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18th National Award for Excellence in
Energy Management 2017
Growth of JSW Steel, Vijayanagar
Barren Land
Inadequate Water Source, No Electricity
Poor Infrastructure, Road And Rail Connectivity
Non Availability Of Coking Coal, Low Quality Iron Ore
Lack of skilled people To Build / Operate
India’s
largest
Steel Plant
This is what we got
And this is what we made of it
2006
3.8
2004
2.5
1999
0.8
2001
1.6
2009
6.8
2011
10
2016
12
2020
16*
JSW : Process Flow
Management Systems @ Vijayanagar
ISO-9001 : 08
1999 2000 2001 2002 2004 2007 2009
ISO 9002:94
ISO14001:96
HSM
Corex-1& 2
SMS-1PP-1
HSM
, Co
rex-
1, S
MS-
1, P
P-1
OHSAS18001:99
ALLDIVISIONS
Re-registration
ISO-9001
OHSAS18001
ISO-14001
Re-registration
ISO-9001 : 08
OHSAS-18001:07
ISO-14001 : 04
2011
Re-registration
ISO-9001 : 08
OHSAS-18001 :07
ISO-14001 : 04
TS – 16949 INITIATED
2013
Re-registration
ISO-9001 : 08
ISO-14001 : 04
TS – 16949 Certification-
CRM
OHSAS-18001 :07
Re-registration
ISO-14001 : 04
TS – 16949 Certification –HSM & CRM2
OHSAS-18001 :07
SA 8000 Initiated
2016
SA 8000:2014 Certification
Re-registration to Revised Standards ISO 9001:15, and
ISO 14001:15 to 46 Units
SOBIS Portal
ISO/IEC 17025:2005
Accreditation –SMS,HSM & CRM
Labs
Imp
lem
en
tati
on
In P
rogr
ess
(
Acr
oss
pla
nt)
ISO
50
00
1
Adoption of management Systems focusing towards improvement in all facets of Operation
2017
Energy Policy
Energy Management System
Identify Opportunities,
Plan
Management
Energy Policy
Energy TeamEnergy Coordinators
PLAN
DO
CHECK
ACT
Execute Action Plan
Review and Improve
Recognize Achievement
Measure MonitorAnalysisAudits
Continual Improvement
HOD DWM Board Analysis
EMC Monitoring
Online Measurement
Heat RecoveryTRTWHRB
External Audit
DMD – Energy Review(Monthly )
PRESIDENT –Energy Review(Weekly)
HOD - Energy Gap (Daily)-DWM
RHF, WHRB CH4 Recovery WHR-Coke Drying
Daily Energy Report
Parameters UOMTarget as per BP (A)
Avg TillJune 17
July 2017
Avg Till July 17 (B)
Variance of SEC (C=B-A)
Total dry solid fuel rate in BF1 Kg/Tp 572 570 567 569
0.007Total dry solid fuel rate in BF2 Kg/Tp 564 565 570 566
Total dry solid fuel rate in BF3 Kg/Tp 533 531 534 532
Total dry solid fuel rate in BF4 Kg/Tp 526 527 531 528
Total solid fuel rate in Cx (Wet) Kg/Tp 974 1009 1008 1009 0.049
Solid Fuel rate i.e
Kg/Tp 57 58.8 58.8 58.8 0.009(Coke breeze & Anthracite) SP
Sinter Plant 2 WHRS steam Gen TPH
55
10.2 10.3 10
0.006Sinter Plant 3 WHRS steam Gen TPH 15.5 22.9 17
Sinter Plant 4 WHRS steam Gen TPH 12.7 12.6 13
LD Gas recovery Nm3/Tls 89 96.7 95.1 96 0.013
CPP#2 WHR power generation MW 26 29 28 29 0.006
Misc (Sp Gases, Power ) Gcal/Tcs
0.148Sp Power (Excl O2, DRI & CDQ) MW 661 649 638.3 646
LS to HM Ratio Ton/Ton 1.041 1.022 1.024 1.023
LPG Consumption TPD 23.33 21.8 23.7 22.3
Specific energy consumption Gcal/Tcs 6.537 6.743 6.72 6.737 0.200
Crude Steel production Tons/day 31,361 30,882 30,460 30,777 584
CO2 Emission TCO2/TCS 2.501 2.647 2.694 2.659 0.158
EOC Report, Vijayanagar
Energy Coordinators Responsibilities
Department coordinator will establish an improved data recording, collection
and analysis system to keep track of energy consumption in coordination with
EMD.
