Steel Coated Product Limited, Vasind
Presenters: Mr. Anish Karahe- Sr. Manager Ms Aditi Chauhan- Jr. Manager
CII National Energy Efficiency Circle Competition O P Jindal Group
Jindal Steel and Jindal SAW JSL Stainless Power Mr. Prithvi Raj Jindal Mr. Sajjan Jindal Mr. Ratan Jindal Mr. Naveen Jindal • Jindal ITF ✓JSW Steel • JSL Media • Jindal Power • Jindal Waterways • JSL Lifestyle • Jindal Petroleum ✓JSW Steel Coated • Jindal Transrail • JSL Architecture • Jindal Steel • Jindal Water Products Ltd • Green Delhi BQS Bolivia Infrastructure ✓JSW Energy • JSS Steel Italia • Jindal Cement Shri. O. P. Jindal • Jindal Urban ✓JSW Infrastructure • PT Jindal Infrastructure Stainless, • Jindal Shipyards ✓JSW Cement Indonesia • Jindal Rail ✓JSW GBS • Jindal Stainless “Where others see walls….., Infrastructure Steel ways I see doors…..” ✓JSW Sports ✓JSW Foundation JSW Group
Kalmeshwar – 0.6 MTPA Vijayanagar – 12 MTPA SCPL
Tarapur – 0.76 MTPA Steel Salem – 1 MTPA 100% Subsidiary of JSW Steel India’s Leading Coated Steel India’s Leading integrated Dolvi – 5 MTPA Producer (1.8 MTPA) Vasind – 0.45 MTPA Steel Producer (18 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 Road Map • Commissioning of PLTCM 2019 • Capacity increased by 300% • MEDA 12th State Level EC Award • CII-GreenCO Certification • CGL Speed Increase • CCL Local Burner Installation 2018 • EMS 14001:2015 Certification 2017 • IMC RBNQA-2016 Excellence • EnMS ISO 50001:2011 Certification 2016 Trophy • OSHAS 18001:2007 Certification • Installation of On Line Skin Pass • CII-2017 Commendation Certificate • CII Energy Audit 2015 • Entitled as Designated • Earned 1871 ESCerts in PAT -1 Consumer of PAT 2013 s • Power Open Access 2012 • RLNG Supply Line From 2011 • Installation of Railway Yard GAIL • Installation of Colour Coating Lines 2003 • Installation of CGL-2
Installation of CGL-1 & CRM-4 1994
1996 QMS ISO 9001 Certification
1990 Installation of CRM-3 1. Specific Energy Consumption Energy Sources
Energy consumed at Vasind RLNG GAIL
Energy Sources
Power Electrical JSW Energy 81576 GCal Power Open Access 31% RLNG 163147 GCal 69% Electrical RLNG Power
6.49 163147 885 81576 RLNG Lacs MMBtu/A GCal/A Lac kWh/A GCal/A Electrical Power Total : 239764 GCal/A
5 1. Specific Energy Consumption Process wise Energy Consumption Annual Consumption FY-18 Area Power(Lac kWh) RLNG(Lac MMBtu) Energy in Gcal Pre-Rolling 50 0.90 27008 Rolling 333 0.04 29500 Galvanizing(GL/GI) 348 3.75 124368 Colour Coating 107 1.80 54723 Auxilary 47 4165 Grand Total 885 6.49 2,39,764 Process Wise Power Consumption kWh Process Wise RLNG Consumption MMBtu Energy in GCAL
2% 5% 6% 11%
23% 12% 12% 14% 28% 38%
Pre-Rolling Pre-Rolling Rolling 39% Rolling 58% 52% Galvanizing (GI/GL) Galvanising Pre Rolling Colour Coating Colour Coating Galvanizing(GI/GL) Auxilary Auxillary CII National Energy Efficiency Circle CompetitionColour Coating 6 1. Specific Energy Consumption Plant capacity Utilization & Reduction in Specific Energy Consumption (Year wise)
Plant Energy Consumption Specific Energy Consumption MTOE/t 0.055 Energy Unit FY 16 FY 17 FY 18 0.050 0.050
0.045 Electricity Lakh Kwh 749.3 887 885 0.042 0.041 0.040 Million Thermal 136574 149571 163147 Kcal 0.035 Specific Energy 0.030 MTOE/t 0.050 0.042 0.041 Consumption FY 16 FY 17 FY 18
