Steel Coated Product Limited, Vasind

Transcription

1 Steel Coated Product Limited, Vasind CII National Energy Efficiency Circle Competition Presenters: Mr. Anish Karahe- Sr. Manager Ms Aditi Chauhan- Jr. Manager

2 O P Jindal Group Jindal SAW JSL Stainless Jindal Steel and Power Mr. Prithvi Raj Jindal Mr. Sajjan Jindal Mr. Ratan Jindal Mr. Naveen Jindal Shri. O. P. Jindal Where others see walls.., I see doors.. Jindal ITF Jindal Waterways Jindal Transrail Jindal Water Infrastructure Jindal Urban Infrastructure Jindal Shipyards Jindal Rail Infrastructure JSW Steel JSW Steel Coated Products Ltd JSW Energy JSW Infrastructure JSW Cement JSW GBS JSW Sports JSL Media JSL Lifestyle JSL Architecture Green Delhi BQS JSS Steel Italia PT Jindal Stainless, Indonesia Jindal Stainless Steel ways Jindal Power Jindal Petroleum Jindal Steel Bolivia Jindal Cement JSW Foundation

3 JSW Group Steel India s Leading integrated Steel Producer (18 MTPA) Vijayanagar 12 MTPA Salem 1 MTPA Dolvi 5 MTPA SCPL 100% Subsidiary of JSW Steel India s Leading Coated Steel Producer (1.8 MTPA) Kalmeshwar 0.6 MTPA Tarapur 0.76 MTPA Vasind 0.45 MTPA Energy Engaged across the value chain of power business (Operational plants capacity: 4,531 MW) Infrastructure Engaged in development and operations of ports (Operational capacity: 70 MTPA Cement Manufacture of PSC, OPC and GGBS cement, (Operational Plants capacity 10.3 MTPA) 3

4 MEDA 12 th State Level EC Award CGL Speed Increase CCL Local Burner Installation EMS 14001:2015 Certification EnMS ISO 50001:2011 Certification OSHAS 18001:2007 Certification CII-2017 Commendation Certificate Road Map Commissioning of PLTCM Capacity increased by 300% CII-GreenCO Certification IMC RBNQA-2016 Excellence Trophy Installation of On Line Skin Pass CII Energy Audit Entitled as Designated Consumer of PAT Power Open Access RLNG Supply Line From GAIL Installation of Colour Coating Lines s 2011 Earned 1871 ESCerts in PAT -1 Installation of Railway Yard 2003 Installation of CGL-2 Installation of CGL-1 & CRM QMS ISO 9001 Certification 1990 Installation of CRM-3

5 1. Specific Energy Consumption Energy Sources Energy consumed at Vasind RLNG GAIL Energy Sources Power GCal 31% RLNG GCal 69% RLNG Electrical Power JSW Energy Open Access Electrical Power RLNG 6.49 Lacs MMBtu/A GCal/A 885 Lac kwh/a GCal/A Electrical Power Total : GCal/A 5

6 1. Specific Energy Consumption Process wise Energy Consumption Annual Consumption FY-18 Area Power(Lac kwh) RLNG(Lac MMBtu) Energy in Gcal Pre-Rolling Rolling Galvanizing(GL/GI) Colour Coating Auxilary Grand Total ,39,764 Process Wise Power Consumption kwh Process Wise RLNG Consumption MMBtu Energy in GCAL 5% 6% 2% 11% 12% 28% 14% 23% 12% 38% 39% Pre-Rolling Rolling Galvanising Colour Coating Auxilary 58% Pre-Rolling Rolling 52% Galvanizing (GI/GL) Pre Rolling Colour Coating Galvanizing(GI/GL) Auxillary Colour Coating CII National Energy Efficiency Circle Competition 6

7 1. Specific Energy Consumption Plant capacity Utilization & Reduction in Specific Energy Consumption (Year wise) Plant Energy Consumption Energy Unit FY 16 FY 17 FY 18 Electricity Lakh Kwh Thermal Specific Energy Consumption Million Kcal MTOE/t Specific Energy Consumption MTOE/t FY 16 FY 17 FY 18 Plant Capacity Utilization Year Unit FY 16 FY 17 FY Capacity Utilization % Installed Capacity Actual Production Lacs ton Lacs ton Capacity Utilization % FY-16 FY-17 FY-18 7

