JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won...

18
1 1 Saving in Everything We Do Sep-2010 JSW Steel Ltd (A Unit of O.P. Jindal Group of Companies) A fastest Growing Steel plant in the country Achieved annual turnover of Rs.19457crores Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry On completion of Project Falcon, JSW Steel will become largest steel plant in single location 2 Saving in Everything We Do Sep-2010 HSM CRM Billet Caster Non - coking coal Coking coal Iron ore Fluxes Coke oven Converter LHF, RH Slab Caster Sintering HMPT Pelletization Beneficiation Corex Blast furnace Lump ore Lump ore JSW : Process Flow Wire Rod / Re Bar Mill

Transcript of JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won...

Page 1: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

1

1Saving in Everything We Do Sep-2010

JSW Steel Ltd(A Unit of O.P. Jindal Group of Companies)

• A fastest Growing Steel plant in the country• Achieved annual turnover of Rs.19457crores• Won Prestigious Steel Minister’s Trophy award

for its Excellence in steel industry• On completion of Project Falcon, JSW Steel

will become largest steel plant in single location

2Saving in Everything We Do Sep-2010

HSM CRM

Billet Caster

Non - coking coal Coking coalIron ore Fluxes

Coke oven

Converter LHF, RH Slab Caster

Sintering

HMPT

Pelletization

Beneficiation

Corex Blast furnace

Lum

p or

e

Lum

p or

e

JSW : Process Flow

Wire Rod / Re Bar Mill

Page 2: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

2

3Saving in Everything We Do Sep-2010

• 100% stamping in both recovery and non recovery type Coke

oven batteries

• Energy Efficient Corex hot metal making unit

• Highest No. of gas holders (6 No.s)

• Largest Corex gas holder (capacity: 1,00,000Nm3)

• Handling 4 types of Gases

• Common CV of 1850kcal/Nm3 for all units

• Captive power plant based on Waste heat generating 65MW

power

• Captive power plant based on 100% byproduct gases• Zero consumption of Petroleum fuel for Iron making• Hot charging of slabs more than 65% in Hot strip Mill furnace• All 3 furnaces operating with Pulverized coal injection• Only Steel plant to deliver CDM benefits• Largest Blast furnace , Largest HSM in India

Uniqueness

4Saving in Everything We Do Sep-2010

Sp Energy Consumption

6.4956.704Gcal/TcsSpecific Energy Rate1

13531475Rs/-Gcal Cost3

52572863082142TonsTotal Crude Steel Produced2

UOM

v Savings with respect to Energy Consumption over 2008-2009 is Rs 148.68 Cr

DescriptionSl No 2009-20102008-2009Cost Analysis

6.98

6.847

6.704

6.495

6.2

6

6.2

6.4

6.6

6.8

7

7.2

2006-07 2007-08 2008-09 2009-10 Expected2010-11

Year

G c a l / T c s

Reduction in Sp Energy Consp over 2008-09 is 3.12%

Page 3: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

3

5Saving in Everything We Do Sep-2010

Gap Analysis w.r.t Global Best

1.295 Gcal/TcsGap

6.495Gcal/TcsSp. Energy of Similar plant

JSW Steel, Vijayanagar Works

5.20Gcal/TcsSp. Energy of Similar plant

POSO, South Korea

Gap Analysis

6Saving in Everything We Do Sep-2010

Gap Analysis (Contd..)

1.011 Gcal/Tcs

Total Gap

Project are under implementation0.123100%Nil100%

Heat recovery from flue gas

stoves and sinter cooler

4

Project are under implementation0.186100%Nil100%

CDQ in recovery type coke

oven3

Projects are on for implementation

in boilers0.32217%83%100%

BF gas Utilization2

To reduce hot metal rate JSW Steel is

installing DRI Plant

0.3894Kg/TLS

1027933Hot Metal rate1

RemarksEffect in Gcal/TcsGapJSWPOSCODescriptionSl

No

Page 4: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

4

7Saving in Everything We Do Sep-2010

• Coke ratio at Corex was lowered by 6.7%. This was achieved by better heating regime and consistent coal availability.

• Coke rate at blast furnace was lowered by 9.3% by increasing thePCI. This was achieved by increased availability of Blast furnace operation.

