of system and instruments are required.
Estimated investment INR 5 -10 lakhs.
Implementation
period
2 -3 months.
Expected benefits
Savings in specific fuel consumption by about 5 - 10%.
Reduction in CO2 emissions by 5 10 %.
Estimated payback on
investment
Less than 6 months.




1A-5 High efficient U-tube cross flow type metallic recuperator (for
furnace oil / gas fired reheating furnaces)
Descript ion
Recuperators are generally heat
exchangers that use the energy in hot waste flue
gases to preheat combustion air. In recuperators
heat flows steadily through the wall from the
heat source (hot flue gas) to the heat receiver (cold combustion air). Increase in air pre-heat
temperature can significantly reduce specific fuel consumption.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Waste heat recovery as high as 80% of the flue gas temperature
can be achieved.
Recuperator designed with optimum surface area
Stainless steel tubes in 1
st
pass and boiler quality steel in second
pass.
Application
Any reheating furnace (with F.O /gas fired), which is not
equipped with a recuperator or existing recuperator operating
with low performance (with recuperator efficiency less than
30% or temperature at recuperator outlet less than 200 0C).
Technological
advantages
High pre-heat temperature for combustion air is achieved.
Better combustion.
Technological
limitations
When the flue temperature is high, dilution with air is
required.
With the use of high temperature recuperator, the combustion
air pipes of burner need to be insulated when air temperature
is more than 400
0
C.
Estimated investment INR 5 20 lakhs (depending on the furnace capacity)
Implementation
Period
2 3 months.
Expected benefits
Savings in specific fuel consumption by 5 - 10%.
Reduction in CO2 emissions by 5 10 %.
Estimated payback on
investment
Less than 6 months.



1A-6 Variable Vol tage Variable Frequency (VVVF) drive
Descript ion
It is a type of adjustable-speed drive used in
electro-mechanical drive systems to control AC
motor speed and torque by varying motor input
frequency and voltage.



Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features Can be added to existing motors & drives.
Application
Reheating furnace blower
TMT pumps
Rolling mill auxiliary motors
Technological
advantages
Energy losses are quite high in case of electrical equipment
running at fixed speed. Thus for optimum utilisation of power,
VVVF drives are most appropriate which delivers required
output for loads of varying type.
Fast and accurate control of torque and speed of drives under
all operating conditions leading to savings in electric power
consumption.
Technological
limitations
Trained operating personnel with some electrical knowledge.
Estimated investment Upto INR 5 lakhs.
Implementation
period
2 3 months.
Expected benefits
Savings in specific power consumption by 2- 3 %.
Reduction in CO2 emissions by 2 3 %.
Estimated payback on
investment
Less than 6 months.






1A-7 Universal spindles & couplings
Descript ion
In rolling mills, spindles & couplings are used
for transmitting power to the rolls from mill
drives/motors.
Universal joint defines as mechanical device
that can transmit torque and rotational motion from
one shaft to another at fixed or varying angle of
intersection of shaft axes.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Has high torque carrying capacity.
Easy to connect or disconnect the coupling.
Application
Any rolling mill with provision of changing over from CI
wobbler.
Technological
advantages
It allows some misalignment between the two adjacent shaft
rotation axes.
Operates with negligible back lash and radial clearance to
improve productivity.
Reduced maintenance.
Technological
limitations
Inter-stand distance is constraint.
Improper design of coupling & spindle can lead to vibration and
significant transmission loss.
Estimated
investment
The cost of eight sets of universal coupling and spindle for
460 mm four stand roughing mill train will be approximately
INR 10 -15 lakhs.
Implementation
period
2 3 months.
Expected benefits
Savings in specific power consumption by 5 8%.
Reduction in CO2 emissions by 5 10%.
Estimated payback
on investment
Less than 1 year.




