01
Waste-Heat Recovery
52 TPH WHRB captures DRI kiln flue-gas energy that would otherwise be lost — free heat converted into usable power.
Product 03 · Power
CaptivePower
20 MW captive generation built on waste-heat recovery from our DRI kiln — the energy backbone that keeps the whole plant running.
01 Product Overview
Power
Captive Power · WHR + AFBC · Sambalpur
Nothing Is Wasted
Our captive power plant turns the DRI kiln’s waste heat into electricity. A 52 TPH waste-heat-recovery boiler (WHRB) captures flue-gas energy that would otherwise be lost, supplemented by a 40 TPH AFBC boiler, driving a 20 MW turbo-generator.
This closed energy loop powers the melt shop and DRI section independent of the grid — lowering cost, stabilising process conditions, and cutting the carbon footprint of every ton of steel we make.
- 0MW
- TG Set
- 0TPH
- WHR Boiler
- 0TPH
- AFBC Boiler
- 0%
- Captive Supply
02 Product Specifications
Technical Specifications
Generation and boiler parameters for our integrated captive power block. Detailed technical documentation available on request.
| Parameter | Value | Type |
|---|---|---|
| Turbo-generator | 20 MW | Extraction-cum-condensing |
| WHR boiler | 52 TPH | Waste-heat recovery |
| AFBC boiler | 40 TPH | Fluidised-bed combustion |
| Steam pressure | 64 kg/cm² | Operating |
| Steam temperature | 480 – 490°C | Operating |
| Heat source | DRI kiln flue gas | Recovered |
| Grid dependency | Nil (captive) | Design |
- 0MW
- TG Set
- 0TPH
- WHR Boiler
- 0TPH
- AFBC Boiler
- 0%
- Captive Supply
- ZeroWaste
- Heat Recovered
- LowCO₂
- Carbon Footprint
03 Key Features & Benefits
Why It Matters To Our Steel
Six reasons captive power is a competitive advantage — from cost to carbon.
04 Generation Process
How It Works
From Waste Heat To Watts
A closed loop that recovers kiln flue-gas heat, raises steam, and generates the power that runs the integrated plant.
01/ 05
Waste-Heat Capture
Hot flue gas leaving the DRI kiln is routed into the waste-heat-recovery boiler instead of being vented — capturing energy at source.
Input Stage
- DRI kiln flue gas
- 52 TPH WHR boiler
Steam Generation
The WHRB, supplemented by a 40 TPH AFBC boiler, raises high-pressure steam at 64 kg/cm² and 480–490°C for the turbine.
Core Process
- 64 kg/cm² operating pressure
- 480 – 490°C steam
Power Generation
High-pressure steam drives a 20 MW extraction-cum-condensing turbo-generator, converting thermal energy into electricity.
Generation
- 20 MW turbo-generator
- Extraction-cum-condensing
Distribution
Generated power is distributed to the DRI kiln, melt shop and auxiliaries — meeting plant demand independent of the grid.
Supply
- Captive distribution
- Nil grid dependency
Monitoring & Control
Boiler and turbine parameters are continuously monitored to keep generation stable as kiln heat and plant load vary.
Control
- Continuous DCS monitoring
- Load balancing
04 Generation Process
How It Works
From Waste Heat To Watts
A closed loop that recovers kiln flue-gas heat, raises steam, and generates the power that runs the integrated plant.
01/ 05
05 Safety & Compliance
Zero Compromise
Safe, Stable, Compliant
Our power block runs to strict safety and environmental standards, with continuous monitoring across boilers, turbine and emissions.
“Every Boiler. Every Turbine. Every Shift. Monitored.”
- 01Boiler Pressure & Temperature MonitoringContinuous
- 02Turbine Vibration & Load ChecksContinuous
- 03Emission & Stack MonitoringContinuous
- 04Water & Steam Chemistry ControlPer Shift
- 05Safety Interlock & Audit Records100%
06 Applications
Where It Powers
What Our Power Runs
Captive generation feeds every energy-intensive stage of the integrated plant — keeping production stable and costs low.
01
DRI Kiln Operations
Reliable power for the rotary kiln and its auxiliaries — the first, most energy-critical stage of the chain.
02
Steel Melt Shop
Stable supply to the induction furnaces and LRF — uninterrupted melting independent of the grid.
03
Plant Auxiliaries
Powering utilities, handling systems and infrastructure across the 165-acre integrated facility.
03 Send an Enquiry
Built to scale
Whether you're a rolling mill sourcing billets, an EPC evaluating sponge iron supply, or an industrial buyer exploring long-term partnerships — reach out. Our sales team responds within 24 working hours.
Sales
sales@brsppl.com
Careers
hr@brsppl.com
Phone
+91 663 XXX XXXX
Hours
Mon – Sat · 9 AM – 6 PM
Business Enquiry
All fields marked with * are required. We respond within 24 working hours.