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    Steel Re Rolling Mills Association of India

    Steel Re-Rolling Mills Association of India Email :

    Sl. No, Name

    1. Shri B.M. Beriwala,


    2. Shri Jagmel Singh Matharoo,

    Vice Chairman

    3. Shri Ramesh Kumar Jain,


    4. Shri Sanjay Jain

    5. Shri Kailasj Goel

    6. Shri G P Agarwal

    7. Shri O P Agarwal

    8. Shri S K Sharda

    9. Shri Sandip Kumar Agarwal

    10. Shri S. S. Sanganeria

    11. Shri Sanjay Surekha

    12. Shri R P Agarwal

    13. Shri S. S. Bagaria

    14. Shri Girish Agarwal

    15. Shri Goutam Khanna

    16. Shri Suresh Bansal

    17. Shri Rajiv Jajodia

    18. Shri Bhusan Agarwal

    19. Shri Mahesh Agarwal

    20. Shri Sita Ram Gupta

    21. Shri Ashok Bardeja

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    Steel Re Rolling Mills Association of India

    SRMA Steel News is a division of Steel Re-Rolling Mills Association of India and takes due

    care in preparing this news. Information has been obtained by SRMA from sources, which it

    considers authentic. However, SRMA does not guarantee the accuracy, adequacy or

    completeness of any information and is not responsible for any errors or omissions or for the

    results obtained from the use of such information. SRMA is not liable for investment decisions,

    which may be based on the views expressed in the News. SRMA especially states that it has no

    financial liability whatsoever to the subscribers/users/transmitters/distributors of this News. And

    no part of this news may be published/reproduced in any form without SRMAs prior written


    We are deeply shocked for sad demise of our Ex.Committee

    member Mr.Ashok Bardeja who passed away on the 2nd of

    August, 2014.

    On behalf of the Chairman, Vice Chairman , Treasurer and

    Committee, General members of the Steel Re-Rolling Mills

    Association of India offer the heartiest condolence for his

    family. We pray to God to give his family enough strength to

    forebear this irreparable loss.

    May His Soul Rest in Peace

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    Steel Re Rolling Mills Association of India

    Executive Summary

    Energy efficient technology is Essential for growth of SRRM sector

    Environment & Safety Focus

    Taxation News


    Latest Steel News


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    Steel Re Rolling Mills Association of India

    Energy is one of the important inputs for the economic advancement of any country. In the matter of

    developing countries, the energy sector assumes a critical importance in view of the ever increasing

    energy needs requiring huge investments to meet them. Enhancement of energy efficiency of an

    industry depends upon the measures taken for energy efficient equipment and system design and

    standard operating practices. Energy efficiency is achieved when specific energy in a specific product,

    process or areas of production or consumption is reduced without affecting output. Upgrading of energy

    efficiency will contribute to energy conservation and is therefore an fundamental part of energy

    conservation promotional policies.

    India has speedily risen in the list of global energy consumers. Increasingly dependent on larger quantities

    of fossil fuel, the country is currently the worlds third largest consumer of energy. Subsequently, it is

    also the fourth largest source of GHG emissions, contributing over four per cent of the 25.2 billion tonnes

    of CO2 released by the world every year. Of the 1.7 billion tonnes of GHGs emitted by India annually,

    the industrial sector accounts for more than 500 million tonnes. The Indian steel sector is one of the

    biggest contributors to this figure, emitting 70 million tonnes of CO2 per year.

    For its direct energy needs, the SRRM sector is heavily dependent on furnace oil, coal, or natural gas.

    This dependence is a drain on these small and medium sized units, forming over a quarter of production

    costs. To compound the issue, fossil fuel use also increases their emission load. While technical

    interventions to improve production efficiency and reduce energy costs are available, their existence is

    largely unknown to the SRRM sector. There is low awareness about energy efficiency and most units lack

    the engineering and technical manpower to adopt energy efficient practices.