• LCP heat rate was lowered by 5.6% and power rate was lowered by 6.8%. This has been achieved by increased availability of gases to Calcining plant.

• LD gas recovery at BOF has improved by 1.7%. It was possible by 100% gas holder availability and installation of gas boosters.

• 5. HSM heat rate was lowered by 4.2% and power rate was lowered by 11.9%. This was achieved by eliminating idle hours of HSM due to non availability of gas and by ensuring more availability of gas to reheating furnace.

• Mills have stabilized its operation due to over all increase in value added products. Power rate of CRM has lowered by 13.25%

• Corex gas utilization has improved from 97% to 97.94% by better gas management.

• Waste heat utilization at non-recovery type coke ovens waste heat recovery power plant was improved and there was increase in power generation from 72.39MWh to 106.23MWh also with increased by-product gas utilization

• Gas based captive power generation has increased with better gasmanagement.

Energy Conservation Initiatives 2009-10.

8Saving in Everything We Do Sep-2010

Energy Saving ProjectsTotal Annu

al Savings

Invest.

Made

Units Million

Rs Million

In terms of

Quantity or

Gcal/Tcs.

Rs Million

Rs Millio

n

Rs Millio

n

1Third Booster to improve LD gas recovery.

2007-08 - -105 Gcal of energy recovered

98 98 45

2 Sand heating in BOF. 2007-08 - -

Annually 550 tons of LPG is

being saved.

24.8 24.8 0.12

3Replace of LPG by Byproduct gas in Boiler Burners.

2007-08 - -

Annually 730 tons of LPG is

being saved.

32.9 32.9

4BF Gas Holder for improving utilization of BF Gas

2007-08

30,000 Nm3/hr of gas

utilized

113 113 220

Sl No

Title of Energy Saving project implemented

Year of Implementa

tion

Annual Electrical Savings

achieved

Annual thermal savings

Page 5: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

5

9Saving in Everything We Do Sep-2010

Energy Saving ProjectsTotal Annua

l Saving

s

Invest. Made

Units Million

Rs Millio

n

In terms of Quantity or Gcal/Tcs.

Rs Millio

n

Rs Million

Rs Million

5Captive power generation has increased from 86.87 MWh to 93.35 MWh.

2008-09 6.48 176.5

By stabilization

of BF gas pressure with the

help of BF gas holder

- 176.5 Nil

6

Waste heat utilization and by product gas utilization has improved at Non recovery type coke oven based captive power plant resulting in increase of power generation from 59.16 MWh to 72.38 MWh

2008-09 13.22 360.2 - - 360.2 Nil

7

By effective control of off blast and increased plant availability increase in the CDI rate by 18.39% over the last year

2008-09 - -

Energy Consumptio

n has increased

from 0.377 to 0.464 Gcal/tcs.

262 262 Nil

8

LPG consumption has been reduced from 12.61 Tons/day to 10.9 Tons/day by replacing LPG by Corex gas in BF flare stack pilot, sand heating system in BOF and in BF boiler by modifying the Corex gasline

2008-09 - -

Energy Consumptio

n has reduced

from 0.015 to 0.0125 Gcal/Tcs.

24.59 24.59 25

Sl No

Title of Energy Saving project implemented

Year of Implementat

ion

Annual Electrical Savings achieved

Annual thermal savings

10Saving in Everything We Do Sep-2010

Energy Saving ProjectsTotal

Annual

Savings

Invest. Made

Units Million

Rs Millio

n

In terms of Quantity or Gcal/Tcs.

Rs Millio

n

Rs Million

Rs Million

9

Corex gas utilization has been improved from 93% to 94.18% by modifying the controls in flaring system

2008-09 - -

Energy Consumptio

n has reduced

from 1.455 to 1.393 Gcal/Tcs.

1003 1003 0.40.14 days

10

LD gas recovery increased by 45.47% over the last year. This has been achieved by taking LD gas holder capital repair and changed the delivery mesh and also additional booster has also been installed to take care of LD gas transport during booster shutdow

2008-09 - -

Energy Consumptio

n has reduced

from 0.190 to 0.132 Gcal/Tcs.

234 234 1Within 2

days

11

Replacement of high pressure high CV corex gas by low pressure low CV BF gas for Ore Drying Furnace

2009 – 10

Energy Consumptio

n has reduced

from 0.015 to 0.012 Gcal/Tcs

73.58 73.58 305

months

12

Interconnection of 4mTPA-7mTPA BF gas line network for ensuring BF gas to CO#3, even during shut down of BF#3 -7mTPA unit.

