Energy audit result of Cao Bang Cast Iron & Steel JSC

Case study

20/08/2019

Cao Bang Cast Iron & Steel JSC is a leading enterprise in the steel industry in Cao Bang province. It specializes in mining, producing, trading, exporting and importing iron, steel and construction materials. The company has also focused on investing in production lines with advanced and modern technologies to increase the product value and improve its competitiveness in the market.

Energy use situation

Currently, Cao Bang Cast Iron & Steel JSC uses mainly electric power, DO oil, coke and coal.

Energy efficiency potential

Energy audit results show a huge energy efficiency potential of Cao Bang Cast Iron & Steel JSC. The total value of potential benefits from all energy efficiency solutions are expected to be VND41 billion /year representing 4.26 % of the total plant energy cost. The total energy savings respectively are 4,238.79 toe/year equivalent to 4.15% of the total plant energy use.

Particular energy efficiency solutions

9 energy solutions are found during energy audit period including air compressor system improvement, turbo blower application and TRT application.

Solution No. 1: Installing inverter for dust filter fan 1st - Basic Oxygen Furnace
Real situation Fans are controlled by damper and valve consuming a lot of energy when the motor starts.	Expected output VFD installed for the fans results in low current when the motor starts and energy savings when fans operate.
Energy efficiency results
Electricity savings: 1,064,574 kWh/year	Investment cost: VND2.66 billion
Cost savings: VND1.591 billion/year	Payback period: 1.67 years
Solution No. 2: Replacing roots blower with turbo blower
Real situation The compression efficiency of 3 roots blowers is average 14.4%, too low compared to the design, resulting in energy losses.	Expected output 2 roots blower are replaced with turbo blowers whose compression efficiency is 75% and the remaining roots blower only operates in case of emergency leading to a remarkable reduction of energy losses.
Energy efficiency results
Electricity savings: 781,272 kWh/year	Investment cost: VND2.5 billion
Cost savings: VND1.168 billion/year	Payback period: 2.1 years
Solution No. 3: Installing a new TRT in the stream of Blast Furnace Gas
Real situation Coal gas passes through the septum valve system before enters the coal gas storage tank results in energy losses in the septum valve system.	Expected output A top-pressure recovery turbine (TRT) is installed and the septum valve system is only used in case of emergency helping recover energy waste in the septum valve system.
Energy efficiency results
Electricity savings: 18,555,840 kWh/year	Investment cost: VND 163.4 billion
Cost savings: VND27.74 billion/year	Payback period: 5.9 years

Huong Ly

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