1A-8 Antifriction roller bearings
Descript ion
Basic purpose of bearing in rolling mills is
to provide a frictionless support and guide a
rotating machine part.
Antifriction roller bearings are more
desirable than fibre/brass cotter bearing due to
their lower friction and reduced lubrication requirement and their coefficient of friction is
0.005.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Less friction due to facet contact.
Better tolerance of products.
Longer life and can be fitted in existing system with
modification.
Application
All mill stands excluding the ones having layout/technological
constraints.
Technological
advantages
An antifriction bearing minimizes torque on spindle leading to
lower power consumption.
Higher mill speed can be achieved with respect to other
bearings.
Technological
limitations
Modification in roll chock design.
Estimated
investment
Approximately INR 3 6 lakhs to cater to 460 mm 3 Hi roughing
mill stand.
Implementation
period
2 3 months.
Expected benefits
The mill utilization goes up by 5%.
Savings in specific power consumption by 3 5 %.
Reduction in CO2 emissions by 3- 5%.
Estimated payback
on investment
Less than 1 year.




1A-9 Installation of Y-roll er table in 3-Hi mill stands of rolling
mills
Descript ion
In three-high (3-Hi) mill, three rolls rotate in one
direction and the metal is fed through two rolls and then
returned through the other pair with middle roll being
common.
Material handling in typical 3 Hi mill train is done manually. A Y-roller table is a
steel fabricated material handling system for automatic transfer of bar from one stand to
another stand.
Roller is skewed for bar to be taken up by Y roller table and feeds the bar between
top roll and middle roll of 3-Hi mill. It improves bar handling, less temperature drop for
next pass and human safety.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Designed based on production handling capacity for automatic
transfer of hot bar
Application 3 Hi mill train rolling billet less than 130 mm cross section.
Technological
advantages
Elimination of temperature variation of stock
Elimination of human error
Technological
limitations
Mill logistics
Estimated
investment
Y-roller table mounted at 1st stand of 480 mm roughing mill to
convey the rolling stock, size 1500 mm wide X 14800 mm long is
around INR 5 - 10 lakhs.
Implementation
period
2 3 months
Expected benefits
Approximate reduction of 3 -4 skilled manpower per shift.
10 % increase in mill utilization.
Savings in specific power consumption by 4 7 %.
Reduction in CO2 emissions by 4 7%.
Estimated payback
on investment
Less than 1 year.




1A-10 Installation of tilting table for 3-Hi mill stand
Descript ion
Re-rolling sector in India in general has 3-
hi mill stands in roughing mill train. The metal is
being fed to various passes manually by hooks &
tongs.
Installation of tilting table towards the
entry side and delivery side of passes between
top-roll and middle rolls ensures smooth guided
entry of metal to the passes and also eliminates the
manual lifting, feeding of the rolling stock. This installation further ensures the constant
temperatures for all the various bars.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Designed based on production handling capacity for automatic
transfer of hot bar.
Application
All 3 hi- rough mill stands excluding the ones with layout
constraint.
Technological
advantages
Elimination of temperature variation
Uniform feeding to passes (lesser damage to front & back ends of
the stock).
Technological
limitations
Possibility of motor drive failure.
Estimated
investment
The approximate cost for the installation of tilting table for a 3-Hi
mill stand, 410 mm dia is around INR 10 -12 lakhs.
Implementation
period
2 - 3 months
Expected benefits
Higher Mill utilization by 5 -10%.
Approximately 3-4 skilled manpower is reduced per shift.
Savings in specific power consumption by 6 - 8 %.
Reduction in CO2 emissions by 6 - 8%.
Estimated payback
on investment
Less than 1 year.




1A-11 Energy efficient drives for rolling
mills
Descript ion
Energy efficient motors are most suitable option
for power intensive steel industries where auxiliary
drives like air blowers, water pumps, oil pumps, compressors etc. are continuously working
for long duration, every day.
Generally in industries, proper sizing of high capacity motors are not practiced,
which draws more power because of low loading or idling operations.
Downsizing such motors and replacing with energy efficient motors will lead to a
considerable savings in power consumptions.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
High efficiency (upto 92%) low running cost.
These motors are more tolerant of overload conditions and
phase imbalance.
Applications All rolling mill auxiliary load motors (upto 315 kW)
Technological
advantages
High quality and thinner steel laminations on starter.
Corrosion resistant.
Less noise and vibration.
Accurate machine tolerances to reduce fixed losses.
Energy efficient motors in conjunction appropriate capacitor
banks offer an ideal environment for operating the drives at
high efficiency and improved power factor.
Technological
limitations
The energy efficient motors are especially suitable for
continuously running drives working for long duration
everyday where energy cost is very high.
Estimated investment INR 8 10 lakhs
Implementation
period
2 3 months.
Expected benefits
Savings in specific power consumption by 4 6%.
Reduction in CO2 emissions by 4 - 6%
Estimated payback
on investment
Less than 1 year.







