Green Steel initiative

Action Plan for FY 2024 – 25 and beyond

for Sustainability focus on SEC and carbon 1
emission reduction
 GSI

Energy (To reduce SEC) Carbon Emissions (To reduce

CO2)
 BEE gives targets
 Mandatory compliance  BEE will start giving
with targets targets from FY 25
 For FY 24-25, Target 7.654 compliance of which will
Gcal/tcs become mandatory.
 Mandatory M & V audit in  FY 23—24, CO2 emission :
FY 25-26 3.583 T/TCS (As per BEE
 SEC (FY 23-24) : 8.21 calculation)
Gcal/TCS,  Baseline audit from BEE
 Monetary Implications by Dec’24.
Involved  Impact on Business
2
 Specific Energy Target (PAT-VII) (Gcal/ tcs)
9

8.57
8.5
8.21
8.06 8.12
8.02 7.98 Target
8 7.88
7.65
7.5

6.5

6
2018-19 2019-20 2020-21 2021-22 2022-23 2023-24 June'24 2024-25

Base Line
Cooling period PAT # VII
3
 Cost implication in non-compliance against PAT # 7
Sr. Particulars Values Remarks
1 Baseline Production (Ton) 29,97,087 Yr 18-19
2 Baseline SEC (Gcal/tCS) 8.058 Yr 18-19
3 Target SEC(Gcal/tCS) 7.654 Yr24-25
4 SEC 23-24 (Gcal/tCS) 8.25 Add value as per BEE
5 SEC June’24 (Gcal/tCS) 8.57
6 Target reduction (Gcal/tCS) 8.058-7.654= 0.408 5% Reduction
7 Difference from target wrt to
8.57-7.654= 0.916 11.9 % Reduction
current SEC, Gcal/tcs
8 Difference from target wrt to 29,97,087*0.916 = Baseline production of
current SEC, Gcal 27,45,332 Fy 18-19
9 Equivalent MTOE 2,74,332 1 MTOE = 10 Gcal
10 21650 (Actual will depend Rs/MTOE (Govt
Cost of Escerts
on Trading Price) Notification Dec-23)
11 Estimated cost of Escerts, Rs
593.9 @ 21650 Rs/Ecerts
Cr
12 At last trading price of Escerts
59.39 Rs 2165 is floor price
(2165 Rs), Rs Cr
The floor price of next PAT cycle could be higher than 2165 Rs.
 Department wise SEC (Gcal/tp)

2023-24 (Gcal/tp)

11.670
3.942

2.542

1.770
1.506

1.235
1.169

1.162

0.802

0.714

0.703
0.576

0.394

0.277

0.101
0.011
COP SP LDP BF DRI SMS RM PM BSM Boile Boile Powe Powe oxy- PGP SAF Ex- Aux
r r r r gen tru- &
RGH) (DCPP) (RGH) (DCPP) sion loss

2023 1.506 0.576 1.169 3.942 2.542 1.162 1.235 0.802 0.714 - - 1.770 0.703 0.011 0.394 11.67 0.277 0.101

-0.108
-24 0.240 0.108 0

-0.240
(G-
cal/
tp)

5
 Department wise SEC (Gcal/tcs)

2023-24 (Gcal/tcs)

2.72

1.16
1.02

0.79

0.66
0.40
0.33

0.30
0.24
0.23

0.22
0.18
0.11

0.11

0.10

0.06
0.04

0.04
0.04

0.02

0.01
0.00
COP SP LDP BF DRI SMS RM PM BSM Boil Boil Pow Pow oxy PGP SAF Ex- Aux Pel- Pel- DRI pan- Calc BF
er er er er gen tru- & let let (SM ther lime cok
RGH (D- (RG (D- sion loss (DRI (BF) S) shot - e
) CPP) H) CPP) ) (SM dolo (BF)
S) (SM
S)

