CII NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2017 JSW STEEL COATED PRODUCTS LTD, TARAPUR WORKS

Transcription

1 CII NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2017 JSW STEEL COATED PRODUCTS LTD, TARAPUR WORKS AMARDEEP SINGH ENERGY MANAGER SANJEEV JAHAGIRDAR MANAGER OPERATIONS

2 JSW GROUP

3 PROCESS FLOWCHART & PLANT FACILITIES Hot Rolling HR Slitter, Pickling Cold Rolling Galvanizing, Galvalume Color Coating Finishing (Cut to length, Profiling) TARAPUR PLANT FACILITIES COLD ROLLING GALVANIZING / COLOR COATING CAPTIVE POWER PLANT GALVALUME 0.72 MTPA MTPA MTPA 30 MW

4 ENERGY CONSERVATION PROJECTS - I Sr. No. Energy Conservation Measures Financial Year Annual Energy Saving Electricity (Lakh kwh) Thermal (M kcal) Annual Saving Rs Lakhs Investment Rs Lakhs 1 Optimization of Induction Oven Cooling Blower at CSD Nil 2 Conversion of Delta Operated Motor to Star Connection (below 5.0 HP) Nil 3 Power Factor Improvement of Captive Power Plant Nil 4 Switching off AC Cooling Tower & Connecting with Main CT at TM Nil Total Nil

5 Sr. No. Energy Conservation Measures ENERGY CONSERVATION PROJECTS - II Financial Year Annual Energy Saving Electricity (Lakh kwh) Thermal (M kcal) Annual Saving Investment & ROI Rs Lakhs Rs Lakhs Months 1 Replacement of Old Pumps by Efficient Pumps 2 Nos Destagging of Boiler Feed Pump at CPP Corrocoating of Circulating Cooling Water pump at CPP Covering of Zinc pot Surface in CSD Lines to Avoid Heat Loss Operation of Color Coating Line Compressor in Closed Loop Replacement of Old Pumps by Efficient Pumps 2 Nos Optimization of Cooling Blower in CSD-5 by Installation of Pyrometer Installation of Quench Tank & Optimization of Cooling Blower in CSD VFD Installation in Agitator Motor at TM Optimization of CCL Cooling Tower Pump by Installing of VFD Operation of Captive Power Plant Cooling Tower Fan by VFD Total

6 Sr. No. Energy Conservation Measures ENERGY CONSERVATION PROJECTS - III Financial Year Annual Energy Saving Electricity (Lakh kwh) Thermal (M kcal) Annual Saving Investment & ROI Rs Lakhs Rs Lakhs Months 1 VFD Installation in cold well pump at CSD VFD Installation in cold well pump at CCL LED Light Replacement 238 Nos Replacement of Old COT pump by Efficient pump Provision of VFD in PA Fan Replacement of Conventional lights by LED lights Replacement of Conventional lights by LED lights Installed VFD in Coolant pump in Cold Rolling Mill Installed VFD in Coolant pump in Cold Rolling Mill Installed VFD in Coolant pump in Cold Rolling Mill Total

7 ENERGY CONSERVATION PROJECTS - IV Sr. No. Energy Conservation Measures Financial Year Annual Energy Saving Electricity (Lakh Kwh) Thermal (M Kcal) Annual Saving Investment & ROI Rs Lakhs Rs Lakhs Months Replacement of Conventional Lighting by LED Lights Nos Replacement of Water Cooled Hearth roll in Furnace by Ceramic Roll Replacement of Ceramic Fiber Lining by Pyro bloc Module in CSD-3 Non-Ox Furnace Technology Up gradation & Redesigning of CSD-1 Furnace Variable Frequency Drive Installation in Boiler Feed Pump Replacement of Water Cooled Hearth Roll in Furnace by Ceramic Roll Total

8 SUMMARY OF ENERGY CONSERVATION PROJECTS Energy Conservation Measures No of Measures Annual Energy Saving Electricity (Lakh Kwh) Thermal (M Kcal) Annual Saving Investment & ROI Rs Lakhs Rs Lakhs Months Nil Investment Nil - < = Rs 5 Lakhs > Rs 5 Lakhs <= 10 Lakhs > 10 Lakhs Total