8 1. Specific Energy Consumption Perform Achieve Trade (PAT) Cycle PAT-1 Energy Consumption (MTOE/T) Notified Baseline Notified Target Verification Energy Saving MTOE ESCerts Awarded Notified PAT-2 Energy Consumption (MTOE/T) Notified Target FY FY FY Energy MTOE/t FY 13 FY 15 FY 16 FY 17 FY 18 FY 19

9 2.Benchmarking Parameter UNIT Tpr Klm Vsd Total Plant Energy Consumption Mtoe Total Equivalent Production MT Energy Cosnumption Mtoe/t Energy Cosnumption (Mtoe/t) Tarapur Kalmeshwar Vasind Benchmarking of Energy data through Energy Report on a monthly basis. Adoption of best practices 9

10 SEC in FY-15 Installation of VFD Installation of LED Automation Process Control Energy Efficient Equipment's Installation of Economizer Boiler. local burner CCL-1 SEC in FY-18 (Current) Installation of PLTCM local burner CCL-2 Installation of LED Process Control Installation of VFD in Cranes Energy Efficient Equipment's SEC in FY-19 (Targeted) Energy Consumption (Mega Cal/t) 2.Benchmarking Road Map of Specific Energy Consumption Reduction

11 3.Energy Saving Projects Implemented Energy Savings & Investment Total Energy Saving (FY-16 to FY-18) GCal Total Saving by Zero Investment Projects (FY-16 to FY-18) 2170 GCal Potential Investment in FY cr Energy Savings GCal Rs Lac FY 16 FY 17 FY 18 FY 16 FY 17 FY 18 Investment Rs Lac Potential Saving In FY GCal FY 16 FY 17 FY 18

12 ZERO INVESTMENT Projects 3.Energy Saving Projects Implemented ENCON Measures.04 Energy Saving (kwh) Savings (Rs Million) Investment (Rs Million) Payback (Months) Auto speed control of CCL Oven Recirculation Fan Speed Control of CAG1 blower with strip temperature in CGL# CAG-2,3,4 & 5 blowers operation with TPH in CGL# Reduction of idle power consumption CGL2 and CRM3 unit water supply system connected with each other and made CGL2 one 30 KW pump off ENCON Measures FY - l Installation of VFD in CRM#4 & CRM#3 Coolant pump Commissioning of On line SPM in CGL# Installation of VFD in Hot Air Generator Provision of drive for POR DC Motor cooling blower CRM#3 & CRM#4 Provision of AC Drive for Pickling Squeeze Roll Hyd Power pack Installation of LED Lights VFD Drives installation for CGL#1 Non ox blower with pressure close loop Total

13 3.Energy Saving Projects Implemented ENCON Measures FY 17 ENCON Measures Energy Saving Electrical (kwh) Thermal (Gcal) Saving (Rs Million) Investment (Rs Million) Payback (Months) ZERO INVESTMENT Projects Optimization of CGL#2 cooling towers VFD Installation in CRM#4 & CRM#3 Fume Exhaust blower Optimization of Air compressors at CGL#1 & CRM#4 Installation of high efficiency 380 CFM Compressor Installation of booster pump for CCL AC Installation of LED Lights Installation of Economizer at 5 Ton Boiler Installation of Bell mouth in Non ox blower TOTAL

14 3.Energy Saving Projects Implemented ENCON Measures Energy Saving Electrical (kwh) Thermal (GCal) ENCON Measures FY - 18 Savings (Rs Million) Investment (Rs Million) Payback (Months) ZERO INVESTMENT Projects CGL #1 Line Fix Power Optimization by increasing Line Speed from 120 to 150 MPM Induction oven output optimization CGL #2 Line Fix Power Optimization by increasing Line Speed from 150 to 200 MPM Closed loop speed control of CGL#2 APC Blowers by using VVVF drive Installation of LED Lights New Energy Efficient Pump(7.5 kw) Installed at ARP Provision of local burner at CCL-1 oven to reduce fuel consumption Pump Motor Speed Optimization by increasing VFD in two nos Re-Circulation Pumps Old motor of 11KW replaced with IE-3 efficiency 7.5 KW motor 20, Total

