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1
Mahindra Sanyo Special Steel Pvt Ltd
CII - 18th NATIONAL AWARD FOR
"EXCELLENCE IN ENERGY MANAGEMENT 2017”
Copyright © MSSSPL Elect. Dept. Aug 2017
2Copyright © MSSSPL Elect. Dept. Aug 2017
CONTENTS Company Profile & Process Flow
ISO 50001:2011 – Energy Management System
Specific Energy Consumption (SEC) reduction trend
Bench Marking (Global and National Bench Marking)
Utilization of Renewable Energy Source
GHG Emission reduction trend
Monitoring & Reporting , Implementation Methodology
ENCON Projects Implemented in last 3 years
Road map for next 3 years for ENCON projects
Employee Involvement & Team Work
Utilization of Waste as fuel
Sustainable Supply Chain Management
Innovation Projects
3
Company Profile
Mahindra Sanyo Special Steel Pvt. Ltd (MSSSPL), following a joint venture between MUSCO (51%), Sanyo Special Steel Co., Ltd (29%) and Mitsui & Co., Ltd (20%). • Location : Khopoli, Maharashtra, India• Established : 1962• Employees : ~2400• Business : Manufacturing & sales of special
steel products• Products : As-cast Ingots, CC-rolled products,
rolled & ingot-forged bars, rings
Copyright © MSSSPL Elect. Dept. Aug 2017
Electric Arc Furnace
Ladle Furnace
Vacuum Degassing
ContinuousCasting
Ingot Casting(Bottom pouring) Forging
Blooming Mill
Bar Mill
Continuous Mill
Heat TreatmentFurnaces
QuenchingTank
StraighteningMachine
Peeling
Inspection
Ring Plant
Dispatch
New Delhi
Kolkata
Chennai
Pune
Mumbai
Khopoli
4
Certification Journey
ISO 9001-Certified in 1993
ISO/TS 16949 -2009 –Re-Certified in 2017
ISO 50001:2011 – Certified in 2013
ISO/TS 16949 -2002 –Re-Certified in 2008
ISO/TS 16949 -2002 –Certified in 2005
ISO 9001 –2000 –Upgradation in 2002
ISO 14001:2015 –Certified
BS OHSAS 18001-2007 –Certified in 2011
ISO 14001 -2004 –Certified in 2010
ISO/IATF 16949:2016 –Audit Completed –Recommended for
CertificationCertification Journey
Copyright © MSSSPL Elect. Dept. Aug 2017
5
ISO 50001 : Energy Management System Journey
20082011Comprehensive Energy Audit by TERI
Energy Audit by Schneider Electric India Pvt. Ltd
Developed Energy Monitoring and Reporting System
Established Energy Management Policy
Set objectives, targets & action plans
2012
2012
2012
2012
ISO 50001:2011 Certified by TUV 2013
Siemens Audit 2013
Must Do Objective
2014 Measurement & Verification by
Schneider
2015 Re-Certification Audit
2017
2016 Re-Certification Received
A journey of a thousand miles begins with a single step in the right direction
Copyright © MSSSPL Elect. Dept. Aug 2017
6
Energy Policy & Policy Matrix
Copyright © MSSSPL Elect. Dept. Aug 2017
S.N. Description
Establishin
g norms for
all process
Capital
expense /
equipment
modification
Sustanbility
/Energy
team/MPRM
/FSC/Goal
sheet
Solar /
wind
energy
External
InternalBEE / MSEDCL / MEDA Budget
1Reduce specific energy
consumption
2Use energy efficient
a) Process
b) Equipment
3 Employee involment
4Information disimenating /
communication
5Establishing energy cons.