9 PLANT ENERGY CONSUMPTION & ABSOLUTE SAVINGS Plant Energy Consumption % Electrical Energy Saving Financial Year Energy Unit Electricity Consumption Lakh kwh Electricity Energy Saving Lakh kwh % Electricity Energy Saving % Thermal Consumption Million kcal Thermal Energy Saving Million kcal % Thermal Energy Saving % Thermal Energy Saving %

10 SPECIFIC ENERGY CONSUMPTION Parameter Unit FY FY FY % Reduction FY FY Coated Production MT Utilization % % 3.16% Electrical SEC Kwh/MT % 3.45% Thermal SEC Million Kcal/MT % 3.23% Electrical Energy SEC Thermal Energy SEC FY FY FY FY FY FY

11 BENCHMARKING ENERGY CONSUMPTION (JSW PLANTS) Plant Electricity Energy Consumption (kwh/t) Plant Thermal Energy Consumption (Gcal/t) Tarapur Vasind Kalmeshwar Tarapur Vasind Kalmeshwar CRM Electricity Energy Consumption CSD Electricity Energy Consumption (kwh/t) (kwh/t) Tarapur Vasind Kalmeshwar Tarapur Vasind Kalmeshwar

12 BENCHMARKING CHALLENGES Input Thickness COLD ROLLING MILL (% REDUCTION) Output Production Reduction Power Consumption mm mm MT % kwh/t Material GALVANIZING / GALVALUME LINE - (RATIO) Output Thickness Width Production Power Consumption mm mm MT kwh/t Material GALVANIZING / GALVALUME LINE (PRODUCT MIX) Output Thickness Width Production Thermal Consumption mm mm MT mmbtu/t Hard Soft Structural Galvanizing Galvalume Paint Coating COLOR COATING LINE (PAINT VOC) Output Thickness Paint Qty Production Thermal Consumption mm Ltr MT mmbtu/t Coating Coating Coating - 1 (Without RTO) Grade of Material Thickness & Width Color Change Utilization Product Mix in Color Coating Line

13 ROAD MAP ENERGY CONSERVATION / MANAGEMENT Energy Conservation Measures Energy Saving Investment Target Date Inverted U Tube Furnace in CSD mmbtu/t 625 Lakhs Oct-17 Energy Efficient Boiler for Process Steam Gcal/t 200 Lakhs Sep MTPA Pickling Line & Tandem Cold Mill 140 Lakh kwh 200 Crores Aug -19 Lower Head Pump for Cooling Tower Pump Lakh kwh 16 Lakh Mar-19 VFD in RTO Combustion Blower at CCL 2.5 Lakh kwh 4 Lakh Mar-18 Execution of Mandatory Energy Audit Findings -Schneider To be Calculated To be Calculated Aug-19 Renewable Energy Projects Energy Saving Investment Target Date Light Pipes Installation 0.97 Lakh kwh 17 Lakhs Mar-19 (Phases) Roof Top Solar Panel Installation 60 Lakh kwh OPEX / CAPEX Dec-17 & Mar-19 Captive / Group Captive Solar Projects RPO Compliance To be Calculated Dec-17 Benchmarking / Baseline Projects Energy Saving Investment Target Date Benchmarking Energy Consumption with M/s Uttam Galva Steel Ltd - - Dec-17 Development of Normalization Factor for Secondary Steel - - Mar-18 Base Line Energy Consumption of Tin Plating Line - - Dec-18

14 INNOVATIVE PROJECTS - I REPLACEMENT OF WATER COOLED HEARTH ROLL BY NON WATER COOLED CERAMIC ROLL 2 Nos Hearth Roll are used in Non Ox Furnace to support the sheet. To cool the temperature of the Hearth Roll, water is passed through it. Water Flow through the Hearth Roll is 36m3/Hr. Temperature Gain of water across the Hearth Roll is 6 Deg C. Vendor Sandvik Asia suggested APM Technique based Non water cooled ceramic roll for this application. Non Ox Furnace Fuel Consumption Before After Annual Fuel Saving Annual Saving Investment ROI Water Inlet Hearth Roll Water Outlet mmbtu mmbtu mmbtu Rs Lakhs Rs Lakhs Months Furnace Temp 1025 o C