15 3.Energy Saving Projects Planned ENCON Measures Electrical Savings (kwh) Thermal Savings (GCal) ENCON Measures Planned FY 19 Savings (Rs Million) Investment (Rs Million) Payback (Months) ZERO INVESTMENT Projects Developing CGG Alloy to reduce RLNG and Power consumption at Alloy Furnace Installation of 1.3 million ton Pickling Linked Tandem Coldrolling Mill with advance energy efficient technology Replacement of conventional lights by 150 Nos LED lights. Using excess Steam of CCL at CRM 4 to heat Coolant in place of RLNG. Modification of CGL-1 Pump house with Energy Efficient Equipment and pipe line redesigning. Installation of new common pump house for CRD & CGL-2 with Energy Efficient Equipment Reduction of Fuel consumption by optimizing Air Fuel Ratio by installing Oxygen analyser at CGL-1 Stack Reduction of Fuel consumption by optimizing Air Fuel Ratio by installing Oxygen analyzer at CGL-2 Stack Provision of local burner at CCL-2 oven to reduce fuel consumption

16 ENCON Measures 3.Energy Saving Projects Planned Electrical Savings (kwh) Thermal Savings (Gcal) ENCON Measures Planned FY 19 Savings (Rs Million) Investment (Rs Million) Payback (Months) CGL-2 furnace modification to Operate in Strip Temperature control mode, in place of Zone temperature control mode Replacement of CGL-1 Furnace water cooled type Hearth roll with Non Water cooled Earth rolls (7 Nos) Installation of 200 KW VFD in CRM3 Air compressor and close loop the motor speed with Header pressure to avoid unloading of compressor. Installtion of VFD for LT and CT operation of crane in 3 nos cranes. Replacement of Old motors with Energy efficient IE-3 motors (45 KW 8 Nos) Replacement of inefficient old ventilation blowers of CRM-4 mill motor with high efficiency blowers. Replacement of inefficient old ventilation blowers of CRM-3 mill motor with high efficiency blowers Total

17 Pickling Linked Tandem Cold Mill BEFORE Investment Rs.800 Cr IN FY - 19 HRS Pickling Cold Rolling Turn around Pickling Linked Tandem Cold Mill (PLTCM) Power 107 kwh/t RLNG 0.1 MMBtu/t Power 60 kwh/t RLNG 0.05 MMBtu/t Energy Consumption Gcal/t Energy Consumption Gcal/t Estimated Energy Saving Million Ton Production Combination of three process Use of Energy Efficient AC motors MV VFD drives & advance Level II automation

18 4.Innovative Projects Implemented Project Selection Suggestions Projects Annual Energy Savings Investment Required Required Down Time Annual Energy Saving Investment required Required down time Score Priority (P1..P2 etc.,) 176 Received GCal Rs in Lacs Days A B C A X B X C * Speed Optimization of CAG P1 CGL #1 Line Fix Power Optimization P1 Closed loop speed control of CGL#2 APC Blowers P2 Pickling Pump Motor Speed Optimization P2 45 Selected 29 Implemented 16 Planned Provision of local burner at CCL-1 oven P3 CGL #2 Line Fix Power Optimization P4 " * " = Priority of SEU to be decided based on above methodology in descending order of score. Eg. P1 top priority and so on B) Investment required (Rs. In lacs) 5 Less than 10 lacs 4 More than 10 lacs 3 More than 15 lacs 2 More than 25 lacs 1 More than 50 lacs 0 Not Identified A) Annual Saving Potential of Energy Consumption in GCal 5 More than 1000 GCal 4 More than 500 GCal 3 More than 250 GCal 2 More than 100 GCal 1 Less than 100 GCal 0 Not Identified C) Required down time (excluding lead time of resources.) 5 Less than One day 4 Less than three days 3 Less than five days 2 Less than seven days 1 More than seven days 18 0 Not Identified

19 VOC to RTO 4.Innovative Projects Implemented Innovation Project and Case Study- Localize Heating Arrangement in Colour Coating Line Before No of Ovens 2 Nos Each Oven - 5 Zones Oven Zone Project Area Hot By Pass Valve RC Fan Combustion Blower To Process Chimney Fresh Air Steam RTO Primary Heat Exchanger Secondary Heat Exchanger Waste Heat Recovery Boiler 19