-0.23
2023 0.33 0.40 0.11 2.72 1.02 1.16 0.23 0.24 0.11 - - 0.79 0.66 0.00 0.04 0.18 0.02 0.10 0.30 0.22 0.04 0.04 0.01 0.06

-0.31
-24 0.23 0.31
(G-
cal/
tcs)

6
 CO2 Emission (tCO2/tp) for FY 23-24
Coke Extrusio
Oven Sinter Purchase Upstream (tCO2/t)
n
(1.308) (0.427) Coke 0.224
(0.182) DRI 1.283
Pellet 0.137
Lime 1.1
Pig Iron 2.027

Blast DRI
Oxyge Furnace (1.434)
n Plant (1.086)
(0.715)
PGP
SMS
MILLS (-
SAF (0.648)
0.089)
(6.177)

LDP PLATE SPECIAL

RAIL
(1.736) (0.352 PROFILE
(1.101)
) (0.256)
Auxiliary &
Losses
7
(0.064)
 CO2 Emission (tCO2/tcs) for FY 23-24
Coke
Oven Sinter Extrusio
(0.28) (0.3) n (0.01)

Blast DRI
Oxyge Furnace (0.59)
n Plant (0.75)
(0.08)
PGP
SMS
MILLS (-
SAF (0.65)
0.01)
(0.1)

LDP SPECIAL
RAIL PLATE
(0.17) PROFILE
(0.21) (0.11)
(0.04)
Auxiliary &
Losses Total (tCO2/tcs ) – 8
(0.06) (3.33)
 SEC and CO2 Reduction Roadmap Summary (Short Term), JSP-Raigarh

Target Reduction For FY

SEC Reduction Plan 24-25
Reduction in SEC Reduction Savings
Gcal/tcs in CO2
Sr. No Initiatives upto 2025 (Based on 3.0 MTPA, tCO2/tcs estimat
Remarks
Prdn of baseline year (Based on 3 ed, Rs
18-19) MTPA) Cr/Year

Techo economics
1 By making additional 20% of liquid steel by scrap route in place of DRI 1.1 0.42 worked out.

Pellet with 1% low

2 Low Silica (1%) Pellet for DRI with consequent increase in FeT 0.14 0.074 150 SiO2 may attract
premium
Thermax study report
3 Maximum utilization of Coke Oven Flue gas for power generation 0.021 0.009 6.45 to be shared.
0.5% increase in Yield in SMS by process optimization, slag management, Fe recovery,
4
charge mix 0.04 0.018 70 Process improvement

Investment on Coal
5 To reduce 4% Moisture in DRI Feed Coal 0.02 0.009 4 Dryer

Process improvement
6 Potential reduction in mill scale in Mills by 0.2% 0.01 0.006 24.7

Process improvement
7 Potential savings by optimizing 1% of End Cuttings of rolled products. 0.01 0.0271 50
Experimental study to
8 Oxygen enrichment of combustion air for maximum utilization in RHF be done.

9 Exploring potential of Hot charging billets/blooms/Slabs in RHF of Mills

For FY 24-25, next 7

Reduction up to 2025 1.33 0.58 months SEC
9 achieved
will be 0.327
 CO2 Reduction Roadmap Summary(Medium and Long Term), JSP-Raigarh

Reduction in SEC
Gcal/tcs Reduction in CO2 Savings
Sr. No Initiatives in Medium and Long Term by 2030 (Based on 3.0 tCO2/tcs (Based on estimated, Remarks
MTPA, Prdn of base 3 MTPA) Rs Cr/Year
line year

1 340 MW power generation (2000 MW installed ) through 2.981 1.14 At corporate level
renewable energy (Solar, Wind)
New Recovery Coke Oven vertical with CDQ (Coke Dry Calculation based
2 Quenching) - 1.1 MT
0.142 0.05 only on CDQ

Utilization of surplus BF gas through BF Gas Holder to replace Oil Decision to be

