PNABM057

ENERGY EFFICIENCY AUDIT REPORT
STEEL PLANT OSTROWIEC
Huta Ostrowiec
Ostrowiec, Poland
PREPARED BY:
INTERNATIONAL RESOURCES GROUP, LTD.

1400 1Street, N.W.
Suite 700
Washington, DC 20005
(202)289-0100
and
Energopomiar
ul. Gen J. Sowinskiego 3
44-101 Gliwice, Poland
37-68-00
U.S. EMERGENCY ENERGY PROGRAM FOR EASTERN & CENTRAL EUROPE
U.S. AGENCY FOR INTERNATIONAL DEVELOPMENT

BUREAU FOR EUROPE
OFFICE OF DEVELOPMENT RESOURCES
ENERGY & INFRASTRUCTURE DIVISION
WASHINGTON, DC 20523
USAID Contract EUR-0015-C-1008-00
May 1992
Energy Efficiency Audit Report - Steel Plant at Ostrowlec
TABLE OF CONTENTS
ACKNOWLEDGEMENTS v
PREFACE vi
1 EXECUTIVE SUMMARY 1
1.1 Plant Background 1
1.2 Results of The Emergency Energy Program 2
2. PLANT PERSPECTIVE 4
2.1 Background Information 4
2.2 Energy Statistics 4
2.3 Operating Status of the Plant 7
3. ENERGY MANAGEMENT 8
3.1 Energy Management Program 8
3.2 Future Requirements/Recommendations 8
4. ENVIRONMENTAL CONSIDERATIONS 10
5. ENERGY EFFICIENCY IMPROVEMENT OPTION 11
5. 1 Low Cost Options 11
5.2 Medium Cost Optio.ns 12
5.3 Capital Intensive Options 13
6. CONCLUSIONS AND RECOMMENDATIONS 15
6.1 Discussion of Options 15
6.2 Additiona! Observations 17
APPENDIX I AUDIT ACTIVITIES
APPENDIX II PARTICIPANTS INOFFICIAL MEETINGS
APPENDIX III GAS ANALYZER RESULTS AND DISCUSSION
APPENDIX IV ENERGY STATISTICS OF STEEL PLANT OSTROWIEC FROM "ANALYSIS

OF ENERGY INTENSITY OF NEW PLANT, MAIN PRODUCTION
PROCESS,' S. PASIERB (ED.)
APPENDIX V COSTS OF ENERGY AND FUELS IN INDUSTRIAL NATIONS 1988 VS

1990
International Resources Group, Ltd. May 1992

ii
APPENDIX VI REVIEW OF NINE ENERGY EFFICIENCY PROJECTS - 1990
APPENDIX VII ECONOMIC ANALYSIS OF MODERNIZATION OF MEDIUM AND

UNIVERSAL ROLLING MILL FURNACES, STEEL PLANT OSTROWIEC
APPENDIX VIII ORGANIZATIONAL CHART (AS OF APRIL 1991)
APPF_.NUIX IX LOAD MANAGEMENT AND OPTIMIZATION SYSTEM DIAGRAMS
APPENDIX X FACILITY LAYOUTS, NEW AND OLD PLANTS
APPENDIX XI ANALYSES OF HEATING OIL, FLY ASH AND DUST FROM ELECTRICAL
ARC FURNACES
APPENDIX XII SPECIFIC ENERGY AND FUEL CONSUMPTION, 1985-1990:
METALLURGICAL PLANT AND STEEL PROCESSING PLANT
APPENDIX XIII ANSWERS TO IRG QUESTIONNAIRE
APPENDIX XIV EQUIPMENT SPECIFICATIONS AND JUSTIFICATIONS
APPENDIX XV EQUIPMENT LIST FOR HUTA OSTROWIEC
APPENDIX XVI JUSTIFICATION FOR A DESKTOP COMPUTER FOR HUTA

OSTROWIEC
APPENDIX XVII RESULTS & BENEFITS OF LOAD MANAGEMENT AND OPTIMIZATION
SYSTEM, INCLUDING GRAPHS MADE BY THE NEW SYSTEM
APPENDI,X%XVIII NEW ORGANIZATION CHART (10/91)
APPENDIX XIX NATURAL GAS CONSUMPTION RESULTS, GRAPHED BY NEW GAS

DEMAND MANAGEMENT SYSTEM
APPENDIX XX LETTER OF APPRECIATION IROM DIRECTOR, MR. KREKORA

Energy Efficiency Audit Report - Steel Plant at Ostr,.wiec
ill
LIST OF TABLES AND FIGURES
Paa.
Table 1. Equipment procured under the A.I.D. Emergency Energy Program 3
Table 2. Energy Requirements for Ostrowiec 5
Table 3. Energy costs (as a % of sales revenue) 6
Figure 1. Location of plants audited by the IRG Team viii
International Resources Group, Ud. May 1992

Energy Efficiency Audit Report - Steel Plant at Ostrowiec
iv
LIST OF ACRONYMS/ABBREVIATIONS
A.I.D. U.S. Agency for Intemational Development
BTu British thermal unit

0C
degrees Celsius
ESP electrostatic precipitator
GCa giga-calorles
GPD General Power Department
IRG International Resources Group, Ltd.
kJ kilo - Joule
kV kilo - volt
kWh kilowatt hours
MCF thousand cubic feet
MPa millipascale
MT metric tons
nm 3 normal cubic meters
psi pounds per square inch
OLMO on-line load management and optimization system
SPO Steel Plant Ostrowiec
zi zloty; unit of Polish currency

Energy Efficiency Audit Report - Steel Plant at Ostrowie:
ACKNOWLEDGEMENTS
The IRG Industry Energy Audit Team for Poland wishes to express sincere thanks to the
plant management and technical personnel for the valuable time and effort spent in preparing
for the audit visit to the plant. The cooperation shown by the plant facilitated the communication
and exchange of ideas and experiences in the area of energy management. IRG also would
like to thank the U.S. Agency for International Development, European Development Resources,
Office of Energy and Infrastructure for coordinating the entire project.
It is the hope of the Audit Team that the exchange established through this initiative be
maintained in the future.

vi
PREFACE
In the wake of the political and economic collapse of the Soviet Union, the nations of
Central and Eastern Europe confront an energy situation for which there is no historical
precedent. Overnight long-standing supply agreements for oil, natural gas and electricity
supplies from the Soviet Union have been curtailed or discarded with attendant dramatic
increases in the prices of these commodities. In addition, as the vei! of secrecy has been lifted
in these nations, the devastating legacy of years of neglect of coal and other fossil fuel pollution
and an aging, largely unsafe, and unregulated nuclear power industry are vital issues that need
to be addressed in light of the fundamental structural reform of these Central and Eastern
European economies. Democracy for these countries means change amidst great political and
economic uncertainly.
To support the transition from Soviet-based dependence to democracy, based on free

market principles, the United States, in 1989, instituted a program to assist the countries of
Central and Eastern Europe with humanitarian aid, technical assistance and direct economic aid.
The U.S. focused initially on Poland and Hungary, where this transition was in its most advanced
stages. Since that initial commitment to Poland and Hungary, the U.S. has expanded its focus
to include Czechoslovakia, Bulgaria, Romania and Yugoslavia as technical assistance recipients
in Eastern and Central Europe. In the future, large scale assistance is likely to be given to the
Baltic States, Estonia, Latvia and Lithuania, as well as the republics of the former Soviet Union -
- and possibly Albania.
Grants and other assistance to Central and Eastern Europe already account for a U.S.
commitment of $1.5 billion since 1989. In Fiscal Year 1991, alone, grant assistance to the
region totaled about $450 million. Many of these sper,ial assistance grants were funded through
the U.S. Agency for International Development, with implementation assistance by various U.S.
agencies and private sector organizations.
One important initiative under the U.S. technical assistance program was the U.S.
Agency for International Development Emergency Energy Program for Eastern and Central
Europe, Component #1: Industrial Energy Efficiency Improvement. This program was designed
to address regional energy sector problems or. a short-term basis and to identify and implement
energy efficiency initiatives. This effort combined in-plant, on-the-job training with identification
and implementation of energy management practices and low-cost measures to be implemented
during the period of the contract work. This report outlines the activities of the Industrial Energy
Efficiency Improvement project in one plant in Poland.
The purpose of the Industrial Energy Efficiency work was to improve in the short-term
the efficiency of energy use by industry. Specific objectives included:
1) fostering improved management of energy use in industrial plants by identifying

and implementing immediately cost-effective "low cost/no cost energy efficiency
improvements;
2) transferring energy auditing and management techniques including financial and

economic analysis techniques; and

Energy Efficiency Audit Report - Steel Plan" at Ostrowiec
vii
3) providing equipment to Implement low-cost options, to improve monitoring and
energy management, and to identify additional energy efficiency opportunities.
To accomplish these objectives the following actions were undertaken:
1) Eight industrial facilities were selected as target plants for audits. The plants
were selected on the basis of:
0 potential for significant energy savings;

0 the likelihood that the plants will continue operating in the new economic
climate;
N applicability of results to similar plants in Poland to which the energy
conservation measures developed in this program could be applied.
2) Two Audit Teams went to Poland on two separate occasions, each Team visiting
four or five plants to perform energy audits and conduct training.
3) The Teams identified, specified, and procured energy efficiency equipment to be

used by the plants to implement short-term energy efficiency improvements.
4) Representatives of the Audit Teams returned to the plants in October 1991 to

assist in implementation of the audit recommendations, and to monitor the
energy improvements actually achieved.
5) The Teams presented a wrap-up workshop for plant managers and technical staff
of the participant plants and other similar plants throughout the country. The
seminar was held in Warsaw October 8-9, 1991.
The Industry Audit Team audited four plants (Figure 1):
Huta Ostrowiec, Steel Plant - Ostrowiec-Swietokrzyska

Zaklady Azotowe Wloclawek, Nitrogen Plant - Wloclawek
Zaklady Azotowe Kedzierzyn - Kedzierzyn-Kozle
Cement Plant Wierzbica - Wierzbica
The Audit Team collected data at every plant on the costs of producing steam and
electricity, primarily using plant records, audit measurements, and interviews with plant officials.
In some cases, the Audit Team counselled the plants in the establishment of systems for cost
accounting in the plant, particularly where it related to energy costs per unit of output. The
Industrial Energy Efficiency activities had tremendous success and generated letters of support
from several plant managers.

II
Wioclawek Nitrogen Production Facility
WARSAW
II
Wierzblca Cement Plant
II
Ostrowiec Steel Plant
Kedzlerzyn Nitrogen Works
Faclory
Figure 1. Location of plants audited by Figure
the IRG1
team.
lx
Program Rationale
While this program was clearly a logical starting point for Improved energy use patterns,
!t is only a beginning. Although all activities under the Industrial Energy Efficiency project were
conducted using a relatively small budget for equipment purchases, the energy savings results
were significant. Thus, the program demonstrated the tremendous potential for energy savings
through low cost and no cost mechanisms. Moreover, these programs represented important
energy savings initiatives that were implemented on a timely basis, within a matter of months.
These initiatives should serve as a cornerstone for a new way of approaching energy
savings in Poland. They represent the lowest cost and most readily implemented energy
savings initiatives available. Furthermote, the energy savings techniques/measures identified
and implemented in this Emergency Energy Program should be applicable to other similar
facilities and process units throughout Poland. As a result, these low cost techniques for
improving energy efficiency, and thereby improving economic efficiency in industrial facilities,
should serve as a model for restructuring energy use in the Polish indusirial sector.
The project alco highlighted a number of issues that fundamentally affect the ability of
industrial entities to solve energy problems. Basic issues such as industrial energy pricing,
environmental regulation, legal reforms, corporate organization and management structure,
personnel training, and the o'verall economic environment all affect the ability of industrial
concerns to implement energy savings oppcrtunities. Thus, the Industrial Energy Efficiency
Improvement project attempted to address issues of micro-level plant organization and
management, training, and economic evaluation at each of the plants. In addition, the IRG
Team has outlined key macro-level issues which must be addressed by the Government of
Poland before comprehensive energy efficiency initiatives are enacted. These issues are
addressed in this report a well as in Industrial Profile Report and the Policy and Institutional
Analysis Report for Poland, both prepared as part of the Industrial Energy Efficiency
Improvement project.
Ultimately, the IRG Team is convinced that the overwhelming potential for energy and
cost savings in the Polish industrial sector will provide sufficient incentive for plant managers
and industrial executives to actively promote the need for reforms that encourage energy
conservation and improved economic efficiency.