20 4.Innovative Projects Implemented Innovation Project and Case Study- Localize Heating Arrangement in Colour Coating Line Major Challenges Solution Proposed In CCL all zones of prime and finish ovens were heated with centralised RTO (Regenerative Thermal Oxidizer). The Temperature Required in Ovens is approximately 400 deg C, For achieving the same we need to increase the RTO Temperature more. Huge Losses due to indirect heating and to Maintain Oven temperature, Required High Volume of hot air Resulting High RLNG Consumption MMBtu/t To fulfil high hot air volume in Ovens, All Blowers running at full speed resulting High Power Consumption - 47 kwh/t Less Utilization due to Frequent Maintenance required for the RTO System It takes longer time, around 4 hrs for Oven heating during Line start up Provision of ZONE WISE LOCAL BURNER in Ovens Provision of FIRING CONTROL Use of Hot Air bypass only for safety Optimization of Valve Blower Speed wrt Product Mix Installation of LEL (Low Explosion Level) Sensor to monitor VOC Concentration Before After Saving (Rs Lac/A) RLNG Consumption (MMBtu/T) Power Consumption (KWh/T) Saving in Energy Avg Production Per Month Diversion due to RTO Tripping (%) RTO Tripping (Nos/ Month) 8 0 Productivity ( Ton/Hr) Saving due to Productivity Total Saving Potential Saving IM 1599

21 VOC to RTO 4.Innovative Projects Implemented Innovation Project and Case Study- Localize Heating Arrangement in Colour Coating Line After Oven Zone Hot By Pass Valve RC Fan Pilot Main Combustion Blower To Process Main RLNG Valve Fresh Air Steam Chimney RTO Primary Heat Exchanger Secondary Heat Exchanger Waste Heat Recovery Boiler 21

22 Before After After Process Saving Optimization (Rs Lac/A) RLNG Consumption (MMBtu/T) Power Consumption (KWh/T) Saving in Energy Avg Production Per Month Diversion due to RTO Tripping (%) RTO Tripping (Nos/ Month) Productivity ( Ton/Hr) Saving due to Productivity Total Saving Innovative Projects Innovation Project and Case Study-Localize Heating Arrangement in Colour Coating Line H O R I Z O N T A L D I P L O Y M E N T At CCL-2 Before After Energy Rs Lac Saving Per Annum RLNG Consumption (MMBtu/T) Achieved -Total Energy Saving Gcal (Rs 6.5 Cr) at CCL-1 Potential Total Energy Saving Gcal (Rs 6.6 Cr) at CCL Without Local Burner With Local Burner After Process Optimization Power Consumption (KWh/T) Without Local Burner With Local Burner After Process Optimization Saving/Annum RLNG MMBtu ( Rs 5.1 Cr) Saving/Annum Power Lac KWh (Rs 1.5 Cr) 22

23 4.Innovative Projects Implemented Innovation Project and Case Study- Reduction of Power Consumption in CGL PROBLEM STATEMENT Previous Galvanizing Line Flow Diagram Energy Consumption t High Fixed Power Consumption, 60% of Total Power Consumption Specific Power Consumption-130 kwh Product Mix Huge Variation in Product Mix Causing Less Productivity Fixed Power Can be Optimized by Speed Increase Automation Furnace controlling with Zone Temperature Control (ZTC) No. of Break Downs were high Power Distribution 39% 61% Fixed Power Variable Power 23

24 Mix Product Wise Power Consumption and Production Sheet Accumulation Capacity of Accumulators Average Power Consumption 130 kwh/t Sheet Accumulation Capacity of Accumulators-350mtr Data Collection Analysis Identification of Fixed and Variable Power Consuming Equipment's Timings of Welding and Cutting during Coil Change Over Variable Power-39% Fixed Power-61% Induction Oven consuming 100% Power at all products. Timings of Welding and Cutting during Coil Change Over- 160 sec 4.Innovative Projects Implemented Innovation Project and Case Study- Solution Proposed One more Recoiler and Bridle added to reduce coil changeover time at exit section Welding time reduced from 160 to 120 secs by reducing the sequence time PID closed loop logic made by taking TPH and Output in closed loop for Induction Oven Drive parameter optimization for process line speed 200 MPM Furnace operation In Strip Temperature Control (STC) in place of Zone Temperature control (ZTC) New Pendant Blower(75 kw) added in place of After Coating Blower(160 kw) to reduce fixed power optimization Both Exit and Entry Looper Height increase to increase the accumulation capacity Furnace Length increase Reduction of Power Consumption in CGL Implemented Budget Req 330 Lac Dropped Budget Req 700 Lac 24