Norms
Bench
marking
6 Usage of renevable energy
7 Energy audits
TERI /
Schinder /
TUV/
Internal
8Complying legal
requirements
BEE certified Energy
Auditor & Manager / audit
by accredited auditor /RPO
Fullfill MEDA
9 Resources provisionBudget /
CEP
10Purchase of energy
efficient product
7
Energy Management Team
Top Management MD,COO,CTO,CFO
Management Representative
Energy Manager (BEE Certified
Energy Auditor)
Steel Melting
Shop
Forge Shop
Blooming Mill
Rolling Mill
Heat Treatment
Project & Purchase
PIR/HR
Cross Functional Team –Trained & Certified as Internal Auditor by TUV - Certification Authority
Allocate resourcesManagement ReviewTarget for Energy Performance Indicators
Planning & Implement Energy Management ActivitiesReport Energy Performance to Top Management
Review of Objectives & TargetsGAP Analysis with CFT
Copyright © MSSSPL Elect. Dept. Aug 2017
8
Energy Policy Deployment
Copyright © MSSSPL Elect. Dept. Aug 2017
Sl. Description Compliance
1Reduce specific energy
consumption
7 % Electrical Energy reduced in last 3 years
13 % Oil consumption reduced in last 3 years
Use energy efficient▪Optimization of Scrap Mixing & Early foaming started through
use of Lump coke through DRI Belt conveyer
▪ 3 Ladles recirculation, Better insulation practice to avoid
temperature drop after VD
▪ Improvement in Ladle Slag lining
▪HTFS Furnace Revamping
▪LED Light & procurment of Star rated AC'S
▪Transparent sheets on roof tops
▪Theme based Energy Month
▪12 Nos. of TUV certified EnMS internal Auditor
▪ 1 BEE certified Energy Auditor & Manager
▪ External Training : 4 , Internal Training for all shop
▪ Total 45 suggestion have been received & 24 have completed
▪ Daily Power analysis in sunrise/DWM meeting
▪ Aspect Document with Top Management
▪ Sustainability report /Flyer
▪ International Benchmarking with BSE Germany
▪ Shop wise & Grade wise monitoring of Power & Fuel
▪Solar Roof Top 20 KWH plant
▪Wind & Solar power procurement through Open Access
▪TUV Recertification Audit completed in F16
▪TUV Surveillance Audit completed
▪ External & Internal Technical Audit completed
▪ Power survey Report Submitted
▪ RPO fulfillment report submitted to MEDA
▪ Completed capex allotment : HTFS furnace revamping etc.
▪ Future Capex required: LED , CC Pit revamping, Transformer
replacement
▪Procurement of IE3 Motors
▪ Procurement of Star rated AC'S
▪ Procurement of Energy Efficient Transformer
7 Energy audits
a) Process
6 Usage of renewable energy
b) Equipment
2
Employee involvement3
4Information disseminating /
communication
Establishing energy cons.
Norms5
8 Complying legal requirements
9 Resources provision
10Purchase of energy efficient
product
9
Specific Energy Consumption (SEC) Reduction
Copyright © MSSSPL Elect. Dept. Aug 2017
There Is Continuous Improvement In Specific Energy Consumption.
10
Specific Energy Consumption (SEC) Reduction
Copyright © MSSSPL Elect. Dept. Aug 2017
10098
9694
91
80
85
90
95
100
F14 F15 F16 F17 F18 Q1
%
Electrical SEC (GJ/MT) reduction trend (%)
100
7969 69 66
30405060708090
100
F14 F15 F16 F17 F18 Q1
%
Thermal SEC (GJ/MT) reduction trend (%)
9 % Reduction
34 % Reduction
Reduction in Specific Power Consumption from 997 to 878 KWH/MTcs• Electrode Regulation in Arc Furnace• Better Ladle Management in Steel
Melting Shop• Reduction in Cycle Time at Arc Furnace• Heat Treatment Furnace Revamping • Energy Efficient Equipment• Best practices at all shops