1. EXECUTIVE SUMMARY
As part of the U.S. Agency for International Development (A.I.D.)-funded, Emargency

Energy Program for Eastern and Central Europe, the International Resources Group (IRG)
Cogeneration Audit Team visited Poland during April 1991 to conduct an energy efficiency audit
of the Steel Plant Ostrowiec in Ostrowiec, Poland. The overall purpose of the audit was to assist
the plant in identifying low-cost or no-cost energy saving opportunities and to train key plant
personnel in modem methods of energy management as practiced in the United States (see
Appendix I for list of activities).
To accomplish this, the Cogeneration Audit Team collected data at each plant to make
informed decisions regarding opportunities for improving energy efficiency. Data were
accumulated from several sources, including plant instrumentation, field measurements (using
a portable Enerac 2000 stack gas analyzer purchased for the project), plant records,
independent reports, and interviews of plant operating personnel. Information about the
measurements taken during the audit and general plant statistics are included in Appendix Ill.
The Steel Plant Ostrowiec was included in the project based on assessments by the
project definitional team, which included IRG Vice President Charles Ebinger and IRG Team
Leader Gerald Decker. Team members evaluated the following issues before deciding which
plants should be included in the project:
a potential for energy savings, from low cost or no cost activities;

a overall economic status (i.e., would the plant survive removal of price subsidies
and/or privatization?); and
* replicability of the project activities and experiences at similar plants throughout
Poland.
Following the April 1991 visit, the IRG Cogeneration Team returned to the U.S. and
arranged for the procurement of equipment to be used by the Steel Plant to implement the low
cost/no-cost energy efficiency initiatives identified.
After the equipment was ordered, the Team returned to Poland in October 1991 to learn
what progress the plant had made in Implementing the recommendations and fo provide
additional advice on equipmen* installation and key energy management issues.
1.1 Plant Background
Ostrowiec is a full range-steel production facility, composed of two plants, located about
six kilometers apart. The older of these two plants was established in 1813; the newer plant was
established in 1970 and has a rolling mill one kilometer long, the longest in Europe.
Main production areas at the facility include open-hearth steel production, electric arc
steel production, rolled product production, iron casting, steel casting, steel construction, heavy
machine construction, forgings, oxygen production, and the production of heat for intra-facility
uses. In 1990, two electric arc furnaces produced 0.88 million metric tons (MT) of steel, and the
open-hearth furnaces produced 76,900 MT of steel.
Intemational Resources Group, Ltd. May 1992

2
In 1990, the plant used 824,421,700 kilowatt hours (kWh) of electricity at a price of 221
z1/KWh ($0.024/kfh at exchange rate of 9,212 z# = US $1). In addition, the plant consumed
98,570,700 nm 3 cf natural gas at a cost of 1500 zf/nm 3, 134,940 MT of coal at a cost of 150,000
zJ/MT, and 48,740 MT of heating oil at a cost of 1,800,000 z1/MT. The plant also used residual
amounts of coke, diesel oil, and gasoline.
Opportunities for low-cost energy opportunities identified by the IRG Cogeneration Audit
Team principally involved improving process and load controls, enhancing combustion
efficiency, ensuring efficient use of steam, and improving the use of thermal energy. In addition,
the Team recommended strategic, operational, and management changes to Improve the plant's
overall economic status.
1.2 Results of the Emergency Energy Program
As part of the audit process, the Team recommended equipment to ba purchased under
the Emergency Energy Program. Items purchased included:
0 Infrared Thermometer
• In-Situ Oxygen Analyzer
0 On-Une Load Optimization System
a Steam Traps
• Energy Management Computer
These recommendations are summarized below in Table 1; this table also summarizes
estimated energy savings for each item, a key criterion used in recommending the purchase of
specific equipment. Given the need for high impact energy savings results, all equipment
purchased had a payba~k period of one year or less. In addition, special attention was given
by the IRG Cogeneration Audit Team to procuring equipment that would produce energy
savings result that could be easily replicated in plants throughout Poland.

3
Table 1. Equipment procured under thi A.!.D. Emergency Energy Program
Eqipmmnt Item: Cost Annual Type of Paybak Coal!

1 Savfngs Savings P.t1d(yrs. j(ons)
Infrared Thermometer I $427 I $1,743 I steam .24 182
In-situ 02 Analyzer [ $4,276 1 $,000.1j combust. .600~J
On-line Load $22,660 $80,000 electrical .28
Optimization System
[Steam Tas$1,009 -- $271 steam f .08 1 n/a

Energy Manage. 4,937 $10,000 process/ .49 n/a
Personal Computer electrical
TOTAL $33,309 $111,51 .29
Based on the current tariff schedule, when this system can help the plant avoid exceeding contracted
demand by 20 MW, itwill reduce the demand charge by $25,000 per year. The system was able to reduce
the peak load at the plant from 20 MW to 12 MW, at a savings of $7,000-$8,000 per month, on demand
charges.
Unlike many other technical assistance projects, this project wasq an action-oriented
initiative designed to demonstrate the potential for energy savings in Poland by actually
implementing energy efficiency projects in selected facilities. This audit report, prepared as a
part of the Emergency Energy Program, is intended to provide the reader with a background
against which to view the actions implemented. Thus, this report outlines the observations,
comments, and recommendations of the IRG Cogeneration Audit Team, gathered during the
initial audit in April 1991, and from subsequent discussions with plant managers.
To allow a more comprehensive evaluation of the projects, specific results will be

presented in the summary reports for the project. This Energy Efficiency Audit Report focuses
on the costs, benefits, and problems associated with each energy efficiency option. In addition,
the report briefly outlines management, training, policy, and institutional factors that affect the
ability of plants to achieve energy efficiency improvements.

2. PLANT PERSPECTIVE
2.1 Background Information
The Steel Plant Ostrowiec Is composed of two plants located InOstrowiec Swietokrzyska,
located about six kilometers apart, The older plant was established in 1813, and the new plant
in 1970. Production facilities are situated cri 1,000 acres of land (750 acres at the new plant and
250 acres at the older plant). The newer, modem plant has a rolling mill one kilometer long,
the longest in Europe. Diagrams depicting the layout of these two plants are presented in
Appendix X.
In 1990, two electric arc furnaces produced about 0.88 millions metric tons of steel, and
the open-hearth furnaces produced 76,900 metric tons of steel.
Primary production activities at Ostrowiec can be divided into the following areas:
E open-hearth steel production

0 electric arc steel production
0 rolled products
* iron casting
N steel casting
0 steel constructions
N heavy machine construction
0 forgings
0 oxygen production
0 the plant heating system.
In 1990, plant sales amounted to approximately US $350 million, of which 50% was from
exports to Germany, Spain, UK, Sweden, Norway, Saudi Arabia, Iran, and (in the past) to the
USSR. The plant yielded a net profit of 18% of sales during this period.
2.2 Energy Statistics
The plant's energy requirements for 1990, shown in Table 2, were largely electricity,
natural gas, and coal. Electricity was primarily consumed to operate automatic control systems,
the electric arc furnace, and standard office and plant electricity requirements (lighting, and
office equipment).
Prices of the energy sources shown above were not stable, even when expressed in US
dollars. As such, it is necessary to view price information with caut!on. The zloty to dollar
exchange rate was 11,100 zf = US $1 in October 1991. However, in April 1991 the exchange
rate was 9,212 zi = US $1. Consequently, these price values should only be used to give a
general indication of prices at the time of the audit.

Energy Efficiency Audit Report - Ste., Plant at Ostrowlec
5
Table 2. Energy requirements for O'trowlec
_______ ___unit Ju"90 PrIca/unit.(zt)

Electric Energy kWh 824,421,700 221
Natural Gas nm 3 98,570,700 1.550
Coal MT 134,940 150,000
Coke MT 4,657 1,113,000
Heavy Heating Oil MT 48,740 1,800,000
Diesel Oil MT 1,562 3,300,000
Gasoline MT 140 5,000,000
1. Electric Power
Electric power used at Ostrowiec is purchased from the grid at 110 kV level. The
contracted power is 150 MW, while the installed capacity is 500 MW. Within the plant, power
is distributed at 6 kV and 380 V levels. The largest amount of electric power consumed within
the plant is in the electric arc furnaces, which account for roughly 70% of all electricity
consumption at the facility.
Power consumption is monitored by a computer system programmed to prevent power

surges and avoid the total power demand exceeding the contracted power. The power demand
tracking system, however, is not sufficiently reliable, since there is no backup computer.
Therefore, plant load currerly cannot be optimized to avoid costly peak demands over the
contracted level.
2. Natural Gas (34,000 kJ/nm 3)
Natural gas is supplied to the plant from the network at two pressure levels: 1.2 MPa,
and 0.35 MPa. The maximum measured gas consumption was 17,500 nm3/hour. The largest
gas consumers within the plant are the pressing plants (36% of total energy consumption) and
the rolling mills (21%).
Natural gas usage currently is not at an optimum level. Previously, there were drastic
instances in which rolled stocks were cooled down in large amounts and heated again before
entering the next step of rolling. Also, pressing procedures need to be optimized by appropriate
programming of the production line.
3. Coal (19.000 kJ/kg)

Coal of less than 1.0% sulfur content is delivered to the plant by rail cars. Coal is used
in boiler plants to supply hot water, at 150/70 0C and 95/70 °C for heating purposes.

6
Approximately 60% of the heat produced is sold to the town of Ostrowlec during the heating
season.
Moreover, steam at 40 bar and 450 00 Is produced In the boilers and used for atomizing
the heavy oil and for heating within the plant; the thermal efficiency of the old boilers Is low.
There are five boilers producing steam, and nine boilers for hot water.
4. Coke (28,000 kJ/k)
Coke is used to proces,, iron and steel castings.
5. Heav Heating Oil (40,000 kJ/ka)
Heating oil with a sulfur content of less than I% Is stored within the plant In two main
reservoirs (5,000 MT each), and in a small reservoir of 100 MT capacity. Heavy oil Is heated by
steam before being pumped to burners, and Is primarily used for heating the rolling products.
6. Diesel Oil and Gasoline
Diesel oil and gasoline figures shown in Table 2 above reflect the quantities of these
fuels used for transportation within the plant itself and between the two facilities. In 1990, total
energy costs for the plant were 13% of the total production costs versus the 7% figure given in
item 25 of the questionnaire (Appendix XIII). Based on information given Inthe questionnaire,
plant energy costs are outlined in Table 3.
Table 3. Energy Conts (As % of Sales Revenue)
Cost (bllnin z) Percent: ofSale"

Niovenue i
Total Product Sales 3,519

Raw Material Cost 1.696 48.2
Energy & Fuel Cost 453.7 12.9
Labor cost (estimated)* 325.3 9.24
Profits** 633 1-1.0
Total 86.3%
* the labor rate was assumed to be approximately 2,000,000 z per person per month.
the estimates of profits were provided by the plant.

7
Costs shown in Table 3 represent 88.3% of total product sales revenue. The remaining
11.7% Includes administration, sales and marketing, research and development, taxes, and other
expenses.
2.3 Operating Status of the Plant
When the IRG Cogeneration Audit Team conducted the Initial audit of Ostrow&ac in April
1991, the Tean observed that the site of the older steel mill facility was not In good condition.
Boilers at the older site were inefficient and the source of significant environmental problems;
in addition, steam lines were not adequately insulated, and the Team observed many places
where steam traps were either poorly maintained or non-existent.
However, during the courv of the projec'. Ostrowiec, with the assistance of the IRG
Team, initiated a plan to replace most steam lines with hot water linea. By the end of 1992, a
new steam to hot water exchanger system will also be installed. Consequently, attention to
steam systems at the plant will not be as important to the future operations of the plant.
At the new steel plant, the boiler house was relatively new and was equipped with a
modem control system. Smoke stacks at this site emitted relatively clean emissions, suggesting
the boilers were operating efficiently and the electrostatic precdpitator (ESP) was working. This
observation was supported by the oxygen and emissions analyses of the flue gas conducted
during the April audit.
The open hearth and electric arc furnaces, however, were noied as serious polluters.
Dust and smoke from the operation of these furnaces was clearly visible, with attendant negative
effects on local air quality (Appendix Xl).
Most of the re-heat furnaces were insulated only with fire bricks. Resulting heat losses
to the ambient air remained a small fraction of the total, however, as the flue gas heat,
measuring approximately 1,000 OF was redirected into the stack, albeit without heat recovery.
Most of these gas-fired reheat furnaces had manual controls, and had no oxygen analyzers
installed.

8
3. ENERGY MANAGEMENT
The steel industry is one of the most energy Intensive Industries in Western nations. In
the case of Ostrowiec, however, energy costs only comprise 13% of total sales, lower than that
of the nitrogen and cement plants visited earlier by the IRG Industry Audit Team.
Nonetheless, the operation and technology practices used at the plant, although botter
than at some other Polish facilities, are far from energy efficient by Western industrial standards.
It is likely that rapidly changing energy costs in 1990 distorted, to some extent, the pattern of
energy use by Polish industries. When energy prices are raised to world levels (e.g. $0.06/kWh
for electricity), Os.rowiec will experience tougher competition on the world market. This will
send a strong message to management that energy efficiency improvements should be a high
priority.
3.1 Energy Management Program
There is an energy management program at the plant. However, energy management

initiatives appear to be the responsibility of only one department, although the general plant
manager showed strong support for this program. The Steel Plant was recently reorganized in
recent months and is in the process of privatization. Due to these transitions, energy
management programs may not have been a top priority for management in recent months.
The General Power Department (GPD) Is responsible for executing the energy
management program. Accordiig ,o a recently revised organizational chart (Appendix XVIII),
the General Power Department now reports to three departments: production, technology and
finance (see previous organizations chart in Appendix VIII). GPD is a utility department,
responsible for power supply from the grid, boilers and hot water/steam supply, natural gas and
heavy oil furnaces, water supply, waste water treatment, oxygen, and compressed air; there are
currently 290 people employed in this area.
The General Power Department presented the IRG Cogeneration Audit Team with nine
projects related to energy savings or efficiency that were either completed or started by the end
of 1990 (Table VI). Most were part of larger technology and/or equipment modernization
projects. In addition, more than a dozen future projects were discussed, each designed to
further Improve energy efficiency at tne plant. The emphasis of these projects was reinforced
by the general manager at the end of the Team's visit to the plant.
Due to the small demand on p. ocessing steam, steel mills seldom present big potential
for cogeneration; this plant was no exception. However, there was an opportunity to build a
small cogeneration plant, when 'he four hot water boilers at the old plant site were originally
budgeted. At the time, inexpensive electricity from the grid made this proposal unattractive.
This situation mirrored one which existed at the Huta Batory (Steel Plant Batory in Silesia), which
was discussed by Huta Batory representatives at the final meeting (see Appendix IIfor list of
participants).

