Energy Management Practices at Tata Sponge

Transcription

1 Energy Management Practices at Tata Sponge Bijay Kumar Agrawal Head(Electrical), CEA(EA-11295) S.K Sahoo, Manager(Operation) S.B.Mohanty, Dy. Manager (Mechanical)

2 Tata Sponge Fact File DRI Capacity : Power Generation: 390,000 MT/Yr 26 MW Consistently earning YoY profits for the past 20 years & paying dividends First DRI company to earn CDM benefits First DRI company to be certified in ISO-9001, ISO & OHSAS st DRI Company to receive TPM Certification in the World. Energy Conservation award from CII (ER) for Frost & Sullivan Green Manufacturing Award (Gold Category) 13 on Quality {4 from CII (ER)} 15 awards on Environmental care 16 safety awards, 4 appreciation on CG, 2 on HR, 1 on value creation,.

3 Manufacturing Process Thermal Energy Use/Loss Electrical Energy WHR/Power Gen/Export 4 4

4 Efficiency Effective The Q Approach WITH WHAT (Philosophies & Tools) Rotary Kiln equipment Power plant equipment. 220KV System equipment Right Mix of Coal Procurement TPM Methodology/ Statistical Tools INPUTS WITH WHOM (Competence/Support) Support from Promoter 3 level structure Competent & skilled Workforce Professional Consultants OUTPUTS BEE/PAT Targets in ToE Energy Policy Energy Audit recommendations Best Practices & Benchmarks Energy Management Reduction in Sp. Energy consumption Compliance to PAT target Reduction in tco2 emission per ton of DRI HOW (Procedures & Methods) Energy Awareness Campaign Approach to Energy Efficiency Improvement Activities Implementation of energy audit recommendations IT Based Systems (KPI tracking, ERP) Automations to check energy wastage Reduction in C/Fe Ratio Reduction in Coal per ton of DRI Sp. Steam Consumption WHAT RESULTS Increase in Power Export to Grid Reduction in SEC(Elec), Reduction in SEC (Thermal)

5 SEC PAT SEC reduction target by BEE Baseline SEC Target SEC Reduction in SEC Y1 Y2 Y3 Baseline SEC : ToE /MT of SI Target SEC : 0.551ToE /MT of SI Baseline production : MT PAT cycle :

6 Energy Policy As an energy intense manufacturer of Sponge Iron through Coal based DRI Kilns & Power Generation through WHRB strives to reduce its energy consumption and costs and promote the long-term environmental and economic sustainability of its operations. We are committed to: Reduce energy use per ton of production by 7.5 % in 5 years in our operations. Ensure continual improvement in our energy performance. Deploy information and resources to achieve our objectives and targets. Uphold legal and other requirements regarding energy. Consider energy performance improvements in design and modification of our facilities, equipment, systems and processes. Effectively procure and utilize energy-efficient products and services. Managing Director Tata Sponge

7 3 Levels Energy Team Structure Managing Director Production Chief Operating Officer A Power Plant Energy Auditor Maintenance & Utilities Core Group1 Core Group2 Core Group3 Core Group 4 Working Group Working Group Working Group Working Group

8 Process for Energy Awareness Campaign Planning Implementation Checking & Review Support & Resources Current level Target Audience Message & communication Channel Assign role & responsibilities Gather & Prepare promotional materials Launch programme Compare present energy consumption level with target level Measure the success of the programme Feedback Report to staff & Management Maintaining Energy awareness section in start up kit to new employees Maintaining the momentum Campaign tool: suggestion scheme, competition, reward & recognition,

9 Awareness Training on ISO 50001(EnMS) BSI Certified Lead Auditors for ISO EnMS: 2 nos 3 days in-house training on awareness on ISO conducted 25 persons from various functional areas participated Effectiveness of the training was evaluated through a test Various forms & formats were developed as a part of implementation of the EnMS Implementation plan was formulated & it is in progress.

10 Approach to Energy Efficiency Improvement Activities Mapping of Energy Consumptions(Electrical & Thermal) Identifying Thermal & Electrical Energy Losses Formulation & Prioritization of Action plans for both Thermal & Electrical ENCON projects Form C F Team for Implementation of the ENCON Projects Data Collection Analysis of Energy losses Develop Kaizen Ideas for ENCON Prioritization of options & kaizen Implementation No Check & Review External Energy Audits PAT Targets/Obligation ISO methodology Best Practices/Benchmark Climate Change Policy New Technologies Training Target achieved? Yes R&R Training Upload in Knowledge Portal Daily review through KPI Tracker, ERP/SAP, Fortnightly review by COO(SB) Monthly review by MD