Reduction in Specific Fuel Consumption from 121 to 86 Ltrs/MTcs
• Oxy- Fuel technology for reheating Furnaces
• Replacement of Recuperator • Efficient Ladle circulation for heat
optimization• Improvement in planning to
optimize heat sequence
11
National & Global Benchmarking Specific Energy Consumption at Steel Melting Shop [KWH/MT]
Copyright © MSSSPL Elect. Dept. Aug 2017
Commodity Steel
Special Steel BENCHMARK Asia/Pacific
Electrical Arc Furnace = 451 KWH/MT
Ladle Furnace = 64 KWH/MT
Source: BSE Data base 2015
Mahindra Sanyo Electrical Arc Furnace = 454 KWH/MT
Ladle Furnace = 120 KWH/MT**Tool & Die (High Alloy)steel production % higher
12
National & Global Benchmarking
Benchmarking for Electrical Arc Furnace (EAF) Power
Copyright © MSSSPL Elect. Dept. Aug 2017
Asia /Pacific EAF = 451 KWH/MT
Mahindra SanyoEAF –451 KWH/MT
Source: BSE (Germany) Data base
525
451
501
475
454 451
400
420
440
460
480
500
520
540
Sanyo Asia/Pacific MSSSPL F15 MSSSPL F16 MSSSPL F17 MSSSPL F18 YTD
KW
H/M
T
Benchmarking MSSSPL Journey
13
Renewable Energy
Copyright © MSSSPL Elect. Dept. Aug 2017
Road Map to Achieve the Target :
1. Installation of 4 MWh Solar Plant ( Roof Top & Ground) within Plant premises
2. Renewable Power procurement through Open Access
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
[CATEGORY NAME], [VALUE]
Power Utilisation from Different Sources (%)
For FY 18 MTOA Permission is given from July’17 – Total Renewable % will be greater than Plan
Actual
14
GHG Emission
Copyright © MSSSPL Elect. Dept. Aug 2017
1. Reduction in scope-1 : 30% (7650 MT)
100%
81%
73%70%
40%
50%
60%
70%
80%
90%
100%
FY 14 FY 15 FY 16 FY 17
Scope-1 Emission Reduction 100%
99%
90%87%
70%
80%
90%
100%
FY 14 FY 15 FY 16 FY 17
Scope-2 Emission Reduction
1. Reduction in scope-2 : 13% (9120 MT)
15
Energy Monitoring & Measurement System
• Over 90 state of art energy meters installed in the plant for strengthening the monitoring system . Monitoring through SACADA System provided by Schneider.
• Initiated IoT study for next level automation for process monitoring & control.
• Planning for motor management with advance Technology like SIMOCODE
Overall Energy Consumption Breakup/Month
Copyright © MSSSPL Elect. Dept. Aug 2017
Steel Melting Shop, [VALUE]Ring Division,
[VALUE]
Blooming Mill, [VALUE]
Heat Treatment & Finishing Shop,
[VALUE]
Forge Shop, [VALUE]
Rolling Mill, [VALUE]
Continous Mill,
[VALUE]
Conditioning, [VALUE]
Miscellaneous, [VALUE]
Utility, [VALUE]
16
Energy Review
Activities Time Slot 15 Min Daily Weekly Monthly Quaterly Half Yearly Annually
Recording
Monitoring
Max Demand Control
Main Receiving Station Shift Incharge
Shift Incharge
Shop HOD/Team
COO
Managing Director
Analysis &
Corrective Action GAP Analysis
Setting Target Shop wise targets
Meetings
Monitoring &
Controlling
112836365No. of reviews in
a year
Top management involvement in day to day activities of energy management . GAP analysis carried out for deviations.
Copyright © MSSSPL Elect. Dept. Aug 2017
Power & Fuel
Shop Unit Budget F 18 Jun-17 Q1 GAP
A B A vs B
SMS Production MT
KWH/Ton on SMS prod - Varibale Power KWH/T
KWH/Ton on SMS prod - Overall Power KWH/T
SMS MT
EBT KWH/T
LF KWH/T
Auxiliaries KWH/T
SMS - Total KWH/T
CC Pit KWH/T
Blm KWH/T
C Mill
Forge Shop Total KWH/T
Bar-Production MT
Bar - Total KWH/T
Heat Treatment kwh/t (HT + Cnd+ Frg ) KWH/T
Heat Treatment kwh/t (HTFS Fce Only ) KWH/T
SMS -Ltrs / Ton (FO) Ltrs/T
