CII NATIONAL AWARD FOR EXCELLENCE IN …greenbusinesscentre.com/energyaward2017presentations...CII NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2017 JSW STEEL COATED PRODUCTS

AMARDEEP SINGH – ENERGY MANAGER [email protected]

SANJEEV JAHAGIRDAR – MANAGER OPERATIONS [email protected]

CII NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2017

JSW STEEL COATED PRODUCTS LTD, TARAPUR WORKS

JSW GROUP

PROCESS FLOWCHART & PLANT FACILITIES

Hot RollingHR Slitter,

PicklingCold Rolling

Galvanizing,

Galvalume Color Coating

Finishing(Cut to length,

Profiling)

TARAPUR

PLANT

FACILITIES

COLD ROLLING GALVANIZING / COLOR COATING CAPTIVE POWER PLANTGALVALUME

0.72 MTPA 0.761 MTPA 0.276 MTPA 30 MW

ENERGY CONSERVATION PROJECTS - I

Sr. No.

Energy Conservation Measures Financial Year

Annual Energy SavingAnnual Saving

Investment

Electricity(Lakh kWh)

Thermal(M kCal)

Rs Lakhs Rs Lakhs

1 Optimization of Induction Oven Cooling Blower at CSD3 13-14 2.11 - 9.76 Nil

2Conversion of Delta Operated Motor to Star Connection (below 5.0 HP)

14-15 0.17 - 0.78 Nil

3 Power Factor Improvement of Captive Power Plant 15-16 2.64 - 13.25 Nil

4Switching off AC Cooling Tower & Connecting with Main CT at TM5

16-17 0.64 - 3.68 Nil

Total 13 - 17 5.56 - 27.47 Nil

ENERGY CONSERVATION PROJECTS - II

Sr. No. Energy Conservation Measures

Financial Year


Investment & ROI


Thermal(M kCal)

Rs Lakhs Rs Lakhs Months

1 Replacement of Old Pumps by Efficient Pumps – 2 Nos 13-14 0.38 - 1.74 5 34

2 Destagging of Boiler Feed Pump at CPP 14-15 6.76 - 31.24 5 2

3 Corrocoating of Circulating Cooling Water pump at CPP 15-16 0.79 - 3.79 4 12

4 Covering of Zinc pot Surface in CSD Lines to Avoid Heat Loss 15-16 0.90 - 4.52 0.5 1

5 Operation of Color Coating Line Compressor in Closed Loop 15-16 2.27 - 11.39 0.5 1

6 Replacement of Old Pumps by Efficient Pumps – 2 Nos 15-16 5.85 - 29.37 4 2

7Optimization of Cooling Blower in CSD-5 by Installation of Pyrometer

16-17 3.40 - 19.58 5 3

8Installation of Quench Tank & Optimization of Cooling Blower in CSD-2

16-17 3.09 - 17.80 5 3

9 VFD Installation in Agitator Motor at TM2 16-17 0.16 - 0.92 2 6

10 Optimization of CCL Cooling Tower Pump by Installing of VFD 16-17 1.31 - 7.54 4 6

11 Operation of Captive Power Plant Cooling Tower Fan by VFD 16-17 4.18 - 23.84 5 3

Total 13-17 29.09 - 151.73 40 3

ENERGY CONSERVATION PROJECTS - III

Sr. No.

Energy Conservation MeasuresFinancial

Year


Investment & ROI


Thermal(M kCal)


1 VFD Installation in cold well pump at CSD3 13-14 4.41 - 20.37 6 4

2 VFD Installation in cold well pump at CCL 13-14 0.68 - 3.13 6 23

3 LED Light Replacement – 238 Nos 13-14 0.21 - 0.96 10 125

4 Replacement of Old COT pump by Efficient pump 14-15 4.33 - 20.01 10 6

5 Provision of VFD in PA Fan 14-15 0.19 - 0.87 6 83

6 Replacement of Conventional lights by LED lights 15-16 1.02 - 5.15 9 21

7 Replacement of Conventional lights by LED lights 16-17 1.30 - 6.23 10 19

8 Installed VFD in Coolant pump in Cold Rolling Mill - 4 16-17 2.42 - 13.79 6 5



Total 13-17 20.26 - 102.98 75 9

ENERGY CONSERVATION PROJECTS - IV

Sr. No.

