JSW STEEL COATED PRODUCTS LTD Kalmeshwar (Maharashtra)

Transcription

1 Second Prize Steel Re-Rolling Mills JSW STEEL COATED PRODUCTS LTD Kalmeshwar (Maharashtra) Unit Profile JSW Steel Coated Products Limited Kalmeshwar is the part of JSW Group, a major player in steel industry with a formidable presence in Steel, Energy, Cement and Ports. JSW Steel Ltd has become a single largest steel plant in India through speed and innovation in short span of time. JSW Steel Coated Products Limited (JSWSCPL) Kalmeshwar, is a 100 % subsidiary of JSW Steel Ltd., having manufacturing facilities of Cold Rolled, Galvanising, Galvalume & Color Coated steel products. JSW Steel Coated Products Limited Kalmeshwar, is strategically located in the geographical center of India to cater the domestic needs of Coated Steel. JSWSCPL Kalmeshwar is the First successful producer of 550 & 600 GSM Zinc Coated Galvanized steel for Solar Power Modules Structures JSW,Kalmeshwar is among few to have ISO 9001: 2008 (QMS), ISO : 2004 (EMS),BS OHSAS: 18001, EN ISO 50001:2011 which have been integrated & Executed successfully all across the plant. 494

2 Specific Energy Consumption 495

3 Energy Conservation Initiatives Turnaround took place at JSW SCPL Kalmeshwar, with lot of energy conservation initiative in last five years. Adoption of new technologies, using of VFD, DC to AC conversion of process units, use of energy efficient equipment, LED, centrifugal compressor & many more energy saving step make one of the most energy efficient complex to JSWSCPL Kalmeshwar among all the three location of JSW SCPL. 496

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5 Second Prize Steel Re-Rolling Mills BHUSHAN STEEL LTD. Dist. Raigad (Maharashtra) Unit Profile Bhushan Steel Ltd. (BSL) Khopoli plant, commissioned in 2004 has been playing a remarkable role in the growth of industrial steel production in India. Bhushan Steel is leading the technological revolution in Indian Cold Rolled Steel Industry today and defining new frontier of customer satisfaction. Be it through technology and product upgrades, R&D efforts or stringent quality control measures, company is consistent in its pursuit of value addition. BSL has also implemented SAP as a process. Bhushan steel is retaining a leading position in national & international market for its range of products like Cold rolled, Galvanized steel, Pre-painted galvanized iron (Color coated), Hardened & tempered steel, High tensile strapping steel for packing material, electrical grade of steel, ERW/ CEW precision tubes for automobile industries & HFW API pipes for petroleum industries. The production capacity of Khopoli Plant is MT per annum of secondary steel including of MT per annum of Cold Rolled Steel, MT per annum of Galvanized Steel, MT of precision tube, MT of Colour Coated Steel, MT of HTSS, MT of Hardened & Tempered Coils & sheets, MT of API Pipes, casing pipes, pipe for low pressure service, round pipes and tube for mechanical and structural pipes and square structural pipe. 498

6 This Plant has facilities such as continuous H&T (hardening & tempering) line with Lead Metal Quenching Bath from EBNER Austria, Allied India and High Tensile strapping line from DAEHYUN, Korea. Precision Tube mills have been installed based on the technology & design from KUSAKABE, Japan and equipment have been supplied by Gallium Industries, (India), and Rollcon (India) having high frequency solid state welders from THERMA TOOL, U.K and Cyber Couplings for smooth transmission from DOLTEL, U.K. Besides these the state of art roller hearth furnace for bright annealing / normalizing of Carbon Steel tubes under protective gas atmosphere from LOI THERM PROCESS GmbH, Germany has been installed. Energy Consumption Trend (SEC) of Last Two Financial Year: Energy Conservation Measures Implemented in : S. Year Annual Annual Fuel Savings Total No. ( ) Electricity Coal FO/LSHS/ Gas (MkCal) Saving (Metric HSD/RFO (Lakh m 3 ) (Lakh kwh) Tonnes) (kl) 1 Condensate Recovery from R.F.O. yard (Tank Farm Area) To achieve reduction in CCL Electrical energy consumption during Idle running of Colour Coating Line. 11 nos. of motors stop automatically after 2 min. of line stop Timer provided through PLC program. 3 Thyristor drive installed at Ammonia cracker No-3 control Panel. 4 VFD drive install at CT Fan No-6. 5 Set the A/G Ratio, Flue Gas analysis of Galume Funace & fine tuning of Burners done. 6 Replace the shaft coupling by a smaller size lovejoy coupling in Skin Pass Mill HP Pump in GP 2. 7 VF Drive used at CAG# (GP#2) WIDER. 8 VF Drive used at CAG#1 (GP#2)WIDER