SMS -Ltrs / Ton (Bio Diesel) Ltrs/MT
BLM O2 M3/MT ( Oxy-Fuel Fce 1,2,3,4,5,6) M3/T
BLM Oil Lts/MT ( Oxy-Fuel Fce 1,2,3,4,5,6) Ltrs/T
BLM Oil Lts/MT (Fce 7,8 W/o Oxy Fuel) Ltrs/T
BLM WHF Oil Lts/MT Ltrs/T
Bar Mill - Ltrs / Ton Ltrs/T
Forging - Ltrs / Ton Ltrs/T
Forging ( Fuel Only . Lts/Ton) Ltrs/T
Forging ( Oxygen Only . Lts/Ton) Ltrs/T
Ltr/Ton on SMS prod Ltrs/T
Oil Only Lts/MT in SMS Prod Ltrs/T
Reasons for
variance
17
Energy Projects F 15
Copyright © MSSSPL Elect. Dept. Aug 2017
Electrical Energy Savings :• 2.7 Mio KWH• 18.9 Mio Rs• 2214 Tons CO2
S.N Name of Project (Electrical Energy)
Annual Electrical Saving achieved (KWH Mio)
Total annual saving (Rs Mio)
Investment Made (Rs Mio)
Tons of CO2 Mitigated (Tons CO2)
Paybacks (Year)
1 Heat Treatment cycle time reduction for another 8 grades(HTFS) 0.02 0.11 0 12.6 Immediate
2 Switching of continuous mill transformer whenever plant is off for more than a shift 0.01 0.04 0 5.04 Immediate
3 Saving on HT relay coordination (plant Electrical) 0.02 0.13 0 15.06 Immediate
4 Impeller trimming in 110 KW cold well pump 0.06 0.42 0.01 48.38 Immediate
6 MD monitoring through PLC and SCADA system(SMS) 1.44 10.36 0.3 1205.82 0.002
7 EBT Electrode regulation (SMS) 0.79 5.68 11.66 661.21 0.22
8 Blooming Mill reheating furnace no.3 & 4-Incoopertion of Oxy fuel Technology 0.3 2.17 5.77 252 0.41
9 Transperent sheets in plant roof (Total Plant) 0.01 0.04 0.05 5.04 1.17
10 VFD for combustion blower of Forging chamber furnace 0.01 0.08 0.02 9.66 2.89
Total 2.66 19.03 17.81 2214.81 0.94
S.N Name of Project (Thermal Energy) Annual Thermal Saving achieved (KL)
Total annual saving (Rs Mio)
Invest Made (Rs Mio)
Tons of CO2 Mitigated (Tons CO2)
Paybacks (year)
1 Blooming Mill reheating furnace no.3 & 4-Incoopertion of Oxy fuel Technology 445 12.02 5.77 1188 0.41
Total 445 12.02 5.77 1188 0.41
Thermal Energy Savings :• 3993 KL • 140.5 Mio Rs• 11860 Tons CO2
18
Energy Projects F 16
*Note : Savings mentioned for F 16 includes projects, suggestions, EnMS process controls and best practices .
Copyright © MSSSPL Elect. Dept. Aug 2017
S.N Name of Project (Electrical Energy)
Annual Electrical Saving achieved (KWH Mio)
Total annual saving (RsMio)
Investment Made (Rs Mio)
Tons of CO2 Mitigated (Tons CO2)
Paybacks (Year)
1 Impeller Trimming Cold Well Pump House 0.1 0.8 0.01 120 Immediate
2 LF Cycle time reduction 2.8 19.5 0 2790 Immediate
3Electrode Regulation SMS and effect of scrap Mix , delays & operational factors. 3.1 22 0 3140 Immediate
4 Pipeline modification from Scale pit pump house 0.1 0.8 0 121 Immediate
5 HTFS Power reduction through furnace revamping 0.1 0.5 0.1 70 26 Modification of HT Breaker 0 0 0.05 5 19
7Replacement of incandescent lights . 145 Nos 40 W lights replaced with T5 Lights 0.004 0.03 0.15 4 57Total 6.2 43.63 0.31 6250
S.N Name of Project (Thermal Energy) Annual Thermal Saving achieved (KL)
Total annual saving (Rs Mio)
Invest Made (Rs Mio)
Tons of CO2 Mitigated (Tons CO2)
Paybacks (year)
1 Oxy Fuel for BLM Furnaces no. 5 & 6 445 12.02 5.77 1188 0.41
Total 445 12.02 5.77 1188 0.41
Electrical Energy Savings :• 7.1 Mio KWH• 49.7 Mio Rs• 5822 Tons CO2
Thermal Energy Savings :• 1437 KL • 31.12 Mio Rs• 4267 Tons CO2
Renewable Energy (Wind+ Solar + RPO) • 5.8% of
total power
19
Energy Projects F 17
*Note : Savings mentioned for F 17 includes projects, suggestions, EnMS process controls and best practices .
