India is the second largest crude steel producer in the world. The crude steel production in India was 125.32MT and steel production was 121.29 MT in FY23.
In FY24, the steel production growth of India is estimated at 4% – 7% (123 – 127 MT). This growth depends on the availability of raw materials such as labour and iron ore.
After the iron and steel industry, aluminium is the second most important industry in India. The aluminium industry has grown by nearly 20X in the past 60 years.
For solar solutions for iron & steel, steel and aluminium factories, we offer the best solar system installation services. Contact us now to install a solar system in your metalwork factory.
Electricity Load in the Metalwork Industry
The electricity load in a steel factory depends on the plant’s production capacity. Generally, the energy requirement for melting is 300 kWh for every tonne of scrap metal. On the other hand, approx 440 – 650 kWh of energy is required to produce 1 ton of steel.
Machinery Used in an Iron & Steel Plant that You Can Run with Solar System
These are the names of some important machinery used in a steel and iron production plant:
Electric Arc Furnaces
Tundish Slide Gates
Continuously Variable Crown (CVC)
Crushers & Screens
Hydraulic Gap Control (HGC)
Ladle Level
Mould Oscillation Control of Continuous Casters
Coil Handling
Automatic Gauge Control (AGC)
Roll Bending And Shifting
Bar Guides In Bar Steel Mills
Blast Furnace Units
Hot Strip Mill
Vibrating, Reciprocating & Reversible Feeders
Silicon Treatment Plant
Working Mechanism of a Steel and Iron Factory
For steel production, there are two different processes: electric furnace and blast furnace process.
For an electric furnace, the main raw material is sponge iron & iron scrap and for a blast furnace, the raw material is iron ore.
In an oxygen furnace, the iron is combined with steel scrap (<30%). After that, very pure oxygen (O2) is blown into the vessel causing a temperature up to 1700°C. The impurities and carbon content are reduced by 90% making the steel liquid.
Why Choose Solar Solutions for Iron Factory
Here are the advantages of using solar solutions for the iron, steel and aluminium industries:
The payback period of solar solutions for metalwork factories is very short, just 4 – 5 years.
With solar system installation, you can save around 70% – 80% of your regular electricity bills.
Solar energy is a renewable source of energy with zero carbon and greenhouse gas emissions.
After solar system installation, you can create a permanent shed against the electric cost inflation.
You can get between 20% – 40% returns/year on your initial investment.
Once invested in solar for steel and aluminium factories, it gives returns for the next 25 – 30 years.
For on-grid/grid-connected solar systems, the annual maintenance cost is just 1% – 2% of your initial investment cost.
Different Solar Solutions for Steel Factories
These are the different solar solutions we offer for steel factories:
Grid-connected Solar Rooftop Plant
Solar Street Light
Solar Submersible Pump
Solar Carport
Why On-Grid Rooftop Solar is a Better Option for Metalwork Factories?
On-grid or grid-connected solar system is one of the best options for steel, iron and aluminium factories as the power requirement is very high.
We always recommend an on-grid solar for your industrial/commercial requirements. The reasons are–
On-grid rooftop solar systems allow you to rescue the grid dependency as the net meter prioritises the usage of solar powered electricity during the daytime.
This solar system does not contain any solar battery. Therefore the overall installation cost is lower than the off-grid and hybrid solar.
The maintenance cost is also low in an on-grid solar system compared to an off-grid or hybrid solar system.
Reasons to Choose Us for Steel, Iron and Aluminium Factory
Here are the reasons to choose us for the best solar installation services for the aluminium, iron and steel factories:
Free Advice From Solar Experts
On our platform, we provide 100% free-of-cost guidance from our experienced solar energy experts. Just you have to contact us, we will assign one expert to guide you. You can solve all your doubts via on-call discussions.
Free Solar Quotation
We help you to get free solar system quotations before the installation process. It includes all information about the solar offerings, including the name and brand of solar components, prices, warranty information, etc.
Verified Local Solar Installers
We always onboard experienced, licensed and verified local installation partners. It helps you get a professional installer who will give high-quality product at a reasonable price.
Unbiased Guidance
We assure you that all of our experts will provide you with unbiased guidance by focusing on your specific requirements under your budget. We will never force you to buy a particular solar component or from a particular installation partner.
24×7 Customer Helpline
In both the pre-installation and post-installation phases, you can ask for help from our 24/7 customer support team. If you face any problem like system faults, warranty claims or any other issues you can reach us anytime during business hours for maintenance requirement.