1B-1 Replacement of existing furnace with new energy efficient
furnace
Descript ion
Energy efficient furnaces are provided
with automatic temperature, pressure control,
high efficiency metallic recuperator and
improved refractory lining.
The heating zone constitutes 70 75% of
the total installed heating capacity while the
soaking zone will be having the balance 30 - 25%
heat load.
Top fired pusher type furnace design
with hearth productivity 300 kg/m
2
/h.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Optimum design of furnace.
Shorter pre-heating zone.
70% of total heat input in heating zone and 30% in soaking zone.
Better combustion system & burners
Optimum refractories & insulation
Waste heat recovery through recuperator
Automation & control system installed.
Application Across all furnace capacity & fuel types.
Technological
advantages
Uniform heating of stock is achieved
Optimum hearth utilization.
Proper combustion.
Air-fuel ration controlled with optimum sp. energy consumption.
Higher efficiency of furnace achieved.
Technological
limitations
Unique design based on fuel type and raw material cross-section.
Higher capital cost.
Estimated investment
INR 1.5 2 crores (for a capacity of 20 tph; Stock : Billets of 110 x 110
mm size)
Estimated
implementation
period
4 6 months.
Expected benefits
In case of furnace oil, the savings in specific fuel consumption by
20 25 %.
In case of pulverized coal, the savings in specific fuel consumption by
35 40 %.
Reduction in CO2 emission by 20 - 40 %.
Estimated payback
on investment
Less than 1 year.




1B-2 Conversion of fossil fuel to CBM based reheating furnace
Descript ion
Coal bed methane (CBM) is a form of natural gas extracted
from coal beds.
Can be utilized as a fuel for re-heating furnace.
Required design modification in furnace to be carried out
along with safety precautions.

Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
CBM is a cleaner, safer, more environmentally friendly fuel than
many other energy sources, including conventional natural gas.
Use of CBM requires certain deign modification in the furnace.
Safety precautions have to be ensured.
All other design features of energy efficient furnace to be
incorporated along with switch over of fuel.
Application
CBM consists of over 90% methane and this can be directly used for
combustion in all types of reheating furnace.
Applicable in areas where CBM is available through pipelines.
Technological
advantages
Calorific value of CBM is approx. 8,500 to 9,000 kcal/kg.
Furnace Efficiency improved because of use of gaseous fuel.
Technological
limitations
CBM recovery is carried out in few parts of the country and initial
investment in mining, transporting CBM is very high.
Tar produced needs to be completely removed from the gas.
Otherwise, it can choke valves, pipelines, burners etc.
Higher running cost of CBM.
Estimated
investment
INR 1.5 2 crores (for a capacity of 20 tph; Stock : Billets of 110 x 110
mm size)
Estimated
implementation
period
4 6 months.
Expected
benefits
In case of furnace oil the savings in specific fuel consumption (along
with furnace modification) by: 20 25 %.
Reduction in CO2 (thermal) emission by 100 %. (net zero CO2
emission)
Estimated
payback
on investment
Less than 1 year.




1B-3 Conversion of fossil fuel to biomass based producer gas
reheating furnace
Descript ion
Biomass Gasification converts solid biomass into a more
convenient gaseous form. The gas so obtained is called biomass gas,
which is combustible having a calorific value of 1050 to 1200Kcal/
Nm3, with an average composition of :-
CO : 20 1%
CH4 : 3 1%
H2 : 20 1%
CO2 : 12 1%
and rest N2.
Unlike fossil fuels, biomass does not add carbon dioxide to the
atmosphere as it absorbs the same amount of carbon while growing. It is the cheapest, eco-
friendly and renewable source of energy.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Biomass gas has calorific value similar to that of producer gas which
is around 1200 kcal/nm
3
.
Biomass briquettes can be used in existing coal based producer gas
plants with certain design modifications.
Application
Across all furnace capacity & fuel types subject to availability of
biomass briquettes.
Technological
advantages
Uniform heating of stock due to better flame controllability with
gaseous fuel.
Carbon neutral fuel and hence, zero CO2 emission.
Technological
limitations
Biomass/ briquettes availability and installation of biomass gas
generation unit.
Estimated
investment
INR 1.5 2 crores (depending upon capacity)
Estimated
implementation
period
6 - 8 months.
Expected
benefits
Savings in specific fuel consumption (along with furnace
modification) by 20 25 %.
Reduction in CO2 (thermal) emission by 100%. (net zero CO2
emission)
Estimated
payback
on investment
Less than 1 year.