Capacity Utilization % Plant Capacity Utilization 105 99.23 101.11 Year Unit FY 16 FY 17 FY 18 100
Installed Capacity 95 Lacs ton 4.5 4.5 4.5 90 87.78 Actual Production Lacs ton 3.96 4.46 4.55 85
Capacity Utilization 80 % 87.78 99.23 101.11 FY-16 FY-17 FY-18
7 1. Specific Energy Consumption Perform Achieve Trade (PAT) Cycle PAT-1 PAT-2 Energy Consumption (MTOE/T) Energy ESCerts Energy Consumption (MTOE/T) Notified Baseline Saving Notified Notified Awarded Notified FY 16-17 FY 17-18 Target Verification MTOE Target FY 18-19 0.0594 0.0575 0.0545 2042.3 1875 0.044 0.0413 0.042 0.041 0.039
Energy MTOE/t 0.065 0.0594 0.06 0.0545 0.055 0.05 0.05
0.045 0.042 0.041 0.039 0.04
0.035 FY 13 FY 15 FY 16 FY 17 FY 18 FY 19 2.Benchmarking
Energy Cosnumption (Mtoe/t) Parameter UNIT Tpr Klm Vsd 0.054 0.0518 0.052 0.050 Total Plant Energy Consumption Mtoe 45728 32723 26143 0.048 0.0463 0.046 0.0446 Total Equivalent Production MT 882519 707310 586721 0.044 0.042 0.040 Energy Cosnumption Mtoe/t 0.0518 0.0463 0.0446 Tarapur Kalmeshwar Vasind
• Benchmarking of Energy data through Energy Report on a monthly basis.
• Adoption of best practices
9 2.Benchmarking Road Map of Specific Energy Consumption Reduction
545 3.46 0.80 9.00 4.99 1.20 2.53 50.1 418 34.9 42.5 0.06 0.12
(Mega Cal/t) (Mega 0.13
0.53 390
Energy Consumption Energy
.
1
2 19
-
15
- -
18 18
-
-
VFD
CCL
Boiler
CCL
Efficient Efficient
Efficient Efficient
(Targeted)
(Current)
SEC in FY in SEC
Automation
Equipment's
Equipment's Equipment's
burner
Installation of Installation
Installation of Installation
burner
Installation of Installation
SEC in FY in SEC
VFD in Cranes in VFD
SEC in FY in SEC
Process Control Process
Energy Energy
Energy Energy
Process Control Process
Installation LED of Installation
local local
Economizer Economizer
Installation LED of Installation
local local Installation PLTCM of Installation 3.Energy Saving Projects Implemented Energy Savings & Investment Energy Savings Total Energy Saving (FY-16 to FY-18) GCal 27673 GCal Rs Lac 1095
22241 191
2832 131 Total Saving by Zero Investment 2600 Projects (FY-16 to FY-18) – 2170 GCal FY 16 FY 17 FY 18 FY 16 FY 17 FY 18
Potential Investment in Investment FY 19 – 103.2 cr Rs Lac
Potential Saving In 852
121 FY19 – 86251.6 GCal 57
FY 16 FY 17 FY 18 3. Energy Saving Projects Implemented ENCON Measures FY - l6 Energy Savings Investment Payback ENCON Measures.04 Saving (Rs Million) (Rs Million) (Months) (kWh) Auto speed control of CCL Oven Recirculation Fan 89000 0.534 0 0 Speed Control of CAG1 blower with strip temperature 84672 0.47 0 ZERO in CGL#1 0 INVESTMENT CAG-2,3,4 & 5 blowers operation with TPH in CGL#1 701568 3.9 0 0 Projects Reduction of idle power consumption 120000 0.72 0 0 CGL2 and CRM3 unit water supply system connected 180576 1 0 with each other and made CGL2 one 30 KW pump off 0 Installation of VFD in CRM#4 & CRM#3 Coolant pump 670000 4 1 3 Commissioning of On line SPM in CGL#1 1080000 6.48 10 18.5 Installation of VFD in Hot Air Generator 79000 0.474 0.3 7.6 Provision of drive for POR DC Motor cooling blower 73000 0.438 0.05 1.4 CRM#3 & CRM#4 Provision of AC Drive for Pickling Squeeze Roll Hyd Power 42000 0.052 0.2 46.2 pack Installation of LED Lights 64800 0.38 0.35 10.8 VFD Drives installation for CGL#1 Non ox blower with 108864 0.6 0.2 3.9 pressure close loop