2009-1060,000Nm3/

Hr Flared gas is used.

367 367 90 3 months

13Increasing BF #3 Gas holder pressure from 1000mmWC to 1085mmWC

2009-10

This has enabled to generate and use

additional 125,000Nm3

/Hr Mixed gas

735 735 0.25 1 day

Payback months

Sl No

Title of Energy Saving project implemented

Year of Implementat

ion

Annual Electrical Savings achieved

Annual thermal savings

Page 6: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

6

11Saving in Everything We Do Sep-2010

Team work in Encon 2009-10

Sl No Project Description FY Responsible Agencies Project status

1

Interconnection of 4mT-7mTPA BF gas line interconnection for ensuring BF gas for gas

mixing station at coke oven#3 even with BF#3 under down condition

2009-10

VP(EMD), Manager (Coke oven), Manager (EMD), Asst. Managers

and technicians

Project has been

completed

2Replacing HP and high CV corex gas by LP

and low CV BF gas for ore drying furnace of pellet plant.

2009-10

VP(EMD),Sr.Manager (EMD),Manager(EMD), Asst.Managers(EMD),

Technicians

Project has been

completed

3 Utilizing mixed gas in corex gas network by

regulating Corex gas pressure in case of one corex gas unit is under shutdown.

2009-10

VP(EMD),Sr.Manager (EMD),Manager(EMD), Asst.Managers(EMD),

Technicians

Project has been

completed

4

Increasing the BF#3 Gas holder pressure from 1000mmWC to 1085mmWC for

ensuring 100% operation of Gas mixing station.

2009-10

VP(EMD),Sr.Manager (EMD),Manager(EMD), Asst.Managers(EMD),

Technicians

Project has been

completed

Encon Team work

12Saving in Everything We Do Sep-2010

Solid Waste Management 2009 - 10

Replacing iron ore5869858698Base mix yardMill scale6

-21212129744Pellet plant & SPdust5

This is 2% of total energy for making

pellet103462199030Pellet plantsludge4

This is 25% of energy for making

sinter2544091372837BOF as coolant,

IM, PP & SP as fluxSteel

making slag3

This is 80% of total energy for making

cement 19256381996666

Cement making, ground granulated

BF slag

Iron making slag2

This is 31% of total energy for making

crude steel15858011558926Power plant, BFs,

Coke ovens & soldCoal & coke

fines1

Equivalent of Energy

Quantity reused /

recycled, t

Generation, TonsWaste used atType of

material Sl. No

Solid waste 2009-10

Page 7: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

7

13Saving in Everything We Do Sep-2010

Specific Water Consumption

2.182009-10

2.932008-09

3.132007-08

ConsumptionYear

Specific water consumption details (m3/Tcs)

This has been achieved due to the following:

1.Waste water utilization at ore Beneficiation plant#2

2.Waste water also utilized for ore washing at BF#3

14Saving in Everything We Do Sep-2010

Carbon Emission Reduction initiatives

23%11 crores60 crores49 croresRs.

Percentage

Variance2009-102008-09

Salesof

Carboncredits

This pertains to carbon credit earned against following projects: 1.By-product gas uses for power generation at captive power plant#1

2.Usage of Waste heat of non recovery coke plant for power generation at captive power plant#2

Page 8: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

8

15Saving in Everything We Do Sep-2010

Future CDM Projects for Green Environment

Total CO2 Reduction

Total annual Saving

Investment

Tons of CO2/Yr

Rs. Rs. Payback months

1Waste heat from B F

Stoves2010 17975 78.8 200 31

2

Installation of Process boiler for utilizing

60,000Nm3/Hr of BF gas

2011 290473 436.26 60 1.5

3

Utilization of BF Gas i.e. 100000 Nm3/hr for

generating steam for power generation

2011 484122 727.08 100 1.65

5CDQ for 1.2 mTPA Non Recovery Coke Ovens 2011 89878 378 750 24

Sl No

Projects

630 18Part of total

package4 TRT for BF 4 2011 149796

16Saving in Everything We Do Sep-2010

Renewable Energy at JSW

• Traffic signals and Street Lighting at steel plant and Townships has been provided with Solar Energy.