9
3.2 Future Requirements/Recommendations
Waste heat from the re-heating furnaces represents the groatest potential for energy
savings at Ostrowiec. More than 90% of the heavy oil fuel and 60% of the natural gas were
consumed in the heating and re-heating furnaces. There are 60 such furnaces in the rolling
mills, and 20 more at the stamping plants. Exhaust gas coming from the furnaces often has a
temperature of over 1,000 OF. Waste heat at such a high temperature can be easily recovered
at a relatively small cost; industry calls this process 'bottom cycle.'
Team members observed the steel plant had done little to recover this waste energy from
the furnaces. According to Dr. Slawomir Pasierb, Director of the Polish Foundation for Energy
Efficiency, most of the steel plants in Poland are in a similar position and do little to recover
waste heat. (see Appendix IV for a detailed anelysis of this subject).
Since 50% of the plant's products are exported, management is aware of the direct effect
of energy efficiency on production costs when electricity and natural gas prices are raised to
world levels ($0.06/kWh, and $5.50/MCF). To meet challenges posed by impending energy
price increases, a comprehensive plant strategy must be developed to decrease energy
consumption at the plant and, thereby, compensate for the energy price increases.

10
4. ENVIRONMENTAL CONSIDERATIONS
Due to oxygen treatment (about 10 nm3/ton of steel) in the electric arc furnaces,
Ostrowiec Is a major polluter in the area, since there is no treatment of oxidation products.
Given the negative impact the plant already has upon the local environment,
environmental impacts of each modernization project must be carefully weighed before the
projects are undertaken. Moreover, specific recommendations Included In Section 5 reflect
concern for the importance of environmental issues.

11
5. ENERGY EFFICIENCY IMPROVEMENT OPTIONS
Energy conservation opportunities were identified by the IRG Cogeneration Audit Team
as a result of observations and audit measurements, plant inspections by other organizations
(le. the Institute for Heat Engineering), or through discussions with plant technical personnel and
managers. Usted below are options for improving energy efficiency use within the plant.
Clearly, all these practices and projects will help conserve energy in the facility. However, given
the reality of scarce rescurces for implementing these projects, the IRG Audit Team
recommended some be given priority; this prioritization is included in Section 6.
This section is designed to present various options discussed during the course of the
Industrial Energy Efficiency Improvement project. In this section, the Team intends to present
the merits and deficiencies of each proposal. Since Team members did not recommend each
proposal be implemented, this section Includes caveats about projects the Team did not
endorse. Specific recommendations are included in Section 6. The ultimate decisions
regarding implementation of alternative options will depend upon the criteria set by the plant
management - including acceptable payback periods, and upon the overall corporate strategy.
The following are the recommendations of the energy Audit Team concerning energy
efficiency improvement options for the short-, medium- and long-term. Equipment
recommended for purchase under the Emergency Energy Program specified in detail in
Appendix Xl, with justifications for the purchase of these items and estimates of return on
investment shown in Appendix XIV.
5.1 Short-term/Low cost options
For the purposes of this report, 'short-term' options will refer to 'no-cost' items which will
not require hard currency, but may require small scale local currency investments, and 'low
cost' items which may require limited amounts of hard currency. Each should be possible
within the existing framework of plant expenditures (ie. zloty purchases, small hard currency
purchases, improved maintenance, and housekeeping) and will have rapid payback periods.
1. Plant load Otimization
This is the most urgent and cost-effective energy efficiency improvement option
recommended by the IRG Cogeneration Audit Team. A proposal from Swietokrzyska
Polytechnic Institute was completed in January 1991, making similar recommendations.
Diagrams of this sytem are shown in Appendix IX. The proposed project will utilize a personal
computer as a central information processor (plus one back-up), and impulse sensors to
transmit the kW demand signals.
The system will record, predict, and optimize the plant load at the "old' site. As the
electricity tariff from the grid varies with demand and time of the day, the natural gas price also
varies with demand and season. Therefore, it will be important to establish a plant load
optimization system at the plant to avoid demand penalties.

12
The installed cost of this system was quoted at US $22,660. Estimated payback pedod
for this system is two months at current electricity and fuel prices.
The Polytechnic Institute previously installed a similar system at the new site, and the
system is functioning well (see Appendix XVII for further details regarding this system).
Ostrowiec management is confident the new system will function as well or better at the old
site.
2. Combustion Gas Analyzer
The boilers (five steam and nine hot water) and heating fumaces could use a gas
analyzer to improve combustion efficiencies. Two portable gas/oxygen (02) analyzers may
be
needed to check the air supply rate, and adjust the oil/gas bumers. Payback period on
this
gas/O 2 analyzer is estimated at two months, based on a 5% savings on coal alone.
3. Internal Cost-Accounting Personal Computer
A personal computer with cost accounting software is needed to monitor the specific
energy consumption data for 15 production units on a daily basis. A real-time information
processor is needed to manage data and transmit the energy cost to the energy management
team in a timely fashion. Payback period for this project is estimated to be no more than
six
months, since the response to energy management will be faster.
5.2 Medium-term/Medium cost options
1. Bottom Cycle - Waste Heat Recovery
The economic advantage of bottom cycle (waste heat recovery) is that the heat source
costs nothing, and the recovery equipment is not as expensive as that of the top cycle
(i.e.,
boiler or combustor). Bottom-cycle heat recovery requires only a heat exchanger.
One disadvantage of bottom cycle may be the mode of furnace operation (i.e.,
discontinuous or intermittent). When not integrated into the plant design from the beginning,
furnaces may be situated far from the heat/steam using processes, causing several problems.
For example, one heating furnace at the rolling mill generates exhaust gas of 40,000 nm 3/hour,
at 550 *C (1,022 OF), which can make 6,220 pounds/hour of steam 650 psi and 650 OF.
Using a 70 % efficiency measure on the theoretical heat rate of 7.85 lb/kWh, the electric
power from a condensing steam turbine is 0.55 MW. On a 300 day/year basis, the electricity
generated from the exhaust gas of this heating furnace is worth US $97,000. at current cost
of
power ( $0.0245/kWh); and US $237,000 when the power cost is raised to $0.06/kWh.
Clearly, the potential economic advantage oi bottom cycling justifies a serious study of
the feasibility of this type of heat recovery system.
2. Modernization of Medium and Universal Rollina Mill Fumaces
This project was investigated by the steel plant, and a report written subject in 1991
(Appendix VII).

13
The cost estimate for Phase I cost estimate was US $200,000 to refurbish the burners
at the Medium Rolling Mill, and related works; this estimate Includes design and engineering
requirements. Estimated savings in natural gas Is 875,000 nm3/year or US $144,000 at the
current gas price of 15,50 zI/m 3. The payback period for this Initiative Is expected to be 1.4
years.
Phase I estimates for the Universal Rolling Mill were about $190,000. This phase will also
include the cost of refurbishing the associated burners and related works, as well as design and
engineering expenses. Estimated savings in natural gas are 5,250,000 nm 3/year or $865,000
at the current gas price. The payback period for this initiative will be about three months.
3. Hot Water Heating in the Plant
The hot water heating initiative is an ongoing project, and was completed by the end of
1991. The steam heating network in the plant was then converted into a hot water system. The
savings in steam loss and water make up will be significant.
4. Hot Water to District Heating Network
Currently 40% of the hot water produced at the steel plant is sold either to the
greenhouse or district heating network. A larger hot water pipeline is being laid to prepare for
more hot water to the district heating network. The annual increase in heating demand from the
district heating network is more than 5 GCal/hour, or about 20 million Btu/hour, the capacity of
one waste heat boiler utilizing the exhaust gas of the I-eating furnace cited in the previous
section.
Bottom cycling of some of th-' heat furnaces can provide more hot water with no
additional fuel cost. The optimal arrangement is to use the bottom cycling to provide the no
cost hot water, and to use existing boilers as a backup system.
5. Fiber Glass Insulation vs Fire Bricks
It is suggested that when the furnace is under periodic operating mode, fiber glass
insulation has an advantage over the conventional refractory type due to its smaller heat
capacity and better insulating characteristics. By introducing fiber glass insulation, savings in
reduction of heat loss could be 3 to 5%, depending on the individual case.
6. Modernization of Heating Furnaces
With new gas/oil burners, new recuperators, and automatic computer control, furnaces
will be more energy efficient.
5.3 Long-term/Capital Intensive Options
1. New Oxygen Plant - 5,000 nm3/hour of0,
Additional 02 injection into the arc furnaces is preferred by the management. When the
02 injection is increased from the current level of 12 ma/MT to 35 m3/MT, steel output from the

14
two arc furnaces will reach 1.4 million MT annually. As a result, the third arc furnace can be
spared, and the electricity consumed substantially reduced from the present level of 650
kWh/MT.
The ultimate goal Is to reach the Japanese level of 400 kWh/MT; that will require an 02
injection of 50 nm3 /MT. Scrap and air pre-heating are the next steps In improving oxygen plant
energy efficiency. The cost of this project is estimated at about $15 million.
2. Continuous Casting Une
This project will replace the present three-line casting with a modem five-line casting,
reducing the cross section to 105 mm x 105 mm (from 220 mm x 220 mm). Special ladles aro
also included to make steel for the stamping plant.
The direct result of this new facility will be the elimination of one heating step at the
rolling mill. There is also the possibility of eliminating the need for one heating furnace at the
stamping plant. The elimination of one heating furnace translates into major savings in both fuel
and electricity. The required capital investment is about $15 to $20 million, with estimated
savings of $2.9 million per year at the current price level. When the energy price level Is raised
during the next two years, the payback period should be approximately 4 years.
3. Modernization of Medium and Universal Rolling Mill Furnaces
The cost of Phase IIis about $1.89 million for the Medium Rolling Mill. The estimated
savings in natural gas is 2.975 million nm3/year, or $490,000 per year at current gas price of
1,550 zI/m 3. The payback is four years.
The cost of Phase IIfor the Universal Rolling Mill is also $1.89 million. The projected
savings is 7.35 million nm 3/year, or $1.2 million per year at current gas prices of 1,550 zt/m 3.
The payback period is 1.5 years.
4. Dust Extraction at Electric Arc Furnaces
The hood structure, heat exchanger, bag houses, and electrostat!k precipitator with
induction fan belong to this category of options. This project is designed to reduce the
particulate pollution on the environment; accumulated dust needs be recycled or disposed of
safely.
5. SO, Reductions
All boilers on site (nine and four) should be retrofitted with sulfur dioxide (SO) scrubbers.
However, since some of the boilers should be retired in the near future, this option should be
coordinated with the General Power Department; any new boilers to be built should have SO
2
scrubbers.