Developing baselines to quantify energy impacts in coordination with EMD.
Evaluate the operating performance of facility systems and equipment to
determine improvement potential in coordination with EMD.
Monitor all the energy parameter and will communicate to concerned within the
time for corrective measure.
Identity energy saving opportunities and implementation with help of
management based on feasibility.
Energy Consumption Over YrsSustenance With Increased Throughput
6.89 6.61 6.62 6.62 6.61
7.808.40
9.309.90
11.10
0.0
2.0
4.0
6.0
8.0
10.0
12.0
FY 13 FY 14 FY 15 FY 16 FY 17
SEC Gcal/Tcs Crude Steel Mtpa
Si No
Project SavingFunds
Investment in Rs Crs
Potential Savings (Gcal)
Potential Savings
(Gcal/TCS)
Potential CO2
reduction (TCO2)
1 BF Gas Supply to CPP 3 & 4 Coal Saving 2.42 1,305,600 0.167 635,447
2 Coke dry quenching in CO 3 & 4 Coal Saving 837 2,028,605 0.260 805,061
3Sinter cooler waste heat recovery in SP 2, 3 & 4
Coal Saving 71.3 465,071 0.060 173,866
4Hot stove waste heat recovery from BF 3 & 4
Fuel gas saving
14.6 81,506 0.010 16,312
5 Coke oven gasline to JSWEL Coal Saving 0.012 105,264 0.013 24,578
6 De-Aerator at 3*25TPH boilerEfficiency Improvement
0.2 1,085 0.0004 -
Total 925.532 3,987,131 0.510 1,655,264
Projects Implemented 2013-14
SlNo
Project SavingFunds
Investment in Rs Crs
Potential Savings (Gcal)
Potential Savings
(Gcal/TCS)
Potential CO2
reduction (TCO2)
120TPH BF gas fired process steam boiler
Coal Saving 11.5 60,586 0.006 43,467
2DRIEG in GMS-1 for Mixed gas generation
Improvement in power generation at CPP 1
0.4 180,222 0.019 71,522
3DRI gas line to power plant SBU I, SBU II, CPP3 and CPP4 for maximum utilization
Reduction in DRI Flare & equivalent Coal saving
70 459,022 0.049 182,165
Total 81.9 699,830 0.074 297,154
Projects Implemented 2014-15
SlNo
Project SavingFunds
Investment in Rs Crs
Potential Savings (Gcal)
Potential Savings
(Gcal/TCS)
Potential CO2
reduction (TCO2)
1Conversion of Corex GH into LD Gas holder
Increased LD Gas recovery
13.4 228902 0.02 95991
2Dynamic Pressure set point for HP Oxygen PRV
Oxygen saving
Nil 168087 0.02 36047
3Nitrogen injection in vaporized LPG
LPG Savings 0.0 52560 0.01 13074
4Installation of Top recovery turbine @ Blast Furnace 1
Electricity Generation
0.4 85042 0.01 35663
Total 13.8 534591 0.05 180775
Projects Implemented 2015-16
SlNo
Project SavingFunds
Investment in Rs Crs
Potential Savings
(Gcal)
Potential Savings
(Gcal/TCS)
Potential CO2
reduction (TCO2)
1Condensate heat recovery system @ 60 TPH boiler
Electricity Generation
0.34 8906 0.0014 1861
2Optimum utilization of oxygen by load management
Oxygen saving
Nil 4104 0.0004 880
2Increased DRI consumption due to up gradation of Gas mixing station
Reduced DRI flaring
1.52 15587 0.001 -
3Interconnection of 60 TPH and 20 & 25 TPH steam network
Reduction of Steam import
3.00 31600 0.003 22692
4VFD Drives for CEP & ID fan of CPP 4
Power Saving 2.57 6048 0.001 -
Total 7.43 66245 0.01 25433
Projects Implemented 2016-17
6.61
5.47
3.03.54.04.55.05.56.06.57.0
SEC, JSW Steel, Vijayanagar
Global Bench Mark ( JFE )
SEC in Gcal/TCS
Global Best in SEC
Global Bench Mark ( JFE ) 5.47 Gcal/TCS
SEC, JSW Steel, Vijayanagar 6.61 Gcal/TCS
Gap in SEC 1.14 Gcal/TCS
Note : JFE SEC Source CSR REPORT 2016
Actions planned to meet global Best
Strategy Impact
1) TRT for BF 2 0.02
2) HSM waste heat recovery for process steam 0.05