Total 3293480 19.05 12.1 127.6 3.Energy Saving Projects Implemented ENCON Measures FY – 17 Energy Saving Saving Investment Payback ENCON Measures Electrical Thermal (Rs Million) (Rs Million) (Months) (kWh) (Gcal)
ZERO Optimization of CGL#2 cooling towers 218000 1.3 0 INVESTMENT 0 Projects VFD Installation in CRM#4 & CRM#3 Fume 360000 2.16 1.8 10 Exhaust blower
Optimization of Air compressors at CGL#1 & 680000 4.04 1.2 3.6 CRM#4 Installation of high efficiency 380 CFM 180576 1.01 1.2 14 Compressor
Installation of booster pump for CCL 210000 1.26 0.2 1.9 AC
Installation of LED Lights 198720 1.1 1 11
Installation of Economizer at 5 Ton Boiler. 1001 2.2 0.15 0.8
Installation of Bell mouth in Non ox blower 13000 0.078 0.2 30.8
TOTAL 1860296 1001 13.15 5.75 135.2 3.Energy Saving Projects Implemented ENCON Measures FY - 18 Energy Saving Savings Investment Payback ENCON Measures Electrical Thermal (Rs Million) (Rs Million) (Months) (kWh) (GCal) CGL #1 Line Fix Power Optimization by 862529 5.13 0 ZERO increasing Line Speed from 120 to 150 MPM 0 INVESTMENT Induction oven output optimization 267000 1.6 0 Projects 0 CGL #2 Line Fix Power Optimization by increasing 2131240 13.12 31.2 28.33 Line Speed from 150 to 200 MPM .
Closed loop speed control of CGL#2 APC Blowers by 135000 0.8 0.6 9 using VVVF drive Installation of LED Lights 105000 0.64 0.52 9.64
New Energy Efficient Pump(7.5 kW) Installed at ARP 23000 0.14 0.18 15.4
Provision of local burner at CCL-1 oven to reduce 20,16000 17357 65 20 3.7 fuel consumption Pump Motor Speed Optimization by increasing VFD 119184 0.73 0.12 1.9 in two nos Re-Circulation Pumps Old motor of 11KW replaced with IE-3 efficiency 7.5 20106 0.12 0.025 2.42 KW motor 14 Total 5679059 17357 109.56 85.28 9.3 3.Energy Saving Projects Planned ENCON Measures Planned FY 19 Electrical Thermal Savings Investment Payback ENCON Measures Savings Savings (Rs (Rs Million) (Months) (kWh) (GCal) Million)
Developing CGG Alloy to reduce RLNG and Power ZERO 73000 1334 3.8 0 0 INVESTMENT consumption at Alloy Furnace Projects Installation of 1.3 million ton Pickling Linked Tandem 48000000 15120 374.5 1000 32.04 Coldrolling Mill with advance energy efficient technology
Replacement of conventional lights by 150 Nos LED 85410 0 0.58 0.5 10.33 lights . Using excess Steam of CCL at CRM 4 to heat Coolant in 60000 1200 3.96 1 3.03 place of RLNG. Modification of CGL-1 Pump house with Energy Efficient 49275 0 0.33 0.4 14.32 Equipment and pipe line redesigning. Installation of new common pump house for CRD & 63875 0 0.43 0.4 11.05 CGL-2 with Energy Efficient Equipment Reduction of Fuel consumption by optimizing Air Fuel 0 257 0.75 0.5 7.94 Ratio by installing Oxygen analyser at CGL-1 Stack Reduction of Fuel consumption by optimizing Air Fuel 0 171 0.5 0.5 11.88 Ratio by installing Oxygen analyzer at CGL-2 Stack Provision of local burner at CCL-2 oven to reduce fuel 2250000 17010 66 20 3.6 consumption 15 3.Energy Saving Projects Planned ENCON Measures Planned FY 19 Electrical Thermal Savings Investment Payback ENCON Measures Savings Savings (Rs Million) (Rs Million) (Months) (kWh) (Gcal)
CGL-2 furnace modification to Operate in Strip Temperature 0 1058.4 3.1 0.2 0.77 control mode, in place of Zone temperature control mode.