15
6. CONCLUSIONS AND RECOMMENDATIONS
The most urgent need at the plant is to implement the on-line electric load optimization
project, since electricity costs represent some 54% of total plant energy costs. The initiative was
in place by September 1, 1991 and had been in operation for a month before the Team arrived
in October.
Portable gas analyzers should be helpful in improving combustion efficiencies of the

(nine and four) boilers. A consistent and responsive (real time) cost accounting system is
necessary for management to make timely decisions on energy efficiency options.
Improved coordination between Ostrowiec and its district heating network is desirable.
The armount of waste heat sources in the plant is sufficient for the growth of the district heating
network for the next five to ten years.
From the discussion of the nine projects related to energy efficiency as reported by GPD
in 1990 (Appendix VI), a strong commitment by management to the energy management
program is evident. Hopefully, management's focus on energy efficiency will not be lost in the
current reorganization.
To implement any effective energy management program in an organization such as

Ostrowiec, located on two sites, is not easily accomplished under the best of circumstances.
Extensive education and training will be needed to change worker thinking and habits related
to energy conservation. With reference to training issues, the General Power Department of the
SPO has done a commendabie job.
Facing rising energy prices in the near future, Ostrowiec has no other choice but to
tackle energy efficiency projects quickly. Results of the energy management program are tied
directly to the economic survival of the entire plant. To improve on the progress made through
this initiatives, a solid energy management program must be firmly in place before any serious
party will show sufficient interest in investment.
6.1 Discussion of Options
1. O0 analyzer system
The original system assigned to Ostrowiec was an eight probe combination, meant for
the group of oil/gas furnaces in the rolling mills. However, it was ultimately determined such
an arrangement was not practical due varying distances among the furnaces. Now a single
probe system is taking its place; this will be installed on one of the four hot water boilers in the
old plant.
2. On-line load management and optimization system (OLMO)
This system was designed, specified, installed, and commissioned by a team from the
Department of Automatic Control of the Swietokrzyska Polytechnic Institute at Kielce. The
system was completed in September 1991 and subsequently commissioned. By the second

16
Audit Team visit (10/91), the system had been operating for one month. At that time,
a
demonstration of the OLMO system was conducted for the team. Team members also met with
and congratulated the group from the Polytechnic Institute for an excellent job done within the
time frame allocated.
Mr. Marian Strezlecki, Chief Power Department, was pleased to report that as a result of
the installation of the OLMO system, the plant was able to reduce contracted power demand
by 7 MW in the first month; this translated into a savings on demand charges of 87.5 million zi
per month. At current exchange rate of 11,330 z1 US $1; the savings calculates to be $7,723
per month. In addition, the system can be further adjusted to eventually remove two more MW
of demand from the grid. That means $2,206 additional savings per month in demand chargos;
total savings could reach $9,930 per month in the near future.
The installed cost of the OLMO system is $22,660. Therefore the payback period of this
project is 2.3 months.
3. Portable gas analyzer
A portable analyzer will be convenient to check combustion efficiencies for 60 heating

furnaces in the rolling mills. However, the experience of the Audit Team with the Enerac 2000
gas analyzer suggests its functions will be limited. A dusty environment will mandate frequent
recalibration, potentially limiting benefits that can be expected from the use of this instrument.
The IRG team has decided the best way to solve plant needs is to contract with
Energopomiar to provide such services with the two portable gas analyzers given to them
following the Team's April 1991 visit.
4. Deskto2 computer
During the audit, Mr. Marian Strzelecki of the Steel Plant presented the Team with charts
and figures of specific energy and fuel consumption by the different departments within the plant
(Appendix XlI), and the energy and material balances around each furnace. Until now, this
information had been calculated, tabulated, and graphed by hand.
These and other technical data represent a vast amount of information that must be
managed in the most efficient way possible. Thus, the need for a modem desktop computer
is quite obvious. Mr. Strezelecki listed seven major areas (see Appendix XVI) where the
computer could provide support for the power/energy management department. The payback
period for this computer was conservatively estimated at six to nine months, but the team
expects the period to be even shorter.
A desktop computer was purchased for Ostrowiec in October 1991 after consulting with
the IRG project manager upon return from the second visit. This computer is a high speed
computing tool (386 CPU and 33 Mhz) with tremendous memory capacity (100 Mb hard disk).
It can be utilized to not only to perform engineering and technical computations, but also
business, finance, accounting, and information management functions.

17
5. Gas load management and optimization program
Since the audit, the power department had initiated a program to reduce the contract gas
load from the distribution network. Submeters were installed at each major production unit, and
meter readings were fed to a central panel. The operator at the central panel had instantaneous
readings for 'qasusage rates in all production units. Summations and projections can be made
periodically using this data. Therefore the total gas demand can be tracked much like in the
electric load management system.
With the help of this system, natural gas demand was reduced from 17,000 m3/hour to
12,000 m3/hour. The gas demand charge is 233 zl/m3/hour/day. The estimated savings in gas
demand charges Is about 35 million zI per month.
6.2 Additional Observations
Ostrowiec has shown the most achievement in energy management program since first
audit in April 1991. The General Power Department (GPD) took full responsibility for
implementing various programs in a short time. The results proved the effectiveness of the
Power Department's actions.
1. On-line load management and optimization system (OLMO)
The IRG Conservation Audit Team was pleased to see the OLMO system was
commissioned in time and produced the short payback as predicted.
Many man-months of diligent work went into this project; It took five technical staff three
months each (15 man-months) to install the system. All individuals involved in the project gave
up their summer vacations to complete the system in a timely fashion.
Leaders from the Technical Institute of Swietokrzyska, Mr. Miroslaw Weislik, Dr. Engr.,
and Mr. Zbigniew Gorazda, Mst. Engr., should be commended for their dedicated work.
2. Off-linegas load management
This program was in the process of being commissioned while the audit team was
visiting the plant; potential savings appeared to be impressive. More information on this system
has been requested by the IRG team.
3. ReorganizatIon
The most profound effect of the team's initial audit was that the plant energy
management program now receives strong support from management. They plan to keep this
energy efficiency drive alive and make it an important part of the plant performance indices.
In April 1991, Ostrowiec was in the process of reorganization. Prior to reorganization,

the Power Department was under the Operations & Maintenance Section of the Production
Department. Since the reorganization, the Power Department is directly under the Technology

18
Department. This direct linking demonstrates again that the management has placed extra
emphasis on the energy management program within their organization.
4. Integration of the District Heating Plant
Little, if any, progress was made on either the combination of the local district heating
system with the hot water boilers of the plant or the waste heat recovery of the furnace flue gas.
A feasibility study should be initiated to explore potential benefits versus costs of these two
projects.

APPENDIX I
AUDIT ACTIVITIES
APRIL 1991
First Day (4/18)
1. Introduction of industry team, US AID program, goals and

objectives, and auditing schedule.
2. Presentation of Huta Ostrowiec energy management team
3. Energy Management seminar by Jerry Decker
4. Gas analyzer measurements at New Plant site
Second Day (4/19)
1. Review of energy efficiency improvement projects in 1990 by

GPD of SPO.
2. Detailed plant tour at old plant site
3. Detailed plant tour at new plant site
4. Gas analyzer measurement at old plant
Third Day (4/20)
1. Discussion of Questionnaire
2. Discussion of energy efficiency improvement projects
Old plant
New plant
Fourth Day (4/22)
1. Meeting with General Director, Mr. Henryk Krekora

2. Discussion on priority ranking o energy saving options
3. More measurements using gas analyzer
4. Discussion of gas analyzer results
5. Briefing on the energy management program at Huta Batory by
Mr. Zygmunt Kasek and Mr. Zdzislaw Krezel.

Energy Efficiency Audit Report - Stsel Plant at Ostrowlec
APPENDIX II
PARTICIPANTS IN OFFICIAL MEETING3

April 1991
Huta Ostrowlec
Henryk Krekora General Manager

Stanislaw Ostrowskl Technical Director
Marian Strzelecki Chief Power Engineer
Stanislaw Suma Assistant Chief Power Engineer
Waldemir Barauski Supervisor - Heating Plant
Zdzislaw Supervisor - Plant Operation
Andrzej Oslak Shift Supervisor - Plant Operation
Stanislaw Baek Supervisor - Heating Plant (old site)
Edward Kosciotek Specialist - Economics
Huta Batory/Chorzow (outside of Katowice)
Zygmunt Kosak Chief - Power Engr.

Zdzislaw Kresel Asst. Chief Power Engr.
International Resources Group
Gerald L Decker Team Leader

Frank Wang Engineer
Tadeusz Swierzawski Engineer
Energopomlar
Edward Magiera
Marian Warachim
Kompekon Consulting
Marck Podslawa
Polish Foundation for Energy Efficiency
Slawomir Pasierb

APPENDIX III
GAS ANALYZER RESULTS AND DISCUSSION
The Energopomiar team took measurements with the Enerac 2000 gas analyzer on two
sets of boiler group at the old plant at Ostrowiec, one set of boiler group at the new plant, and
several gas fired, and heavy oil fired heating furnaces at new plant.
Results indicated that the thermocouple was dead and that the 02, C02, and S02 analyzers
did not work properly. The S02 readings were zero, which should not have been the case (there
is reason to doubt the accuracy of S02 readings taken at the Cement Plant Wierzbica).
The thermocouple was proven to be defective after the engineers measured the
resistance: the ENERAC 2000 registered zero resistance, compared with the eight ohms
mentioned in the manual.
Experiences and information related to this portable gas analyzer will be discussed with
Messrs. Adam Zemla and Zdzislaw Gieras, the instrument team that supported the cogeneration
team.
Both supporting teams were scheduled to meet at the next plant, at Wloclawek. Both
analyzers can be used to measure the same flue gas, and check out the results.
COMBUTION R OFRD T-*"T 12

cam:-us-,ION 7ETPER
INT'F_=URCEB, :OR N
7
-7V: iNW,"?3 'C.
TME: 1:52:29
DAT_: 94/18/91 TIME: 1d:51:-3
DATE: 94/i8l9!
-_ BITUMINOUS: 11790 ETU/T_; =
;--- SiTUMINOUS,: iim
!7_TUJ/.:
COMBUSTION ----
'CI-NCY: 9£.9 ,."
PMBIENT -P-Aj--: 29 °C COMBUSTION --.-
CI-NY: *2. "
5TACK TE-PERATU-E: 75 °C aMBI--NT .-P..TU-E: 29 C
OXYGEN: I =.7 STACK "=Mo=-4TU72: is •C
CARBON MONOXIDE: 18 PPM OXYGEN: .5.8 ?-
CARBON DIOXIDE: 94.0 : CARBON MONOXIDE: 15 PvM
COMBUSTIBLE GPSES: 9.9 ?. CARSON DIOXIDE: 03.9 :
STACK DRAFT (INCHE- H'20): -1.9 COMBUSTILE=GASES 9.0_.
EKC---S AIR: 277 :: STACK DR- (iNC,- ,i20): - 91.?
OXIDES oF NIm-T.O.GN: ,4%=PPM xC-S AIR: 2-595
SULFUR DIOXIDE: a -PM OXIDeS OF Ni-.OGEN: d- PPM
CARBON MONOXIDE alA M: 59 PPM SMLU. DIOXIDE: D
?tM '
CARBON MONOXIDE ALCA=: 52 ?PM
MODE:PPM O.Y=.--RL'E:
M.D. :PPM OXY._.=--=TR-::

APPENDIX IV
ENERGY STATISTICS
The following statistical information was taken from the *Analysis of Energy Intensity of
New Plant, Main Production Process,' Part II. Katowice: Research and Development Center for
Energy Economy, S. Pasierb (ed.). The statistics focus on the energy intensity of the Steel Plant
Ostrowiec.
Cost Structure of Purchased fuel anc electricity (1989):
Electricity 734,689 Mwh 54.44%

Natural Gas 53,756 x (10) NM 20.2 %
Heating Oil 45,734 MT 18.35%
Coal 100,524 MT 6.40%
Coke 4,300 MT 0.01%
Total energy and fuel cost: 11,943,703,000 z#
Electricity and fuel consumption breakdowns by production units (1989):
Electric Arc Plant 47.77%

Small Rolling Mills 21.45%
Stamping plant 11.55%
Heat Treatment Plant 2.56%
Machine Work Plant 0.43%
Construction Steel Plant 0.32%

APPENDIX V
COSTS OF ENERGY AND FUELS IN INDUSTRIAL NATIONS

1988 VS 1990

Energy Efficiency Audit Report. Steel Plant at Ostrowlec
V;-1
APPENDIX VI
REVIEW OF NINE ENERGY EFFICIENCY PROJECTS - 1990
ENERGY EFFICIENCY IMPROVEMENT MEASURES

AND ITS RESULTS AT NINE PLANTS
1 HEAT TREATMENT PLANT (HOT) Energy Saving

o The change of working technology 223 x 103m3 natural gas
of rolls at the heat treatment plant
2. ELECTRICAL STEEL PLANT 688 KWh/t Y 1989

o Installation of water cooling of 654 KWh/t Y 1990
coat and refractory of arc furnaces = 34 KWh/t
and using of oxygen In steel production
It Is taken 20 KWh/t steel
production In year 1990,-633.561 t
Energy saving 633.561 t x 20 KWh/t
- 12.6x 10 KWh
3. WATER TREATMENT
o The cleaning of rain water and the using of this

water to supplement the circulation water
(decreasing of electricity consumption at
the pumps) 76,000 KWh
4. STEEL MILL (ROLLING MILL)
o The stopping of heating fumace of steel mill

by means of the adapting of heating furnace of
Universal Rolling Mill for both Rolling Mill 138,700m 3 natural ,as
5. LARGE ROLLING MILL
o The starting of new heating furnace with 840,000m 3 naturalaas

automatic process of burning Decreasing 8 m3 mg/t
Production 105 x 103 t

Energy Efficiency Audit Report - Steel Plant at Oatrowlic
Vi -2
6. OPEN HEARTH STEEL PLANT 1990 August, 291 m3 mg/t
o The stopping of one open-hearth furnace

1991 January, 206 m3 mg/t
(The improvement of organization) '&= 85 m 3 mg/t
It is taken 500 m3 mg/t

Production 45,000 t/y
Energy Saving 45,000 t/y x 50 m3 mg/t

= 2,250,000 m 3
7. BOILER HOUSE
o The stopping older boiler house

for space heating (natural gas consumption) 468,000 m 3
8. PIPE CASTING PLANT
o The modernization of cupola furnaces Starting now

The Installation of second row of nozzles
9. NON-FERROUS CASTING PLANT
o The using of induction furnace instead 100,000 m3 natural gas

of gas-fired furnace
Total natural gas saving 4,019,700 m 3 = 134.4 TJ

electricity saving 12,676,000 KWh = 45.5 TJ
179.9 TJ
International Resources Group, Ud. May 1992

VII - 1
APPENDIX VII
ECONOMIC ANALYSIS OF MODERNIZATION OF MEDIUM

AND UNIVERSAL ROLLING MILL FURNACES,
STEEL PLANT OSTROWIEC
MEDIUM ROLLING MILL - The limited scope of the modernization