Energy Conservation MeasuresFinancial

Year


Investment & ROI

Electricity(Lakh Kwh)

Thermal(M Kcal)


1Replacement of Conventional Lighting by LED Lights -503 Nos 14-15 0.44 2.05 30 178

2Replacement of Water Cooled Hearth roll in Furnace by Ceramic Roll 14-15 439 14.80 22 18

3Replacement of Ceramic Fiber Lining by Pyro bloc Module in CSD-3 Non-Ox Furnace 15-16 1381.1 37.93 22 7

4Technology Up gradation & Redesigning of CSD-1 Furnace 15-16 15.66 3864.7 184.71 446 29

5Variable Frequency Drive Installation in Boiler Feed Pump 15-16 11.86 59.53 60 12

6Replacement of Water Cooled Hearth Roll in Furnace by Ceramic Roll 16-17 1708.6 35.60 22 7

Total 13-17 27.96 7393.4 334.62 602 22

SUMMARY OF ENERGY CONSERVATION PROJECTS

Energy Conservation MeasuresNo of

Measures


Investment & ROI


Thermal(M Kcal)


Nil Investment 4 5.56 - 27.47 Nil -

< = Rs 5 Lakhs 11 29.09 - 151.73 40 3

> Rs 5 Lakhs <= 10 Lakhs 10 20.26 - 102.98 75 9

> 10 Lakhs 6 27.96 7393.4 334.62 602 22

Total 31 82.87 7393.4 616.8 717 14

PLANT ENERGY CONSUMPTION & ABSOLUTE SAVINGS

Plant Energy Consumption

Energy Unit

Financial Year

2014-15 2015-16 2016-17

Electricity Consumption Lakh kWh 1793.04 1671.08 1701.72

Electricity Energy Saving Lakh kWh 11.89 40.99 22.29

% Electricity Energy Saving % 0.66 2.45 1.31

Thermal Consumption Million kCal 210393 234998 224100

Thermal Energy Saving Million kCal 439 5245.67 1708.6

% Thermal Energy Saving % 0.21 2.23 0.76

0.66

2.45

1.31

% Electrical Energy Saving

0.21

2.23

0.76

% Thermal Energy Saving

SPECIFIC ENERGY CONSUMPTION

Parameter Unit FY 2014-15 FY 2015-16 FY 2016-17% Reduction

FY 2015-16 FY 2016-17

Coated Production MT 696460 616735 672442 - -

Utilization % 91.52 81.04 88.36 10.48 % 3.16%

Electrical SEC Kwh/MT 231.90 225.59 223.88 2.72 % 3.45%

Thermal SEC Million Kcal/MT 0.3374 0.3359 0.3265 0.44 % 3.23%

231.9

225.59223.88

215

220

225

230

235

FY 2014-15 FY 2015-16 FY 2016-17

Electrical Energy SEC

0.33740.3359

0.3265

0.32

0.33

0.33

0.34

0.34

FY 2014-15 FY 2015-16 FY 2016-17

Thermal Energy SEC

BENCHMARKING – ENERGY CONSUMPTION (JSW PLANTS)

213.88

165.35 165.57

0

50

100

150

200

250

Tarapur Vasind Kalmeshwar

Plant Electricity Energy Consumption (kWh/t)

0.276

0.295

0.286

0.26

0.27

0.28

0.29

0.30


Plant Thermal Energy Consumption (Gcal/t)

130.77

101.37 92.56

0

50

100

150


CRM Electricity Energy Consumption (kWh/t) 89.02

77.665.34

0

20

40

60

80

100


CSD Electricity Energy Consumption (kWh/t)

