Energy Conservation for thePhilippine Steel and IronIndustries: Case Studies
Loreto C. Carasi
Philippine Council for Industry and Energy
Research and Development
Department of Science and Technology

17 November 2006
Twin Tower Hotel, Thailand

OUTLINE About DOST/PCIERD
 PCIERD EE & C Initiatives
 EE&C for the Philippine Steel and Iron Industry
 Conclusion

DEPARTMENT OF SCIENCEAND TECHNOLOGY (DOST)
Premier science and technology bodyzMandates:
zCentral direction, leadership & coordinationz Policy, program & project formulationz Councils, R&D Institutes, Service Institutes,
Regional Officesz

DOST Sectoral Planning Councils
Philippine Council for Industryand Energy Research andDevelopment (PCIERD)
Philippine Council for Agriculture,
Forestry and Natural Resources
Research and Development (PCARRD)
Philippine Council for Aquatic andMarine Research and Development(PCAMRD)
Philippine Council for Advanced Scienceand Technology Research andDevelopment (PCASTRD)
Philippine Council for Health Researchand Development (PCHRD)

z R&D
z INSTITUTION

BUILDINGz MANPOWER

DEV’T ANDSCHOLARSHIPz SEMINARS AND

CONFERENCESz TECHNOLOGY

TRANSFERz POLICYDIRECTIONSPCIERD Mandates
Industry & energy policies, strategies,
plans and programs

Fund programming & allocationProject & program monitoringExternal fund generation

Services Offered by PCIERD
 Provides Grants-in-Aid (GIA) Grants applied S&T scholarships
 Disseminates & promotes S&Tinformation
 Supports scientific & technologicalservices

SECTORAL COVERAGEFOOD & FEED PROCESS /CHEMICAL TEXTILE AND GARMENTS MINING & MINERALS METALS & ENGINEERING ENERGY TRANSPORTATION
 CONSTRUCTION
 ENVIRONMEN DISASTER AND MANAGEMENTPCIERD EE & C Initiatives
Capacity Building

Establish Core of Experts in the RegionFactory Energy Audit on SMEs

GAP Funded

PCIERD Funded

Infrastructure Support

Provision of equipment

Policy SupportReport to DOE the DOST’s Energy Savings

Establishment of Vehicle Research and TestingFacility

Promotion of Biofuels

EE & C for the Philippine Steel and Iron
IndustryzObjectives of the program:z To provide technological exchange of information andexpertisez To conduct human resources developmentz To conduct energy audit and technical assessment onthe selected industries
z To establish network and linkages among the localand Japanese industries

Company AProductszPlain and deformed steel bars and rods for concrete
reinforcement

Production capacityz

250,000MT per year

Total Energy consumption per yearzElectricityzz

25 Mw-hrFuelsz

9,500 Kilioliters

Number of employeesz147

Locationz

Metro Manila

Furnace(1) Air Temp
To burner(7) Surface Temp
(3) Flue Gas Loss
(8) Burner(2) Recuperator(4) Flame Loss
(6) Discharging Operation(5) Induce Air

Findings:
1. Preheated Air : Defective instrument to grasp the preheated air temperature
2. Recuperator: Defective recuperator tubes
3. Waste Gas Loss: Temperature of outlet is 798 oC% Oxygen in flue gas is 3.8%
4. Heat Loss from Charging Door: Temp. of gas from charging door is 691 oC
Open space is measured at 0.92 m2
5. Induced Air from Discharging Door: Amount of air is 4,900 m3 per hr
6. Discharging Operation: No problem
7. Heat Loss from Surface: Temperature of furnace shell external surfaces(roof and side walls) is 90-100oC
7. Burner: Straight type burners is used

Cooling System (Pumps)
 Skid Furnace
 Operates well Mill Motor loading is low Quench Motor loading is low

Compressors
 Loading and Unloading time : Ok
 Load requirements vs. Delivery capacity: Ok
 Discharge Pressure vs. Required Pressure atthe User Side : Decrease the dischargepressure gradually Leakage Along Supply Line Draining of MoistureImplemented Measures
Furnace:z

Instrument wirings on the control panel were modified to getreadings of pre-heated airz

Repair of recuperator to eliminate air leakagezInstallation of “heat curtain” at the charging door of furnace
to minimized heat loss (Later replaced with sliding-platetype)z

Reduction of induced air from discharging doorz

Improvement of burner combustion efficiencyz

Minimizing heat loss from furnacez

Improvement of furnace data monitoringImplemented Measures
Pumps/Blowers:z

Improvement of combustion blower motor loadingz The 100 HP motor for combustion blower was replaced with a75 HP motor. The motor loading was increased from 70% to95%.

z

Repair of Rolling Mill Circulating Pumpz The impeller was replaced and the seal ring was repaired.
Motor loading was increased from 70% to 95%.