(VARIANT I)
Pusher furnace No. Inv. 452/59

Output - 20 t/h, after modernization 25 t/h
Natural gas consumption in year 1990 72 m3 natural gas/t
after modernization 67 m3 natural gas/t
1,520 m 3 natural gas/h
The scope of revamping
o The change of burners (19 pieces), now - 13 pieces

o The adapting of the air and gas pipelines to new terms (conditions)
o The installation of the supporting pipes to support slipper pipes at the down
heating zone
o The installation of the automatic regulation of burning process
o The carrying out of the additional work, at the refractory in the changed part of
the furnace
o The sup,..,menting of the existing recuperator by means of the two rows of the
pre-heating elements
Total cost of carrying out of this project: 1,732,202,000 zt

including the documentation (designer work) 113,202,000 z1
o Results:
- Natural gas saving - yearly 875,000 m3

- Operation cost saving 997,500,000 z!
(at the currently natural gas price) 1,140 zI/m 3 natural
Pay back time is about 2 years
UNIVERSAL ROLLING MILL - The limited scope of the modernization

(VARIANT I)
Pusher furnace No. inv. 452/56
Output furnace - 18.7 t/h, after the modernization 25 t/h
-
Natural gas consumption of natural gas in year 1990 - 97 m3/t
after the modernization 67 m3/t
1,520 m3/h

VII -2
The scope of revamping
o The change of burners (19 pieces), now 11 pieces

o The adopting of the air and gas pipelines to new terms
o The installation of the supporting pipes to support slipper pipes at the down
heating zone
o The installation of the automatic regulation of burning process
o The carrying out of the additional works at the refractor in the changed part of the
furnace
o The supplementing of the existing recuperator by means of the two rows of the
pre-heating elements.
Total cost of carrying out of this project: 1,732,202,000 z1
o Results:
- Natural gas saving - yearly (in the comparison

to specify energy consumption in year 1990) 5,250,000 m3
- It Is cost saving in the comparison
to year 1990: 5,985,000,000 z1
Pay back time - 1/2 year

THE COMPLEX MODERNIZATION OF FURNACES ACCORDING TO THE VARIANT II
MEDIUM ROLLING MILL - The full modernization
The scope of the proposed modernization

It proposes the carrying out of the full documentation of furnace at the partial remaining of the
furnace basement at partial remaining of the pusher installation and at the discharge roller table,
including:
o The installation of recuperator by furnace

o Tho carrying out of the flue gas channel after recuperator of the existing chimney
channel
o The equipment - the automatic regulation of 'burning' process with the auditing
and the measurement
o The carrying out of refractory by two fibre insulation (eventual - it is not taken at
this project, but it could give the national gas saving about 10% of the currently
consumption)
o Total cost of the carrying out of this project 14.2 x 10P zI
Including the documentation (designer work) 243,038,000 z1
The cost of fitting up 3,335,800,000 z1
o Results
- The foreseen (estimated) gas consumption 55 m3 natural g/t

- The energy saving - yearly 7,000 x 25 (72 - 55) = 2,975,000 m3

VII 3
- It is the cost saving
2,975,000 m3/y x 1,140 zI/m 3 = 3,391,500,000 zI =
Pay back time 14.2: 3.39 = about 4 years
UNIVERSAL ROLLING MILL - The full modernization
The scope of the proposed modernization
o The construction of the new furnace on the adopted basement of the furnace
(paitial changed basement)
o The installation of the recuperator by the furnace
o The carrying out of the flue gas channel after the recuperator to the existing
chimney-channel
o The equipment - the automatic regulation of the burning process with the auditing
and the measurement
o Total cost is same as the furnace of Medium Roll;ng Mill,

it is: 14,2.100 z1
o Results
- The foreseen (estimated) gas consumption: 55 m 3 zI

- The natural gas saving - yearly:
25 x 7,000 (97 - 55) = 7,350,000 m3
. It is cost saving: 7,350,000 m3 x 1,140 zI/m 3 = 8.4.109 z1
- Pay back time: 14.2: 8.4 = 1.6 years
It was showed above, the most profitable project is the modernization of Universal Rolling
furnace. At the rebuilding time of furnace, it is possible, to use the non-working furnace of sheet
mill. It is possible to gain good effects without the production losses. The less profitable
modernization of the Medium Rolling furnace (in comparison with the modernization of Universal
Rolling Mill furnace) gives the significant national gas saving too.
We propose to undeitake the decision as soon as possible, to avoid the energy losses and to
gain the profit.
Huta Ostowiec
(Steel Plant Ostowiec)
Head Energy Management
Maran Stnelecki, Msc. Eng.

Energy Efficiency Audit Report - Steel Plant at Oetrowlec
APPENDIX VIII
ORGANIZATIONAL CHART (AS OF APRIL 1991)

Functional and Organizational Chart of GPD at SPO
NAC Z E LNE K I E RO0N NI C TNO0
ZAKZAa ENERGETYCZNT R-s JU1021
IKIERCVIIA ZAKADU M,
NREYCN - U-2 YIAL CIEPLOWNI ZN

UTOIL R-s U-13 Z-CA K-KA DIS TECHI RAC. ZUZ N isU2
KIERWMIK WTOZIALU I KIEROWMIL UTOZIALU I Z-CA K-KA 0/STECH I RC. 2hZ EMERGII I
EKOiNEMISIA 1 EIONW4ISTA I DA KWMCN
NISTRZ ZN II
-ITZU OZIAL UTRZYMNPJIA
RUCIJ lit- U- 5 GER63K OZIAL U.
-KIEROFAIL OZIALuI
ODDZIAL TLEUGJII R-s U- 6 HISTRZ 4~ ZESP. PLAN. ZUZ. MEDIOW EWIER. isU
KIEWIL ODDZIALU I ZESP. ROZLICZEW KOSZTOCifl if .F3
EKSPLOATACJA Rfs Ul 61
HISTRZ ZNIANOU 4 HITZZINW RZZEMAPA
IITR
-ITR
j-.-------------
-DZA PAIM R. U 0OSR ZIA. PROGH. ANALI RAC. EMERG. iRs U. 2
KIERMMIK ODDZIALU KIERMIIIK DZIALU 1

I
MISTRZ ZNIANiOUV ZN 4 UTOZIAL CIEPLUNI UIP ifs U-13EEGT
NISTRZ ZNIANOWY UIP ELEKTRYK 3

/. KIEROWI. UTOZIALU 1LNSAj2
NISTRZ LEOOMSR
IEZYNIER RUICHU
EMERGETTCZNEGO 121
UTRZYMANIE ifUCHU R-f 3 OZ'A UTEZYNAIIA RUCHU i JR 5
MISRZ 1 1KIEROWNIKMDIALU IILEETYCU

.U1
IKIERMMIK UTDZALU I
EKSPLOATACJA jU 6
R-s EKWNENSTRA 1
EKONGIISTA 1
1
WYOZOZA1L
1 TR 12 ODZIAL PODSTACJI ISIECI ZN
KIEROUNIK
IRMKCDIL
-
R-f-s
I j
ZNIAMOWY ZN
NISTifZ 4 ITA AINW
MISTRZ 31 OZIA. PODSTACJI I STECI ZIIP ifs
WDZIAL.GspoDARKI WOREJ ZHIjRs U. 4 KEMI DIL
UTRZYMANIE RUCIT
MISTRZ
IX - 1
APPENDIX IX
LOAD MANAGEMENT AND OPTIMIZATION SYSTEM DIAGRAMS

15kV 15kV GZP GSZ1 110kV 110kV
Up
4r6kV 6kV 9"U Up 6kV 6kV
Steel Plant Ostrowiec
Figure 1. Current Accounting/Management System

GPZ GSZ1 11OkV 110kV
15kV 15kV I
I ',;P'I',
Up
UZ
z E p Tr2 " Tr O
I
r4 T Tr3
6kV 6k V
-41
6kV 6kV
L Steel Plant Ostrowiec
Figure 2. Proposed Load Management/Accounting system

Overload
Isolation and Measuring of iI I MW

Forming of Energy and
Impulses Block Prediction of Remaining Time
Overloading
Gl Mn, Sec
Figure 13. Block Diagram of a Power Control System

APPENDIX X
FACILITY LAYOUTS, NEW AND OLD PLANTS
Intemational Resources Group, Ltd. May 1992

- IS,- EEJ 0
ww. -
W o.. ,W
'"
r .D.,,1"
!I
Site
-Pa rNewPlan
/ Powierzchnia Z-du P=16ha62a50rm 2

LI1
°"
"
il
___ .____ _
-
C- >*
-F--
'I IN
1-i
-- 7 Site Plan - Old Plant
Powierzchflia Z-du P=35 ha BgaO~fl

Energy Efficiency Audit Report- Steel Plant at Ostrowlec
APPENDIX XI
ANALYSES OF HEATING OIL, FLY ASH AND

DUST FROM ELECTRICAL ARC FURNACES

Analysis of Heating Oil
Analiza oleju apaiowego
- ciqtar wia~ciwy
3
0,87 0,95 g/cm
- temp. krzepniocia
+ 1200 - + 250C
- lepkoSd
w 5000 - od 120 cat - 199 cat
w 8000 - od 6 cst - 35 cat
- warto 6 opalowa
43200 kJ/kg ,'-'
GO6wy F vifyk Hly
rnir 4t 1 Strzei.icl
Analysis of Fly Ash From Electrostatic Precipitation
Analiza pylu dymnicowego z elektrofiltra

kota WP-120 wykonana w I-nzej dekadzie
atvccnia 1991r.
CaO - 7,22 ,%
SJO. - 51J 4%
MgO - 3,19 %
A12 03 - 21,6 %
Fe2 03 - 6,04 %
so_ - o,5 ,g
strata zra 4 -nIa - 2,02 %

pczostaloa6 na s-cie o oczku 0,06 mm - 40 %
If...Jill..
Analysis of Fly Ash From ARC Furnaces
Popi6l. lotny z piec6w elektrycznych
zawartod siarki w przeicz-.u na SO -

3 2,27 6
zawarto~d strat pra-nia w 1000 0 C - 2,83 %
g.eto6 w.adciwa - 4,13 g/cm 3
g-sto~d nasypowa - 0,64 kg/dcr 3
powi-rzchnia wa'ciwa - 9200 cm3 /g

przesiew prz-z sito o boku oczka
kwadratowego 0,06 mm
- 93,6 46
I.tIn Go,o,,nki
C*6,.-n'-,En,pty~zw'
Xil - 1
APPENDIX XII
SPECIFIC ENERGY AND FUEL CONSUMPTION, 1985-1990:

METALLURGICAL PLANT AND STEEL PROCESSING PLANT
International Resources Group, Ltd.

May 1992
XI - 2
Specific Energy and Fuel Consumption,
Metallurgical Plant and Steel Processing Plant
1985-1990
Universal Rolling Mill
105
Gaz
z Iemny
m3/Mg 89
47
Energia
etektryczna 41 46
kWh/Mg 38 38
77096
Produkcja 75916 - 75866
mg
65498
1 458U4
1985 1986 1987 1988 1989 1990 rok

XII - 3
Large Rolling Mill
105
Gaz
93 98
Zieny
m3/Mg 89
76
Energia
eLektryczna 65
kWh/Mg
59 62
61
120452
Produkcja
mg 8O 104942
88538
1985 1986 1987 1988 1989 1990 rok

May 1992
Energy Efficiency Audit Report - Steel Plant at Ostrowie,
XlI - 4
Industrial Steel Plant
277
Energia 275
etektryczna268
k~h
25811
82252
Produkcja 8253
Mg 7607 7 L-= 7994
7308
1985 1986 1987 1988 1989 1990 rok

May 1992
XlI - 5
Open Hearth Steel Plant
Gaz 235
232 228
zfemny 223 224
m3/mg m3/NO I217
Energia 23
S22 21
etektryczna 8 I ] 19 20
kWh/Mg
Produkcja 90310
88017 88505
Mg
84395
81100
1985 1986 1987 1988 1989 1990 rok

May 1992
Xl - 6
Hammer Plant
Gaz ziemny I 161

zi emny
144
I[
m3/Mg
S123
S112
106
130
Energia
etektryczna 97
kWh/Mg - 91
82
73
9580
Produkcja 9249 9276
Mg L 911092j 8933
mg
7144
1985 1986 1987 1988 1989 1990 rok

XII - 7
PIpe Casting Plant
Gaz 171
Gaz
ziemny 144 14444 155
m3/Mg 128 1"'q
76
Energia
etektryczna 53 54
48
kWh/Mg 44
42186
Produkcja 41289 41744
Mg
32912
15341
1985 1986 1987 1988 1989 1990 rok

May 1992
Energy Efficiency Audit Report- Steel Plant at Ostrowiec
Xl - 8
Electric Steel Furnaces
15
Gaz Ga I 14 14
z i ecrmny
m3/14g
11 11
10
Energia 705
687 [ 688
etektry---m
kWh/Mg
879224
Produkcja
mg 761174 7960785031
644693
1985 1986 1987 1988 1989 1990 rok

May 1992
Xli - 9
Spring Steel Plant
409
Gaz
z fefny 294 303
m3/Mg
255
149
Energia
eektryczna 89 92
kWh/Mg
9256
9092 9{9 95
Produkcja
Ng 8042
2910
1985 1986 1987 1988 1989 1990 rok