BENCHMARKING CHALLENGES

COLD ROLLING MILL – (% REDUCTION)

ThicknessProduction Reduction

Power ConsumptionInput Output

mm mm MT % kWh/t

2.2 0.317 400 85.6 147.78

2.6 0.899 400 65.4 113.57

GALVANIZING / GALVALUME LINE - (RATIO)

Material

OutputThickness

Width ProductionPower

Consumption

mm mm MT kWh/t

Galvanizing 0.696 1000 200 93.83

Galvalume 0.696 1000 200 138.42

GALVANIZING / GALVALUME LINE – (PRODUCT MIX)

Material

Output Thickness

Width ProductionThermal

Consumption

mm mm MT mmbtu/t

Hard 0.50 1000 200 0.581

Soft 0.50 1000 200 0.769

Structural 0.50 1000 200 0.973

COLOR COATING LINE – (PAINT VOC)

Paint Coating

Output Thickness

Paint Qty

ProductionThermal

Consumption

mm Ltr MT mmbtu/t

Coating -1 0.38 18500 1000 0.650

Coating- 2 0.38 17000 1000 0.679

Coating - 1(Without RTO) 0.38 18500 1000 1.000

Grade of Material Thickness & Width Color Change Utilization Product Mix in Color Coating Line

ROAD MAP – ENERGY CONSERVATION / MANAGEMENT

Energy Conservation Measures Energy Saving Investment Target Date

Inverted U Tube Furnace in CSD-3 0.0684 mmbtu/t 625 Lakhs Oct-17

Energy Efficient Boiler for Process Steam 0.250 Gcal/t 200 Lakhs Sep-17

0.8 MTPA Pickling Line & Tandem Cold Mill 140 Lakh kWh 200 Crores Aug -19

Lower Head Pump for Cooling Tower Pump 12.46 Lakh kWh 16 Lakh Mar-19

VFD in RTO Combustion Blower at CCL 2.5 Lakh kWh 4 Lakh Mar-18

Execution of Mandatory Energy Audit Findings -Schneider To be Calculated To be Calculated Aug-19

Renewable Energy Projects Energy Saving Investment Target Date

Light Pipes Installation 0.97 Lakh kWh 17 Lakhs Mar-19 (Phases)

Roof Top Solar Panel Installation 60 Lakh kWh OPEX / CAPEX Dec-17 & Mar-19

Captive / Group Captive Solar Projects RPO Compliance To be Calculated Dec-17

Benchmarking / Baseline Projects Energy Saving Investment Target Date

Benchmarking Energy Consumption with M/s Uttam Galva Steel Ltd - - Dec-17

Development of Normalization Factor for Secondary Steel - - Mar-18

Base Line Energy Consumption of Tin Plating Line - - Dec-18

INNOVATIVE PROJECTS - I

REPLACEMENT OF WATER COOLED HEARTH ROLL BY NON WATER COOLED CERAMIC ROLL – 2 Nos

Hearth Roll are used in Non Ox Furnace to support the sheet. To cool the temperature of the Hearth Roll, water is passed through it.

Water Flow through the Hearth Roll is 36m3/Hr. Temperature Gain of water across the Hearth Roll is 6 Deg C.

Vendor Sandvik Asia suggested APM Technique based Non water cooled ceramic roll for this application.

Hearth RollWater Inlet

Water Outlet

Non Ox Furnace

Furnace Temp – 1025oC

Fuel Consumption Annual Fuel Saving

Annual Saving

Investment ROIBefore After

mmbtu mmbtu mmbtu Rs Lakhs Rs Lakhs Months

6780 0 6780 35.6 22 7

INNOVATIVE PROJECTS - II

Cooling Blower- 1

Cooling Blower- 3

Quench Tank

Cooling Blower- 4

Cooling Blower- 5

Cooling Blower- 2

Heating Furnace

Zinc pot

INSTALLATION OF QUENCH TANK & OPTIMIZATION OF COOLING BLOWER IN CSD2

Galvanizing Sheet after coating in Zinc pot are cooled in APC (After Pot Cooling) section by APC Blowers.

