ENERGY MANAGEMENT DEPARTMENT

          Previously known as ‘Energy & Economy Department’, its main objective is to economize the process and suggest the best method to minimize the energy consumption in an otherwise highly energy consuming steel plant. Total energy required in making 1 T crude steel is at present around 7.0 Gcal. [1 Gcal =10⁹ cal.]

          Steel industry consumes a lot of energy; in 2001-02, e.g. the coke ovens consumed around 1.1086 Gcal/T of coal charged while sinter plant and blast furnace consumed 0.7035 and 3.9697 Gcal/TCS respectively. Similarly various sections like SMS, CCP, Roll Mills, Boiler House , etc. have their own energy demands. Before modernization (when O.H. furnace was operating), the energy consumed was 10-11 Gcal/TCS which has sufficiently lowered down to around 7 Gcal/TCS; the saving of 5 Gcal/TCS is really a great achievement by EMD.

The department has four broad sections:

1.     Gas Control: The energy in the plant is in the form of combustible gases, i.e. mainly BF gas & CO gas. To maintain proper continuous supply to different energy demanding sections of the plant in any climate 24 hours a day 365 days a year, even during emergency is the duty of this section. The main control room monitors  therefore the whole distribution through various instrumentation meters.

2.     Thermotechnique unit (4 nos.): Two units; primary site (CO, BF, etc.) and finishing site (reheating furnaces in Rolling Mills) maintain the proper fuel to air (O₂) rates. The combustion survey of flue gases by Orsat analysis is done from time to time and the new better ratios of flue to air are maintained.

3.       Thermotechnique gas control: The whole processed is monitored and controlled from the section.

4.     Light Mechanic Maintenance: The major functions of this section is to look the gas-safety of the plant pipelines (which contain highly inflammable gaseous compounds). It includes looking after 16 km long CO, BF, BOF & mixed lines, 7 km nitrogen pipeline, and 4 km long inter-plant compressed air line; giving the gas clearance for jobs on pipes; looking after bleeding of BF, BOF, or steam gases.

In addition, to ensure continuous gas supply, gas holders for BF gas, BOF gas & CO gas function as reservoir to hold the excess or to supply in emergency are also provided. The capacities of this gas holders are 100000 m³, 50000 m³ and 4000 m³ respectively of BF, BOF, CO gases each in turn having a specified lower limit as well.