Overview of Indian Iron & Steel Sector - Shanghai, China Prakash Tatia Former Chairman SIMA, India 23rd May, 2018 - International Energy Agency
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Overview of Indian Iron & Steel Sector
Shanghai, China
Prakash Tatia
Former Chairman
SIMA, India
23rd May, 2018
AGENDA About SIMA Present Indian Steel Scenario Present Indian DRI Scenario Salient Features of National Steel Policy (NSP) 2017 India’s Commitment on Reduction in Emission Intensity Issues and Challenges for the Indian Steel Industry
About SIMA Sponge Iron Manufacturers Association (SIMA) – an all India apex industry body of Indian DRI industry. Established in 1992 with headquarter in Delhi. Main Functions • Fulfills the multi-dimensional role of providing a common platform for exchanging knowledge, experience & growth related aspects. • Reviews the industry vis-à-vis Government policies, global developments and market feasibilities and inter-act with different Govt. agencies. • Maintains database of Industry statistics.
About SIMA Main Functions • Organizes national and international technical seminars to update the members about the latest technological • “4th India International DRI Summit- 2018” being organized on 13th August, 2018 in Delhi, India. • Brings out an in-house magazine “DRI UPDATE” • Organizes medical camps, training / skill development programmes etc.
Present Indian Steel Scenario • Major growth in the steel sector took place after the deregulation and liberalization in 1991-92. • On account of rapid industrial development and investment in infrastructure etc, from a modest crude steel capacity of 22 MT in 1991-92, India has achieved a capacity of 128 MT and crude steel production of more than 100 MT in 2017. • India has become 2nd largest global steel producer during 2017-18. • Iron and Steel Industry contributes around 2% to the Gross Domestic Product (GDP). • It has an output multiplier effect of nearly 1.4x on GDP and employment multiplier factor of 6.8x . • Indian steel industry employs about 0.5 million people directly and about 2.0 million people indirectly.
Route wise Steel Production in India
• Contribution of EAF and IF route to total steel production in the country increasing.
• In 1991-92, EAF and IF contributed merely 28%. Increased to 55% in 2009-10 and
presently at 57- 58%.
120%
% Contribution to total steel production
100%
28% 36% 48% 55% 56% 58% 58% 56% 57% 58% 57%
80%
60%
40%
20%
72% 64% 52% 45% 44% 42% 42% 44% 43% 42% 43%
0%
Contribution of IF&EAF Route
Contribution of BF/Corex-BOF RoutePresent Indian DRI Scenario • India’s growth story started with the initiative of Ministry of Steel, GOI when they together with UNDP set up a demonstration plant at Paloncha in 1980 to test the suitability of Indian iron ore and coal for the production of DRI. • Major growth in coal based sector from 2003-04 to 2008-09. • Domestic DRI capacity increased by about 280% in nine years during 2005-14. • India is the only country in the world making DRI from coal gasification . • India is the largest DRI producer in the world for the last 14 consecutive years and accounts about 25% of world production.
Structure of Indian DRI Industry
1. Number of Operating Plants
Gas Based 5 Nos
Coal Based 315 Nos
Total Plants 320 Nos
2. Capacity
Gas Based 12.60 million tonnes/year
Coal Based 33.40 million tonnes/year
Total 46.00 million tonnes/yearTop DRI Producers
(Million Tonnes)
Country 2016 2015 2014 2013 2012
India 18.47 17.68 17.31 17.75 20.05
Iran 16.01 14.55 14.55 14.46 11.58
Saudi Arabia 5.89 5.80 6.50 6.10 5.70
Russia 5.70 5.44 5.35 5.33 5.24
Mexico 5.31 5.50 5.98 6.13 5.59
World Total 72.76 72.64 74.69 74.92 73.14
India %age 25.38 24.34 23.17 23.69 27.41
Source: MidrexNational Steel Policy (NSP) 2017
Main Objectives
(I) Create a technologically advanced and globally competitive steel
industry that promotes economic growth .
(II) Attain self sufficiency in steel production using own raw materials
and energy resources.
(III) Increase per capita steel consumption to 158 Kg by 2031 from
61 Kg.
(IV) Operate steel industry in environmentally responsible manner
and reduce carbon foot print.National Steel Policy (NSP) 2017 Salient Features • Crude steel capacity by 2030-31 300 MT • Crude steel production 255 MT • Finished steel production 230 MT • DRI Demand/Production 80 MT • Per capita finished steel consumption 158 Kg
DRI Demand / Production as per NSP NSP projected DRI demand / production = 80 MT by 2030-31 from a current level of 21 MT Assumptions Steel Production through BF-BOF 60-65% Steel Production through EAF/IF 35-40% DRI Coal Based Production 70% DRI Gas Based Production 30%
India’s Commitment on Reduction in Emission Intensity • COP-21 summit, held during 30th Nov to 12th Dec 2015 at Paris, a new pathway has been identified called the Paris Agreement, to address the Climate Change issues in the post 2020 scenario. • India ratified the Paris Agreement on 2/10/2016 and had committed to reduce the emissions intensity of its GDP by 33 to 35 percent by 2030 from 2005 level. The Agreement entered into force on 4 November 2016. • Govt. of India has committed to reduce GHG emission per unit of GDP by 33-35% by 2030 vis-à-vis 2005 level as per India’s Intended Nationally Determined Contributions (INDCs).