• All the Guest houses have been provided with solar hot water facility.

• Jatropa cultivation has been initiated at Vidyanagar township and will be extended to around 75acres.

• The total energy generated is about 390000 units and a saving of Rs. 1033500. by solar photo voltaic Cells.

Page 9: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

9

17Saving in Everything We Do Sep-2010

Environment projects-2009-10

• 3 new de-dusting systems at RMHS#2 (crusher building, screening building & proportioning building) to control the fugitive emissions.

• Tyre washing facility near beneficiation plant #1 to arrest the carry over of dust from the truck tyres on to the road.

• Installation of pneumatic conveying system at BF#1 de-dusting system. This has resulted in reducing the downtime of the de-dusting system due to the problems encountered at the dust conveying arrangement.

• 5 de-dusting systems of Coke ovens – Installed at the coal crusher house, coke screening & coke cutter house.

• 10 no. of stack monitors to monitor the dust level on a continuous basis.

• 3000 m3/hr. Compressor to cater to the new de-dusting systems & dry fog dust suppression systems

18Saving in Everything We Do Sep-2010

• AAQ at 3 stations to monitor PM 2.5, PM 10, TSP, SO2, Nox & CO on a continuous basis

• SGP at SMS1 to granulate the slag.

• DSS at RMHS junction houses & yards to control the fugitive emissions from yards & junction houses.

• Gas cooling at SP1 to control the temperature & hence reduce the damage to the electrodes.

• Pneumatic conveying at PP to utilize the bag filter dusts from various plant units.

Environment projects-2009-10

Page 10: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

10

19Saving in Everything We Do Sep-2010

ISO - NCRs for 2009-10( OCT09- Mar10)

• To collect the dust generated during hot metal handling. Present Level: SPM 3763 microg/m3 Target : SPM 1500microg/m3. Objective :To collect the dust generated during blowing.

• Present level: SPM 4063 microg/m3 during blowing Target: SPM 1500 microg/m3 1. No action plan to implement the above evidenced. 2. SPM level not monitored since January 2009 to till date.3. Since it is significant environment aspect auditee needsto take measures to control and bring it to the target level / norms as required by the applicable Environment act (EP Act 1986 amended in 1999).

20Saving in Everything We Do Sep-2010

ISO Corrective action 2009-10

• Management to take the decision reg. Performance of Secondary De-dusting Systems for Mixer and Converter 2.

• EMD being central authority for monitoring dust levels help from EMD required to monitor the dust levels in these areas.

• Risk assessment of SP1- JB1C2 conveyor being reviewed and revised with immediate effect.

• Testing has been done but test report is awaited. As soon as the test certificate is recd. same will be submitted for inspection

Page 11: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

11

21Saving in Everything We Do Sep-2010

ISO Preventive action 2009-10

• As per the MOM of MRM No.36 dt.23/07/09, a circular has been issued to ensure usage of PPE’S in the work zone till the desired levels are achieved. The copy of the circular is attached. 2. EMD has agreed to continue monitoring the dust levels in these areas as it was done earlier.

• Henceforth, corrective and preventive action shall be taken after any incident after reviewing the risk assessment of the concerned activity.

• Test Certificates will be avl. in time. Follow up will be initiated with Safety Dept. so that test certificates are recd. in time.

22Saving in Everything We Do Sep-2010

Energy Based Innovative projects 2009-10

• Installation and commissioning of BF gas network interconnection of 4mTPA and 7mTPA operating at varied operating pressure with control system:Net Saving: Rs 36.792Crores

• Replacement of high pressure and high CV corex gas by low pressure and low CV BF gas for ore drying at Pellet plant:Net saving: Rs 91.98crores

• Up gradation of BF gas holder pressure from 1000mmWC to 1075mmWC Net saving: Rs 168.192crores

• Utilizing 970mmWC mixed gas in 1000mmWC corex gas network during one Corex gas unit under Shutdown condition by controlling pressure in Corex gas networkNet saving: Rs 50crores

Page 12: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

12

23Saving in Everything We Do Sep-2010

Up gradation of BF gas holder pressure from 1000mmWC to 1075mmWC (Innovative project)

• BF#3 gas holder was designed for a pressure of 1000mmWC • Before commissioning of gas holder, BF gas network was operated

with a pressure of 1150mmWC.• It was experienced that, there was fluctuation of BF gas pressure in

the upstream side of gas mixing station near Oxygen plant.• Outlet of this mixing station was against Corex gas network

pressure of 950 to 980mmWC.• Due to fluctuation of upstream pressure 970 to 1000mmWC at Gas

mixing station, mixed gas generation i.e BFG+COG was varying in between 30000Nm3/Hr to 40000Nm3/Hr.