3 in RHF (with oxygen enrichment)
0.074 0.08 taken as per
expansion plan
Heat Recovery and power generation from waste gases of EAF
4 (SMS-3)
0.033 0.008
Heat recovery from waste Flue gases by Steam Generation in RHF Project being
5 of Plate Mill
0.033 0.008 executed.
Decision to be
6 Reduction in 40 kg/thm of PCI in BF by using NG 0.030 0.05 taken (NG Pipeline)

7 Installation of top recovery turbines in BF #2 0.029 0.01 9.4 Decision to be

taken
13MWp Solar panel at various roof tops and other locations of 6.5 NFA initiated but
8 JSP, Raigarh
0.019 0.007 rejected
Installation of Solar panel at Roof top of Rail forging plant (800 0.38 Project being
9 KW Solar Power Generation)
0.001 0.0004 executed.

10 Natural Gas based/Syn Gas based DRI of 2.0 mt capacity

10
Reduction by 2030 3.345 1.35
 CO2 Reduction Roadmap Summary, JSP-Raigarh

Reduction in SEC
Gcal/tcs Reduction in CO2 Savings
Sr. No Initiatives in Medium and Long Term by 2030 (Based on 3.0 tCO2/tcs (Based on estimated, Remarks
MTPA, Prdn of base 3 MTPA) Rs Cr/Year
line year
Feasibility to be
11 Green Hydrogen based DRI explored
Feasibility to be
12 CO2 Capture and Storage explored
Feasibility to be
13 Use of Green Hydrogen in Blast Furnace explored

Feasibility to be
14 CO2 Capture and Utilization explored

11
 Effort to control Specific Energy Consumption and Carbon emissions
reduction : Immediate actions to be taken

# Action planned Strategy for execution

Maximizing utilization of Blast Furnace
1 Gas balancing. Surplus gas to be used in Mills and minimize/avoid other fuels. BF gas Holder required
Gas
Maximizing utilization of Coke Oven Minimize waste of Coke Oven Gas through Stack at about 900 deg C and maximize use in Power Plant. BF
2
Gas Gas currently used in Power Plant to be minimum. Surplus BFG from here to be used in Mills
Maximize the Yield in SMS with a Minimum target for increasing Yield is 0.5% through Slag management ( controlling slag weight and FeO
3
particular charge mix in Slag to optimum level), optimizing oxygen blowing,
By working out best combination of available charge for best productivity based on oxygen blowing
4 Improving Productivity in SMS
requirement and power available. A dynamic model to be evolved
By selection of proper raw material (low silica)for DRI production ( raw material prices are dynamic and
5 Additional overall improvement in SMS hence continuous watch on market prices). A well planned strategy needs to be evolved for Techno-
economic evaluation of raw materials
6 Maximizing Yield from Mills Considerable saving potential available in some areas of Mills. Most prominent is reduction in scale loss
Minimizing costly Fuel consumption in There is surplus BFG is available. More BFG can be made available by maximizing proper use of Coke
7
Reheating Furnaces of Mills Oven gas for Power generation.
Exploring potential of Hot charging of
8 Potential to be explored
Billets/ Blooms/Slabs in RHFs of Mills
This will reduce SEC and carbon emission significantly. Techno economics needs to work out considering
price, yield, power consumption, Flux requirement, productivity, refractory life vis-à-vis DRI. Considering
9 Use of more Scrap in SMS all factors Scrap may be cheaper with significant reduction in SEC and Carbon emission targets and
improving our ESG and earn a good name among various stakeholders, including investors, bankers. This
will also add value in exports and grabbing of orders like in NEOM Project.
Flue gases from RHFs in Mills are coming out at considerably higher temperatures with lot of sensible heat
which is wasted. Recuperators are installed to recover some of heat. But efficiency of recuperators needs
Minimizing waste heat from RHFs of
10 to be evaluated as Flue gases are still going at higher temperatures. Excessive consumption of BFG in Rail
Mills
Mill about 1000 Nm3/T, while in India itself the specific consumptions have been reported around 450
Nm3 and even less