5 Nos of Blowers are used for cooling of the sheet

Temperature requirement at exit of the Cooling blower-5 is < 40 Deg C

In House Quench Tank Developed for cooling of the sheet with logic to APC Blowers for controlling in auto

PowerConsumption Power

Saving

Annual Power Saving

Annual Saving

Investment ROI

Before After

kWh kWh kWh kWh Rs Lakhs Rs Lakhs Months

3310 2463 847 3.09 17.8 5 3

TECHNOLOGY UPGRADATION – NON Ox FURNACE (CSD-1)

Parameter Before After

Non Ox Section

Capacity 12 TPH 16.5 TPH

Furnace Type Direct Heating Non Ox

Firing Control On/Off Ratio Control

Zone Temp Control Zone Temp Strip Temp

Recuperator NA Yes

Exhaust Blower DOL VFD

Combustion Blower DOL VFD

Non water cooled Roll 0 4

RTF Section

Firing Control On/Off Pulse Firing

Zone Temp Control Zone Temp Strip Temp

Soaking Section

Zone Temp Control NA Strip Temp

Energy Consumption

Power Consumption 55 kwh/t 40.5 kwh/t

Thermal Consumption 0.65 mmbtu/t 0.508 mmbtu/t

DHF RTF SOAKING JET COOLER

NON OX RTF SOAKING JET COOLER

Pyrometer Pyrometer Pyrometer Pyrometer

Pyrometer

Low Furnace Temp resulted in less production. Old Technology

Line Speed increased to 150 mpm by upgrading the Direct Heating Furnace with other energy saving measures.

750 Deg C

1000 Deg C

ENERGY AWARENESS & INVOLVEMENT

External –

720 Hrs

Technical Training,

KEP- BEE

EnMS 50001, Internal Auditor Training

PAT, Escerts Trading

Awareness

• Display, Email, Awareness SessionEnergy Policy

• Received – 102 Nos for FY 15-17Suggestion

• Display, Email, Awareness SessionEnergy Review, SEU, EnPI

• 14th Dec to 20th DecEnergy Conservation Week

• Distribution of 1600 LED BulbsDELP - EESL

• Distribution & display of energy saving Pamplets, Display Board

• Training duration – 1548 Hrs Internal Training

• Communication - Energy Performance Evaluation Criteria

Vendor - PO

• Plant, Process level awareness, TeamObjectives & Targets

Fee

Reimbursement

Scheme for Energy

Auditor / Manager

Exam

MANAGEMENT OF EC PROGRAMS/ TARGET SETTING

Management Commitment

Assess Current Situation

Set Goals & Targets

Implementation & Operation

Checking

Review & Evaluate

Appointment of MR

Scope & Boundaries

Energy Management Team – 10 Nos

Energy Policy , Resources Assignment

Energy Review

SEU Assessment & List – 10 Nos

RPO & PAT Target, Other Legal

Opportunities , Baseline

Prioritizing Opportunities Objectives & Action Plan EnPI Verification Plan- EMT

Responsibility – Process Owner Competence, Training & Awareness -1548 Hrs Design Procurement Operational Control, Energy Manual

Monitoring & Measurement Plan Metering Plan – Energy Meter List Audit Plan , Control of Records Compliance Assessment, CAPA

Review of Energy Policy Review of Objectives , Action Plan Review of EnPI Resources, System Improvement CAPA Approval

ENERGY MONITORING / FORMATEnergy Consumption Data of July-17

Power Consumption RLNG/Coal / HSD Consumption

Total

Required

G Cal /t

Total

Actual

G Cal /tEquipment Production

kwh /t KWH Gcal G cal/t MMBTU/t , KL/t MMBTU,Mt , KL Gcal G cal/t

ABP Require Actual Required Actual Required Actual Required Actual ABP Require Actual Required Actual Required Actual Required Actual