• With 1000mmWC pressure of gasholder, there would be drop in pressure up to 10mmWC and it would not have been possible to generate mixed gas.

• Therefore, a proposal was made that gasholder pressure to be 1200mmWC.

• Accordingly a static load on piston was calculated and was foundthat, column foundation and structural can’t take that much of load.

• Further, it was found that, pressure of 1075mmWC will be suitable as around 200Tons of weight on gas holder piston will be safe with existing foundation and columns.

24Saving in Everything We Do Sep-2010

• But it was found that, there is not much area on top of the piston to accommodate concrete load of 200Tons.

• Therefore a decision was taken to use pig iron available at plant site. Hence pig iron were anchored by concrete.

• The pressure achieved was 1075mmWC.• This has enabled us to generate mix gas up to 160000Nm3/Hr.

Otherwise the gas was being flared. • So there is gain of 125000Nm3/Hr of mixed gas. • This has helped us also in generating mixed gas for largest

HSM reheating furnaces.• Overall mixed gas generation was possible up to

165000Nm3/Hr• Cost of mixed gas Rs. 1.22/ Nm3• Cost of modification Rs. 25Lakhs• Benefit works out to be 168crores/Anum

This work is one of its kind in any steel plant. This has made the gas network viable and for generating desired quantity of mixed gas for stable operation of plant.

Up gradation of BF gas holder pressure from 1000mmWC to 1075mmWC (Contd..)

Page 13: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

13

25Saving in Everything We Do Sep-2010

PistonDome

Pig Iron added to increase the weight

of Piston

Concrete Blocks

Concrete

Rubber Seal

Shell

Piston Rest Blocks

Gasholder Dome

Designed Pressure -1000 mmWCPressure Increased by Adding Pig Iron -1075 mmWC

BF-3 Gasholder (Innovative project)

26Saving in Everything We Do Sep-2010

Energy Conservation projects 2010-2011

0.2468Total

0.1Rs 8 MillionBF gas to power plant for power generation5

0.02Rs 8 MillionUp gradation of EMC SCADA4

0.0128Rs. 8 Million

Replacement of HP Corex gas by BF gas for 2nd Ore drying furnace of

pellet plant

3

0.05Rs 50 Million

Interconnection O2 and N2 header of all Oxygen plant for flexibility of

operation so as to operate all units

2

0.064Rs.600 MillionInstallation of 2 No.s of BF

gas fired boilers for process Steam

1

Effect on Sp.Energy in Gcal/Tcs

Investment Project Description Sl No

A

Page 14: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

14

27Saving in Everything We Do Sep-2010

Energy Conservation measures 2010-2011

B

Total Effect on Sp.Energy Consumption = A+B= 0.347Gcal/Tcs

0.1002Total

0.02Increasing TRT power generation

from 3MWh to 8MWh3

0.012Increasing the utilization of

Corex gas from 97.94 to 98.94%

2

Reduction of BF coke rate from 518 to 480kg/THM

0.0682

Increasing BF Coal rate from 66. 23 to 100kg/THM

1

Effect on Sp.Energy in

Gcal/TcsProject Description

SlNo

28Saving in Everything We Do Sep-2010

Best Practices Observed On Energy Front

• Preparing Energy budget with regard to by- product gas yield, Gas CV, Heat rate, Power rate, Utility utilization in shops. Budget as per experience and Energy improvement projects

• Energy Management through SCADA.

• Delay strategy followed by shops during short and long shutdowns.

• Low cost, No cost solutions for energy related problems.

• Planning and implementation of Energy conservation projects under Capex.

• Continuous work for Energy security.