25 4.Innovative Projects Implemented Innovation Project and Case Study- Reduction of Power Consumption in CGL Total Energy Consumption Reduced by 20 kwh/t from 120 kwh/t to 101 kwh/t. Total Energy Saving of 48 Lac kwh/a. Energy Saving of Rs 280 Lac per Annum. Highest Production in FY Lac Ton Productivity Increased by 18% 25

26 4.Innovative Projects Implemented Innovation Project and Case Study- CAG-3 CAG-2 CAG-1 Colling After Galvanization Blower CAG- 26

27 4.Innovative Projects Implemented Innovation Project and Case Study- Colling After Galvanization Blower PROBLEM STATEMENT Solution Proposed Installation of VFD at all the CAG Blowers Earlier all CAG blowers use to run at full speed despite of low TPH resulting excess power consumption 174 Unit /Hour. Optimization and controlling of CAG blowers speed in accordance of TPH Logic can be made by taking TPH in closed loop with the speed of the blower Solution Implemented Installation of VFD at all CAG Blowers Logic made for CAG-2,3,4 &5 by taking Blower Speed and TPH in Closed Loop Logic made for CAG-1 by taking Blower Speed and Strip Temperature in Closed Loop with the help of pyrometer

28 Power Consumption Power Consumption (kwh)/day 4.Innovative Projects Implemented Innovation Project and Case Study- Results Colling After Galvanization Blower Power Consumption Vs Line TPH Annual Power Consumption & MORE LESS THAN 25 Line TPH Before After Total Energy Saving of GCal/A APRIL TO NOV DEC JAN FEB MARCH APRIL Months FY-16 Energy Saving of Rs 43.7 Lac/A 28

29 5.Utilization of Renewable Energy Sources School Roof top Solar Power Roof top Solar Power Project has finalised to install 1500 kwp roof top solar power system in FY-19 Installation of Root Top Solar Panels JVM School 4.07 Lac Units Solar power purchased through Open access from M/s Modern India Use of Transparent Sheet for natural lighting in plant FY Total Power (MU) RPO TARGET REC PURCHASED Value NON NON SOLAR SOLAR Rs Lac SOLAR SOLAR FY FY FY TOTAL Renewable Energy Installation of 1500 KWp Roof Top Solar Power system is on progress 29 Rain Water Collection From Plant Shed Capacity- 300 KL Size- 10 M*10M*3M Rain Water Harvesting Use of ECO -VENTILATOR

30 5.Utilization of Renewable Energy Sources SOLAR ROOF TOP SURVEY 30

31 6.Utilization of Waste Material Year Name of Fuel Quantity Used (MT) GCV (KCal/Kg) Energy Utilized Gcal/Year Paint Solvant Paint Solvant Paint Solvant Weast Energy Utilized Gcal/Year

32 91.6 GHG Emission Scope-1 (Kg Co2 /Ton) GHG Inventorization GHG Emission Scope-2 (Kg Co2 /Ton) 0.59 Tree Plantation Installation of RTO Installation of WHR Boiler 32

33 8. Green Supply Chain Facilitate a railway yard in premises for cost and Energy efficient transportation of finish goods and raw material. Total material transported through train MT/Month, Reduction in cost of transportation w.r.t. Road-100 Rs/T Saving in transportation cost Rs 70 Lacs/Month Reduction in Energy consumption Gcal/Month-KM (@ 8.2 KWh/1000T-KM by Train 0.04 Ltr/T-KM by road Source-irfca.com) Install RLNG line from GAIL station to convert fuel type from LPG to RLNG, to reduce transportation cost and wastage of fuel during loading and unloading. Also the cost of RLNG is cheaper then LPG. (Total Production 4.45 Lac/Annum,Saving on Fuel cost 199 Rs/T, Total Saving Rs 881 Lac/Annum) Procurement of Energy Consuming Products based on Life Cycle Cost and considering most Energy Efficient Product PR To Payment Total Paperless Invoicing 33