Replacement of CGL-1 Furnace water cooled type Hearth roll 262800 5518.8 17.99 2.2 1.46 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 146000 0 0.99 0.7 8.4 of compressor. Installtion of VFD for LT and CT operation of crane in 3 nos 54750 0 0.37 1.5 48.3 cranes. Replacement of Old motors with Energy efficient IE-3 motors 112128 0 0.76 1.6 25.1 (45 KW 8 Nos) Replacement of inefficient old ventilation blowers of CRM-4 mill 429240 0 2.91 1.5 6.1 motor with high efficiency blowers. Replacement of inefficient old ventilation blowers of CRM-3 mill 254040 0 1.72 1.5 10.4 motor with high efficiency blowers. Total 51840518 41668.8 478.69 1032.5 25.816 Pickling Linked Tandem Cold Mill
BEFORE Investment Rs.800 Cr IN FY - 19
Turn HRS Pickling Cold Rolling Pickling Linked Tandem Cold Mill around (PLTCM)
RLNG RLNG Power Power 0.1 0.05 107 kWh/t 60 kWh/t MMBtu/t MMBtu/t
Energy Consumption Energy Consumption 0.081 Gcal/t 0.064 Gcal/t
Estimated Energy Saving-42792 Gcal/A @ 1.3 Million Ton Production
Combination of three Use of Energy MV VFD drives & advance process Efficient AC motors Level –II automation 4.Innovative Projects Implemented Project Selection Annual Required Annual Required Priority Investment Investment Energy Down Energy down Score (P1..P2 Suggestions Required required Projects Savings Time Saving time … etc.,)
GCal Rs in Lacs Days A B C A X B X C * 176 Speed Optimization of CAG 676.2 0 1 4 5 5 100 P1 Received CGL #1 Line Fix Power Optimization 741.8 0 1 4 5 5 100 P1 Closed loop speed control of CGL#2 APC 116.1 8 0 2 5 5 50 P2 Blowers
Pickling Pump Motor Speed Optimization 102.5 1.2 1 2 5 5 50 P2 45 Provision of local burner at CCL-1 oven 19090.8 200 6 5 1 2 10 P3 Selected CGL #2 Line Fix Power Optimization 2062.5 312 10 5 1 1 5 P4
" * " = Priority of SEU to be decided based on above methodology in descending order of score . Eg. P1 top priority and so on… 29 B) Investment required (Rs. In A) Annual Saving Potential of Energy C) Required down time (excluding lead time Implemented lacs) Consumption in GCal of resources.) 16 5 Less than 10 lacs 5 More than 1000 GCal 5 Less than One day Planned 4 More than 10 lacs 4 More than 500 GCal 4 Less than three days 3 More than 15 lacs 3 More than 250 GCal 3 Less than five days 2 More than 25 lacs 2 More than 100 GCal 2 Less than seven days 1 More than 50 lacs 1 Less than 100 GCal 1 More than seven days 18 0 Not Identified 0 Not Identified 0 Not Identified 4.Innovative Projects Implemented Innovation Project and Case Study- Localize Heating Arrangement in Colour Coating Line
VOC to RTO Before
• No of Ovens – 2 Nos Oven Zone • Each Oven - 5 Zones
Project Area
RC Fan Combustion Blower Hot By Pass Valve To Process Chimney
Fresh Air Steam
Primary Heat Secondary Heat Waste Heat RTO Exchanger Exchanger Recovery Boiler 19 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 Provision of ZONE WISE LOCAL BURNER in Ovens centralised RTO (Regenerative Thermal Oxidizer). The Temperature Required in Ovens is approximately 400 deg C, Provision of FIRING CONTROL For achieving the same we need to increase the RTO Temperature more. Use of Hot Air bypass only for safety
Huge Losses due to indirect heating and to Optimization of Valve Blower Speed wrt Product Mix Maintain Oven temperature, Required High Volume of hot air Resulting High RLNG Consumption- 0.86 MMBtu/t Installation of LEL (Low Explosion Level) Sensor to monitor VOC Concentration To fulfil high hot air volume in Ovens, All Blowers running at full speed resulting High Potential Saving Power Consumption - 47 kWh/t Saving Before After (Rs Lac/A) RLNG Consumption (MMBtu/T) 0.86 0.65 263 Less Utilization due to Frequent Maintenance Power Consumption (KWh/T) 47 43 46 required for the RTO System Saving in Energy 309 Avg Production Per Month 11000 12500 1260 Diversion due to RTO Tripping (%) 0.2 0 30 RTO Tripping (Nos/ Month) 8 0 It takes longer time, around 4 hrs for Oven heating during Productivity ( Ton/Hr) 20 25 Line start up Saving due to Productivity 1290 Total Saving 201599IM 4.Innovative Projects Implemented Innovation Project and Case Study- Localize Heating Arrangement in Colour Coating Line After VOC to RTO