Air Compressors:z

Minimized air leakage in the systemz Conduct leak test for the air supply
z Correction of air leakages in the system is a continuing
programMill bay LightingzUsed/installed skylights at strategic locations inside the mill toenhance illumination.

Fuel and Power Consumption Trends
PowerElectricity
108

50

106
45

104

40
35

102

30

100

25
20

98

15

96
10

94

5092
2001

2002

2003

2004

2005

2001

2002

2003

2004

2001

2002

2003

2004

2005

Fuel, Lit/ton

45.88

45.77

42.9

39.26

36.51

Power, Kw-hr/ton

97.22

98.28

106.58104.04

98.87

2005

Amount of Energy (2004)
Energy Savings
Particular%
8.48

Savings (Peso)
4.167 MKw-hr/ton%
Reduction in Power
2.54
2.38
TOTAL ENERGY SAVINGS

Savings (Peso)
1.418 M

Reduction in Fuel

Lit/ton
3.64

5.585 M

Amount of Energy (2005)

Particular
Reduction in Fuel

Energy Savings
Lit/ton% Savings (Peso)
2.75
7.0
3.4M

Kw-hr/ton% Savings (Peso)
Reduction in Power
5.17
4.97
2.8 M
TOTAL ENERGY SAVINGS
6.2M

PlansLengthen the heating zone of the furnace to reduce fluegas temperaturez Additional insulation on the furnace shell outside
surfacesz Use of inverter control for the TTL process pumps
z Replacement of straight-type burners to swirl typeburnersz Close Monitoring of plant power factor to ensure PF isalways at its optimumz Recycling of used oil and greasez Provision of pneumatic lubricatorz Continue the checking/repair of air leakages in the plantz

Company BProductszDeformed bars

Production Capacityz

121,337.22 MT per year

Annual Energy Consumption (average)zz

Electricity = 13.4 MWH
Fuels = 4,114 kiloliters

Number of Employees
z185

LocationzMetro Manila

Furnace(1) Air Temp
To burner(7) Surface Temp
(3) Flue Gas Loss
(8) Burner(2) Recuperator(4) Flame Loss
(6) Discharging Operation(5) Induce AirFindings:
1. Preheated Air Temp : Low @ 224oC
2. Recuperator: Check leakage
3. Waste Gas Loss: Waste gas temperature at recuperatror inlet is quite low at 665oC
4. Heat Loss from Charging Door: Temp. of gas from charging door is 680 oC
Open space is measured at 0.92 m2
5. Induced Air from Discharging Door: Amount of air is 1,100 m3 per hr
6. Discharging Operation: 2-3 billets are discharged together, and the 2nd and 3rd billetscannot be rolled coz its temp. has lowered and thus require
further heating
7. Heat Loss from Surface: Temperature of furnace shell external surfaces(Ceiling: 100-130, Side: 85-95oC
8. Burner: Straight type burners is used
9. Furnace Scale Generation: The ave. concentration for waste gas oxygen concentrationis 1.7%

Implemented Measuresz Replacement of existing recuperatorz Installation of insulation curtain at the inlet door of thefurnacez Reduce opening time of billet discharge doorz Reduction of waste gas oxygen concentration from 1.7%
to 1.3%z Raising the furnace pressure settingz Optimization of Billet Reheating Furnace
z Application of cladding insulation on the oil pipe lines
z Increase setting of oil heaters at the main line (soakingand heating zone) from 90oC to 110oC
z Set-up energy conservation group

Fuel and Power Consumption Trends
Electricity

Power40
3530
25
20
15
10
5
0

109.5
109
108.5
108
107.5
107
2003

2004

2003

2005

2004

2003

2004

2005

Fuel, Lit/ton

36.39

33.45

30

Power, Kw-hr/ton

109.19108.56108

2005

Amount of Energy (2004)
Energy Savings
Particular%
8.08

Savings (Peso)
4.206MKw-hr/ton%
Reduction in Power
0.63
0.51
TOTAL ENERGY SAVINGS