Page 15: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

15

29Saving in Everything We Do Sep-2010

Energy Security Efforts at JSW

• Optimizing the PCI (Pulverized Coal Injection) to reduce costly coke in all Blast furnaces

• Utilizing more than 15% non coking coal in coke ovens

• Corex gas utilization is > 98.4%

• Efforts are on for BF gas utilization > 95% by 2012

• Has Installed TRT @ BF#3 i.e. for High Top pressure blast furnace

• About to install CDQ for recovery type coke ovens and produce 50MWh power generation

• JSW Steel is set to get Natural gas, another important measure for Energy Security

30Saving in Everything We Do Sep-2010

Energy Report

On Date Till date Parameter Unit Target On Date Till dateCO 1&2 Gross Coke % 74 70.8 71.2No of pushing Nos 112 108 108Waste heat power Mwh 64 55.6 53.5Power Rate Kwh/tp 12 16.42 16.51CO3 Gross Coke % 74 72.4 72.5Specific heat Gcal/Tdc 0.65 0.61 0.61CO 3 gas yield Nm3/tdc 310 332 315Tar yield % of tdc 3.2 2.85 2.91No of pushings Nos 224 221 216.5Power Rate Kwh/tp 55 57 57Gaseous Heat rate Gcal/T 0.007 0.007 0.007Coke Breeze Heat Gcal/T 0.388 0.402Power Rate KWh/T 40 42 39 Gaseous Heat rate Gcal/T 0.007 0.006 0.006Coke Breeze Heat Gcal/T 0.194 0.150Power Rate Kwh/T 40 38 39Gaseous Fuel rate Gcal/T 0.12 0.13 0.131Power Rate KWh/T 70 65 6710600 293540

Sinter Plant 1 6469 184574

Pellet Plant

Sinter Plant 2 7838 207757

For June 28, 2010

ProductionShops

1165724265

Coke oven 1&2

Coke oven 3

Energy Management Department

673482409

Daily Plant Energy MIS

Page 16: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

16

31Saving in Everything We Do Sep-2010

Energy Report

On Date Till date Parameter Unit Target On Date Till dateCoal Rate Crx 1 Kg/Thm 815 900 867Coke Rate Crx 1 Kg/Thm 170 185 199Oxygen Rate Crx 1 Nm3/Thm 560 615 744Nitrogen Rate Crx-1 Nm3/Thm 125 144 288Gas yield Crx 1 Nm3/Thm 1680 1,638 1,817Coal Rate Crx 2 Kg/Thm 815 963 899Coke Rate Crx 2 Kg/Thm 170 159 191Oxygen Rate Crx 2 Nm3/Thm 560 630 615Nitrogen Rate Crx 2 Nm3/Thm 110 122 118Gas yield Crx 2 Nm3/Thm 1680 1,812 1,798Corex gas C V Kcal/Nm3 1855 1,870 1,898Power Rate KWh/Thm 85 109 113Coke Rate BF 1 Kg/Thm 520 452 466CDI Rate BF 1 Kg/Thm 80 100 90Gas yield BF 1 Nm3/Thm 1750 1,609 1,675Oxygen Rate BF 1 Nm3/Thm 70/100 48 46Nitrogen Rate BF 1 Nm3/Thm 50 48 46Heat rate (stoves) Gcal/Thm 0.63 0.45 0.44Coke Rate BF 2 Kg/Thm 520 469 452CDI Rate BF 2 Kg/Thm 120 100 77Gas yield BF 2 Nm3/Thm 1885 1,793 1,930Oxygen Rate BF 2 Nm3/Thm 55 55 45Nitrogen Rate BF 2 Nm3/Thm 50 65 83Heat rate (stoves) Gcal/Thm 0.50 0.59 0.60Power Rate KWh/Thm 50 48.8 53.55