3) Automatic process control system at ASU 0.02
4) SP WHRS for coke drying 0.09
5) Optimisation of Solid fuels 0.20
6) Off Gas recovery system for new SMS 0.04
7) Rebuilding of CO 1& 2 0.18
8) Improving the gas utilization 0.13
9) Improve % of hot charging in Mills 0.01
10) Charge mix in SMS EAF 0.18
11) Quality Raw material 0.12
12) Increase energy efficiency of HPT & energy efficient fan blade in CT of CPP
0.05
13) Methane recovery replacing LPG using COG 0.01
14) Improving the productivity 0.05
Overall Impact 1.15
Power Generation Vs Consumption
6%
94%
Import from JSWEL
Consumption from Captive Power
856MW57MW
Generation is 920 MW Complex Consumption is 913MW
Power Generated from fuel Gas & Waste Heat is 66.84%
of Complex consumption607 MW
Net Generation is 856 MW
29%
59%
3%8%1%
CPP- Gas
CPP-Coal
TRT
CDQ
SIP
Best Practices Replicated on Energy Front through Associates
S.No
Name of associate / vendor
Name of service
provided to vendor
Per unit Energy consumed prior to implementing
Encon
Per unit energy consumed after
implementation of Encon
% improvement
Type of inputs / projects
provided to the vendor/
associate
1
LindeIndia Ltd,1800 Tpd
Electricity for Plant Operation
Specific power consumption
0.64KWH/NM3
Specific power consumption
0.61KWH/NM34.68
Power, water, LPG and Mixed gas.
2 JSWIGPLElectricity for Plant Operation
Loss of 1.5MT Argon
Loss of Argon Nil 15kwh SavingPower, water, LPG
and Mixed gas.
Total waste used as fuel 65.54% of Total
Energy consumed
SlNo
Type of Waste Fuel usedQuantity of waste fuel used Annual
UOMEquivalent of
Conventional energy used (kWh of electricity )
Waste fuel as % of total
energy
1Coal fines and dust from RMHS, Corex
1962715 Tons 5070348 25.23
2 Granulated slag 7791015 Tons 3473494 17.28
3 Sludge 245788 Tons 268830 1.34
4 Flue Dust 244542 Tons 267468 1.33
5 Tar 122375 Tons 433410 2.16
6 Process steam from WHRS 394264 Tons 113351 0.56
7 Electricity from WHRS 238200 MWH 238200 1.19
8 TRT Power generation 181598.5 MWH 181599 0.90
9 Corex 4539135 Gcal 1891306 9.41
10 BF gas 11337150 Gcal 4723813 23.51
11 CO gas 6454803 Gcal 2689501 13.38
12 LD gas 1787936 Gcal 744973 3.71
Total 20096294
Recycling of waste
Waste Utilization-Slag
As Agreegate
Crusher
Dry Pit Slag
850 TPD
PSC/GGBFS
Cement
11200 TPD
Slag Sand
Sand
314 TPD
GBF
10400 TPD
Iron Making Slag
Sand Blasting
PS Balls
50 TPD
As Aggregate
Crusher
876 TPD
EAF slag
Cement Plant
50 TPD
Iron Making
388 TPD
Bund Making
4627 TPD
Metallics
1172 TPD
Crushing
6160 TPD
Steel Slag
6241 TPD
76%Present 91%Future
Actions Planned:
1. Dry pit slag , EAF PS Balls & EAF Slag to be sold as aggregate
2. Steam aging of LD Slag ( +10 mm)
3. HMDS Slag to be used in Sinter making
4. LHF Slag for cement making
5. LD Slag fines for bund making 19
Waste Utilization-Dust and Sludge
Iron makingGCP sludge
Cyclone dust
Sinter plantESP dust
DRIGCP sludge
SMSGCP sludgeMill scale
HSMMill scale
CRMOxide dustETP sludge
Coke ovenCDQ fines
LP MillsSludge
Mill scale
Cement PondPond sludge
Bag filter dust
SMSIron making
RMHSLCP
MPP
MSB
WWP
Basemix
SP
SMS
PP
SP
Processed at
Used at
Source
Environmental Initiatives
1. Sewage Treatment by MBR
Treated sewage to meet potable water quality
Replaced 3000 m3/day of fresh water
MBR+ RO + Evaporator
4000 m3/day
Replace fresh water
2. ZLD at Coke Oven
Oil removal
Recovery of alkali
Reduces footprint by 25%
3. Ceramembrane
4. EAF Slag Atomisation