Oven Zone
RC Fan Pilot Main Combustion Blower Hot By Pass Valve To Process Chimney Main RLNG Valve Fresh Air Steam
Primary Heat Secondary Heat Waste Heat RTO Exchanger Exchanger Recovery Boiler 21 Innovative Projects Innovation Project and Case Study-Localize Heating Arrangement in Colour Coating Line
After Process Saving Saving Per Annum Before After H D Before After Optimization (Rs Lac/A) O I Energy Rs Lac RLNG Consumption (MMBtu/T) 0.86 0.55 0.45 513 R P I L 1.7 0.8 67500 500 Power Consumption (KWh/T) 47 41 35 137 Z O 95 65 2250000 150 Saving in Energy 650 O Y N M 650 Avg Production Per Month 11000 14000 14000 2520 T E 4200 6000 1512 Diversion due to RTO Tripping (%) 0.2 0 0 30 A N 0.2 0 14 RTO Tripping (Nos/ Month) 8 0 0 L T 8 0 Productivity ( Ton/Hr) 20 25 25 At 8 12.5 Saving due to Productivity 2550 1526 CCL-2 Total Saving 3200 2176
0.86 RLNG Consumption (MMBtu/T) 50 47 Power Consumption (KWh/T) 0.9 Achieved -Total Energy Saving-19091 Gcal (Rs 6.5 Cr) at CCL-1 0.8 46 41 0.7 42 0.55 0.6 Potential- Total Energy Saving-18945 Gcal (Rs 6.6 Cr) at CCL-2 0.45 38 35 0.5 0.4 34 0.3 30 Without Local Burner With Local Burner After Process Without Local Burner With Local Burner After Process Optimization Optimization
Saving/Annum RLNG- 68880 MMBtu ( Rs 5.1 Cr) Saving/Annum Power- 20.1 Lac KWh (Rs 1.5 Cr)22 4.Innovative Projects Implemented Innovation Project and Case Study- Reduction of Power Consumption in CGL
PROBLEM STATEMENT Previous Galvanizing Line Flow Diagram
Energy High Fixed Power Consumption, 60% Consumption t of Total Power Consumption Specific Power Consumption-130 kWh
Fixed Power Can Huge Variation in Product Mix Product Mix Causing Less Productivitybe Optimized by Speed Increase Power Distribution Furnace controlling with Zone Automation Temperature Control (ZTC) No. of Break Downs were high 39% 61%
23 Fixed Power Variable Power 4.Innovative Projects Implemented Innovation Project and Case Study- Reduction of Power Consumption in CGL Identification of Fixed Mix Product Wise and Variable Power Power Consumption Solution Proposed Consuming and Production Equipment's One more Recoiler and Bridle added to reduce coil Data Collection changeover time at exit section Welding time reduced from 160 to 120 secs by Sheet Accumulation Timings of Welding reducing the sequence time Capacity of and Cutting during Accumulators Coil Change Over PID closed loop logic made by taking TPH and Output in closed loop for Induction Oven Implemented Budget Req Variable Power-39% Drive parameter optimization for process line speed 330 Lac Average Power Fixed Power-61% 200 MPM Consumption Induction Oven 130 kWh/T Furnace operation In Strip Temperature Control consuming 100% (STC) in place of Zone Temperature control (ZTC) Power at all products. New Pendant Blower(75 kW) added in place of After Analysis Coating Blower(160 kW) to reduce fixed power optimization Both Exit and Entry Looper Height increase to Timings of Welding Sheet Accumulation increase the accumulation capacity Dropped and Cutting during Capacity of Budget Req Coil Change Over- Accumulators-350mtr 700 Lac 160 sec Furnace Length increase 24 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 18- 2.17 Lac Ton Productivity Increased by 18% 25 4.Innovative Projects Implemented Innovation Project and Case Study- Colling After Galvanization Blower CAG-3
