Energy Efficiency in Steel

Sector of Pakistan
Pakistan is an energy deficient country.
Growing resource constraints, rising energy
prices and consumer demand for
environmental friendly products are some of
the challenges faced by the Pakistan steel
industry. We have selected Siddiqui steel
re-rolling mill for our project which is a
part of Siddiqui group of industries. It is a
steel re-rolling mill, not a steel mill. The
difference between the steel mill and a re-
rolling mill is that the re-rolling mill does
not produce its own raw material and take it
from an outside supplier whereas a steel mill
makes its own raw material and dont have
to go to outside supplier. It was established
in 1980 and it is a privately held business.
Siddiqui mill is trying hard to attain energy
efficiency by reducing energy loses thus
contributing towards reducing productivity-
energy efficiency deficit of the Industry.
Process:
The mill acquires raw material which is
called Ingot from an outside supplier. Ingot
is then cut into two pieces and pushed into
furnace. It is heated inside the furnace at
1200 C for approximately 3 hours. After
being heated, red hot bar comes out which is
then passed through rollers which increase
its length and decrease its width. Finally it is
placed into open atmosphere where it cools
down and gets strengthened.





Problems:
After thoroughly analyzing whole process,
six problems were identified. These
problems were:
Heat losses due to furnace
openings
No temperature control
Incorrect furnace draft (Lack of
pressure control)
Power factor improvement
Improper heat distribution
Blower fan
We have scrutinized these problems very
carefully and proposed solutions which are
practical in nature and can be implemented.
Solutions to these problems are given below.
Solutions:
Problem of heat loss can be solved
by closing the furnace windows and
if any opening is necessary, it should
be kept small. Openings should be
sealed properly with furnace doors.
Problems of No temperature
control and improper furnace draft
can be solved by installing proper
equipment. This equipment, which
includes Pressure and Temperature
control device, cost approx. 1.1
million. According to our
calculation, this solution, if
implemented, will result in estimated
9% decrease in fuel consumption and
cost of installing equipment can be
recovered in approx. 8 months.

Power factor improvement requires
maintenance of metals and use of
lubricants to reduce resistive power
which decreases power factor. The
better the power factor, the greater
the result is.
Burners should be aligned properly
to avoid touching the material, so
that the heat is distributed properly.
Flame should not be touched or
obstructed.
Problem of blower fan can be
solved by installing variable speed
drivers. According to our
calculations, it will result in
reduction in power consumption
which will eventually increase
efficiency.
Conclusion:
Solutions which we presented in our report
are practical in nature. One of the solutions
has already been implemented, that solution
was of the problem heat losses due to
furnace openings. Siddiqui steel mill has
installed furnace doors and openings are
sealed properly to avoid heat losses. When
we asked them about net affect on
efficiency, they told us that it increased their
efficiency to estimated 6% and resulted in
gas savings of 0.1m approx. So, if we make
a sincere effort towards our goals, they can
be achieved and we can make progress in
our energy efficiency sector.

Openings are Closed









Furnace has Openings

Openings are sealed.