First Prize Sponge Iron MSP STEEL & POWER LTD. Dist. Raigarh (Chhattisgarh) Unit Profile One of the growing Steel manufacturing companies in India, MSP Steel & Power Ltd. has a diversified portfolio, ranging from pellets, sponge iron, billets, power, TMT, structural's etc. On the fast track to building a new India, the MSP group is now a Rs. 2700 crore turnover enterprise with a wide range of products and a pan India presence.msp Steel & Power Ltd was incorporated in the year 1968. In the year 2002 the company set up an integrated steel plant at Raigarh, Chhattisgarh. Today it is an integrated steel plant with backward integrated facilities to manufacture pellet and captive power. Besides, it boasted of facilities like bar and structure mills, coal washery & billet units. Company goal is to be the most admired, continuously growing company with operational excellence, driven by innovation, technology and motivation to enhance sustainable industrial and business growth. 473
Description About Process/Sub-Process M/s. MSP Steel & Power Ltd. is having various sections for manufacturing the following products: 1. Sponge Iron Plant, Capacity 307500 MTPA 2. Captive Power Plant, Capacity 665760 MWh 3. Steel Melting Shop, Capacity 261109 MTPA 4. Pellet Plant, Capacity 900000 MTPA 5. Rolling Mill (TMT), Capacity 80000 MTPA 6. Structural Rolling Mill, Capacity 128000 MTPA Specific Energy Consumption Division Wise Sr.No Division Energy Consumption Kwh/Mt 2013-14 2014-15 2015-16 1. Pellet 79.95 78.56 64.42 2. SID 71.61 69.18 64.52 3. SMS 1043.26 946.49 916.75 4. RMD 103.06 102.21 101.24 5. RMS 88.45 82.89 79.31 474
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Energy Conserved through measures taken during last year 1. Electrical Energy Saving initiatives Sr Description No Saving / of Investment No. Installation year (KWH) (Lacs.Rs) 1. Installation of MV & LV 13 5586000 380 VFD in CPP 2. Installation of LV VFD in SID 8 2457908 30 3. Installation of LV VFD in Pellet 73 9759508 175 4. Rationalization of drives capacity - - - a) By Replacement of motors 18 89000 No Investment with lower capacity b) By star -delta alternation 7 under capacity 5 Installation of Energy Efficiency 5 39000 13 Lighting X-mer 6 Replacem ent of conventional 125-2.5 lights with LEDS 7 Installation of capacity Banks 1 Improvement in 12 (2000KVAR) in Mills Division. Power Factor 476
2. Thermal Energy Saving Initiatives:- 2.1 SID DIVISION * Specific coal consumption (C/Fe) reduced from 0.48 to 0.42. a) By replacement of cartable with higher grade b) Reduction of FC in Ash char. 2.2 Pellet Division * Specific Thermal energy consumption reduced from 528.53 Mcal/Mt to 358.15 Mcal/Mt a) By Kiln Burner gas channel Tip modification. b) By replacement of refractory with higher grade. c) By proper sealing of cooler, Kiln Inlet & outlet. d) By proper sealing inside TG to avoid thermal losses. e) By replacing FO with coal gas. 2.3. On-line Rolling i.e. direct billet charging in LSM division. INITIATIVES CONTINUED 1. Continuous internal Electrical & Thermal Audit & Review. 2. LV & MV VFD's Installation in Place of conventional drives in phase manner. 3. Replacement of HPSV & Other old lights with LED lights in phased Manner. 477
Second Prize Sponge Iron SHYAM CENTURY FERROUS LTD. RI-Bhoi Dist. (Meghalaya) Unit Profile Shyam Century ferrous Limited is located in Meghalaya, Ri-Bhoi Dist, Industrial Estate Rajabagan, Byrnihat, which is 20 Km away from Guwahati (Assam). This is a unit of the Shyam Group of Industries. The Group is one of the front runners in the Iron & Steel sector in the Eastern Region and features amongst the largest manufacturers of Ferro Alloys in the country. The Group has also diversified into several core infrastructure sectors such as power (biomass, waste heat, thermal and hydro-power), cement, logistics and industrial parks. The Group, with a turnover of more than Rs.3,500 crores, provides direct-indirect employment to more than 14,000 people. The plant was commissioned in December 2001 with installed capacity of 14400 MT per year but now the capacity is increased from 14400 MT to 21600 MT. The major product is Ferro Silicon. At present plant has three (3) submerged arc furnace with capacity of 9 MVA each. Energy source of plant is 13.8 MW coal based captive power plant & earlier the plant had a Contract Demand of 1800 KVA with State Electricity Board. Presently the plant has surrendered MeECL Contract Demand of 1800 KVA on 26-09-2012 and from 27-09-2012 we have been drawing power from IEX through Open Access System. 478
Energy Consumption Specific Energy Consumption Trend 479
Energy Conservation Initiatives The unit is taking following Energy Conservation Measures in our plant: Replaced 250 Watt HPSV lamp in various area of plant by 85 Watt CFL. Minimized air leakage in APH and infiltration in flue gas duct from APH outlet to ID inlet. Higher capacity of submersible pump in intake river area has been replaced by lower capacity pump for optimum performance with higher efficiency. By replacing the pump water is available throughout the seasons with consuming less energy for making availability of intake water. Minimized specific power consumption/mt for production of Ferro silicon by improving raw material quality & operation. Minimized specific fixed carbon consumption/mt by increasing Lamcoke quantity & decrease charcoal quantity for fixed carbon purpose. Bed coil protection has been provided for minimize the bed coil leakage as a result improve the plant availability and to extend bed coil life. % of Aux. power consumption reduced by taking necessary measures in air system & water system in CPP. Diesel consumption reduced by less stroking of charge material in furnace by improvement of raw material quality. Minimized breakdown of the plant by proper preventive maintenance to increase plant availability & load factor of the plant to reduce specific power consumption. Cooling water system improved by condenser cleaning, all coolers cleaning and reduced energy consumption. Improved operation by adopting the new technologies and replaced the manual operation with auto operation in wherever possible in CPP and Ferro Alloys and utilizing better quality of raw material, maintained the fixed carbon by better combination of the raw material. Also by maintaining the raw material from moisture & handling loss reduced the consumption. 480