34 8. Green Supply Chain Corporate Citizenship at JSW Communication Through Purchase order- Regular engagement with different stakeholder groups forms an integral part of our business strategy. With best of our efforts, we strive towards transforming our stakeholder engagement into an active two-way dialogue. We strive to be a responsible corporate citizen and conduct our business with this aim in mind. Our policies are based on the ideology of maintaining transparency and openness in the Management and Board dealings. Our executives contribute to the ideologies and work towards embedding robust corporate governance principles in their practices. Cutting edge technology combined with our application and customer service skills help us to create value for all our stakeholders. With growing scarcity of primary and non-renewable sources of energy, we are striving to minimize our energy consumption through process optimization and energy conservation initiatives while deploying new technologies. Since inception, we have consistently aggregated competencies from diverse cultures, educational backgrounds and domain experience with a singular objective: to accelerate growth. We reinforced this focus through an institutionalized multi-hierarchical training extending from steel manufacturing to holistic personality development which commences from day one of employment, followed by specialized trainings at regular intervals. We strive to maintain the highest standards for the safety and wellbeing of our employees which minimize injuries and casualties during day-to-day operations. Our safety team conducts regular training programmes to instil the concept of maintaining safe operations among our employees and to educate them on the safety norms and procedures to be followed in case of any incident. The JSW group believes in the policy of People First and the objective of our activities is to make a tangible difference in the lives of the people in the areas surrounding our operations. As a responsible organization, we are committed to investing a minimum of 2 percent of our PAT towards community development. Employees are encouraged to contribute upto 40 hours towards community development activities per employee per year. Promoting on a wider platform The JSW Earth Care Awards is aimed at highlighting action of direct relevance to tackle challenges posed by climate change. The award extending over SAARC region is for excellence in climate change mitigation and adaptation. JSW is fundamentally committed to sustainable business and the 9 principles of National Voluntary Guidelines on Social, Environmental and Economic Responsibilities of Business (NVGs) it has been pursuing in spirit while at JSW Steel Limited reporting on GRI framework assured by third party independently (since FY 2005) on International Standards for Assurance Engagements (ISAE) The policies in the context of these principles are Board approved and a Committee of Board comprising 3 Independent and 3 Executive Directors is overseeing the same, quarterly. CSO structure implements the sustainability oversight reporting. All of us at the JSW Group are committed to live by these tenets. Supplier Meet You shall comply with the Business Responsibility/Sustainability policies of JSW Steel Coated Products Limited which can be referred to on our website: " olicy.shtml" We expect our supplier to be in line with JSW Vision, Mission & Values to achieve common goal of the Organization. Vision: Nurture Leadership in Coated Products by Creating Value for Stake Holders in Environmentally Sustainable Way Mission: Supporting India's growth in core economic sectors with Speed and Innovation Values: Transparency, Strive for Excellence, Dynamism & Passion for Learning. We are an ISO 9001:2015 company. We take utmost care of our environment. We encourage our suppliers to have QMS and EMS certification, please inform us if you need any type of assistance in the process of certification. Please help us to save our environment 34

35 Engagement With Stack Holders 8. Green Supply Chain Distribution of Energy Efficient 2500 Chulha in Near By Villages It is High Efficiency and Low Smoke Generate Installed 400 Nos LED Street Lights in Vasind Village Energy Awareness and Recognition to Employee and Society. 35

36 9. Team Work, Employee Involvement & Monitoring Energy Management System (EMS) The EMS is On-line real time measuring system, captures data from 170 nos. Digital power & RLNG 7 meters. Unit wise average power consumption as required. Facility to analyse variable. Diagnostic facility available for any interruption in system. SAP Integrated. Unit wise online reporting.

37 Energy Policy ISO Annual Objective Audits Review Monitoring Reward 9. Team Work, Employee Involvement & Monitoring Management of energy conservation programs Board Displayed Awareness sessions Energy Review, SEU, EnPI EC--> COC OPCOM Individual KRA Internal Cross location audits, External Audits SPICE, Daily, Weekly, Monthly Power & Fuel consumption Monitoring through EMS Quiz, Suggestion, Slogan, Best performer S P I C E Review Safety Systems, Compliance & Governance People Innovation & Quality Management Customer Delight Energy, Environment & Safety Energy Conservation Awareness Society Benchmarking Training Processes, Practices Internal, External, Technical, EnMS trainings Trainings 2250 Nos. Energy Efficient Chulla Distribution 40 Nos Solar Street lights in near by Villages 2500 Nos LED Bulbs distributions Audit Auditors Training, Awareness In House Trainings Technical Trainings (Drive/ PLC/ automation BEE Energy Audit ISO Audits External Audits