1B-4 Revamping / modernisation of pulverised coal fired re-heating
furnace
Descript ion
Most of the steel re-rolling mill units in India
use pulverized coal as fuel.
However, in general, most of these reheating
furnaces are of obsolete design and are not equipped
with waste heat recovery, automatic temperature and
pressure control, and good insulation lining.
The following areas of the furnace needs to be
revamped for efficient operation
Waste heat recovery system suitable for pulverized coal firing.
Modified pulverized coal firing system to ensure use of hot gas.
Automatic control of air-fuel ration for controlled heating.
Furnace excess air & pressure control through automatic damper and
online oxygen analyser.
Improved combustion system with specially designed burners.
Improved pulveriser to provide better mesh size of coal.
Improved refractory lining.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Separate hopers with silo and air filter system placed above burners.
Specially designed burners allow use of hot preheated combustion air
and also proper mixing of fuel and air.
Air fuel flow controlled through automatic control system.
Improved design of pulveriser installed.
Improved furnace design along with optimum refractories &
insulation.
Application All pulverized coal fired reheating furnace.
Technological
advantages
Uniform stock temperature.
Higher furnace productivity.
Better mixing & combustion of pulverized coal
Technological
limitations
Requirement of trained operating staff.
Higher capital investment.
Estimated
investment
INR 1 1.5 crores (depending upon capacity)
Estimated
implementation
period
3 - 6 months.
Expected
benefits
Savings in specific fuel consumption by 20 25 %.
Reduction in CO2 emission by 20 25%.
Estimated
payback
on investment
Less than 1 year.



1B-5 Revamping existing furnace with energy efficient top fired
re-heating furnace
Descript ion
In general most of the SRRMs uses reheating
furnace which are not equipped with good waste heat
recovery system, automatic temperature and pressure
control, heat recovery system and good insulation lining.
The following areas of the furnace needs to be
revamped for efficient operation
Furnace Design
Heat Distribution pattern.
Temperature & pressure control
Automatic damper with online oxygen analyser
High efficiency metallic recuperator
Improved refractory lining
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Controls for desired temperature, pressure & air fuel ratio.
Waste heat recovery upto 500
0
C with a flue gas temperature of 700
0
C will
be achieved.
Online oxygen analyser will indicate the excess air present in the furnace
which in turn will help in reducing scale losses. The excess air will be
controlled through automatic damper.
Improved refractory lining will be provided to reduce radiation losses.
Furnace design based on optimum hearth utilization ( 300 kg/ m
2
/h).
Separate combustion air and fuel pipelines for different zones of furnace.
Application Re-heating furnaces of all capacities and different fuel options.
Technological
advantages
Uniform stock temperature.
Higher furnace productivity.
Radiation losses from walls and roofs can be minimized.
Higher waste heat recovery.
Technological
limitations
Requirement of trained operating staff.
Estimated
investment
INR 1 1.5 crores (depending upon capacity)
Estimated
implementation
period
3 - 6 months.
Expected benefits
In case of furnace oil the savings in specific fuel consumption by
20 25 %.
In case of pulverized coal the savings in specific fuel consumption by
30 35 %.
Reduction in CO2 emission by 20 - 30%.
Estimated payback
on investment
Less than 1 year.