    Still SRRM sector is not energy efficient due to lack of experience in accessing external funds, of

    incentives to cater to small-scale energy efficiency projects, Outdated technologies and practices, Low

    information and awareness levels on the developments in the sector, Inappropriateness of generic energy-

    efficient technologies (EETs) developed, Low research and engineering base and other institutional

    linkages. Need for Energy Conservation To harness the high energy saving potential and its benefits,

    bridging the gap between demand and supply, reducing environmental emissions through energy saving

    and to effectively overcome the barrier, the government of India enacted the Energy Conservation Act-


    The Act provides the much needed legal frame work and in institutional arrangement for embarking

    on an energy efficiency drive. Improving Energy Efficiency In Steel Rerolling Sectors The Centre for

    Engineering & Technology (CET), Ranchi, is the inhouse design engineering and consultancy

    organization of Steel Authority of India (SAIL). Under the UNDP assisted project for energy efficiency

    improvement in steel rerolling sector comprising mainly small and medium enterprises (SME), CET

    with SAILCON was entrusted for suggesting methods for improving energy efficiency for rerolling

    industries located in north and western part of India and again study for preparation of feasibility report

    for improving energy efficiency in SRRM sector.


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    Steel Re Rolling Mills Association of India

    Globally growing consumption of energy has gone in the certain level with rising concerns about

    its conservation. Apart from being expensive and

    prone to sudden price fluctuations, the

    overwhelming majority of energy sources are non-

    renewable. Therefore, the conservation of energy is

    considered vital not just to avoid wastage of a

    precious resource, but also to slow down the rapid

    depletion of coal, oil, and natural gas resources.

    However, with the environmental movement

    gaining ground in the past 30 years, the

    ramifications of unsustainable energy use are no

    longer confined to economics alone. As the bulk of

    greenhouse gas (GHG) emissions is a result of

    fossil fuel burning, conservation of energy is today

    intrinsically linked to the climate matter. As

    halting fossil fuel use is not an option without the

    viability of alternative sources, the only way to

    reduce energy use and manage emissions is

    therefore to maximize its efficiency.

    The Steel Projects core technical objective was to

    facilitate access to energy-efficient technologies (EETs)

    for steel re-rolling mills (SRRMs). The report surveyed

    SRRM units across clusters, observing technology and

    production processes and identifying opportunities for

    EET interventions. The report stated that SRRMs in

    India are typically of two types, each having its own

    technical specifications. Bar mills are ingot-/ billet-based

    rolling mills, with a typical capacity of 50100 tonnes

    per day (TPD). They are equipped with a roughing mill

    an intermediate mill, a finishing mill, rotary shearing,

    repeaters, and a thermo-mechanically treated (TMT) line

    with a cooling system (i.e., TMT cooling line, hot water

    pump, cold water pump, pinch roll, controls, and DC

    motors). the SRRM sector.

    The focus of energy-efficiency initiatives in India has

    been limited mostly to the large industries. There has

    been little progress in creating an energy-efficiency

    culture among the thousands of small and medium

    enterprises (SMEs) dotting the industrial landscape, even

    though it is an acknowledged fact that the nation can

    achieve tremendous energy savings through

    interventions in the SME sector (defined as enterprises

    with a cumulative investment of between ` 2.5 million to

    ` 100 million in the Indian context.

    The steel re-rolling mill (SRRM) sector too has largely

    been overlooked, with most energy-efficiency

    interventions in the steel sector being limited to the large

    integrated steel plants. The performance of the Indian

    SRRM sector on key energy-efficiency parameters was

    far from optimum. When compared with global SRRMs,

    it was found that re-rolling mills in India tend to

    consume up to 1.8 times more fuel oil than their foreign

    counterparts. Where coal is used instead of fuel oil, the

    difference is as much as three times


    Current Design & Operating Practice In Steel Rerolling

    Mills was observed that most of the rerolling mills are

    manually operated with least measurement and

    monitoring equipment. All the mills have batch type

    operation methodology and operated for 8-10 hours.

    Reheating furnaces are operated for 12-14 hours

    including preheating time of 3-4 hours. In most of the

    rolling mills firing in furnaces are stopped at around 5-

    6.00 pm and firing is restarted at around 4-5.00 am.

    While shutting down the furnace all the openings of

    furnace are closed loosely and one opening in the flue

    tunnel is kept open. Most of the furnaces are constructed

    based on the similar furnaces in nearby industry or as

    advised by local designers without proper drawing or

    consideration of thermal heat balance.

