Implementation of a Demonstration Project for Adopting Regenerative Burner Technology in India
－Estimated Annual Reduction in CO2 Emissions is 6,000 Tons－
April 28, 2016
New Energy and Industrial Technology Development Organization (NEDO)
NEDO has agreed with India’s Ministry of Steel (MOS); Ministry of Finance, Department of Economic Affairs (MOF/DEA); and the Steel Authority of India Limited (SAIL) to implement a demonstration project on a high-performance industrial furnace. The parties signed a memorandum of understanding on April 28, 2016. The purpose of the project is to utilize a regenerative burner in a reheating furnace in India as an energy-saving technology which will serve as a countermeasure against a rapid increase in energy demand. NEDO estimates that the demonstration project will reduce the annual energy consumption and CO2 emissions of a steel plant by 2.1 million liters heavy oil equivalent and 6,000 tons.
In India, rapid economic development has led to a surge in energy demand, and there is an urgent need to address energy and environmental problems. As a result, there is growing interest in adopting energy-saving technology being utilized in advanced countries.
Japan and India are making efforts to improve their cooperation in the energy sector. At the ministry level, the two countries are discussing energy-saving policies through the Japan-India Energy Dialogue. In addition, the Public and Private Collaborative Meeting between Indian and Japanese Iron and Steel Industry is being led by the Ministry of Economy, Trade and Industry.
In the 1990s, regenerative burners were jointly developed by Japan’s industrial furnace and burner manufacturers and heating furnace users with the support of the Ministry of International Trade and Industry (now the Ministry of Economy, Trade and Industry) and NEDO. Regenerative burners have thus been adopted for use in various kinds of industrial furnaces in Japan.
Because of Japan’s experience in this area, NEDO agreed with India’s Ministry of Steel, Ministry of Finance, and the Steel Authority of India Limited (SAIL) to implement a project to demonstrate a high-performance industrial furnace, and the parties signed a memorandum of understanding on April 28, 2016. Japan’s technology for regenerative burners will be promoted and disseminated throughout India as the production of crude steel and automobiles expands.
Over the next two years, construction work will be completed to revamp the existing heating furnace at the project site* located at SAIL’s Rourkela Steel Plant (RSP) in the state of Odisha. It is expected that after the installation of regenerative burners, annual energy consumption and CO2 emissions will be reduced by about 2.1 million liters heavy oil equivalent and 6,000 tons when producing one million tons of steel.
The energy-saving effect of the project will allow RSP to serve as a showcase for adopting new technology. It will also improve the global energy demand and supply balance by promoting large-scale energy-saving technology, such as utilizing regenerative burners in India’s steel industry.
2．Operation Principle of Regenerative Burner
Compared to the existing heating furnace, fuel efficiency will increase by about 30%, and compared to the existing waste heat recovery system using a recuperator (a metallic heat exchanger), an additional 10% in energy savings will be achieved. At the same time, it will be possible to achieve about a 50% reduction in NOx emissions, which contribute to global warming and are harmful to the human body.
The regenerative burner to be used has a built-in heat accumulator consisting of a pair of burners. The two burners fire alternately. For example, when one burner fires, the other one absorbs exhaust gas and releases it through the heat accumulator. The heat accumulator stores the heat using sensible heat from the exhaust gas. The combustion and exhaust processes of the burners then alternate. Combustion air will be supplied through the accumulator being preheated by the high-temperature accumulator.
Fig. 1 Operation Principle of Regenerative Burner
3．Revamping Existing Heating Furnace
At one of RSP’s plate making facilities, heat recovery is achieved using a recuperator (air preheated by a metallic heat exchanger) in the existing slab reheating furnace. As upper burners in the preheating zone and burners in heating zones No. 1 and No. 2 consume more fuel due to their high-intensity combustion, they will be changed to regenerative burners (24 burner sets in the three upper zones will be removed and 12 pairs of regenerative burners will be installed) in order to save more energy.
Fig. 2 Revamping of Existing Reheating Furnace
Rourkela Steel Plant of SAIL in Odisha State
Blast Furnace: 4.46 million tons, Units: 5
Hot Rolling Facility: 1 (2 heating furnaces)
Plate Making Facilities: 2
The demonstration project will be carried out at one of the plate making facilities.
4．For more information, please contact;
NEDO Energy Conservation Technology Department, Tel: +81-44-520-5284
NEDO International Affairs Department, Tel: +81-44-520-5190