3.1 Direct rolling
Descript ion
Direct rolling process is
a technical evolution of hot
charging, where continuous
cast billet is directly pushed to
the rolling mill, without the
need of intermediate process of
reheating.
The direct rolling
process can be adopted in composite units by controlling the secondary cooling of the
continuous casting machine by means of Programmable Logic Control (PLC), hydraulic
cutting of billets, high-speed transfers of hot billets, and a canopy covering over the
conveyer belt.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Induction furnace facility of suitable capacity installed.
High temperature tapping of liquid metal practiced.
Continuous casting machine (preferably with double strand casting)
installed.
High temperature achieved at CCM cooling bed.
Sequence casting to get required capacity of hit billets.
Secondary cooling of CCM controlled.
Hydraulic shear installed to reduce cutting time.
High speed transfer (with canopy cover) of hot billets to rolling mill.
Design modification in roll pass design to handle hot billets.
Application
Direct rolling is applicable to all the composite SRRM units subject to
availability of required capacity of hot charge from continuous
casting machine.
Technological
advantages
The need for a re-heating furnace is eliminated, resulting in a
complete heat saving due to this redundancy.
Technological
limitations
Requirement of trained operating staff.
Maintenance of PLC based system.
Estimated
investment
INR 1.5- 6 crores (depending on whether CCM is installed)
Estimated
implementation
period
6 8 months
Expected
benefits
Savings in specific fuel consumption by 80 - 100 %.
Reduction in CO2 emission by 80 - 100 %.
Estimated
payback
on investment
Less than 1 year.








5.1 Regenerative burners
Descript ion
Regenerative burners use the heat of flue gases to preheat the air and gases going to
the burners thus optimising the heat input at the source itself.
Set of burners used in the entire length of the furnace.
Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
Air preheat temperatures of around 1000
0
C are achievable resulting
in exceptionally high thermal efficiency.
Eliminates installation of blowers and pre-heating zone.
Application All gaseous fired reheating furnaces.
Technological
advantages
High thermal efficiency can be achieved through pebble bed
regenerators or with honey comb type regenerators.
Uniform heating of the stock as almost flameless combustion takes
place.
Increased production from existing facilities
Reduced emissions of carbon dioxide and carbon monoxide.
Technological
limitations
Good instrumentation as pre-requisite.
Unclean gas may affect valves and other change over mechanism.
Estimated
investment
INR 3-6 crores (depending on the no. of burners required)
Estimated
implementation
period
6 8 months
Expected
benefits
Savings in specific fuel consumption by 35 40 %.
Reduction in CO2 emission by 25 - 30%.
Estimated
payback
on investment
Less than 2 years.



5.2 Oxy-fuel combustion system
Descript ion
Oxy fuel burners use pure oxygen to substitute completely / part of combustion air
thus reducing the nitrogen component of
combustion air and hence, reducing sensible
heat loss by reduced volume of flue gas.
Also, lean gases can also be used with
oxy-fuel burners and still required temperatures
can be attained.

Salient features, Investment & Benefi ts
The following table describes the salient features, applications, technological advantages,
limitations and cost benefit of the above technology option:
Salient features
The mass and volume of the flue gas are reduced by approximately
75%.
Because of the reduced flue gas volume, less heat is lost in the flue
gas.
The nitrogen percentage in flue gas reduced drastically.
Application All types of re-heating furnace irrespective of type of fuel.
Technological
advantages
Fuel savings.
Lean gases can also be used.
Low flue gas volume leading to lesser sizing of flue outlet and
chimney
Technological
limitations
Provision of oxygen cylinder bank.
Cooling media for burners.
Requirement of proper control mechanism to maintain needed
temperatures.
Estimated
investment
Approx. INR 3.5 crores (with oxygen plant / cylinders and one set of
burners as spare)
Estimated
implementation
period
6 8 months
Expected
benefits
Savings in specific fuel consumption by 30 - 35 %.
Reduction in CO2 emission by 30 - 35 %.
Estimated
payback
on investment
Less than 2 years.
Reference
Study Report to Ascertain Extent of Replication of Energy Efficient Technologies in Steel
Re-rolling Mill Sector in India 2012-2013, prepared by SAIL-CON.
Data gathering report on Eco-Tech Options, updated by RDCIS-SAIL in 2011-2012.






















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New Delhi, India. Pin Code - 110 003
Tel: 91 11 46532333. Fax: 91 11 24627612
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