    The location of burners is also not placed at technically

    suitable locations resulting in uneven temperature

    distribution in the furnace. Due to this most of the

    heating is done in the soaking zone only resulting in

    uneven soaking, more burning loss and more heat loss.

    Heat recovery system/equipments installed are not

    effective in most of the furnaces. Flue gas analyser to

    indicate partial/complete combustion is also not

    generally installed. Refractory in the furnace are

    provided by hunch without consideration of thermal

    requirement resulting in either more heat loss from the

    furnace all and roof or damage to the refractories.

    Pollution control equipments installed in the flue gas

    circuit is not integrated scientifically

    Photo UNDP India

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    Steel Re Rolling Mills Association of India

    Proposed measures for improving energy efficiency in

    steel rerolling sectors Generally the rerolling mill

    industrialists are very innovative and enthusiastic to

    accept low cost changes and install facilities with

    immediate results. They need proper technical guideline

    and specifications only. In SME sector there is

    considerable scope of improvement in energy efficiency

    as short term measure with least time and cost

    involvement. Some of the measures are indicated below

    :- Immediate measures/standard operating practices :

    1. While shutting down the furnace all the openings of

    furnace are to be closed properly closed and damper in

    the flue tunnel just outside the furnace to be closed and

    one opening after the damper is to be kept open. This

    will reduce ingress of the air drastically into the furnace

    after shutting down. 2. Basic instrumentation equipment

    for measuring parameters of fuel oil and air pressure and

    temperature to be maintained in the working condition

    and monitored regularly. 3. Production to be planned in

    advance to avoid delay. Further same type of material to

    be charged at a time. Mixed charging to be avoided.

    Furnace pressure to be maintained not more than 1-

    1.5mm WC.

    4. Charge to be heated in heating zone and soaking

    zone burners should be used for soaking of the charge

    for making the temperature distribution uniform with

    minimum temperature difference with core. 5 Use of

    skilled manpower and maintaining of standard operating

    practices. Skilled manpower pool may be created by

    giving proper training to the operators by experts This

    will help in energy saving of around 3-5 percent and

    burning loss will also be reduced.

    Short Term Measures Zone temperature, air fuel ratio &

    furnace pressure control It is recommended to operate

    furnace with following control system - Zone

    temperature control for individual zones - Air/fuel oil

    ratio control for individual zones - Furnace pressure

    control - Air and fuel oil flow measurement - Oxygen

    content in flue gases control - Local gauges as per

    requirement for monitoring Variable Speed Drive For

    Combustion Air Blower VVVF type AC drive controller

    shall be introduced for blowers. This will help to

    regulate the speed depending upon the requirement of

    combustion air at the varying furnace demand or during

    break-down in mill or during mill setting or low load

    conditions. [source steelworld]

    High Efficiency Recuperator For Preheating Combustion

    Air Properly designed waste heat recovery recuperator

    is recommended for preheating combustion air to about

    300 degree C for both heating zone and soaking zone

    burners. The present air preheat temperature is only 0-

    180 degree C. Energy Efficient Burners And Atomizing

    Blowers The existing burner capacity needs to be

    rechecked and recommended to replace these burners

    with energy efficient burners. Also, a separate blower

    shall be provided for atomizing the fuel. This will help

    in energy saving of around 5-10 percent and burning loss

    will also be reduced 1.5 to 0.5 percent. Long Term

    Measures Long term measures like replacement of

    existing reheating furnaces with modern design furnaces

    having oxyfuel burners/recuperative burners will further

    reduce the energy consumption to optimum level.

    There is vast scope of improving energy efficiency of

    rerolling mills in India. Industrialists are innovative and

    ready to accept the changes which give them immediate

    savings and results with least investment. The help they

    need is technical specifications, standard operating

    methodology and training to their manpower by experts

    in this field. At the same time they need technical as well

    as monitory support.

    Regenerative Burners for Reheating Furnaces - A

    regenerative burner is a heat recovery system that

    recovers the waste heat of the furnace exhaust gas to

    heat-up the combustion air of the furnace. The

    regenerative burner use...


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