Table Of ContentEnergy Efficiency
and Conservation in
Metal Industries
Energy Efficiency
and Conservation in
Metal Industries
With Selected Cases of
Investment Grade Audit
Lt. Swapan Kumar Dutta
Jitendra Saxena
Binoy Krishna Choudhury
First edition published 2023
by CRC Press
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© 2023 Lt. Swapan Kumar Dutta, Jitendra Saxena and Binoy Krishna Choudhury
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ISBN: 978-0-367-74324-6 (hbk)
ISBN: 978-0-367-74327-7 (pbk)
ISBN: 978-1-003-15713-7 (ebk)
DOI: 10.1201/9781003157137
Typeset in Times LT Std
by Apex CoVantage, LLC
We seek blessings from our parents and the departed soul of
our senior- most member, the late Prof Swapan Kumar Dutta,
to whom we dedicate this book.
Contents
Preface.....................................................................................................................xiii
Acknowledgments ....................................................................................................xv
Authors ...................................................................................................................xvii
Chapter 1 Energy Efficiency and Conservation ....................................................1
1.1 Historical Perspective ................................................................1
1.2 Metal Industries: Local and Global Perspectives ......................1
1.3 Energy Conservation Global Imperatives .................................2
1.4 Energy Efficiency and Conservation: Future Trends
and Scope...................................................................................4
1.5 Energy Efficiency and Conservation Activities: Metal
Industries ...................................................................................6
1.5.1 Energy Efficiency, Conservation and Processes
of Steel Plants from an Indian Perspective ..................8
1.5.2 Discussion and Analysis ..............................................10
1.6 Conclusion ................................................................................11
References ..........................................................................................11
Websites ...................................................................................13
Chapter 2 EE&C Policy Considerations ..............................................................15
2.1 Energy, Environment, Economy and Society ...........................15
2.1.1 United We Progress, Divided We Regress ..................15
2.1.2 Social Evolution with Energy, Environment
and Economy ...............................................................17
2.2 EE&C and Sustainable Development .......................................18
2.2.1 Energy Trilemma ........................................................18
2.2.2 Challenges before Metal Industries ............................20
2.2.3 Overcoming Challenges before Metal Industries .......20
2.3 International Agreements and Protocols .................................27
2.3.1 Local to Global and Global to Local ..........................27
2.3.2 Objectives and Purposes of Selected
Agreements and Protocols ..........................................31
2.3.3 Countries’ Preparedness ..............................................32
2.4 National Policy Drivers ...........................................................34
2.4.1 Think Globally and Act Locally ................................34
2.4.2 Some Points to Ponder While Considering a
Regulatory Framework ...............................................38
2.4.2.1 Subsidy vs. Directives .................................38
2.4.2.2 Protection vs. Competition ..........................39
2.4.2.3 Negotiations vs. Restrictions .......................39
vii
viii Contents
2.4.2.4 Green Primary Metal Production vs.
Recycling .....................................................39
2.4.2.5 Total vs. Per Capita .....................................40
2.5 EE&C Policy Considerations: Tips on the Top ........................41
2.5.1 EE&C Policy Needs to be Technology Savvy ............41
2.5.2 EE&C Policy Needs to be Pragmatic ..........................42
2.5.3 EE&C Policy Needs to be Coherent ...........................45
2.5.4 EE&C Policy Needs to be Short- /Medium- /
Long- Term ...................................................................45
2.5.5 EE&C Policy Needs to be Evolving Yet Binding .......45
2.5.6 Suggestive Flow Chart for Preparation of an
Effective Policy for EE&C in Metal Industries ..........45
2.6 Concluding Remarks on EE&C Policy ....................................47
References ..........................................................................................48
Websites ...................................................................................49
Chapter 3 Energy Efficiency and Conservation Technologies .............................51
3.1 Introduction ..............................................................................51
3.2 Thermodynamics and EE .........................................................52
3.3 Going Beyond Thermodynamic Efficiency .............................56
3.4 Motor Systems ..........................................................................61
3.4.1 Existing Motors ...........................................................61
3.4.2 Motor Alignment .........................................................61
3.4.3 Sizing of Motors ..........................................................61
3.4.4 Use the Most Efficient Motor ......................................61
3.4.5 Maintenance Issues ....................................................63
3.4.6 Variable- Speed Drives ...............................................63
3.4.7 Motor Characteristics .................................................63
3.4.8 Power Factor ...............................................................63
3.4.9 Motor Efficiency and Field Test for
Determining Efficiency ..............................................64
3.4.10 No Load Test ..............................................................64
3.5 Electric Furnace Systems ........................................................65
3.5.1 Dust Vacuum Equipment ............................................66
3.5.2 Continuous Foundry Equipment ................................66
3.5.3 Heating Furnace .........................................................66
3.6 Furnace Systems ......................................................................68
3.7 EE&C in (Chemical) Unit Operations ......................................70
3.7.1 EE&C in (Chemical) Unit Operations in I&S
Industries .....................................................................71
3.7.1.1 EE&C in (Chemical) Unit Operations
in I&S Industries: Blast Furnace .................71
3.7.1.2 EE&C in (Chemical) Unit Operations
in I&S Industries: Sponge Iron Plant ...........73
Contents ix
3.7.1.3 EE&C in (Chemical) Unit Operations
in I&S Industries: Hot Strip Mill (HSM) ....74
3.7.2 EE&C in (Chemical) Unit Operations in the
Aluminum Industry .....................................................75
3.7.3 EE&C in (Chemical) Unit Operations in
the Aluminum Industry: Captive Renewable
Power Plants ................................................................76
3.7.4 EE&C in (Chemical) Unit Operations in the
Copper Industry ...........................................................78
3.8 EE&C in WHR, CHP and Other Utilities ...............................80
3.9 Conclusion ................................................................................81
References ..........................................................................................81
Websites ...................................................................................82
Chapter 4 Metal Manufacturing Processes and Energy Systems .......................83
4.1 Generic Characteristics of Metals and Metal Industries .........83
4.2 Ferrous and Non- Ferrous Metallurgy ......................................83
4.2.1 Types of Metals ..........................................................85
4.2.1.1 Types of Metals: Ferrous ............................85
4.2.1.2 Types of Metals: Aluminum .......................87
4.2.1.3 Types of Metals: Silver ...............................88
4.2.1.4 Types of Metals: Copper .............................88
4.2.2 Common Applications of Metals ...............................88
4.2.2.1 Common Applications of Iron and
Steel: Cast Iron ...........................................88
4.2.2.2 Common Applications of Aluminum .........89
4.2.2.3 Common Applications of Silver .................89
4.2.2.4 Common Applications of Copper ...............90
4.3 Energy Systems in Metal Industries ........................................90
4.3.1 Generic Use of Energy ................................................91
4.3.2 Process Energy Systems .............................................92
4.4 Smelting and Refining .............................................................92
4.4.1 Ferrous Metal Industries ............................................92
4.4.1.1 Iron and Steel: Integrated Steel Plant .........92
4.4.1.2 Mini Steel Plant ..........................................98
4.4.2 Non- Ferrous Metal Industries ....................................99
4.4.2.1 Aluminum Manufacturing Process
Energy System ............................................99
4.4.2.2 Silver Manufacturing Process
Energy System ...........................................102
4.4.2.3 Copper Manufacturing Process
Energy System ...........................................102
4.5 Energy and Mass Balance ......................................................103
4.5.1 Digitization of the Steel Making Process and
Incorporation of the Circular Economy for
Energy Efficiency ......................................................105