Copyright © MSSSPL Elect. Dept. Aug 2017
S.N Name of Project (Electrical Energy)
Annual Electrical Saving achieved (KWH Mio)
Total annual saving (RsMio)
Investment Made (Rs Mio)
Tons of CO2 Mitigated (Tons CO2)
Paybacks (Months)
1Optimization of Scrap Mix, Early Foaming started through use of Lump coke in EAF 2.08 15.0 0 1700 Immediate
2LF Cycle time reduction & Better insulation practice to avoid Temp. drop after Vacuum Degassing 0.96 6.92 0 787 Immediate
3HTFS Furnace Revamping & Refractory work
0.6 4.29 1.25 490 4
4Installation of Energy Efficient Equipment like Transformer, LED Light , Star rated AC’S, IE3 Motors 0.04 0.27 1.02 35 22
5 KAIZENS, Suggestion, Best Practices 0.03 0.21 0 25 Immediate
Total 3.7 26.0 2.27 3030
S.N Name of Project (Thermal Energy) Annual Thermal Saving achieved (KL)
Total annual saving (Rs Mio)
Invest Made (Rs Mio)
Tons of CO2 Mitigated (Tons CO2)
Paybacks (Months)
1
Replacement of Old Manifold with new result in Delay reduction, Saving in Oil consumption at FRG Shop
263 6.05 2.50 800 5
2Modification of Burner Block in Furnace at FRG shop
176 4.04 0.25 530 1
Total 439 10.09 2.75 1330
Electrical Energy Savings :• 3.7 Mio KWH• 26.0 Mio Rs• 3030 Tons CO2
Thermal Energy Savings :• 439 KL • 10.09 Mio Rs• 1330 Tons CO2
Renewable Energy (Wind+ Solar) • 6.95% of total
power
Cumulative Saving from FY 15 to FY 17
Electricity MIO Kwh 14
Fuel KL 5869
T-CO2 MT 28523
Cost Mio Rs. 276
20
Energy Projects F 18– 20
Road Map from FY 18 - FY 22
1. Reduce Specific Power Consumption by 20 % 2. Reduce Specific Fuel Consumption by 35 %3. Utilization of Renewable Energy : 20 % of
total power consumption4. Reduction of Scope-1 emission by 35 %5. Reduction of Scope -2 emission by 40 %
* Base year is FY 13
Copyright © MSSSPL Elect. Dept. Aug 2017
Projects F 18 F 19 F 20
Control Cooling Pit Revamping –BLM & FRG
Solar Power 4 MW Installation
Waste Heat Recovery
Natural Gas – All reheating Furnace
Sl.No. Projects Description Estimated Saving (MU/Year)
Estimated Tons of CO2 Mitigated(T CO2/Year)
1.Waste Heat recovery for Power Generation from EBT Furnace waste flue gases
8.64 7084
2. Control Cooling Pit Revamping at Blooming Mill & Forge Shop 0.92 755
3. Installation of Solar Plant of 4 MWh in Plant premises 6.96 5700
4. Natural Gas for all reheating Furnace instead of Furnace Oil 0.6 3200
21Shaswati Council Meeting
Energy Month Celebrations
Team Work In Energy Conservation
Cross Functional Teams
Copyright © MSSSPL Elect. Dept. Aug 2017
Energy Team
Shop Floor Training for Energy Conservation
Nos. of KAIZENS during FY 17 : 346
Nos. of suggestions received during Energy
Month : 45
Total suggestions implemented : 24
Total saving achieved after implementation all
suggestions : 34641 KWH/Year
22
Utilization of Waste as Fuel
Copyright © MSSSPL Elect. Dept. Aug 2017
Waste Utilization Process Flow
Canteen Food Waste Waste Transport
Bio Gas generation
& Storage Gen-SetStreet Lighting
23
Utilization of Waste as Fuel
Copyright © MSSSPL Elect. Dept. Aug 2017
Food Waste Utilization For Promoting Green & Clean Energy –
MSSSPL has initiated food waste utilization drive in collaboration with KMC (Khopoli Municipal Corporation) –To generate Electricity from Food Waste.