Salient Features of India’s INDC • To put forward and further propagate a healthy and sustainable way of living based on traditions and values of conservation and moderation. • To adopt a climate friendly and a cleaner path than the one followed hitherto by others at corresponding level of economic development. • To reduce the emissions intensity of its GDP by 33 to 35 percent by 2030 from 2005 level. • To achieve about 40 percent cumulative electric power installed capacity from non-fossil fuel based energy resources by 2030 with the help of transfer of technology and low cost international finance including from Green Climate Fund (GCF). • To create an additional carbon sink of 2.5 to 3 billion tonnes of CO2 equivalent through additional forest and tree cover by 2030
Salient Features of India’s INDC • To better adapt to climate change by enhancing investments in development programmes in sectors vulnerable to climate change, particularly agriculture, water resources, Himalayan region, coastal regions, health and disaster management. • To mobilize domestic and new & additional funds from developed countries to implement the above mitigation and adaptation actions in view of the resource required and the resource gap. • To build capacities, create domestic framework and international architecture for quick diffusion of cutting edge climate technology in India and for joint collaborative R&D for such future technologies. • MoS had submitted its INDCs for reducing GHG emissions in Iron & Steel sector which inter alia projects average Sp. CO2 emissions intensity to reduce from 3.1 T/Tcs in the year 2005 to 2.64 T/Tcs by the year 2020 and 2.4 T/Tcs by the year 2030
Template on INDC Mitigation Information/Various Programs BF-BOF based Integrated Route Baseline Emission Scenario in 73 million tonnes @CO2 2005 in CO2 eq emission intensity of 3.10 T/Tcs Mitigation scenario projection in 216-234 Million Tonnes @ CO2 2020 in CO2 eq in the proposed emission intensity of 2.4-2.6 existing programmes T/Tcs (Avg 2.5T/Tcs) Mitigation scenario projection in 462-504 million tonnes @ CO2 2020-2030 in CO2 eq in the emission intensity of 2.2-2.4 proposed programmes Tonnes/Tcs (Avg 2.3 T/Tcs)
India’s Commitment on Reduction in Emission Intensity Way forward to achieve the Target: Crude steel production in India in 2016-17 was 97.44 MT, out of this, production through BOF route is 43%. EAF is 27 % and Induction Furnace is 30%. CO2 emission intensity (BF-BOF) route is high @ 2.3 -2.8 T/Tcs as on 2016-17 which needs to be curtailed to meet the above emissions targets.
Issues and Challenges for the Indian Steel Industry In order to achieve the emission targets, Indian Steel Plants need to primarily focus on the improvement on the fuel rate, BF Productivity etc. which can be achieved through the following: a) Improved Quality Raw Materials b) Increase in hot Blast temperature ( >1000 deg. C) c) High Top pressure d) More allocation/ budgeting of clean fuel like NG etc. e) Maximum Capacity utilisation of plant and equipment f) Use of more scrap g) Adoption of energy efficient technologies
Recommended Technologies for Fuel/Electricity and CO2
Emission Reduction
Effect of Technology
Sl.No. Title of Technology Electricy Savings Fuel Savings CO2 Reduction
KWh/t of Product GJ/t of Product Kg-CO2/t of Product
Sintering
1 Sinter Plant Heat Recovery(Steam Recovery - 0.251/t-sinter 23.9/t- sinter
from Sinter Cooler Waste Heat)
2 Sinter Plant Heat Recovery ( Power Generation 22.1 kWt/t-sinter - 19.9/t-sinter
from Sinter Cooler Waste Heat)
3 High Efficient(COG)Burner in ignition - 0.011/t-sinter 0.50/t-sinter
Furnace for Sinter Plant
Coke Making
- 1.9/t-coke 135/t-coke
4 Coke Dry Quenching (CDQ)
150 kWh/t-coke - 74.9/t-coke
5
Coal Moisture Control (CMC) - 0.3/t-coke 27.6/t-coke
Iron Making
6 Top Pressure Recovery Turbine (TRT) 50 kWh/t-pig iron - 45.0/t-pig iron
7 Pulverized Coal Injection (PCI) System - 1.55/t-pig iron 147/t-pig iron
(at 125kg coal inj)
8 Hot Stove Waste Heat Recovery - 0.08/t-pig iron 7.8/t-pig ironRecommended Technologies for Fuel/Electricity and CO2
Emission Reduction
Effect of Technology
Sl.No. Title of Technology Electricy Savings Fuel Savings CO2 Reduction
KWh/t of Product GJ/t of Product Kg-CO2/t of Product
Steelmaking
9 Converter Gas Recovery Device - 0.84/t-steel 79.8/t-steel
10 Converter Gas Sensible Heat Recovery Device - 0.126/t-steel 12.0/t-steel
11 Ecological and Economical Arc Furnacee 150 kWh/t-steel - 135/t-steel
12 Waste Heat Recovery from Electric Arc Furnace 87.7 kWh/t-steel - 78.9/t-steel
Common System
13 Regenerative Burner Total System for - 0.17-0.21/t-billet 16.2-20.0/t-billet
reheating furnace
General Energy Savings & Environmental Measures
14 Energy Monitoring and Management System - 0.12/t-steel 11.4/t-steel
15 Cogeneration(include Gas Turbine Combined 47.5%(HHV) [*5] - 56.1/t-steel
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