Blast Furnace 2 3609 86029

Blast Furnace 1 2841 74352

Corex 1 2207 55246

Corex 2 2003 56535

For June 28, 2010

ProductionShops

Energy Management Department

Daily Plant Energy MIS

32Saving in Everything We Do Sep-2010

Energy Report

On Date Till date Parameter Unit Target On Date Till dateCoke Rate BF 3 Kg/Thm 525 437 450CDI Rate BF 3 Kg/Thm 150 105 87Gas yield BF 3 Nm3/Thm 1800 1,601 1,782Oxygen Rate BF 3 Nm3/Thm 50 90 84.87BF 3 Nitrogen Rate Nm3/Thm 50 36 58B F 3 Power rate KWh/Thm 160 147 160Heat rate (stoves) Gcal/Thm 0.50 0.49 0.53B F gas C V Kcal/Nm3 750 750 750Heat rate Gcal/Ton 0.75 0.75 0.79Power rate KWh/Ton 34 37 35Oxygen rate Nm3/Tls 54 57 59Nitrogen rate Nm3/Tls 28 50 46Power Rate KWh/Tls 45 42 43Hot Metal rate Ton /Ton 1.027 0.996 1.024LD Gas Recovery Nm3/Tls 100 113 107Argon Rate Nm3/TSla 2.00 1.20 1.39Power Rate KWh/TSla 18 18 19Oxygen rate Nm3/Tls 54 59 59Nitrogen rate Nm3/Tls 28 45 39Power Rate KWh/Tls 45 70 69Hot Metal rate Ton /Ton 1.027 1.216 1.235LD Gas Recovery Nm3/Tls 100 0 0.00Argon Rate Nm3/TSla 2.00 1.82 2.15Power Rate KWh/TSla 18 30.6 30.0Heat rate Gcal/Tp 0.27 0.279 0.368Power Rate KWh/Tp 90 80 88

SMS 2 7140 177882

CCP 2 7049 174687

HSM-1 227290

LCP 1875 46786

9903

259675

256235CCP 1

SMS 1 10238

10153

192424Blast Furnace 3 8273

For June 28, 2010

ProductionShops

Energy Management Department

Daily Plant Energy MIS

Page 17: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

17

33Saving in Everything We Do Sep-2010

Energy Report

On Date Till date Parameter Unit Target On Date Till dateHeat rate Gcal/Tp 0.27 0.863 0.402Power Rate KWh/Tp 90 419 190Heat rate Gcal/Tp 0.35 0.31 0.372Power Rate KWh/Tp 160 156 212Heat rate Gcal/Tp 0.4 0.29 0.552Power Rate KWh/Tp 110 109 175Heat rate Gcal/Tp 0.298 0.90 0.165

380 66113 Power Rate KWh/Tp 95 613 129BF gas consumption Nm3/hr 165000 103,908 94,669Corex Gas Cons Nm3/Hr 85000 98,513 96,305Total Generation MWh 100 104 99Corex Gas Cons Nm3/Hr 25000 19,410 21,454BF gas consumption Nm3/Hr 175000 136,333 120,111Total Generation MWh 120 111 107Plant load MWh 360 291 285Specific power KWH/Tcs 560 406 447

Iron 4 mTPA BF # 3 SMS #1 SMS # 2 HSM-1 CRM Total/day3.90 0.05 3.80 3.90 0.52 0.39

Losses (%) Corex gas 1.65 CO Gas 0.11 BF 1 & 16.62 BF 3 Gas 15.56Specific Energy Consumption 6.67 (with BP norm) On date 6.34 Till Date 6.50

Energy Management Department

Electricity

HSM-2 728 79444

Daily Plant Energy MIS

Shops

LPG

For June 28, 2010

Remarks: 1)Good Hot metal rate in SMS -1 i.e 0.996 Thm/Tls. 2) Good Coke rate in Blast Furnace -1, 2 & 3. 3) Good CDI rate of Blast Furnace -1 i.e 100 Kg/Thm.

14.87WRM & Others JPOCL BOC # 1 & 20.20

Production

104

CRM CPL CRM CCM

2796

WRM 1702

1.91 0.20

29025

CPP-2 111 2976

BRM 2094 29892

CPP-1

34Saving in Everything We Do Sep-2010

ENERGY – A Major Thrust at JSW

JSW Steel Since inception has taken care of Energy Efficient technologies

JSW Steel Cares for Energy

• Daily Energy Review during ED(O) & HOD’s Meeting

• Energy is reviewed during weekly cost meeting

• SEC is the Key Result Area for Senior and Top Management

• CEO Reviews Energy during weekly production performance meeting

• CEO Reviews Energy during monthly production meeting

• MD Reviews performance of Energy conservation activities, future plans and encourages team for achieving set goals.

Page 18: JSW Steel Ltd - greenbusinesscentre.com Award... · JSW Steel Ltd (A Unit of O.P ... • Won Prestigious Steel Minister’s Trophy award for its Excellence in steel industry • On

18

35Saving in Everything We Do Sep-2010