7 S. Year Annual Annual Fuel Savings Total No. ( ) Electricity Coal FO/LSHS/ Gas (MkCal) Saving (Metric HSD/RFO (Lakh m 3 ) (Lakh kwh) Tonnes) (kl) 9 VF Drive used at HAD Comb blower in GP-2 Wider. 10 VF Drive used at CAG# (GP#2)WIDER. 11 Reduce speed of Spooner blower by doing modification in GP-2 PLC depending on line speed and size of coil. 12 VFD Installation on 4 HI MILL-1, Coolant System. 13 VFD Installation on 4 HI MILL-2, Coolant System. 14 Installation of LED Light W in Transformer Room (MILL AREA) 15 H&T- 1 Electrical Control Room AHU Motor Controlled by VFD. 16 H&T- 2 & 3 Electrical Control Room AHU Motor Controlled by VFD. 17 Grinding Line-1 Electrical Control Room AHU Motor Controlled by VFD 18 Strip Grinding Line Control Room Lights controlled by DOOR CLOSER SYSTEM. 19 During Line Idle Condition HYD.Motor Controlled (CRS 1,2,3& 4) 20 Main Control Room AHU Motor-1 Controlled by VFD. 21 Main Control Room AHU Motor-2 Controlled by VFD. 22 Provided V.F. Drive of (6Hi Mill-2 ECR) AHU Blower motor (11kw ) for controlling the speed of motor as per air flow (temp.) requirement. 23 VFD provided in GP#2 PHF Comb. Blower-1 Total

8 Energy conservation measures in last 5 years: New technology Initiatives for Energy Conservation: (1) KVX System: BSL has implemented KVX module for fuel treatment technology that helps reduce fuel consumption by 5% and CO emission by 30%. KVX system infuses energy in the hydrocarbon chain, intra molecular, and pro item, to improve the kinetic of fuel. (i) Substantially reduce energy consumption. (ii) Drastic decrease in CO emission. (iii) Significantly lower soot formation. (iv) Lower maintenance cost and downtime. (v) Increase in plant and equipment efficiency. KVX System on gas fired Boiler KVX System on Color Coating Line Furnace Investment: Rs 36,00,000 Investment: Rs 40,00,000 Saving: Rs. 1,13,81,076/yr Saving: Rs. 1,18,36,000/yr 501

9 (2) Installed approx more than 40 VVF drives in last 5 years in the plant: Energy Policy: 502

10 Management System (EnMS 50001: 2011) Certificate: 503

11 Certificate of Merit Steel Re-Rolling Mills JSW STEEL COATED PRODUCTS LTD Tarapur (Maharashtra) Unit Profile JSW Steel Coated Products Ltd- Tarapur plant is acquired in 1982 and it is India's largest producer and exporter of Coated Products to Europe, Africa, North and South America and Middle East regions. Plant marks one of the first milestones for JSW Steel Ltd, by commissioning first Galvanizing line (CSD-I) in JSW group. The plant has five cold rolling mills, five GI/GL coating lines (two dual pot lines and three ultrathin product lines) with a total capacity of MTPA to produce value added Galvanized & Galvalume products and two Color Coating lines with a capacity of MTPA. The complex also has 30 MW captive power plant. Hot Rolled Coil (HRC) is sourced from JSW Steel Ltd, Vijayanagar & Dolvi plants.jsw Steel Coated Products Ltd, Tarapur is a certified QMS ISO 9001:2008, OHSAS ISO 18001:2007, EnMS ISO 50001:2011 unit. 504

12 Major Achievement / Initiatives in FY Certification of EnMS ISO 50001:2011. Certification of OHSAS ISO 18001:2007. Technology Upgradation & Redesigning of CSD-1 Furnace. Achievement of Potential Saving in Boiler Feed Pump. Distribution of 8000 LED lights under DELP Scheme. Energy Consumption: Parameters Unit FY FY Coated Production MT Electricity Consumption Lakh kwh Specific Electricity Consumption kwh/mt Thermal Consumption Million kcal Specific Thermal Consumption Million kcal/mt

13 Energy Conservation Measures Energy Conservation Annual Energy Saving Annual Measures Saving Investment Electricity Thermal Rs Lakhs Rs Lakhs (Lakh kwh) (Million kcal) Replacement of ceramic fibre lining by pyro bloc module lining in Non-Ox furnace in CSD-3 Technology Upgradation & Redesigning of CSD-1 Furnace Corrocoating of Circulating Cooling Water pump Variable Frequency drive Installation in Boiler Feed Pump Power Factor Improvement of CPP Nil Replacement of Conventional lights by LED lights Covering of Zinc pot Surface to avoid heat loss Operation of CCL Compressor in closed loop Replacement of old pump by Efficient Pump Total

14 Energy Policy 507