CAG-2 CAG-1
CAG -
26 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 Logic can be made by taking TPH in closed loop run at full speed despite of low with the speed of the blower TPH resulting excess power consumption – 174 Unit /Hour. Solution Implemented Optimization and controlling of CAG blowers speed in Installation of VFD at all CAG Blowers accordance of TPH 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 4.Innovative Projects Implemented Innovation Project and Case Study- Colling After Galvanization Blower Results
Power Consumption Vs Line TPH Annual Power Consumption
200 180 4167 160 174174 174 174 174 174 174 174 140 155 120 120 100
(kWh)/Day 2458 80 95 2356 2247 2314 2245 60 75 40 58 Power Consumption 45 Power Power Consumption 20 0 35 & 33-35 30-32 28-30 25-28 20-25 LESS MORE THAN 25 APRIL TO DEC JAN FEB MARCH APRIL Line TPH NOV Before After Months FY-16 Total Energy Saving of 676.16 GCal/A. Energy Saving of Rs 43.7 Lac/A 28 5.Utilization of Renewable Energy Sources
School
Roof top Solar Power Roof top Solar Power 4.07 Lac Units Solar power Use of Transparent Project has finalised to Installation of Root Top purchased through Open Sheet for natural install 1500 kWp roof top Solar Panels JVM access from M/s Modern lighting in plant solar power system in FY-19 School India
RPO TARGET REC PURCHASED FY Total Power Value NON NON (MU) SOLAR SOLAR Rs Lac SOLAR SOLAR
FY 16 72 364 6196 379 6442 109 Rain Water Collection From FY 17 84 847 8469 868 8431 156 Plant Shed Capacity- 300 KL Size- 10 M*10M*3M FY 18 84 1671 8771 1671 8771 118
TOTAL 240 2882 23436 2918 23644 383 Rain Water Use of Harvesting ECO -VENTILATOR Renewable Energy Installation of 1500 KWp Roof Top Solar Power system is29 on progress 5.Utilization of Renewable Energy Sources SOLAR ROOF TOP SURVEY
30 6.Utilization of Waste Material
Year Name of Fuel Quantity Used GCV Energy Utilized (MT) (KCal/Kg) Gcal/Year 2015-16 Paint Solvant 3240 7000 22680 2016-17 Paint Solvant 3892 7000 27244 2017-18 Paint Solvant 3988 7000 27916
Weast Energy Utilized Gcal/Year 29000 27916 28000 27244 27000
26000
25000
24000
23000 22680
22000
21000
20000 2015-16 2016-17 2017-18
31 7. GHG Inventorization
GHG Emission Scope-1 (Kg Co2 /Ton) GHG Emission Scope-2 (Kg Co2 /Ton) Tree Plantation
91.6 0.59 84.5
72.4 0.57
0.56
15-16 16-17 17-18 15-16 16-17 17-18
Installation of RTO Installation of WHR Boiler
32 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- 70000 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 -30.3 Gcal/Month-KM (@ 8.2 KWh/1000T-KM by Train and @ 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 8. Green Supply Chain
Corporate Citizenship at JSW Communication Through Purchase order-
You shall comply with the Business 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 Supplier Meet Responsibility/Sustainability policies of JSW into an active two-way dialogue. Steel Coated Products Limited which can be 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 referred to on our website: Management and Board dealings. Our executives contribute to the ideologies and work towards embedding robust corporate governance principles in their practices. Cutting edge technology "http://www.jsw.in/companies/Sustainability_P combined with our application and customer service skills help us to create value for all our olicy.shtml" stakeholders. With growing scarcity of primary and non-renewable sources of energy, we are striving We expect our supplier to be in line with JSW to minimize our energy consumption through process optimization and energy Vision, Mission & Values to achieve common conservation initiatives while deploying new technologies. Since inception, we