Savings (Peso)
0.444M

Reduction in Fuel

Lit/ton
2.94

4.65 M

Amount of Energy (2005)

Particular
Reduction in Fuel

Energy Savings
Lit/ton%
Savings(Peso)
3.45
10.31
5.074M
Kw-hr/ton%

Reduction in Power
0.56
0.52
TOTAL ENERGY SAVINGS

Savings(Peso)
0.377 M

5.451M

Plansz BRF heat conservation (charging and dischargingside)z BRF waste gas temperature monitor and control
z Use of stand alone electric furnace in preheating predetermined steelz Demand KW monitor and control
z Make-up water volume monitor and control
z Compressed air leakage monitor and control

Company CProductsz

Galvanized and Pre-painted Sheets/Coils

Production capacity per year (average)z

Continuous Galvanizing Line (CGL)zz34,703 tons

Color Coating Line (CCL)z

27,588 tons

Total Energy Consumption (average)zElectricityz

CGLz

z

1,058 MWh per year

CCLz

845 MWh per yearTotal Energy Consumption (average)z

Fuel consumption per yearz

CGL

Fuel Oil:577,728 litersz LPG: 256,513 kgs.
zzCCLz

LPG: 492,170 kgs.

No. of employees
z170Location
zLagunaPower and Electricity Consumption Trend
Continuous Galvanizing Line (CGL)

2003

2004

Energy Consumption
BFO/SFO, Liters
LPG, Kgs
Power, Kw-hr

625,497
290,349
1,196,234

529,959
222,678
920,634

Rate of Consumption
BFO/SFO, Lit/ton
LPG, Kg/ton
Power, Kw-hr/ton

17.1727.971
32.841

16.0696.752
27.914

Power and Electricity Consumption Trend

Color Coating Line (CCL)
2003

2004

Energy Consumption
LPG, Kgs
Power, Kw-hr

576,477
954,965

407,863734,896

Rate of Consumption
LPG, Kg/ton
Power, Kw-hr/ton

19.10631.65016.31329.393

Particulars
Reduction in Fuel

Energy Savings
Kgs. per ton ofproduct% Savings

Savings (Peso)

LPG
zCGL
zCCL

1.219
2.793

15.3
14.6

1.327 M
2.304 M

60.654 M

157.1

1.075 M
0.305 M

Lits. per ton ofproductBunker Oil
zCGL

1.103
KW-hr/ton

Reduction inPower
zCGL
zCCL

4.927
2.257

TOTAL

5.665 M

Implemented Measures
System Improvementz Improved treading time from 5-6 minutes to 3 minutes
z Installation of cartridge type coaters to reduce
downtime in changing colors and replacing paint coaterrolls
z Installation of 12.5 MT overhead crane to handle bigger
coil materials
z Installation of horizontal direct fired LPG preheaterz Change technology from zinc lead-lead-zinc hot dip
galvanizing to a modified John Lysaght processz Installation o direct fired LPG coil heaterz Conduct study on peak kW
z Reduced demand at CGL furnacez Reduced demand at CCL ovenz Improvement of power factor from 81% to 94%
z Improvement of light distribution at CCLzPlansz Decommission boiler using BFOz Shift of fuel materials from BFO to SFO
z Improve burner firing at LPG preheaterz Decommission air dryers, exhaust gas from LPG

direct fired alkali heaters used as air dryers
z Decommission smoothener rolls drive of 7.5kW
z Waste heat recovery at LPG heaters and dryers
z Conduct efficiency tests in ovens and furnaces fortemperature profiling

Common measures implemented
Minimizing heat loss from furnace
z Improvement of burner efficiency
z Improvement of pump motor loadingz Minimized compressed air leakage
zCommon plans
Heat conservation on the reheating furnacez Waste gas temperature monitor and control
z Demand kW monitor and control
z Make-up water volume monitor and control
z Compressed air leakage monitor and controlzConclusion
The participating factories shows positive response.
zz

Recommended measures or areas of improvement suggestedby the experts have been implemented and it was reported that
there was a great improvement in plant efficiency andsignificant savings was realized.
Local skills were enhanced and they can now do energy audit
by their own.

The significance of Energy Conservation and Management
has been recognized, which is evident to their new initiatives.
zzz

Setting-up of company’s energy conservation targets
Creation of energy managers and auditors
Energy conservation are discussed during management
meetings

PCIERD Website
http://www.pcierd.dost.gov.ph