MSSSPL Contribution
KMC Responsibility Waste collection- 0.3 T / Day
Waste transfer to KCM Facility Waste segregation Gas generation Electricity generation Plant Capacity
Energy saved by recycle of waste during FY 17
Total Refractories Recycle = 423 MT
Total Power saved under scope III at manufacturing end =100674 KWH (238 KWH/MT Specific Electricity Consumption)
Total Mill Scale Recycle = 4626 MT
Total Power saved = 9252 KWH
24
Aspect Vision
Scope - 1 emission reduction by 10%
Scope - 2 emission reduction by 5%
Scope - 3 emission reduction by 5%
Water consumption reduction by 10%
Collaborate to have environmentally and socially responsible suppliers only
Mode of Engagement
Copyright © MSSSPL Elect. Dept. Aug 2017
Organized sector 7 workshops65% Tier I Suppliers engaged
Capacity Building & Alignment, Deep Engagement
Unorganized Sector4Workshops + 2Follow-up sessions
25 Tier-1 Suppliers engaged
Capacity Building through Story Telling, Mitigation of Social Hotspots
Sustainable Supply Chain Management
25
Sustainable Supply Chain Policy and CoC in placed
Collection of baseline data and audit framework in place
Use Of SoFi for supplier data base
Capacity Building of Suppliers through supplier meet
Best Supplier award
collaborative projects based on circular economy
Participating in Road Testing of a GHG footprinting tool by India GHGP and
Climate Miles
Creating a pool of certified Internal Auditors on BS 8903 Framework
Copyright © MSSSPL Elect. Dept. Aug 2017
Actions & Initiatives
26Copyright © MSSSPL Elect. Dept. Aug 2017
Innovation Project 1 Resource Intensity & Recycle Input – Improved Liquid Metal Yield (%)
Action taken for Improved Liquid Metal Yield1. Controlling of Scrap Quality wrt contamination and density2. Preventing over oxidised of bath by controlling oxygen during Melting &
Injecting more carbon.3. Use of Smaller Slag Pot for Liquid Metal dumping after Casting.
Need of the Moment : To recycle waste efficiently and promptly so as to save time, energy and environment.
Specific Contribution: The recovery time of Skull was drastically reduced, ease of recovery increased, liquid metal wastage reduced.
Method Implemented: As compared to earlier, where the liquid metal was directly dumped on the ground, Now collecting the liquid metal in small slag pots and then using the solidified mass for steel making helped to achieve the specific contributions as mentioned above.
27
Results
Innovation Description: Earlier, process involved dumping of liquid metal on ground after casting. This
process led to formation of irregular skull and inclusion of dust in the skull hence making the recovery hard.
The recovery of skull consumed more time and also it required Oxygen to cut that skull.
After the introduction of small slag pots, the dust contamination and irregularities in shape were diminished & Recovery time reduced
In future, direct hot metal can be used to charge back in Electrical Arc Furnace to decrease power greatly while increasing efficiency.
Copyright © MSSSPL Elect. Dept. Aug 2017
Average Yield Improvement (%) 1%
Reduction in Electrical Arc Furnace Power (KWH/MT) 3
Power saving /Year (KWH) 4,80,000
Cost saving / Year (MIO Rs.) 3.36
Reduction in CO2 Emission (T-CO2 )/Year 394
28Copyright © MSSSPL Elect. Dept. Aug 2017
After Implementation
250X200 ɸ Cast No-CXXXX
Grade- XYZ
250X200 ɸ Cast No-CXXXX
Grade- XYZ
250X200 ɸ Cast No-CXXXX
Grade- XYZ
Dummy Bloom
160x160 ɸ
250X200 ɸ Cast No-CXXYY
Grade- ABC
250X200 ɸ Cast No-CXXYY
Grade- ABC
250X200 ɸ Cast No-CXXYY
Grade- ABC
FURNACE (20 T)To Roller Table for Rolling Process
Dummy Bloom is removed with help of crane
250X200 ɸ Cast No-CXXXX
Grade- XYZ
250X200 ɸ Cast No-CXXXX
Grade- XYZ
250X200 ɸ Cast No-CXXXX
Grade- XYZ
250X200 ɸ Cast No-CXXXX
Grade- XYZ
250X200 ɸ Cast No-CXXYY
Grade- ABC
250X200 ɸ Cast No-CXXYY
Grade- ABC
FURNACE (20 T)To Roller Table for Rolling Process
Innovation Project 2 :
Reduce use of cast separator (partition) of Continuous Casting Route Material in
Furnace
29
Project Details
Copyright © MSSSPL Elect. Dept. Aug 2017
Before After implementation
A dummy Bloom of lesser size is used to identify / Separate two different cast charge in Furnace
A smaller tapper cut on both ends in last Bloom of each heat cast in Continuous Casting Route material Now we are charging such Bloom at
end of cast & it is use to identify /separate cast charge in furnace.
