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TOWARDS AN ENERGY EFFICIENT NATION

TOWARDS AN ENERGY EFFICIENT NATION. ISO 9001 INSTITUTION. Emerging steel markets and their impact on coking coal and coke. Dr. Kalyan Sen CFRI. TOWARDS AN ENERGY EFFICIENT NATION. ISO 9001 INSTITUTION.

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TOWARDS AN ENERGY EFFICIENT NATION

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  1. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Emerging steel markets and their impact on coking coal and coke. Dr. Kalyan Sen CFRI

  2. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION India Govt. thrust on infrastructure projects, lower interest rates, booming economy: The steel production is expected to grow at rapid pace. The buoyancy in Indian steel market is a combination of demand for exports, mainly to China and a positive outlook in certain sectors. This will lead to increased demand of good quality coking coal and Low ash metallurgical (LAM) coke.

  3. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Estimated Demand of Met Coke • By 2011-12 India would require 31 million tonnes (mt) • 12.5 mt produced & consumed by main producers • 18.5 mt will be required by secondary steel producers out of which 14 mt need to be produced by Merchant coke producers. 31 mt of coke is equivalent to ~ 44 mt of washed coking coal!! What are the supply sources ?

  4. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Fuel supply chain • Existing trend (2002-03) • Import of coke 2.245mt • Import of coking coal 12.947 mt • Washery Cleans ~ 8 mt

  5. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Fuel supply chain • Future projection (2011-12) • Import of coke 4.5mt • Washery cleans ~ 8 mt (The output of the existing washeries is likely to decline) • Import of coking coal 30 mt ? Considering steep increase in price of both coke & coking coal and their availability, the situation is rather gloomy

  6. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Constraints of price & availability Coke imports in india were 2,782mt in 02-03 out of which 89% was from China.. • Coke price rise • Explosion in coke demand in China • Large rise in Chinese coke production costs • Gradual erosion of coke capacity out side of China • The rise in coke price coupled with its unavailability has become the biggest challenge confronting the secondary sector pig iron industry

  7. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Coking coal having good coking properties, low sulphur and ash contents has become world wide a costly and rare commodity. • Additional global sources for long term availability • China & USA- envisaged increased production will mostly be consumed by the respective countries. • Indonesia - a meagre amount may be available • Russia - a lot , but requires major infrastructural investment

  8. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Scope for utilsation of Indigenous resources Area for Improvement Quality Quantity Cost Culture Optimisation

  9. Indian Coal Scenario: Total Coal Reserves 246 Bt TOWARDS AN ENERGY EFFICIENT NATION Others ISO 9001 INSTITUTION 6% Semi-coking 11% HVC 3.0% 15% MVC 13.0% 84.0% 50% LVC Coking Non- coking 19% Prime coking Inferior grade 68% GSI, Jan.2004

  10. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Imperatives for enhancing washed coal production • Renovation & modernisation of existing washeries to maximise the output at desired quality; with further deterioration of feed quality the washery output, in the absence of drastic modernisation programme , is going to decline. • Installation of fine coal treatment plant to treat the ‘waste’ slurries & the freshly generated fines to produce Cleans in the ash range 10-14%. • Installation of new washeries to treat the Low Volatile NLW coals (LVC coal, if prepared judiciously, has the potentiality to offer excellent quality coke)

  11. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION The challenge of minimising the import dependency on desired fuel can be met • by increasing the capacity of washed coal production, adoption of innovative coke making technology and PCI route. • by utilising abundantly available non-coking coal through adoptation of alternate routes of steel making

  12. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Characteristics of LVC(NLW) • High raw coal ash 35-45% • High Maturity Ro = 1.3 • Low volatile matter content 15-20% • High Inertinite content (60-70%) • Poor washability potential

  13. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Beneficiation in existing washeries • 2-product circuit • About 70-75% with 40-45% ash with no market outlet

  14. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Beneficiation in existing washeries • 3-product circuit • LVCC requires disposal of 20% as reject • 50% middling with 41% ash (outlet ?)

  15. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Coals of western Jharia coalfields need a different beneficiation strategy INTEGRATED MULTI-STREAM BENEFICIATION

  16. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION 4-Product Circuit • Cleans (25-30%), 17-18% ash • Cleans II (18-20%), 22-28% ash • Middlings (20-22%), 34% ash • Rejects (28-30%), 60-65% ash

  17. Suggested beneficiation scheme: TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION • Coal crushed to a nominal top size of 100/75 mm and screened at lower size, 25/20/13 mm • Coarser fraction ( oversize) treated in washing unit to produce POWER COAL (~ 34% ash) • Finer fraction (undersize) deep beneficiated for metallurgical coal of ash 17-18% • Combined rejects (ash 50-55%) sent to FBC boilers

  18. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION For a typical SR - process, Judicious beneficiation of available coal is a necessity

  19. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Beneficiation strategy Category I: Non-coking coal (ash 30-40%) Jigging Cleans 75-80% (ash 25%) Reject (ash 60-65%) (FBC boiler)

  20. Beneficiation strategy …... TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Category III: LVC coal (ash > 35%) 3-pdt Jig4-pdt washingUser Yld% (A%) Yld% (A%) Total Cls --- 24-27 (17-18) Steel Jig Cleans 50 (22-24) -- Corex Cleans II --- 18-20 (25-30) Corex** Middling 20-22 (34) 20-22 (33-35) Power Reject 28-30 (60-65) 25-30 (55-65) FBC

  21. Thank You

  22. TOWARDS AN ENERGY EFFICIENT NATION ISO 9001 INSTITUTION Scope for utilsation of Indigenous resources Area for Improvement Culture Quality Quantity Cost Optimisation

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