15 INNOVATIVE PROJECTS - II INSTALLATION OF QUENCH TANK & OPTIMIZATION OF COOLING BLOWER IN CSD2 Galvanizing Sheet after coating in Zinc pot are cooled in APC (After Pot Cooling) section by APC Blowers. Cooling Blower- 3 5 Nos of Blowers are used for cooling of the sheet Temperature requirement at exit of the Cooling blower-5 is < 40 Deg C Heating Furnace Cooling Blower- 2 Cooling Blower- 4 In House Quench Tank Developed for cooling of the sheet with logic to APC Blowers for controlling in auto Power Consumption Before After Power Saving Annual Power Saving Annual Saving Investment ROI Cooling Blower- 1 Quench Tank Cooling Blower- 5 kwh kwh kwh kwh Rs Lakhs Rs Lakhs Months Zinc pot

16 TECHNOLOGY UPGRADATION NON Ox FURNACE (CSD-1) 750 Deg C 1000 Deg C DHF RTF SOAKING JET COOLER Pyrometer NON OX RTF SOAKING JET COOLER Pyrometer Pyrometer Pyrometer Pyrometer Low Furnace Temp resulted in less production. Old Technology Line Speed increased to 150 mpm by upgrading the Direct Heating Furnace with other energy saving measures. Parameter Before After Non Ox Section Capacity 12 TPH 16.5 TPH Furnace Type Direct Heating Non Ox Firing Control On/Off Ratio Control Zone Temp Control Zone Temp Strip Temp Recuperator NA Yes Exhaust Blower DOL VFD Combustion Blower DOL VFD Non water cooled Roll 0 4 RTF Section Firing Control On/Off Pulse Firing Zone Temp Control Zone Temp Strip Temp Soaking Section Zone Temp Control NA Strip Temp Energy Consumption Power Consumption 55 kwh/t 40.5 kwh/t Thermal Consumption 0.65 mmbtu/t mmbtu/t

17 ENERGY AWARENESS & INVOLVEMENT Energy Policy Suggestion Display, , Awareness Session Received 102 Nos for FY EnMS 50001, Internal Auditor Training Energy Review, SEU, EnPI Display, , Awareness Session Technical Training, KEP- BEE PAT, Escerts Trading Awareness Energy Conservation Week 14 th Dec to 20 th Dec External DELP - EESL Distribution of 1600 LED Bulbs 720 Hrs Pamplets, Display Board Distribution & display of energy saving Fee Internal Training Vendor - PO Objectives & Targets Training duration 1548 Hrs Communication - Energy Performance Evaluation Criteria Plant, Process level awareness, Team Reimbursement Scheme for Energy Auditor / Manager Exam

18 Review & Evaluate MANAGEMENT OF EC PROGRAMS/ TARGET SETTING Management Commitment Assess Current Situation Set Goals & Targets Implementation & Operation Appointment of MR Scope & Boundaries Energy Management Team 10 Nos Energy Policy, Resources Assignment Energy Review SEU Assessment & List 10 Nos RPO & PAT Target, Other Legal Opportunities, Baseline Prioritizing Opportunities Objectives & Action Plan EnPI Verification Plan- EMT Review of Energy Policy Review of Objectives, Action Plan Review of EnPI Resources, System Improvement CAPA Approval Checking Responsibility Process Owner Competence, Training & Awareness Hrs Design Procurement Operational Control, Energy Manual Monitoring & Measurement Plan Metering Plan Energy Meter List Audit Plan, Control of Records Compliance Assessment, CAPA