May 1992
May1992*
Xil - 10
Stamping Plant
827
Gas Sol
z i toy - 744
m31Ng 721
661
644
441 441
Energia
etektryczna
425
kWh/Mg
S391
54642
Produkcja 54269
Mg 51552J 53069 o+
53041
L47800
1985 1986 1987 1988 1989 1990 rok

May 1992
Energy Efficiency Audit Report. Steel Plant at Ostrowiec
XII - 11
Electric Rework
Gaz 15
zteny 14 14
m3/Mg
10
705
Energia 701
eLektryczna 687 J 680
kWh/Mg
Produkcja 8 L
g300 1785031
Hg 761174
644693
1985 1986 1987 1988 1989 1990 rok

May 1992
1,.
XII- 12
Construction Steel
318
Energia Erwrga 295 300 8
9 I I
etektryczma
kWh/Ng 225
206
12030
11726 [ L11007
Produkcja 10354
mg 9862 J _ 7
8688
1985 1986 1987 1988 1989 1990 rok

May 1992
XII - 13
Another Small Rolling Mill
Nazut 80
79 78 79
kg/Mg 75
74
142 145
Energia 139 137 - - 138
eIektryczna
kWh/Ng
600850
Produkcja
mg 578967
570642 572623
540619
500995
1985 1986 1987 1988 1989 1990 rok
Mg;

XII. 14
Construction Steel
Energia 145 147

etektryczna 133
kWh/Mg 123
124
112
6703
Produkcja 6302 6414

6202
Mg mL5610
I61 6 1
1985 1986 1987 1988 1989 1990 rok

Xii- 15
Machinery Steel
282
Energia 263
257
elektryczna
kWh/2Mg
237
23047
Produkcja 22102
20836 2
Mg
19579 ......
1985 1986 1987 1988 1989 1990 rok

May 1992
Energy Efficiency Audit Report- Steel Plant at Ostrowlec
XII - 16
Small Rolling Mill
Gaz 98
ziemny
m3/Mg 93
91
91 90
89
Energia 116
•Lektryczna
kWh/Mg 102
93
48209
Produkcja
mg 45558
44318
41753
38915
1985 1986 1987 1988 1989 1990 rok

May 1992
XII - 17
Medium Rolling Mill
72
Gaz
66
ziemny
r'3/Mg. 63
62 59
Energia 80
et ektryczna
kWh/Mg
57 57
56 56
84068 85954
Produkcja
Mg Mg [ 70522
42953
1985 1986 1987 1988 1989 1990 rok

Xl - 18
Metalurgical Plants
Gaz 61758 60243

59728
z erny 568054028
zfemy 560 - 53756
10-3 m3 __6
777624 774948
753045
Energia 724785 7 9
etektryczr/
620343
1758684
237238
Wartosc
produkcj i
mLn zL 67953
40595
29905
22887
1985 1986 1987 1988 1989 1990

May 1992
I
XII. 19
Processing Steel Plants
73619
Gaz 70895 73485
z femy 65536
10-3 m3
56583
-- 44543
69654
Energ2a 67282 67979
6
etektriczna
MWh 59350
- 49474
931967
143142
Wartosc
produkcj i
mln zL 47926
30251
23212
L17982
1985 1986 1987 1988 1989 1990

XIII - I
APPENDIX XIII
ENGLISH TRANSLATION OF ANSWERS TO IRG QUESTIONNAIRE
*Energy Audit Questionnaire'
1. Huta 'Ostrowieco
2. 27-400 Ostrowiec Sw.

ul. Nowotki 8
3. mgr inz. Marian Strzelecki
4. Ckowny Energetyk Huty
5. 521 -62
6. telex 0612581 Fax 51234
7. Ministerstwo Przemyst. - Stalowy
8. Zaktad Hutniczo-Przetw6rczy - 1813 r.

Zaktad Metalurgiczny - 1970 r.
9. 13558
10. 360 days - 8784 hours
11. The supply is realized through the Supplies Department by a rail and motor
transport.
There are some transport departments at the plant: The internal rail one,
the internal
motor one, and the external motor one. The production is realized by production
lines
at production departments. These departments also realize the storage
and the full
shipment (with participation of the Sales department). There are also some
divisions at
the plant: technological service, repair division, economic and financial division,
welfare
division.
12. (1) Steel production in arc furnaces 3 x 140 Mg and 2 x 50 Mg
(2) Steel production in the O.H. (open-hearth) furnace

- 50 Mg
(3) Rolled products:
Reinforcement bars and smooth bars (straight and coils)

0/10 _ 0/30
Sheet metal - gauge over 5 mm

May 1992
XIII. 2
U.M. (universal) plate
Angle sections, channel sections and I-sections
(4) Production - flat-die forgings from 300 kg to 100 Mg
- die forgings
(5) Production - steel casting

- iron casting
- nonferrous metals casting
- iron pipe casting (water-main)
(6) Production - steel constructions for building industry

- machine building constructions
(7) Mechanical metalworking
(8) Heat treatment

13. Heat production (hot water and steam)
5 steam boilers
9 water heaters
* Oxygen production - 4 oxygen blocks with space-time yield 3400 m3/h
* Compressed air production - 15 air compressors
* Pota.L'3 water production - 7 abyssal wells
* Industrial coding water production
80 pumps
installation for water treatment and coding
14. Central heating and hot water -282 764 GJ/year

Electric energy -68 414 MWh/year
We don't keep the books in a sphere of striking a balance of materials and energy
for
the production.

May 1992
C(
Energy Efficiency Audit Report - Steel Plant at Ostrowlaec
XIII - 3
Raw Material Quantity Derivation Transport Cost [billion

z1
Scrap 1,000,000 Mg the country railway 750
Rolled products 20,000 Mg a 70
Blooms 150,000 Mg
Carbon electrodes 300
4,000 Mg import 100
Refractories 32,000 Mg the country railway & motors 60
Pig iron 122,600 Mg they country & import railway 184
Lime 60,000 Mg The country motors 16.5
Dolomite 6,300 Mg railway 2.3
Ore 142,000 Mg import a 2.8
Ferroalloys 28,000 Mg the country & import railway & motors 204
Acetylene 150 Mg the country motors 4.8
Nitrogen 320,000 m3
Argon 707
25,600 m 3 610
16. Scrap -105,000 Mg
17. Waste materials

slag and dust from the boiler house
dust from the dust extraction of electric furnaces
steel scrap and non-ferrous metals ore
sindges from the paint shop
18.
Product Unit Production (for a year) Value of the sale

Open-health steel Mg 76,866 117 bin z1
Electric steel Mg 879,224
Rolled products 1291 bin z1
Mg 825,939 1204 bin z
Steel casting Mg 3,150 6 bin
Iron casting Mg 17,472 32 bin z1
zf
Steel and machine constructions Mg 14,898 62 bin z
Forgings Mg 53,041 107 bin z1

May 1992?
Energy Efficiency Audit Report - Steel Plant at Ostrowlac
XIII - 4
19. and 20. Energy and Fuel consumption in the steelworks *Ostrowiec" In 1990
Fuel Meta t urgical plant Steel processing plant Together

Electric Energy 774,948.000 KWh 49,473.700 KWh 824.421.700 KWh
Natural Gas 54,028.2 x 103m3 44542.5 x 103m3 98570.7 x 10
Coal 98,952 Mg 35988 Mg 134940
Coke 4657 Mg
Mazout 4657
48,470 Mg 48470
Gas oil 1443.9 Mg 118.2 Mg
Leaded petrol 1562.1
139.9 Mg 139.9
Heat consumption (in steam and hot water)
665,900 GJ S33,000 GJ 1,198,900 GJ

Compressed air 105150 x 10 m3
3
81000 x 103m3 186150 x 103m 3
Water 109533 x 103m3 18200 x 103m3 127733 x 103m3
Oxygen 14400 x 103m3 500 x 103m3 14900 x 103 m 3
21.
Electric energy
221 zf/kwh
Natural gas 1,550 zj/m 3
Coal
150,000 zf/Mg
Heating oil (mazout)
1,800,000 zf/Mg
Gas oil
3,300 zf/kg
Leaded petrol
5,000 zf/kg
Coke
1,113,000 zf/Mg
Heat
26,500 zf/GJ
Air 37,500 zI/1 0 3m 3
Water 120,000 zI/1 0 3m 3
Oxygen 1,500 zk/m 3
Prices are changing
110 kV, 15 kV, 6 kV, 500 V, 380 V, 220 V, 50 Hz
Natural gas - 1.2 MPa. 0.35 MPa and low pressure

Net calorific value (n.c.v.) - 34,400 kJ/m 3
Steam - 4 MPa, 4500C, 0.6 MPa - 2000C
Coal - n.c.v. - 19,000 kJ/kg
S content - to 1%
Heating oil (mazout) - 40,000 kJ/kg
S content - to 1%
- gas oil - 42,700 kJ/kg
- leaded petrol - 43,300 kJ/kg
- coke - 28,000 kJ/kg
. hot water "C.O"(central heating) - 150/700C, 95/700C
- air - 0.5/0.6 MPa

May 1992
XIII - 5
- water - 0.2/0.8 MPa
- oxygen - 1.5 MPa oxygen cylinders - 16 MPa
23.
Steam temp. - 3200C

-
pressure - 0.4 MPa
delivery - 18 Mg/hour
Natural gas - max 17,500 m3/h
composition - n.c.v. 34,000 kJ/m 3
3
sulfur - 100 mg/m
methane - 85%
hydrogen sulfide - 20 mg/m 3
nitrogen - 1.13%
mechanical impurities - 100 mg/m 3
C02 - 0.29%
24.
Production Unit Kind of Energy Quantity for a year
Electric furnaces Electric energy 574.624 MWh
Natural gas 9417 x 103 m3
Rolling mills Eiectric energy 96079 MWh
(The furnace androllers) Natural gas 20,812 x 103f'3
Stamping plant Electric energy 20,158 MWh
(Presses & furnaces) Natural gas 35,049 x 103m3
Heat-treating furnaces Electric energy 1,900 MWh
Natural gas 7,942 x 103m 3
Production equipment for Electric energy 4,503 MWh
steel companies
Spring production Electric energy 434 MWh
Equipment Natural gas 3
1,189 x 10 m3
Mechanical treatment Electric energy 4,961 MWh
Equipment
Cupolas Electric energy 3,862 MWh
Coke
3,862 Mg
25. 7%
26. If it is possible to change heating oil - natural gas

If it is possible to change acetylene - propane - butane gas
If it is possible to change acetylene - natural gas
If it is possible to change acetylene -leaded petrol and oxygen
27. 423,599 GJ/year

May 1992
*'i
XIII - 6
28. Transport - 104,663 GJ
We don't keep the books in a sphere of energy consumption for mechanical operations.
29. We have 2 heating oil reservoirs - 5,00 Mg each and 1 reservoir - 100 Mg
Steam heating with the pipeline route.
30. Type WP-20 (in winter)
Electric energy and natural gas - stabilized consumption\
31. Basic data are in the items 19, 20, 21.
The joint cost of consumption is:
Electric energy
183 bin z1
Natural gas 153 bin z1
Coal
20 bin z1
Coke
5 bin z
Heating oil (mazout) 87 bin zi
Gas oil
5 bin z
Leaded petrol 0.7 bin z1
We've bought total electric energy
32. 4.5 GJ/one million zt of production.
33.
Product Carrer in3 , KWh

Indicator
kg/Mg
Open-hearth Steel Natural gas 228
Electric energy 20
Electric Steel Natural gas 11
Electric energy
600
Rolled Products Natural Gas 24
Electric energy 116
Heating oil 79
Iron Casting Coke 221
Natural gas 141
Electric energy 72
Steel Casting Coke 119
Natural gas 142
Electric anergy
81
34. 500 HW

XIII 7
35. Not
36. As tem 33
37. Not
38. Not
39. Not
40. Not
41. Not
42. Data for a month

43. Max 170 MW - at the average 109 MW
44. 0.95
45. It doesn't concern us
47. It doesn't concern us
48. We have some plans but now they aren't timely

49. - The steam boiler type OR-32 producer "Rafaka' 32 Mg/H, steam pressure 4MPa, 4500C
- Coal consumption 5.4 Mg/h - 23,000 kJ/kg, efficiency -70%
- Three steam boilers type OR-1 6 - producer "Fakop" 12.5 Mg/h, steam pressure 4MPa,
450°C efficiency - 75%.
- The steam boiler type WLF - producer 'Winer Lokomotiv'
16 Mg/h, 1.6 MPa, 3500C
- Coal consumption 3.2 Mg/h 23,000 kJ/kg, efficiency
- Coal consumption 6 Mg/h 23,000 kJ/kg, efficiency 73%
- The water heater type WP-1 20 - pulverized-fuel one, once-through one-producer
'Rafaka" yield 120 GJ/h, 150°C
- Fuel consumption 28.5 Mg/h - 21,000 kJ/kg, efficiency - 79%
50. It fills up circulating cooling water in Kamienna river
The water hardness 7 - 9 german degrees
pH 7.4- 7.8
51. The water treatment composition:
1) Decarbonization and coagulation in granellers

2) Water treatment in ion-exchange columns and cation exchangers.
It obtains water parameters:
total hardn6ss - marks (?)
pH= 8 9
p =0.5 . 1/2 mval/l m 1 2.5 mvaJ/I

Xll - a
52. 15% - 20%
53. 590,000m 3
54. Maximum winter consumption - 90 Mg/h
55. We reorganize the plant
56. It has to by 1990
57. The programme comprises the following tasks:
(1) To change roller working practice;

(2) To implement water-cooling arc furnaces;
(3) To implement steel refining;
(4) To change of filling up with water-cooling;
(5) To set working a new heat furnace of the rolling mill;
(6) To eliminate the O.H. furnace;
(7) To eliminate the oLjsolete water boiler house;
(8) To modernise cupolas;
(9) To implement induction furnaces instead of gas furnaces for non-ferrous metals
smelting
58. Chief Power Engineer of the plant - Straelecki Marian, full time - University of
Mining and Metallurgy working period - 17 years
6 persons division is planning and accounting for energy and fuels
- 10 persons division supervise using machinery and repairing
59. Does not exist

60. (1) Energy consumption total analysis of the Metallurgy Plant
(2) Balances of a part of heat - treating furnaces and heat furnaces
- Wat-hour meters and var-hour meters - local
- Reducing pipe measurement of quantity of natural gas - local
Main reducing pipe measurement of oxygen, water and pressed air
production - local
The plant has not any remote measurement and transmission systems
62. We have very little literature
63. Energy consumption depends on:
Total supervision in all production departments, also through Main Power

Engineer Department;
- Control of unitary energy consumption indicator for a month;
- Production equipment routine repairs.

