Jindal Shadeed Iron and Steel 5 year s of DRI Operation 1
JSIS Process Overview Jetty DR Plant HBI Stock yard EAF Scrap yard Rolling Mill Billet Rolling Mill (to be added) Jayesh K Dalal-26th April 2016
Jetty draft of 19m, 2 berths vessels carrying 180,000 MT of material, 2 Grab type Ship Un-loader & loader JSIS Capacity Overview Total Raw Material Storage of 360,000 MT DR- 1.5 MTPA gas based Midrex Technology, commissioned on 05.12.2010, major products- HBI & HDRI Rolling Mill -1.4 Million ton Capacity March 2016 SMS- 2.0 MTPA capacity, 200 T EAF, 200 T LRF, 200 T VD, 8 strand continuous combi caster, Commissioned on 24.04.2014, major productsbillets, rounds 3
Plant Specification Design Capacity : 1.5 MTPA Design Operating Hours : 8000 Design Production : 187.5 TPH Reformer Tubes : 480 Tubes (16 bays / 5 tubes-bay) Briquetting Machines : 4 Briquetting Machines (55 t/hr ) Furnace Dia : 6.65 M Hot Transport : Direct Gravity through Midrex Furnace Metallization : 93% Min Carbon : 1.7% Min Discharge Temp (HDRI) : 650* C 4
Year-on Year Production 5 th 2010- December Plant Commissioned 2011-2012: Production : 1,242,253 MT 3 Briquetting Machines 2013-2014: Production : 1,468,463 MT HBI Operation 2015-2016: Production : 1,509,130 MT Surpassed Rated Capacity 2012-2013: Production : 1,519,787 MT Surpassed Rated Capacity 2014-2015: Production : 1,419,670 MT NG Restriction 2016-2017: Production : 1,500,000 MT* Planned Production 2 4 6 5
Operating Hours at a glance: 2011-12 7,816 1 st Year Operation 2012-13 8,327 2 nd Year Operation with HBI 2013-14 8,125 3 rd Year Operation 2014-15 8,621 4 th Year Operation Highest Operating Hours 5th Year Operation 2015-16 8,219 6
Plant Availability at a glance 05 04 03 02 01 Plant Availability : (Calendar Hours-Total Down Time)/(Calendar Hours-Outside Sources-Scheduled Downtime 7
Operational Availability at a glance 05 Achieved Highest Plant Availability in 2014 04 03 02 01 Operational Availability : (Calendar Hours-Total Down Time)/(Calendar Hours) 8
Equipment Maintenance practices: 9
Aim of Preventive Maintenance in JSIS 10
Unique Maintenance Practices at JSIS Latest condition monitoring tools are in use to scheduled actions to prevent failure and avoid its consequences to optimizing preventive maintenance program. 1. CSI 2130 & 2140 for vibration analysis. 2. FLIR P640 IR Thermography camera for thermal imaging. 3. CSI MINLAB 5200 for oil analysis. 4. Handheld vibration pen for shift crew. SAP PM Module is being used for computerized Maintenance Management. Refurbishment of used components and development of OEM substitute components to reduce cost of new procurement & also enhance the life span. 11
Pro-active Maintenance at JSIS The decision is taken by utilizing a combination of, Operation /maintenance check list. Historical trends of various operating parameters. Off line Condition monitoring tools, i.e. thermal imaging, vibration monitoring. Tribology, thickness measurement and other nondestructive testing methods, to obtain the actual operating condition of the equipment. 12
Pro-active Maintenance at JSIS Maintenance actions are carried out by combination of, Predetermined Preventive and Condition based Maintenance. Around 45 days of plant operation is completed, short shutdown is taken for 12-24 hours to restore the equipment to its original operation state. The short shutdown opportunity is used for Condition based maintenance for all critical equipment that directly affects the production which is mainly based on Periodic inspection, monitoring, and diagnosis. Long shut down planned once in a year or two years for the period of 15-20 days depends on the plant condition. 13
Break Down Details 14
Reduction in Shutdown Hours: 2013-2014 207 Hours 2014-2015 127 Hours 2015-2016 90 Hours Annual Shutdown is Not Considered in Reduction in Shutdown Hours, Planned and Breakdown hours are considered 15
Reduction of oxide consumed : 20% 2013-2014 0.72% 0.61% 2014-2015 2015-2016 0.47% 0.40% Target 2016-2017 16
Reduction of NG consumed in Shutdown: 1 2013-2014: 0.93% 2014-2015: 0.70% 2 3 2015-2016: 0.57% Reduction in NG Consumption will result Increase in Productivity. 17
Reduction of Power consumed Shutdown: 2.88% 2.37% 1.94% 18
Recognition for Best Industry practices and business processes Sultan Qaboos Award for Industrial Excellence 2015-16 19
World class products while getting awards and accolades Frost & Sullivan s "2016 Steel Manufacturing Product Line Strategy Leadership Award, GCC'', GIL 2016: Middle East 20
Oman- imparting technical knowledge to the world Our DR plant has been awarded by Midrex as the best performing 1.5 MTPA plant in the world Training given to team from USA in operational efficiency in Oman 21
Awards Received in Midrex Seminar-2015: 22
THANK YOU 23