have consistently aggregated competencies from diverse cultures, goal of the Organization. educational backgrounds and domain experience with a singular objective: to accelerate growth. Vision: Nurture Leadership in Coated We reinforced this focus through an institutionalized multi-hierarchical training extending from steel manufacturing to holistic personality development which commences from day one of Products by Creating Value for Stake Holders employment, followed by specialized trainings at regular intervals. in Environmentally Sustainable Way 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 Mission: Supporting India's growth in core 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. economic sectors with Speed and Innovation The JSW group believes in the policy of ‘People First’ and the objective of our activities is to Values: 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 Transparency, Strive for Excellence, towards community development. Employees are encouraged to contribute upto 40 hours Dynamism & Passion for Learning. towards community development activities per employee per year. Promoting on a wider platform The JSW Earth Care Awards is aimed at highlighting action of We are an ISO 9001:2015 company. We direct relevance to tackle challenges posed by climate change. The award extending over take utmost care of our environment. We SAARC region is for excellence in climate change mitigation and adaptation. JSW is fundamentally committed to sustainable business and the 9 principles of National encourage our suppliers to have QMS and Voluntary Guidelines on Social, Environmental and Economic Responsibilities of Business EMS certification, please inform us if you (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 need any type of assistance in the Engagements (ISAE) 3000. 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 process of certification. Please help us to the same, quarterly. CSO structure implements the sustainability oversight reporting. save our environment All of us at the JSW Group are committed to live by these tenets. 34 8. Green Supply Chain Engagement With Stack Holders
Distribution of Energy Installed 400 Efficient 2500 Chulha Nos LED in Near By Villages It Street Lights is High Efficiency and in Vasind Low Smoke Generate Village
Energy Awareness and Recognition to Employee and Society.
35 9. Team Work, Employee Involvement & Monitoring Energy Management System (EMS)
• The EMS is On-line real time measuring • Unit wise average power • Facility to analyse system, captures data from 170 nos. consumption as required. variable. Digital power & RLNG 7 meters.
• Diagnostic facility available for any • Unit wise online • SAP Integrated. interruption in system. reporting. 9. Team Work, Employee Involvement & Monitoring Management of energy conservation programs Review Energy Policy Board Displayed Awareness sessions S Safety Systems, Compliance & Governance ISO 50001 Energy Review, SEU , EnPI P People Annual Objective EC--> COC→ OPCOM→ Individual KRA I Innovation & Quality Management Audits Internal Cross location audits, External Audits C Customer Delight Review SPICE, Daily, Weekly, Monthly E Energy, Environment & Safety Monitoring Power & Fuel consumption Monitoring through EMS Energy Conservation Awareness Reward Quiz, Suggestion, Slogan, Best performer Society
2250 Nos. Energy Efficient Chulla Distribution Benchmarking Processes, Practices 40 Nos Solar Street lights in near by Villages Training Internal, External, Technical, EnMS trainings 2500 Nos LED Bulbs distributions
Trainings Audit
Auditors In House Technical BEE Energy External Training, Trainings (Drive/ Trainings ISO Audits Awareness PLC/ automation Audit Audits 9. Team Work, Employee Involvement & Monitoring Energy Conservation Target Setting & Monitoring PLAN