600 TPD PS Balls
Use in sand blasting
5. Peripheral Greenery Development
287 Acres. FY16: 213 Acre
Approved by MoEFCC
6. CO2 Injection in BOF
Water saving: 1000 m3/day
8. Waste to Wealth Plant
• 1000 TPD Sludge &
Dust recycle
• Fe in Product: 63%
9. River Sand Alternative
• 800 TPD capacity
• Included in IS 383-2016
First
in
India
First
in
India
• 650 TPD capacity
• Mill scale use inSecondary coolant in SMS
Value Addition Through Innovative Solid Waste Management
7. Mill Scale Briquetting plant
First in
India
2.91
2.76
2.81
2.68
2.60
FY 13 FY 14 FY 15 FY 16 FY 17
TRT in Blast Furnace 3 & 4
Fuel Gas flare reduction
WHRS at SP & BF Stoves
Gas fired Process Boiler
Optimum Utilization of DRI Gas
CO2 Emission, T CO2/TCS
TRT in Blast Furnace 1
Increased LD Gas recovery
EAF, DRI &
BRM-2
18 193539 41
76
FY13 FY14 FY15
LPG Cons in TPD
TPD Crs/Annum
High LPG Cons due to
Capacity addition
Challenge & Thought process
Increase of LPG by 84% against 11%
production increase.
Return COG usage along with LPG
Food for thought
Value stream analysis
Why LPG
It is opted as fuel for most of the
applications due to its cleanliness,
reliability and not solely on heating value.
Nitrogen injection in vaporized LPG
Heating17%
Pilot41%
Oxy Fuel
Cutting42%
Understanding Needthrough Value stream
analysis
Project -1
Static Mixing
Nitrogen injection in vaporized LPG
LPG-N2 Gas Mixing Station
Gas Mixing Station Logic
In House ideaDevelopment
Static mixing designed & Logic developed without external help
Injection of gaseous nitrogen in vaporised done beyond OEM
Implemented without taking shutdown in a
record time period of 12days with support of visionary leadership.
Project -1
N2 Injection in
vaporized LPG
Fuel
substitution
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0
0.5
0.6
0.7
0.8
0.9
1.0
1.1
Cru
de
ste
el
pro
du
ctio
n i
n M
TP
M
TCS in MTPM LPG in TPD
LP
G C
on
su
mp
tio
n in
TP
D
N2 injection started
Addition of new facilitiesDRI, CRM-2
Before N2 injection After N2 injection
18 19
35
24 21
39 41
76
5246
0
20
40
60
80
FY13 FY14 FY15 FY16 FY17
TPD Crs/Annum
LPG Savings TPD Rs Crs/Annum
Saving achieved 14 24-30
Nitrogen injection in vaporized LPG
Implemented idea taking risk, This self driven
project saving LPG beyond OEM
First time implementation on national level
Project -1
-30000
-20000
-10000
0
10000
20000
30000
40000
1 8 15 22 29 36 43 50 57 64 71 78 85 92
To/From Buffer SMS Cons ASU Gen
Time in MinO
xyg
en
Flo
w in
Nm
3/H
r
Buffer
vessel
4*200 18
Bar
31
Bar
A
S
USMS
O2 from
Buffer
O2 to Buffer
O2 from
Buffer
O2 to Buffer
Oxygen Balance in Steel making
1St Cycle 2nd Cycle
Optimum utilization of oxygen
2712521344
98
175
0
50
100
150
200
0
10000
20000
30000
40000
50000
60000
2013-14 2014-15
Venting Nm3/Hr Liquid TPD
Supply set point 18Bar
Project -2
High Pressure Oxygen Distribution
Demand 84275
ASU-1
CONV 1 & 2
CONV 3 & 4
CONV 1
CONV 2
CONV 3
Units – Nm3/Hr
Supply = 79775
15000
13000
23000
23000
5775
SM
S-2
15000
13000
23000
23000
SM
S-35775
Others LRS,HMPT Mills, etc
1500
AutoScarfing
3000
ASU-2
ASU-3
ASU-4
ASU-5
EAF
1995
2004
2006
2007
2012
SM
S-1
Optimum utilization of oxygen Project -2
PlantFlow in
Nm3/Hr
Storage
volume in
NM3
Filling
time
ASU-1 15700 10400 40
ASU-2 13000 3250 15
ASU-3 23000 10400 27
ASU-4 23000 10400 27
ASU-5 5775 5200 54
Total 80475 39650 30
Solution Challenge
Interconnecting the HP oxygen lines i.e. 31 Bar.