Energy Efficiency Audit Report - Steel Plant at Ostrowec
XIII - 9
64. It analyses total department/product consumption for a month
65. We use the following units: KWh, m, Mg, tpu, J
66. Yes
67. The plant registration comprises only large receivers. We estimate measuring equipment
as insufficient one.
68. We periodically compare actual energy consumption with the former one (for a year and
five years). Other analyses are limited.
69. It plans unitary energy consumption indicators for a production unit.

It limits 15-minutes maximal power.
It limits maximal natural gas and oxygen consumption.
70. Information about energy consumption aren't too important for a consumer because
costs of production include costs of energy.
71. For some persons as symposiums in power engineering firms and institutions in the
country.
72. It plans production equipment routine repairs for a year.
K
U.S. EMERGENCY ENERGY PROGRAM FOR EASTERN AND
CENTRAL. EUROPE
Component #1
Industrial Energy EfIiciency
Energy Audit Ollestionnnirc
A. Identification
1. Name of Company/Plant:
2. Address:
3. Name of Person Interviewed/Completing Form:
4. Title/Position:
5. Telephone:
6. Fax (or Telex):
7. Industry in which the factory is classified:
Mining Construction Materials Paper

Textiles Mechanical/Electrical Chemicals
Oil Refining Food Processing Steel
Other
S. Date of factor, commissioning:
9. Number of Employces:
10. How many hours/day does the plant operate (average)? Days per year
(averae-)?
11. Please provide details on plant operation (eg., procurement, fabrication,

schecUl 1,
inspection, packaging, storage, shipping).
2
B. Processing Activities
12. Provide a flow sheet of the plant indicating major operations.
13. List the different process units (manufacturing stages), eg., boiler, electricity
generation, oxygen plant, compressed air.
14. Provide a materials and energy balance for such non-process functions as lighting,
heating, ventilation, air conditioning (if any), and materials handling.
C. Raw Materials and Products
15. List all major raw materials consumed:
Raw Quantity Mode of Transport

Material Consumed Origin to the Plant Cost
16. List and quantify any recycled or re-used materials.
17. Are by-products or waste products of this plant utilized elsewhere?
18. List all major products:

Actual
Units of Plant Annual Value
Product Production Capacity Production of Sales
4
E. .Ener.y Utilizntion
24. What process units/departments are the major consumers of each type of energy?
Process Type of
Unit Energy Quantity Efficiency
25. What percentage, approximately, do energy costs represent in relation to total

production costs?
26. List any alternative fuels that could be used with or without modification of the
plant.
27. How much energy is used in heating/cooling buildings?
28. How much energy is used for mechinic.,! )%indling and transport within the plant?
29. Are fuel oil tanks heated? If so, how are they heated and how is the system
controlled?
30. Does the plant encounter energy time of day or seasonal energy demand constraints
(especially for electric power and natural gas)?
5
F. Ener,-v Consumption Data
31. Give the latest annual consumption data:
Fuel Cirrent Quantity Total

Type Units Price Consumed Cost
Current kWh Total

Electrici"y Price Consumed Cost
Purchased:
Self-Generated:
32. What is the overall ratio of energy consumption per unit

of plant output (eg.,
GJ/product unit)?
3". Give specific energy consumption ratios for different
fuels used (eg., million metric
tons of fuel oil/product unit).
G. ElectricirvConsumption
34. What is the total installed capacity of motors and other
equipment (kw)? Specify
voltage levels utilized.
35. Is electricity generated at the plant'?
36. W hat is 0e ration of clecricit.\ per unit O f plant OUlpUt (eg.,

kWh/product unit)?
37. If yes, what type of generator is installed (eg. diesel, gas turbine,
steam turbine, waste
heat boilers)?
3S. What self-generating capacity is installed? (kw)
6
39. How much electricity was generated by the plant last year (kWh)?
40. Fuels used for self-generation:
Fuel Quantity Heat Content

Type Units Consumed of Fuel
41. Is self-generation capacity to be increased?

42. Are there data available on daily and seasonal variations in eiec:ricity consum.ption?
Is there a daily load curve available?
43. Give electricity demand: peak and average.

44. What is the average power factor for the plant?
H. Combined Heat and Power Generation (Cocenerationn
45. Is there a cogenera:ion system installed at 6ic plant?
46. If yes, provide the following:
Level of Level of
Heat Steam and
Energy Production Elec. Prod.
Source. (GJ/hr) (kw)
47. When was the system installed? 7
48. Are there plans to install cogeneration systems or

to increase the capacity of an
existing system?
I. Boilers
49. Provide data for each boiler:
MaKer:
Type/Model:
Capacity:
Steam Pressure:
Temperature:
Normal Consumption
of Fuel:
Fuels Used:
Average Efficiency:
50. What is the source of boiler feed water?

51. Wha, water treatment is used? \Vhat is the water quality
after treatment?
52. What percentage of condensate is re-used?
5L. What is the consumption rate of water?
54. What is the peak demand for steam?

J. Encry Mniwneenit nnd Conservationi
55. Provide an organizational chart and brief overview of positions,. responsibilities,

management policy directives, internal accounting policy, and quality assurance
policy.
56. Does the plant currently have an energy conservation/savings program?
57. If yes, what does this program consist of? What are the energy savings?
58. Who is responsible for energy management?
Namce:
P-osition:
Full Time/part time?
Qualifications, Experience?
Is there an "energy team"? If so, how many?
59. Is there an "energy committee"? If yes, list the members of the committee and their
titles. What are the tasks and responsibilities of the energy committee?
60. What energy conservation measures have been identified to date?
61. What instruments/equipment are currently available to conduct energy audit work?
62. Does the plant have adequate information and literature concerning energy
conservation and audit procedures?
63. Ho." is encrgy consumpLion examined and controlled?
by senior management only? by each plant within the company?
as a routine matter, or from time to time?
when was the last complete review performed?

9
64. What analysis of energy consumption is carried out?
-- According to department (eg., offices, process plant, maintenance)?
-- By major equipment (eg., furnaces, boilers, electrostatic fillers)?
-- By end-use (eg., lighting, process heat, rotating equipment)?
-- By major product line?
-- By total monthly consumption?
65. What units of measurement are used? Are the consumption patterns or diff"rent
forms of energy converted into a common unit of measurement?, eg., kilocalories,
BTU, or kWh?
66. Does the analysis include study of the relation between energy used and level of
production?
67. Describe the present extent of record-keeping of energy consumption for all forms
of energy consumed. Are records available of the energy consumed in the different
parts of the plant? By major individual consuming equipment? By department?
68. Is the currcnt energy consumption compared with energy consumed in prev'iOus
periods, or with other similar plants? Are adjustments to energy consumption made
for variations in products quality, in the quality or type of raw materials, in climatic
conditions, in capacity utilization?
10
69. Are specific, quantitative objectives set by management?
-- for total energy consumption?
-- for'specific energy consumption?
-- for energy savings (eg., percentage reduction)?
-- for improvements in specified processes or manufacturing

stages?
70. Are energy data considered important in the overall

management information
system?
71. What action has been taken to educate personnel in energy
conservation procedures?
72. Is there formal sygtCem of preventive maintenance?

(Give details).
XIV- 1
APPENDIX XIV
EQUIPMENT SPECIFICATIONS AND JUSTIFICATIONS

May 1992
APPENDIX XV
EQUIPMENT LIST FOR HUTA OSTROWIEC
1. One set of 02 analyzers by Johnson Yokogawa which contains:
" one (1) probe with zirconian cell, #Z021 D-L-1 00-A*U
" one (1) probe protector, #Z021 R-L-1 00-A*U
" one converter, #ZA8C-S-3-N-O-N-E*B/AP2
2. IBM compatible personal computer, Model ASY 386SX-33 MHZ,

2MB mem,w/2FD(1-1.2; 1-1.44); AT I/O, 101 KB,100 MB
Conners IDE HD; SVGA Color Monitor(1024 RES); Alps
printer/6 ft cable, 24 pin,132 col wd, LQ; op & M/S
manuals; and Lotus 123 software ver 3.1
3. Two infrared thermometars, Cyclops 3 by Davis Instruments.
4. One on-line load management and optimization system as

specified in Appendix IX of IRG audit report-Huta
Ostrowiec.
The current staff at the Steel Plant Ostrowiec have limited experience and skills related
to the use of desktop computers. Thus, it is unrealistic to expect the staff to take full
advantage of this new tool at the outset. However, the staff must begin somewhere.
An
introductory course and practical workshop on desktop computers, tailored to plant-specific
needs, would be a productive technical assistance initiative that would complement
the
objectives of the Emergency Energy Program.

APPENDIX XVI
JUSTiFICATMtN OF A DESKTOP COMPUTER

FOR
HUTA OSTROWIEC

May 1992
SUBSTANTIATIONS
OF
COMPUTER BENEFITS
TO: TERNATIONAL RESOURCES GROUP

FROM: Marian Strzylecki, Chief of power department
Huta Ostrowiec
CC Mr. Gerald Decker
Mr. Frank Wang
Date: 10/07/91
A computer (PC) and printer as specified by the US AID purchase

issued to Fancy Electronics LTD will be utilized in our power order
department
to serve the following tasks:
1. On-line monitoring of electric power and fuel usages, and
optimization
of fuel usages.
2. Cost accounting; financial and material balances.
3. Economic evaluations, and financial analysis.
4. Management reports, and billing sections.
5. Production cost analysis, and calculations on energy and
fuel cost per
unit production.
6. Cost estimation, and scheduling of maintenance OPERATION
and major
overhauls.
7. Computer aided design (CAD), and calculation of production
process,
steam distribution, and so on.
In addition to the above direct savings in electric power and

this computer system shall give our general power department fuel usages,
degree of office automation. As a result, we shall eliminate a higher
positions, and still achieve a more effective administration two clerk
in our
department.
Our conservative estimate on the payback of such a computer

system is six
(6) months, after a three (3) month of commissioning (set-up)
period.
APPENDIX XVI!
RESULTS AND BENEFITS OF LOAD MANAGEMENT

AND OPTIMIZATION SYSTEM, INCLUDING GRAPHS MADE BY THE NEW SYSTEM
International Resources Group, Ltd, May 1992

GRAPHS PRODUCED BY THE LOAD MANAGEMENT AND OPTIMIZATION SYSTEM
1. Demand vs. Time with projections
2. Demand in half-hour intervals
3. Demand in 15 minute intervals
4. Time distribution of maximum demand

5. Table of maximum power demand in 15 minute intervals, energy consumption and
power factor
10/03/91
RESULTS AND BENEFITS
OF
LOAD MANAGEMENT AND OPTIMIZATIONS
The system was put into service on 9/01/91.