PreRolling

HR Slitter 51,997 2.5 2.0 129,993 105,094 112 90 0.00 0.00 - -

0.076 0.076

Pickling 52,877 9.0 6.34 6.7 335,404 354,058 288 304 0.01 0.01 - -

ETP+MEE PLANT 52,877 1.9 2.3 100,466 119,894 86 103 0.00 0.00 - -

Steam to Steel Plant (PKL) 52,877 1.0 0.5 52,877 27,062 45 23 0.00 0.00 0.013 0.013 713 713 3,492 3,492 0.066 0.066

PreRolling 52,877 9.0 11.7 11 618,740 606,108 532 521 0.010 0.010 - 0.013 0.013 713 713 3,492 3,492 0.066 0.066

Rolling

CRM-1 15,943 114.0 115.1 115.2 1,835,199 1,836,747 1,578 1,580 0.10 0.10 - -

0.107 0.107

CRM-2 5,260 133.0 149.3 148.1 785,476 778,921 676 670 0.13 0.01 - -

CRM-4 5,578 157 186.8 186.0 1,041,970 1,037,258 896 892 0.17 0.17 - -

CRM-5 17,313 84.0 89.5 89.0 1,549,514 1,541,300 1,333 1,326 0.08 0.03 - -

CRM-6 7,221 157.0 164.9 163.4 1,190,815 1,179,746 1,024 1,015 0.14 0.14 - -

Rolling 51,315 116.6 124.8 124.21 6,402,974 6,373,972 5,507 5,482 0.107 0.107 - - - - - - - - -

Galvanising (GI/GL)

CSD-1 6498 42.0 51.8 50.9 336,531 330,533 289 284 0.04 0.04 0.630 0.634 0.588 4,120 3818 1,038 962 262 0.15

0.262 0.268

CSD-2 4413 53.0 67.8 71.7 299,113 316,306 257 272 0.06 0.01 0.750 0.750 0.746 3,310 3293 834 830 210 0.19

CSD-3 20295 106 114.8 114.5 2,330,668 2,323,832 2,004 1,998 0.45 0.45 0.680 0.707 0.774 14,344 15701 3,615 3,957 911 0.19

CSD-4 3378 95 107.8 106.4 364,284 359,458 313 309 0.09 0.01 0.430 0.523 0.545 1,767 1843 445 464 112 0.14

CSD-5 16628 131.9 128.4 125.9 2,135,448 2,093,116 1,836 1,800 0.11 0.03 0.610 0.647 0.655 10,755 10887 2,710 2,743 683 0.16

GP Sliter/Alloy F/C 4,819 5.0 6.0 5.8 28,914 27,795 25 24 0.00 0.00 280 280 71 71 18 0.01

Galvanising (GI/GL) 51,212 101.3 107.3 106.4 5,494,957 5,451,040 4,726 4,688 0.092 0.092 0.640 0.675 0.699 34,575 35,821 8,713 9,027 0.170 0.176

Colour Coating (PPGI/PPGL)

CCL1 10,278 40.0 36.2 35.9 371,550 368,936 320 317 0.03 0.03 0.700 0.700 0.706 7,195 7256 1,813 1,828 457 0.178

0.201 0.200CCL2 10,723 36.0 36.3 35.5 389,138 380,676 335 327 0.03 0.03 0.650 0.650 0.643 6,970 6894 1,756 1,737 443 0.162

Colour Coating (PPGI/PPGL) 21,001 38.0 36.2 35.7 760,687 749,612 654 645 0.031 0.031 0.674 0.674 0.674 14,165 14,149 3,569 3,566 0.170 0.170