How to Complete Installation of Solar Panels for Metalwork Industry
These are the steps to complete solar panel installation for the metalwork industry from Das Energie:
Step 1: Please visit our Contact Us page and fill up the form correctly with your requirements and contact details. Once we get your installation request, our expert solar system advisor will reach you as soon as possible via phone call. If you have any doubts regarding our solar services or the solar systems, you can ask them.
Step 2: To help you get the exact price of your solar system, we will arrange a site visit at your location. A local installation partner will reach your metalwork shop/factory. After a detailed site visit, within 1-2 days, you will receive a detailed plan and quotation.It includes details on solar components’ prices, quantity, warranty period, etc. of the solar components.
Step 3: After getting the price structure, if you confirm the installation, our installation partner will start the process as soon as possible. Even if you require any changes we will make further customisation in the quotation (if possible).
For net metering applications or any other help post installation, you can reach our team and we will guide you.
Cost Of Solar Installation Solutions for Metalwork Industry
To get the exact costing details of the solar solutions for metalwork factory, you can contact us at 9830795307 or email us at connect@dasenergie.com.
We are the best solar installer for iron and steel factories. We follow a different approach to share you the price details. Here we arrange a site visit with our trusted and local solar system installation partners. After that, we will share the exact details of your solar system. The information in the solar quotation includes important details such as the cost and brand of solar components, warrant information, and solar financing options (if any).
ROI of Installing Solar Solutions for Iron, Steel and Metwork Factory
Follow this table to get an idea about the Return on Investment after installing solar in your iron factory:
Solar System Size
Monthly Generation
Monthly Savings
180 kW
27,000 unit
Rs. 3,24,000
460 kW
69,000 unit
Rs. 8,28,000
850 kW
1,27,500 unit
Rs. 15,30,000
Solar Installation Cost for Plastic & PVC Factory
The cost of solar installations in the Plastic industry depends on multiple factors such as system size, solar components, installation location, etc.
So, it is nearly impossible to determine the exact price without a site visit. To discuss solar and to book the site visit contact us via call at 9830795307 or drop us an email at connect@dasenergie.com
Reach us and get help from experts!
Types of Solar Installation Solutions for Plastic Industry
On our platform, we offer these solar solutions, especially for plastic industry:
Grid-connected/On Grid Solar Power Plant,
Solar Submersible Pump
Solar Street Light with the Factory Premise
Solar Carport in Plastic, Rubber and PVC Factory
ROI for Investing in Solar Solutions for Plastic Industry
This is an estimated return on investment for investing in solar energy:
Solar System Size
Monthly Generation
Monthly Savings
250 kW
37,500 unit
Rs. 4,50,000
450 kW
67,500 unit
Rs. 8,10,000
600 kW
90,000 unit
Rs. 10,80,000
Note- Per day electricity generation = 5 units and 1 kWp = Rs. 12
Challenges of Metalwork Industry – Iron, Steel, Aluminium Industry
These are the main challenges of the metalwork industry:
Generally, most of the factories in this industry use Diesel as their power backup source. The price inflation of diesel increases the production cost of the factories.
Some factories use coal as their main power source. But this releases more carbon in the environment.
Even if you use grid electricity to power your factory, it is also not cost-effective. With the price inflation of electricity, the energy source is not also affordable.
Energy Consumption For Different Works in a Steel Factory
Follow this table to learn about the energy consumption by different sections in a steel factory:
Blast Furnace
54%
Coke Ovens
12%
Steel Making
09%
Sintering
08%
Slabbing & Blooming
03%
Hot Rolling
09%
Cold Rolling
05%
Source: Ornate Solar
Examples of Solar Installation at Steel Factory
Here are some steel factories using solar solutions:
Installation Location
City
Solar Plant Capacity
Belmarks Metal (India) Private Limited
Indore
79 kW
Vikas Stainless Pvt Ltd
Hissar
319 kW
Krishna Iron Strips And Tubes PVT LTD
Raipur
512 kW
What is Waste Heat Recovery?
Hot exhaust water gases (10%) and molten slag (35%) are the sources of Waste Heat Energy in the steel production process. The utilisation of waste heat recovery is the process of efficient steelmaking where the waste energy can be recycled and reused as an energy source. There are different waste heat sources in a steel plat such as–
Hot slags
Hot off-gases
Hot intermediate products like slabs, billets etc.
Cooling water
Using the WHR method, all of the waste energy of all these sources is reused in the metalwork industry. This also helps in carbon emission reduction and cost savings.