Management Assess current Goal Setting Commitment situation
▪ Appointment of MR, Scope & ▪ Energy Review, Base Line calculation ▪ SPICE based goal from top Boundaries ▪ Power chart preparation Management. ▪ Energy Management Team – 10 Nos ▪ SEU identification:JJ-EnMS-PR-01 ▪ Prioritizing Opportunities ▪ Establishment of Energy Policy, ▪ Upcoming Energy conservation ▪ Objectives & Action Plan Resources measures ▪ Verification Plan- EMT
Review Monitoring Implementation
▪ Daily energy consumption ▪ Process Owner ▪ Monthly review in EC/COC/OPCOM by monitoring ▪ Action plan and monitoring of top management through EMS energy Targets ▪ Monthly review by EMT ▪ Calibration of measuring Equipment ▪ Review Metering Plan ▪ CAPA preparation for deviation ▪ Audits ▪ Energy conservation projects ▪ Energy conservation projects
ACT CHECK DO
38 9. Team Work, Employee Involvement & Monitoring Budget Allocation and Review Meetings RPO Compliance Energy Conservation Measures Budget for FY 18 Allocated Solar REC Non Solar Budget (Rs Lac) (Nos) REC (Nos) (Rs Lacs) CGL #2 Line Fix Power Optimization by increasing Line Speed 312 1685 8846 202 from 150 to 200 MPM . CGL #1 Line Fix Power Optimization by increasing Line Speed 0 from 120 to 150 MPM Review Meetings Induction oven output optimisation for CCL PPGI material 0 DAILY REVIEW MONTHLY REVIEW Closed loop speed control ofCGL#2 APC Blowers by using VVVF 6 drive Review by Plant Review at Director level in Head with all HOD's EC Meeting Installation of LED Lights 5.2 New Energy Efficient Pump(7.5 kW) Installed at ARP 1.8 Review by Review at President level in Departmental Head COC Meeting Provision of local burner at CCL-1 oven to reduce fuel consumption 200 with Energy Team DOL Starters replaced with VFD at Pickling Recirculation pumps Review at Plant Head level in 1.2 OPCOM meeting and optimized energy consumption by reducing speed to 1075
Review by HOD & EnMS Old motor of 11KW replaced with IE-3 efficiency 7.5 KW motor 0.25 M.R. with Energy Fig 8 Management Team (10 Nos) Total 326.4 9. Team Work, Employee Involvement & Monitoring Awareness & Involvement of Employees in Energy Conservation programme
20 No. of Energy training No. of people trained 16 500 450 14 15 400 357
10 7 300 5 5 200 150 5 2 100 0 FY 16 FY17 FY 18 0 No. of In house Training External Trainings FY 15-16 FY 16-17 FY 17-18
40 Contd…. 9. Team Work, Employee Involvement & Monitoring Awareness & Involvement of Employees in Energy Conservation programme Mega Quiz Energy Exhibition
Slogan 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. QMS 9001 2015 FY-18 We shall encourage use of renewable energy and promote awareness of energy conservation among I EnMS 50001 2011 persons working for and on behalf of our organization.
S Turn Over - 2867 cr OHSAS 18001 2007 Date : 01.11.2015 Dileep Bhatt O Revision No. 5 President EMS 14001 2015 ENCON Spent – 8.5242 cr
Highlights
PLTCM Using advance Technology PLTCM First in Maharashtra, Estimated Energy Saving of 42792 Gcal/A .
PAT Achieved 1875 ESCerts in PAT-1 and already achieved 0.042 MTOE/T by FY-18 in PAT-2
ENCON Total 29 Energy Conservation Measures completed.
Saving Total Energy Saved- 27673 Gcal, Rs 1417 Lac.
CO2 Emission Total 9004 Tons CO2 Emission reduced by reducing Energy Consumption.
RenewableRo Installation of Roof Top Solar Power of 1500 kWp, Procured 4.07 Lac Solar Units & 100% Energy RP RPO Compliance. 43 Awards….
CFBP – Council for Fair IMC RBNQA -2016 CII -2017 Business Practices Award- Excellence Trophy Commendation 2017 Certificate
MEDA 12th State Level EC Award
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