Economic results:
A reduction of power demand from 19.5 MW to 12.5

MW.
This yields a monthly saving of

7,000 X 12,500 = 87,000,000 zl
@ 1.0 USD = 11,400 zl exchange rate, the savings in
US dollars are
$7,675.00 per month
2 MW will be reduced next. That will save $2,193. per month in addition.
With this system Hu4 a Ostrowiec can predict an optimal
level of power
demand and consumption.
liii II USTROWIE[
5] '1i 1? 0 1.11 iTEEL
U S WORKS
~!**1rilosTR01-J1EC S141ETOKRZYSKI
* --- ''Imr GE~RALDT L,*rir

n
mr F P E'I;IIvrlr;
* 199 1 r. v). n7
* '. **~*1' ~ j - '7 , ' 7t yr i.C 'ic- w'i .j i 'I"j~ "'k qc1'
-1 r 21y3.l ic7.-ri i - ov'rr i 1 pn'i :, oh(, 1J~ i qiw '' -1~w
. 'Yi g i"''1fjyi 71 I7'.'t '1 r :1 iw ri Qr
,...,,~~~~~~~ 1'* ) r''~ r I

7 ni'~V
n' zn~'' k~n,n !7 -,-r
j.' -~n'rrYI; i
'' r
-,.
ch ti
nflnk-f
0 r po .L n zm[ih
Ar~Q~bl Dc1Lfl
u.~.t
. . .. 7.400 OsIrowlo Sw
aokhlod 1iH lels-Ptteiwlvtely
l6,. 0612511
.. i " 1.1,e, siu-34
Mlr RObert Loks leigroet aaO-oo

E., Pafn Ise; 0012621
oroup L'T 11i,1out 241-42

international qRRsourO e
1400 I Stret tW.
Sulte 700
vC 20005 -.
L Waehington
Fox /202/ 28'1-7601
As,,nt/ o.,t, 02.oS.1991.
with
I jIedly inform you that ace, To our agreement
oot of work
Teohnipal University of J(ielce the ptll
It mosTof in, progremgli purohese of aquipment
and obmmisioning Is 22 660 UB,
Rest o~f the data aco to my previous fox on 30,07.1991.
HeBet regards.
II.
I~utI
0141
Date: 09-24-1991 VIA FAX 011-48-472-51234
To: Marian Strzelecki CC: Jerry Decker

General Power Engineer
Huta Ostrowiec b
27-400 Ostrowiec Post.It brand !rensmIa memo 7571
Poland
From: -'Frank S. Wang Z-

IRG Fax 71/ .. Fax
Fax # 517-799-9343
Subject: Presentation on the newly installed load management system at
Huta Ostrowiec
Marian, we would like very much to have the team from the Technical
University in Kielce to give a 30 minutes presentation at
workshop on the new load management system beinT install2d our forthcoming
at your plant.
The workshop is to be held at the Ministry o. Indostry in Warsaw, on the
morning of October 9th.
The team from Kielce can deliver their presentation in Polish. There will
be an overhead projector, and 35 mm slide projector available for them to
use at the workshop.
They should be ready fo=' discussion, and answering questions from the
audience. The afternoon, and evaning is for one to one discussion with
any particular group that is interested in your system.
T am sorry for this short notice. We really want to have them in our
workshop.
Please give us a phone call between 9:00 am to 12:00 pm, Michigan time on
9/25/91, and tell us if they accept our invitation. During that period of
time, Mr. Decker, Dr. Heiny, and I will be together at Omn Tech. The
phone number you should use is (517) 631-3377.
it is very important that you call us at above number on the morning
9/d5/91, as we are arranging the last few tims slots for speakers at of
our
workshop.
PS: I have recei Ad your fax of 9/5/91. The instruments should be
arriving Poland by now. Please keep in touch with Mr. Magiera of
Energopomiar, an they shall ship the instruments to all the plants. The
eight probe oxygen analyzer is for the oll fir6Q lizating turnaces. The
portab le gas analyzer "Enerac 2JO0" is available through Energopomlar.
Waiting for your call.
Figure 1. Power Demand vs Time in Minute with Projection
16
3122
IL _
. 8 E
06 12 15
(:3U.I
Time (min) "
Figure 2. 24 Hour History of Power Demand in 30 Minutes Interval
16
0
141
12
0
((D
CL
co 8
aC)
o 6 aa
105
10
0 2 4 6 8 10 12 14 16 18 20 22 24
Time
r,\ '
Figure 3. 24 Hour History of Max Power Demand in 15 Minute Interval
0
14,
162
0
0
i20
77
10i
0 - 1 -
010 12 14 16 18 20 22 24
Time
Figure 4. Frequency Distribution of Maximum
Power Demand
U
.a
40
0
E
E0.6
c 0.4
0
C
IL
2.0 3.0 4.0 5.0 6.0
Maximum Power (MW)

Figure 5
REPORT OF MAXIMUM POWER, ENERGY CONSUMPTION PER HOUR
AND POWER FACTOR ZH-P HO
on February 10, 1991
STEEL PLANT- OSTROWIEC
Time
(h o ur) E11___"___28" I
32
Max. Power for 15 Min. (MW)
8 43"3 Jsrje O
P.60
c" ...
Cos 0
00 3.25 3.15 3.15 3.10 3.30 0.95

01 3.20 3.10 3.10 2.95 3.10 0.97
02 2.65 2.70 2.70 3.05 2.86 0.94
03 3.05 3.00 3.00 3.10 3.08 0.95
04 3.10 3.15 3.15 3.00 3.10 0.96
05 3.10 2.90 2.90 2.75 2.94 0.95
06 3.25 4.20 4.20 5.05* 3.80 0.95
07 4.90 5.10* 5.40* 5.75* 5.20 0.93
08 5.85* 5.70* 5.70* 5.55* 5.88 0.95
09 5.50* 5.25* 5,20* 4.55 5.63 0.97
10 4.50 4.20 4.90 5.35* 4.66 0.90
11 5.25* 5.25* 5.05* 5.20* 5.40 0.94
12 5.30* 4.65 4.70 4.65 4.99 0.96
13 4.50 4.00 3.75 3.30 4.41 0.98
14 2.60 3.00 3.45 4.10 3.16 0.98
15 4.20 4.00 3.60 4.05 3.95 0.96
16 4.05 3.20 3.30 3.20 3.99 1.00
17 3.35 3.30 3.40 3.30 3.28 0.97
18 3.30 3.20 3.35 3.35 3.34 0.94
19 4.35 3.60 3.55 3.50 3.59 0.92
20 3.40 4.00 3.90 3.85 3.61 0.96
21 3.85 3.75 3.90 3.30 3.88 0.98
22 3.25 3.60 3.25 3.50 3.63 0.96
23 3.50 3.35 3.45 3.45 3.63 0.96
24 hours cos 0: 0.95

Monthly cos o: 0.95
Energy Consumption per 24 hrs: 90.75 MWh
Energy Consumption from the Month Beginning: 181.50 MWh
Average Time of Quarter (of an huur): 899.05 s
APPENDIX XVIII
NEW ORGANIZATION CHART (10/91)

May 1992
ORGANIZATION CHART OF OSTROWIEC STEEL MILL
lechnicat Diretor
281. Z-CA K-KA D/S TECH.-PROD. f676 U6
Z-CA KXA D/S TECHNICZNO-PftDLIKC1 11
Powe'r Otoartmmnt
1
ZE2. WYDZIAL ENERGETYUiNY R180 U-19 284. jiIHDZlAl
CIEPL6IU R1 U12 TO jG CY NERGTYK0U
KIEROWNIKYYDOZIALU fI TKIEROWNIK WYTZIALU I LWY ENENSE1YK
I
EXONMIST IKONOISTATEO.l ZES. PLAN. I AN.EK.GOS.P*8 ft. 0 U. 2'
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283.31UTRIYMANIE RUCHU ft. 25 U-2

APPENDIX XIX
NATURAL GAS CONSUMPTION RESULTS, GRAPHED BY NEW

GAS DEMAND MANAGEMENT SYSTEM

NATURAL GAS CONSUMPTION RECORDS OF HUTA OSTROWIEC
These graphs show the flow per 24 hour period for each production department in the
plant. In addition there is an hourly demand chart for each production department.
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APPENDIX XX
LETTER OF APPRECIATION FROM DIRECTOR, MR. KREKORA

May 1992
DYREKTOR HUTY
ft.Cerulld L. D E K E i?
International Resources Group
Dear Sir,
Taking fh oppotr-unify of ynur successive visit in our

plant we would
Iike to express otur bes: l.hanks for your devotion and
implPment-alinn of IUS A I D "Indd'strial Energy Efficiency siuccessful
Improvement"
program in 11af "Ostrowier"
The suggestions we reccived and the financial assistance

a.sur. our efforts in two nain directions:
- relIahie energy sipply at. proper prices
- Pner'gy consuming at so high efficiency as economically

possible
I hope wp will continue our succesful cooperation and
that you will proceed wi 'liour assistance in the next atages of this
program.
We wish you many success in your job.
Yours sincerely
General Manager
J.Henryk K R E K 0 R A
1st ro.wir qnkrzvqli, 1Ql.10.03.

27-400 Ostrowiec Sw.
Huta ,,OSTROWIEC", 27-400 Ostrowlec Swltokrzyskl - Zaklad Hutnczo-Przetw6rczy

ul. Newotki 8
Telefori: 526-81 do 91
Telex: 0612581
1nt:orint Lonq I Telefax: 512-34
Zaklad Metalurglczny
I' 1) rcrs, G )rou
p ul. Samsonowlcza 2
Telefon: 220-00
Tel x: 0812621
Teel~ax: 241-42
Znak Data: 05 .!().1 991
E fe k t y
z wrowndzeni ,ikindu "LOAD MANAU'E"iT -)YSTEM"
:;vstem zqczlt swo,j pr'ac 01.09.1991 roku.
P;"fpkty ePonomiczne:
Zmrii,j.sz-nip mocy uinownej z 19,5 iIW np 12,5 41W, co w efek
ciq d.,je miesiJzne oszczqdno.ci w oplqtach:
7.0OO kW x 1?.500,- zt/kW = S7.500.000,- zt
orzy kursie 1 'JSD = 11.400,- zi = 7.675 US[)

vlysti)ilismy Ju2 o zmnJe,jszenie o dalsze 2 MW, co daloby
dodstkowo:
2.000 I'/ x 12.5(),- zt/kW = 25.000.000,- zi = 2.193 USD
Uzvskinte pelnej informacji z systemu pozwoli dobrP6 tq moc
na makIympinte technicznym i ekunomicznyn poziomie.
it'",
.w b MI ,;'
11V I
.

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ENERGY EFFICIENCY AUDIT REPORT

STEEL PLANT OSTROWIEC

INTERNATIONAL RESOURCES GROUP, LTD.

U.S. EMERGENCY ENERGY PROGRAM FOR EASTERN & CENTRAL EUROPE

U.S. AGENCY FOR INTERNATIONAL DEVELOPMENT

USAID Contract EUR-0015-C-1008-00

APPENDIX II PARTICIPANTS INOFFICIAL MEETINGS

APPENDIX III GAS ANALYZER RESULTS AND DISCUSSION

APPENDIX IV ENERGY STATISTICS OF STEEL PLANT OSTROWIEC FROM "ANALYSIS

APPENDIX V COSTS OF ENERGY AND FUELS IN INDUSTRIAL NATIONS 1988 VS

International Resources Group, Ltd. May 1992

APPENDIX VII ECONOMIC ANALYSIS OF MODERNIZATION OF MEDIUM AND

APPENDIX VIII ORGANIZATIONAL CHART (AS OF APRIL 1991)

APPF_.NUIX IX LOAD MANAGEMENT AND OPTIMIZATION SYSTEM DIAGRAMS

APPENDIX X FACILITY LAYOUTS, NEW AND OLD PLANTS

APPENDIX XIV EQUIPMENT SPECIFICATIONS AND JUSTIFICATIONS

APPENDIX XV EQUIPMENT LIST FOR HUTA OSTROWIEC

APPENDIX XVI JUSTIFICATION FOR A DESKTOP COMPUTER FOR HUTA

APPENDI,X%XVIII NEW ORGANIZATION CHART (10/91)

APPENDIX XIX NATURAL GAS CONSUMPTION RESULTS, GRAPHED BY NEW GAS

International Resources Group, Ltd. May 1992

Figure 1. Location of plants audited by the IRG Team viii

International Resources Group, Ud. May 1992

A.I.D. U.S. Agency for Intemational Development

BTu British thermal unit

ESP electrostatic precipitator

GPD General Power Department

IRG International Resources Group, Ltd.

kWh kilowatt hours

MCF thousand cubic feet

nm 3 normal cubic meters

psi pounds per square inch

OLMO on-line load management and optimization system

SPO Steel Plant Ostrowiec

zi zloty; unit of Polish currency

International Resources Group, Ltd. May 1992

International Resources Group, Ltd. May 1992

To support the transition from Soviet-based dependence to democracy, based on free

1) fostering improved management of energy use in industrial plants by identifying

2) transferring energy auditing and management techniques including financial and

International Resources Group, Ltd. May 1992

To accomplish these objectives the following actions were undertaken:

0 potential for significant energy savings;

3) The Teams identified, specified, and procured energy efficiency equipment to be

4) Representatives of the Audit Teams returned to the plants in October 1991 to

The Industry Audit Team audited four plants (Figure 1):

Huta Ostrowiec, Steel Plant - Ostrowiec-Swietokrzyska

International Resources Group, Ltd. May 1992

Wierzblca Cement Plant

Kedzlerzyn Nitrogen Works

International Resources Group, Ltd. May 1992

As part of the U.S. Agency for International Development (A.I.D.)-funded, Emargency

a potential for energy savings, from low cost or no cost activities;

1.1 Plant Background

Intemational Resources Group, Ltd. May 1992

1.2 Results of the Emergency Energy Program

International Resources Group, Ltd. May 1992

Eqipmmnt Item: Cost Annual Type of Paybak Coal!

[Steam Tas$1,009 -- $271 steam f .08 1 n/a

TOTAL $33,309 $111,51 .29

To allow a more comprehensive evaluation of the projects, specific results will be

International Resources Group, Ltd. May 1992

2.1 Background Information

E open-hearth steel production

_____ _unit Ju"90 PrIca/unit.(zt)