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2015 PA Strategic Energy Management ShowcaseGerdau Sayreville Mill

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Topics to be Covered:

• Steel making process introduction and energy challenges• Lessons Learned in Certification• Interaction with Auditors• Importance of Good Metering• SEUs• Pumphouse upgrade leading to energy savings

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3Scrap received by rail and truck loaded on ConSteel Conveyor by Gantry crane

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Scrap fed into Electric Arc furnace and melted to 3000 deg. Using 3 24” diameter graphite electrodes

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5Steel is tapped into ladle when final temperature is achieved

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Ladle is transported to Ladle Heating station with crane for final additions and temperature

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7Ladle is place on casting turret and opened to begin casting

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Tundish (see insert) is filled and individual slidegates opened to begin casting into copper molds

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Billets are cut to length using automatic torches and taken to reheat furnace in Rolling Mill or stored in inventory

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Red Hot billets taken to Rolling Mill reheat furnace directly from caster using a billet buggy drastically reduce reheat energy.

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11Billets discharge reheat furnace into rolling stands

12Up to 14 rolling stands used to achieve final bar size

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13Final bars are sent to cooling bed from 120’ to 180’ lengths

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Bars are sheared to length using gauge stop and 500 ton shear (left in picture)

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Bars are bundles using automatic tyers and rolled onto surge table to be picked up for storage or shipment using magnet cranes

16Finished products ranging from 20’ to 60’ staged in warehouse

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17Finished product can also be directly loaded to railcars

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Finished product can be loaded directly from production line to trucks also or from warehouse stacks

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19All finished goods either by rail or truck are weighed prior to delivery to customer

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Lessons Learned in Certification

• Pre-existing ISO 9001 & ISO 14001▫ Don’t reinvent the wheel▫ Modify existing manual to include EnMS▫ Draw from existing resource’s expertise▫ Seek auditor training in all standards

• Perform and document thorough energy review• Select manageable SEUs using relevant criteria• Ensure general awareness across the workforce

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Challenges

• Document Control▫ Uncontrolled forms found in operating area▫ Awareness Training presentation uncontrolled

• Scope and Boundary• Procurement Process▫ All CAPEX purchasing considered in EnMS▫ Added all non-CAPEX equipment over 300KW

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Working with Auditors

• Be sure to fully educate the auditor to understand the process

• Use two way dialog, agree on direction• Don’t be argumentative, but firmly state views

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Metering

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Criteria for Selecting SEUsStep 2.5.4 Criteria and Ratings for Prioritizing Energy Opportunities

This form can be used to list and define criteria for prioritizing energy opportunities (also known as “energy projects”) using a 4-point rating scale (e.g. 1-2-3-4 or 5-10-15-20, etc.) and defining each point on the rating scale for each criterion.

This method for prioritizing energy opportunities assumes that all criteria would be of equal importance (i.e. weighted equally). Higher ratings numbers result in higher need for Priority

CRITERIA RATING SCALE and DESCRIPTION

[1] [2] [3] [4]1) Safety & Environmental Increased negative impact

on environmental, health, and/or safety conditions

No change to environmental, health, and/or safety conditions

some Improvement environmental, health, and/or safety conditions

Substantial Improved environmental, health, and/or safety conditions

2) Energy consumption Less than 5% 5%-20% 20%-40% 40% and above

3) Opportunity for Improvement Less than 5% 5%-10% 10%-20% 20% and above

4) ROI 5 yrs and over 2yrs - 5yrs 6 months - 2yrs 0-6 months

5)

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SEU PrioritizationStep 2.5.4 Worksheet for Prioritizing Energy Opportunities

This worksheet can be used to rate energy opportunities using the criteria and rating scale you have defined in the table above. Transfer a brief description of each criteria from the table above into the brackets of the appropriate column. Incude a brief title or description of the opportunity

(or project) in the far left column. Rate each opportunity against each criteria. The opportunity score is obtained by multiplying the rating numbers together for each opportunity. Compare the opportunity scores to determine the priority. Higher opportunity scores reflect higher

priority. Score over 40 will be considered an SEU.Description of Opportunity [Criteria #1]

Assigned Rating

[Criteria #2] Assigned

Rating

[Criteria #3] Assigned Rating

[Criteria #4] Assigned

Rating

Opportunity Score (1 x 2 x 3 x 4)

Reheat Furnace: Hot charge control 4 3 2 2 48

Ladle Preheater 3 2 4 3 72

Tundish Dryer 4 1 3 3 36

Water Pumping System (replacing CT-2 & CT3) 2 1 3 2 12

Mill Stand Motors 2 2 1 2 8

Air Compressor Systems 2 1 3 3 18

EAF & LHS 2 4 2 3 48

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Machine Cooling Water System Upgrade

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Results in Energy Savings

• Baseline Energy consumption from Energy Review

• New Automation to allow monitoring and control

• Trials of Various operating parameters• Developed Operating Standards• Cost of operation of the water system reduced

by 61.3%