12
 Effort to control Specific Energy Consumption and
Carbon emissions reduction : Medium and Long Term
Plans
# Action planned Strategy for execution
Life of our existing CO Batteries may be about 3 more years. We can
Vertical Coke Oven further run for extended period, but maintenance cost could be higher
1 Batteries with Dry with aging of these Batteries. We have to prepare ourselves for Long
quenching term and hence plan for Vertical Coke Oven Batteries with Dry
quenching.
Since Natural gas pipeline is planned with in one year, it is preferred to
2 Natural Gas based DRI go for it. In future, when Hydrogen is available commercially at
affordable prices, Natural Gas based DRI can be replaced by Hydrogen.
CO2 in Angul Plant is separated from Syn gas and from waste gas
coming out from DRI shaft. Huge amount of CO2 is available, which is
Carbon capture and
3 released into atmosphere as of now. This CO2 can be used for
Utilization
conversion to chemicals like methanol, ethanol and other chemicals. We
should start working on this from now and take a lead role.

4 Renewable Energy It is understood, more than 1 GW of Solar Power is planned at Rajasthan.

Considerable amount of sensible heat is wasted in off gases. Although

Use of Sensible Heat in the gas generation is not on continuous basis, still the sensible heat can
5
waste gas form NOF, EAF be recovered by use of accumulators. A promising area since we have
3.6 million tonne production by this route
13
 Green Steel Making Technologies

# Technologies Description
Involves using biomass (such as wood or other organic waste) to
Bioenergy-based Steel
1 produce bio-coke or other reducing agents, lowering the carbon
Production
footprint compared to traditional coke-based methods.
- Uses pure oxygen instead of air for combustion, producing
2 Oxy-Fuel Combustion exhaust gases with a higher concentration of CO2, making it easier
to capture and process.

14
 Improvements Required in SAP booking
Plant Subject
DRIQ 1. CTO to be increased to avoid booking of sponge iron in accretion. It impacts material balance &
requirement of BEE
2.Char generation should not be booked in name of micro fines
BF Nut coke & coke fines generated from purchased coke should have separate SAP code & booking
to be maintained. It impacts material balance & requirement of BEE. Coke fines generated from
purchased coke & its consumption should have separate sap code

Gas facility 1.BF gas booking in SAP should match with balance report provided by gas facility department

QC 1. Proximate analysis & GCV of all byproducts (DC dust, DSC dust, FES dust, ABC dust, Char,
settling pond coke fines to be maintained in SAP
2. All the proximate analysis & GCV should be in AR (As Received) basis & be booked in SAP in AR
basis also to help to automate CO2 emission from SAP platform

15
 Roadmap for CO2 reduction for FY 24-25
and Beyond
4
3.58 3.26 3.25
3.5

3 With 15%
additional Max. use 2.31 2.23
of CO • CCUS
2.5 scrap in
waste • Green
steel making Hydrogen
2 gas to PP RE ( Solar, Wind)
Gas Holder • Projects
1.5

0.5

0
23-24 24-25 25-26 26-27 27-28 By 2047

tCO2/tcs

Note : 3.58 tCO2/tcs value is as per BEE (Bureau of Energy Efficiency ) 16

calculation sheet
 Roadmap for SEC reduction for FY 24-25
and Beyond

Gcal/tcs With 15%

additional
8.6
scrap in
8.43 8.43 steel making
8.4
8.21
8.2

7.8
7.65 7.61
7.6

7.4

7.2
23-24 Q1 (24-25) Q2 (24-25) Target Projected Result

17
# Projects Evaluation Consideration

Renewable
1 Use of 280 MW of RE power at Raigarh location
Energy

SEC and CO2 calculations are based on current BF

2 Gas Holder
gas flaring

18
Thank You!

19