11 Encon Projects(illustrative) implemented-electrical Energy Replacement of Impeller of Kiln #2 ID fan motor (3.3KV,260KW motor) Replacement of under loaded LT motors with correct size motors of DE system of Kiln#1 & Kiln#3 Auto Operation of Cooling Tower fan motors (2X22KW) of Kiln#3 with Sponge Temperature. VFDs for pump motors running in throttled condition( 2X90 KW Hot Well Pump Motor & Cold well pump motor of Kiln#3) Different VFD panels for odd & even set of SAB motors of Kiln#1 Delta to star connection for cooling tower motors (2X15KW)of Kiln #1 Use of day light in mechanical workshop & conveyor galleries by replacing some of the GC sheets with transparent sheets. Improvement of power factors at MCC level and maintain at >0.95 Lighting control through timers.

12 Encon Projects(illustrative) implemented-thermal Energy Use of 100% South Africa Coal (both feed & injection) and use of 0-3 mm fines in feed side without rejecting any fines. Changing the coal ratio from 60:40 to 45:55 (feed: injection) (Period 15th Jun'2014 to Till date) Kiln Shell Painting with heat resistant Paint to reduce the radiation temperature by 20 degree cent. Covering the coal heap from exposure to moisture at Paradeep Port to reduce moisture absorption. Covering the coal heap at TSIL yard to reduce wind loss.(0.19% in from 0.31% in ) Covering coal in transit (wagon & truck) to reduce loss. (Transit loss reduced from 1.08% in to 0..55% in ) Use of "Thermact" as additives in feed coals for proper combustion of coal inside the Kiln-2(efficiency improvement) Top Management s involvement in enhancing productivity. Operative plants at more than design value( daily production is ranging between 1250 to 1350 MT /day against design capacity of 1250MT/day, 7.8 MW from 7.5MW PP and 19.2MW from 18.5MW PP)

13 Arrangement showing feeding of Thermact (catalyst) inside the Kiln After application of Heat Shield Paint on the kiln shell

14 Covering of Coal at Yard Covering of Coal at Paradip Port Brining Coal in covered wagon

15 Snap Shot of the KPI tracking system

16 Ratio Lead/KPI/Efficiency Measures Carbon to Iron(C/Fe) Ratio Good (Upto Dec'15) (Target)

17 MT of Coal /MT of DRI Lead/KPI/Efficiency Measures, Contd.. Good Specific Coal consumption(ground) per ton of DRI (Upto Dec'15) (Target)

18 MT of Coal /MT of DRI Lead/KPI/Efficiency Measures, Contd.. Good Specific Coal consumption(fed to Kiln) per ton of DRI (Upto Dec'15) (Target)

19 Steam in Ton/MW Lead/KPI/Efficiency Measures, Contd Specific Steam consumption (7.5MW Power Plant) 4.38 Good (Upto Dec'15) (Target)

20 Steam in Ton/MW Lead/KPI/Efficiency Measures, Contd Specific Steam consumption (18.5MW Power Plant) 4.37 Good (Upto Dec'15) (Target)

21 Kcal/Kg of DRI Lag/KPM/Effective Measures, Contd Good Specific Thermal Energy Fed to kiln(kcal/kg of DRI) (Upto Dec'15) (Traget)

22 kwh/mt of DRI Lag/KPM/Effective Measures, Contd Good Specific Electrical Energy Consumption (Upto Dec'15) (Target)

23 Million Units Lag/KPM/Effective Measures, Contd Good Power Export (Upto Dec'15) (Target)

24 MJ/MT of SI Specific Energy Consumption (MJ/MT) including losses Good (Target)

25 Status of Specific Energy Consumption (SEC) achieved as per M&V report under Perform Achieve Trade(PAT) methodology We are the only Designated Consumer under Iron & Steel sector in Odisha state who has submitted all the requirements of PAT compliance within deadline of 30 th Jun 15. Total DCs under Iron & Steel sector:- India:67nos ; Orissa:15 nos Notified Baseline SEC: 0.581ToE/MT Notified target SEC: ToE/MT. Reduction target: 0.03ToE/MT Over Achieved SEC reduction target. We have claimed quite a good nos of Energy Saving Certificates for our effort.

26 tco2/t of DRI Environmental Concerns CO 2 emission Good (Target)

27 ENCON Projects- Ongoing The following pilot projects have been taken up with the help of external agencies to improve thermal energy efficiency of the plant. 1) Working further with supplier to improve life of the paint to reduce the radiation loss. 2) Exploring technological options (Oxygen Enrichment) to improve utilization of Thermal Energy. 3) Exploring technological options for recovery of heat which is being lost a)from exhaust gas (which is at C ) b)indirect cooling of product from 1050 C to 100 C

28 Thank You