19 ENERGY MONITORING / FORMAT Energy Consumption Data of July-17 Power Consumption RLNG/Coal / HSD Consumption Equipment Production kwh /t KWH Gcal G cal/t MMBTU/t, KL/t MMBTU,Mt, KL Gcal G cal/t ABP Require Actual Required Actual Required Actual Required Actual ABP Require Actual Required Actual Required Actual Required Actual Total Required G Cal /t Total Actual G Cal /t PreRolling HR Slitter 51, , , Pickling 52, , , ETP+MEE PLANT 52, , , Steam to Steel Plant (PKL) 52, ,877 27, ,492 3, PreRolling 52, , , ,492 3, Rolling CRM-1 15, ,835,199 1,836,747 1,578 1, CRM-2 5, , , CRM-4 5, ,041,970 1,037, CRM-5 17, ,549,514 1,541,300 1,333 1, CRM-6 7, ,190,815 1,179,746 1,024 1, Rolling 51, ,402,974 6,373,972 5,507 5, Galvanising (GI/GL) CSD , , , , CSD , , , CSD ,330,668 2,323,832 2,004 1, , ,615 3, CSD , , , CSD ,135,448 2,093,116 1,836 1, , ,710 2, GP Sliter/Alloy F/C 4, ,914 27, Galvanising (GI/GL) 51, ,494,957 5,451,040 4,726 4, ,575 35,821 8,713 9, Colour Coating (PPGI/PPGL) CCL1 10, , , , ,813 1, CCL2 10, , , , ,756 1, Colour Coating (PPGI/PPGL) 21, , , ,165 14,149 3,569 3, Others Adminstration ,000 26, DG AUX SUPPLY ,000 84, Store & Canteen ,000 21, Others 51, , , Total 51,212 13,405,358 13,312,736 11,529 11, ,740 49,971 ###### 16, Normalized Energy Consumption for the Month of July'

20 ENERGY MANAGEMENT SYSTEM ENERGY MANAGEMENT SYSTEM SCHNEIDER ELECTRIC

21 GHG EMISSIONS GHG Emissions Unit FY FY FY Scope 1 Emissions tco Scope 2 Emissions tco Total GHG Emissions tco

22 RENEWABLE ENERGY SOURCES RPO Compliance 100% Financial Year Solar RECs Non Solar RECs REC Cost (Rs in Lakhs) FY FY RAIN WATER HARVESTING KL FY FY to Solar Roof Top Panel Captive Solar Projects Light Pipe TRANSCULENT SHEET IN EACH SHED

23 SOLAR ROOF TOP SURVEY

24 UTILIZATION OF WASTE DESIGN RATING OF RTO FOR VOC FUEL CONSUMPTION CCL1 300 to 700 Kg/Hr CCL2 300 to 440 Kg/Hr 30-35%

25 GREEN SUPPLY MANAGEMENT Transportation Replacement of LPG by RLNG Transportation Truck Container by Railway Rake 2,47,286 tco2 MITIGATED 36,65,185 tco2 MITIGATED

26 ENVIRONMENT INITIATIVES TREE PLANTATION 3000 Nos / YEAR DONATION OF 1000 SAPLINGS TO ITI 3 CHECK DAMS 215 MILLION LTRS / COST RS 61 LAKHS WATER STORAGE BANK 10 CR. LITRES

27 CSR BUS STOP WITH LED LIGHTS AUDITORIUM WITH LED LIGHTS AWARENESS IN SCHOOLS / ITI PAINTING COMPETITION - SCHOOLS RURAL ELECTRIFICATION WITH SOLAR PANEL, LED LIGHTS, TABLE FAN

28 Energy Saving Measures CII - ENERGY AUDIT Annual Energy Saving Potential Electricity (Lakh Kwh) Thermal (Million Kcal) Status / Target Date Annual Energy Saving Electricity (Lakh Kwh) Improve Power factor of captive power plant 2.64 Implemented 2.64 Install Light pipe 0.97 Mar-19 (Phases) Optimize the compressed air system Dec -16 (U/P) 2.27 Install VFD for Coolant pump for CRM 4.56 Implemented 8.12 Install correct size pump for cooling tower Mar-19 (Phases) 1.47 Install VFD for Boiler feed water pump Implemented Install Micro turbine in place of PRDS Dropped Install VAM based Heat pump Dropped Covered the Zinc pot surface 4.33 Implemented 0.90 Install VFD for CSD-5 Dilution Blower 0.14 Dropped Install VFD for CSD-2 chromic dryer 0.12 Dropped Total

29 ACHIEVEMENTS Energy Conservation Award MEDA Third Prize MEDA First Prize MEDA First Prize MEDA Second Prize BEE Certificate of Merit

30 THANKS