38 9. Team Work, Employee Involvement & Monitoring Energy Conservation Target Setting & Monitoring PLAN Management Commitment Appointment of MR, Scope & Boundaries Energy Management Team 10 Nos Establishment of Energy Policy, Resources Assess current situation Energy Review, Base Line calculation Power chart preparation SEU identification:jj-enms-pr-01 Upcoming Energy conservation measures Goal Setting SPICE based goal from top Management. Prioritizing Opportunities Objectives & Action Plan Verification Plan- EMT Review Monitoring Implementation Monthly review in EC/COC/OPCOM by top management Monthly review by EMT CAPA preparation for deviation ACT Daily energy consumption monitoring through EMS Calibration of measuring Equipment Audits Energy conservation projects CHECK Process Owner Action plan and monitoring of energy Targets Review Metering Plan Energy conservation projects DO 38

39 9. Team Work, Employee Involvement & Monitoring Budget Allocation and Review Meetings Solar REC (Nos) RPO Compliance Non Solar REC (Nos) Budget (Rs Lacs) Review Meetings Energy Conservation Measures for FY 18 CGL #2 Line Fix Power Optimization by increasing Line Speed from 150 to 200 MPM. CGL #1 Line Fix Power Optimization by increasing Line Speed from 120 to 150 MPM Budget Allocated (Rs Lac) Induction oven output optimisation for CCL PPGI material DAILY REVIEW Review by Plant Head with all HOD's Review by Departmental Head with Energy Team MONTHLY REVIEW Review at Director level in EC Meeting Review at President level in COC Meeting Closed loop speed control ofcgl#2 APC Blowers by using VVVF drive Installation of LED Lights 5.2 New Energy Efficient Pump(7.5 kw) Installed at ARP 1.8 Provision of local burner at CCL-1 oven to reduce fuel consumption Review at Plant Head level in OPCOM meeting DOL Starters replaced with VFD at Pickling Recirculation pumps and optimized energy consumption by reducing speed to Fig 8 Review by HOD & EnMS M.R. with Energy Management Team (10 Nos) Old motor of 11KW replaced with IE-3 efficiency 7.5 KW motor 0.25 Total 326.4

40 9. Team Work, Employee Involvement & Monitoring Awareness & Involvement of Employees in Energy Conservation programme No. of Energy training No. of people trained FY 16 FY17 FY 18 No. of In house Training External Trainings FY FY FY Contd.

41 9. Team Work, Employee Involvement & Monitoring Awareness & Involvement of Employees in Energy Conservation programme Mega Quiz Energy Exhibition Slogan

42 10. Implementation of ISO Steel Coated Products Ltd. Energy Policy We are committed to efficient utilization of all types of energy. We shall achieve this through continual improvement in energy performance by: Monitoring and controlling consumption of all types of energy. Setting energy conservation objectives and targets and provision of information and resources for their implementation. Purchase of energy efficient products and services. Use of energy efficient designs in new, modified and renovated equipments and processes. Comply with all applicable legal and other requirements related to energy use, consumption and efficiency. Reviewing Energy Policy, Energy Objectives & Targets annually and updated as necessary. We shall encourage use of renewable energy and promote awareness of energy conservation among persons working for and on behalf of our organization. Date : Revision No. 5 Dileep Bhatt President I S O QMS EnMS OHSAS EMS FY-18 Turn Over cr ENCON Spent cr

43 Highlights PLTCM Using advance Technology PLTCM First in Maharashtra, Estimated Energy Saving of Gcal/A. PAT Achieved 1875 ESCerts in PAT-1 and already achieved MTOE/T by FY-18 in PAT-2 ENCON Total 29 Energy Conservation Measures completed. Saving CO2 Emission Total Energy Saved Gcal, Rs 1417 Lac. Total 9004 Tons CO2 Emission reduced by reducing Energy Consumption. Renewable Energy Ro Installation of Roof Top Solar Power of 1500 kwp, Procured 4.07 Lac Solar Units & 100% RP RPO Compliance. 43

44 Awards. CFBP Council for Fair Business Practices Award IMC RBNQA Excellence Trophy CII Commendation Certificate MEDA 12 th State Level EC Award 44

45 45