Others

Adminstration 0.6 0.6 0.5 33,000 26,019 28 22 0.00 0.00 - - - - -

0.002 0.002DG AUX SUPPLY 1.2 1 1.7 75,000 84,573 65 73 0.00 0.00 - - - - -

Store & Canteen 0.1 0.1 0.4 20,000 21,412 17 18 0.00 0.00 - - - - -

Others 51,212 2.5 2.6 128,000 132,004 110 114 0.002 0.002 - - - - - - - - -

Total 51,212 13,405,358 13,312,736 11,529 11,449 0.225 0.224 48,740 49,971 ###### 16,084 0.308 0.314 0.533 0.538

Normalized Energy Consumption for the Month of July'17 0.495

ENERGY MANAGEMENT SYSTEM

ENERGY MANAGEMENT SYSTEM – SCHNEIDER ELECTRIC

GHG EMISSIONS

GHG Emissions Unit FY 2014-15 FY 2015-16 FY 2016-17

Scope 1 Emissions tCO2 256470 239422 253254

Scope 2 Emissions tCO2 1125 958 360

Total GHG Emissions tCO2 257595 240380 253614

RENEWABLE ENERGY SOURCES

RPO Compliance – 100%

Financial Year Solar RECs Non Solar RECsREC Cost

(Rs in Lakhs)

FY 14-15 740 12570 214.45

FY 15-16 694 11795 201.22

FY 16-17 1479 14786 162.65

FY 10-11 to 16-17 2940 58417 1229.15

TRANSCULENT SHEET IN EACH SHED

RAIN WATER HARVESTING – 21600 KL

Solar Roof Top PanelCaptive Solar

ProjectsLight Pipe

SOLAR ROOF TOP SURVEY

UTILIZATION OF WASTE

DESIGN RATING OF RTO FOR VOC FUEL CONSUMPTION

CCL1 – 300 to 700 Kg/Hr CCL2 – 300 to 440 Kg/Hr 30 - 35%

GREEN SUPPLY MANAGEMENT

Transportation – Replacement of LPG by RLNG

2,47,286 tCO2 MITIGATED

Transportation – Truck Container by Railway Rake

36,65,185 tCO2 MITIGATED

ENVIRONMENT INITIATIVES

TREE PLANTATION – 3000 Nos / YEAR DONATION OF 1000 SAPLINGS TO ITI

3 CHECK DAMS – 215 MILLION LTRS / COST RS 61 LAKHS WATER STORAGE BANK – 10 CR. LITRES

CSR

BUS STOP WITH LED LIGHTS AUDITORIUM WITH LED LIGHTS AWARENESS IN SCHOOLS / ITI

PAINTING COMPETITION - SCHOOLS RURAL ELECTRIFICATION WITH SOLAR PANEL , LED LIGHTS, TABLE FAN

CII - ENERGY AUDIT

Energy Saving Measures

Annual Energy Saving Potential

Status / Target Date

Annual Energy Saving


Thermal (Million Kcal)


Improve Power factor of captive power plant 2.64 Implemented 2.64

Install Light pipe 0.97 Mar-19 (Phases)

Optimize the compressed air system 11.92 Dec -16 (U/P) 2.27

Install VFD for Coolant pump for CRM 4.56 Implemented 8.12

Install correct size pump for cooling tower 15.49 Mar-19 (Phases) 1.47

Install VFD for Boiler feed water pump 10.30 Implemented 11.86

Install Micro turbine in place of PRDS 43.44 Dropped

Install VAM based Heat pump 3.52 1090 Dropped

Covered the Zinc pot surface 4.33 Implemented 0.90

Install VFD for CSD-5 Dilution Blower 0.14 Dropped

Install VFD for CSD-2 chromic dryer 0.12 Dropped

Total 97.43 1090 27.26

ACHIEVEMENTS

Energy Conservation Award

2008-09 MEDA – Third Prize

2011-12 MEDA – First Prize

2014-15 MEDA – First Prize

2015-16 MEDA – Second Prize

2015-16 BEE – Certificate of Merit

THANKS

Documents

CII NATIONAL AWARD FOR EXCELLENCE IN …greenbusinesscentre.com/energyaward2017presentations...CII NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2017 JSW STEEL COATED PRODUCTS