Benefits :Average Rolling /Month = 4800 MT Average Dummy Bloom / Month = 150 Nos.Average Wt. of Partition = 250 KGTotal Wt. / Month = 37.5 MTTotal Oil Saving /Month = 1.5 KL @ 40 Ltrs/MTTotal Oil Saving /Year = 18 KL Cost Saving /Year = 5.4 LakhsT-CO2 reduced / Year = 55 MTAlso it leads to Human Safety - Reduce work in Hot Condition
30
Innovation Project 3
Replacement of Housing Colony Transformer
Copyright © MSSSPL Elect. Dept. Aug 2017
As per previous records we can reach to a conclusion that we have almost achieved savings at major areas so after brain storming we have decided to go for further energy losses in equipment section. Major gateways of power to an industry are power transformers. So we have started analysis of power transformers.
After Power analysis & Test report – Concluded to replace 1000 KVA Transformer
Problems Addressed : Transformer is 48 years old – outdoor open bushing type transformerAs per test report – Furan content found more than 2.5 mm/Kg, Which is not permissible limitTransformer Loading – 20 %, Breakdown were more, Total Loss -825 Min.No- load loss – 2000 W & Load Loss – 7000 W
Conclusion Drawn : As Transformer is 20 % loaded – Decided to Install 500 KVA Transformer
31Copyright © MSSSPL Elect. Dept. Aug 2017
Before After
RESULTTransformer Capacity : 1000 KVATransformer Loading : 20 %Transformer No-Load Loss : 2 KWHTransformer Load Loss : 7 KWHBreakdown Time : 825 Minutes
(Past Three years Data)
500 KVA60 %0.8 KWH3.2 KWH0 Minutes (1 year Data)Yearly Power saving of 8500 KWHCost Saving : Rs. 60,000T-Co2 saved : 7 MT
32
Water Management Resulted In Energy Saving
Initiatives taken to reduce specific water consumption
Use of STP treated water for industrial top up after filtration Underground piping is taken above ground Rain water harvesting
More than 400 hrs.
Pumping Saved per year
23,011 Kwh /Year
Energy Saved
Results :
Total Water withdrawal decreased by 13%
Specific Water consumption per ton of production Improved by 25%
Copyright © MSSSPL Elect. Dept. Aug 2017
33
MSSSPL | Awards & Recognitions
Copyright © MSSSPL Elect. Dept. Aug 2017
16th National Award for Excellence in Energy Management 2015:Energy Efficient Unit in Steel Sector & Most useful presentation in Steel
Sector
17th National Award for Excellence in Energy Management 2016:Excellent Energy Efficient Unit in Steel Sector & Most useful presentation in
Steel Sector
Article on Best Practices case study at MSSSPL had been published in Institute of Industrial Productivity –BEE NEWSLETTER magazine
34
MSSSPL | Awards & Recognitions
Excellence in Energy
Management 2015 & 2016Energy Efficient Unit
Game Changer Award
2015
Mahindra Sustainability
Award 2013
Innovation Award
2015
Best Improved Plant
Safety 2014
Copyright © MSSSPL Elect. Dept. Aug 2017
35Copyright © MSSSPL Elect. Dept. Aug 2017
Way ahead..
Mahindra Sanyo becomes 1st steel
company from India to signed SBT Commitment
in March 2017
Announce Science Based Target for
Mahindra Sanyo by March 2018
To anticipate government legislation on carbon pricing To avoid intermediary/transaction costs associated with
trading permits in national schemes in favor of factoring in these prices internally
To justify investments that may have smaller margins without a carbon price
To manage risk for future investments To monetize and record social cost
Internal Carbon Pricing