Impractical considering different BOOoperators, Layout and feasibility of suchinterconnections
SS Ring Main of 18-20Bar with controlsystem.
Difficulty in ECR at 5 different oxygen plant, High investment, Shutdown of Plants and safety
Optimum utilization of oxygen Project -2
Dynamic set-point control philosophy for each ASU independently
Proposal to have variable supply set point in a defined narrow range for PRV operation 18.0-18.6Bar, instead of fixed supply set point for effective utilization of Buffers
Buffer Pressure Set point to PRV
=> 27 Bar High set point
< 27 Bar with a
hysteresis of 6 BarLow set point
Optimum utilization of oxygen
2712521344
9569 9278
98
175
130
93
0
20
40
60
80
100
120
140
160
180
200
5000
15000
25000
35000
45000
55000
2013-14 2014-15 2015-16 2016-17
Venting Nm3/Hr Liquid TPD
0.02
Gcal/TCS0.001
Gcal/TCS
ASU participation in supplying oxygen based on its capability at that instant
Project -2
LD Gas recovery
In contrast to Oxygen Generation and Buffer system, LD Gas will be
generated in batch wise process and ideally it will be supplied consistently by
utilizing Gas holder to consumers.
LD Gas was not fully recovered and fluctuating supply of LD Gas to network
was leading to delays in rolling mills due to limited Gas holder capacity.
OEM had suggested to install GH for Steel making unit-2, it was having
huge capex investment and area requirement.
If GH is commissioned at SMS-2 solving above all, Gas would have flaring
till its commissioning (higher lead time) and SMS-1 would remain handicapped
Project -3
Simulation used for explaining complex scenario effectively
Power
plant
DDGV
GMS
LD-1
DN 2500
DN 1100
Mills
&
Boilers
LD-2
Mixed
Gasline
Corex
Gasline
DN 2500
Corex
GH
From
Corex 1&2
INLET
closed
OUTLET
CPP#1
GMS
2X60K BOOSTER
Control valve to
maintain GH level
Mix Gas
LD Gas
Corex Gas
BF Gas o Pressure & CV fluctuation
o Low Recovery due to controlled export
Proposed LD Line
Approx dist: 140Mtrs
Valve A Valve B
Conversion of Corex GH into LD GH Project -3
70 73.0 74.085.4
93.2
FY 13 FY 14 FY 15 FY 16 FY 17
LD Gas Recovery Nm3/TLS
6165
3733
11 12 14
FY-16 Q-1
FY-16 Q-2
FY-16 Q-3
FY-16 Q-4
FY-17 Q-1
FY-17 Q-2
FY-17 Q-3
Mills Total Delay No of Hrs/Qtr
ImplementedImplemented
Conversion of Corex GH into LD GH Project -3
Savings– 0.02 Gcal/TCS
SlNo
LocationArea in Acres
Solar Capacity
in MW
Estimated generation
in MW
1Raw Water Pond @Vidyanagar
265 76 12.87
2New Raw Water Pond @ Gonal
600 171 29.14
3 Vidyanagar Roof Top 12 3 0.49
4 V V Nagar Roof Top 7 2 0.28
5Shankar Hill Town Roof Top
10 2 0.40
6Industrial Shed Roof Tops (Mills)
125 31 5.31
Total 1018 285 48.50
Solar roof top projects in progress
Artist’s Impression Of a Floating Solar Power Plant
Mills Roof Top for Solar panel installation
