Steel Coated Product Limited, Vasind · 100% Subsidiary of JSW Steel India’s Leading Coated Steel...

CII National Energy Efficiency Circle Competition

Presenters:

Mr. Anish Karahe- Sr. Manager

Ms Aditi Chauhan- Jr. Manager

Steel Coated Product Limited, Vasind

Jindal SAW JSL StainlessJindal Steel and

Power

Mr. Prithvi Raj Jindal Mr. Sajjan Jindal Mr. Ratan Jindal Mr. Naveen Jindal

• Jindal ITF

• Jindal Waterways

• Jindal Transrail

• Jindal Water

Infrastructure

• Jindal Urban

Infrastructure

• Jindal Shipyards

• Jindal Rail

Infrastructure

✓JSW Steel

✓JSW Steel Coated

Products Ltd

✓JSW Energy

✓JSW Infrastructure

✓JSW Cement

✓JSW GBS

✓JSW Sports

✓JSW Foundation

• JSL Media

• JSL Lifestyle

• JSL Architecture

• Green Delhi BQS

• JSS Steel Italia

• PT Jindal

Stainless,

Indonesia

• Jindal Stainless

Steel ways

• Jindal Power

• Jindal Petroleum

• Jindal Steel

Bolivia

• Jindal Cement

Shri. O. P. Jindal

“Where others see walls…..,

I see doors…..”

O P Jindal Group

3

Steel

India’s Leading integrated

Steel Producer (18 MTPA)

Vijayanagar – 12 MTPA

Dolvi – 5 MTPA

Salem – 1 MTPA

SCPL

100% Subsidiary of JSW Steel

India’s Leading Coated Steel

Producer (1.8 MTPA) Vasind – 0.45 MTPA

Tarapur – 0.76 MTPA

Kalmeshwar – 0.6 MTPA

▪ Engaged across the value chain of power business (Operational plants’ capacity: 4,531 MW)

Energy

▪ Engaged in development and operations of ports (Operational capacity: 70 MTPA

Infrastructure

Cement

▪ Manufacture of PSC, OPC and GGBS cement, (Operational Plants capacity 10.3 MTPA)

JSW Group

s

2018

2017

2016

2015

2019

• Commissioning of PLTCM

• Capacity increased by 300%

• CII-GreenCO Certification• MEDA 12th State Level EC Award

• CGL Speed Increase

• CCL Local Burner Installation

• EMS 14001:2015 Certification

• EnMS ISO 50001:2011 Certification

• OSHAS 18001:2007 Certification

• CII-2017 Commendation Certificate

• IMC RBNQA-2016 Excellence

Trophy

• Installation of On Line Skin Pass

• CII Energy Audit

• Earned 1871 ESCerts in PAT -1

20112012

• Installation of Railway Yard

1994Installation of CGL-1 & CRM-4

2003 • Installation of CGL-2

1990 Installation of CRM-3

• Power Open Access

• RLNG Supply Line From

GAIL

• Installation of Colour Coating

Lines

1996 QMS ISO 9001 Certification

2013• Entitled as Designated

Consumer of PAT

Road Map

5

Energy

Sources

RLNG

Electrical

Power

6.49

Lacs MMBtu/A

885

Lac kWh/A

163147

GCal/A

81576

GCal/A

RLNG163147 GCal

69%

Power81576 GCal

31%

Energy consumed at Vasind

RLNG

Electrical Power

Energy Sources

GAIL

JSW Energy

Open Access

RLNGElectrical

Power

Total : 239764 GCal/A

1. Specific Energy Consumption

11%

12%

52%

23%

2%

Energy in GCAL

Pre-Rolling

Rolling

Galvanizing (GI/GL)

Colour Coating

Auxillary

Annual Consumption FY-18

CII National Energy Efficiency Circle Competition 6

6%

38%

39%

12%

5%

Process Wise Power Consumption kWh

Pre-Rolling

Rolling

Galvanising

Colour Coating

Auxilary

14%

58%

28%

Process Wise RLNG Consumption MMBtu

Pre Rolling

Galvanizing(GI/GL)

Colour Coating

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

1. Specific Energy ConsumptionProcess wise Energy Consumption

7

Plant capacity Utilization & Reduction in Specific Energy Consumption (Year wise)

Plant Energy Consumption

Energy Unit FY 16 FY 17 FY 18

Electricity Lakh Kwh 749.3 887 885

ThermalMillion

Kcal136574 149571 163147

Specific Energy

Consumption MTOE/t 0.050 0.042 0.041

Plant Capacity Utilization

Year Unit FY 16 FY 17 FY 18

Installed Capacity Lacs ton 4.5 4.5 4.5

Actual Production Lacs ton 3.96 4.46 4.55

Capacity Utilization % 87.78 99.23 101.11

0.050

0.042 0.041

0.030

0.035

0.040

0.045

0.050

0.055

FY 16 FY 17 FY 18

Specific Energy Consumption MTOE/t


87.78

99.23 101.11

80

85

90

95

100

105

FY-16 FY-17 FY-18

Capacity Utilization %

PAT-1Energy Consumption (MTOE/T) Energy

Saving

MTOE

ESCerts

AwardedNotified Notified

Target

Baseline

Verification

0.0594 0.0575 0.0545 2042.3 1875

PAT-2Energy Consumption (MTOE/T)

Notified Notified

Target FY 16-17 FY 17-18 FY 18-19

0.044 0.0413 0.042 0.041 0.039

0.0594

0.0545

0.05

0.042 0.0410.039

0.035

0.04

0.045

0.05

0.055

0.06

0.065

FY 13 FY 15 FY 16 FY 17 FY 18 FY 19

Energy MTOE/t

Perform Achieve Trade (PAT) Cycle


9

0.0518

0.0463

0.0446

0.040

0.042

0.044

0.046

0.048

0.050

0.052

0.054

Tarapur Kalmeshwar Vasind

Energy Cosnumption (Mtoe/t)Parameter UNIT Tpr Klm Vsd

Total Plant Energy Consumption Mtoe 45728 32723 26143

Total Equivalent Production MT 882519 707310 586721

Energy Cosnumption Mtoe/t 0.0518 0.0463 0.0446

• Benchmarking of Energy data through Energy Report on a monthly basis.

• Adoption of best practices

2.Benchmarking

545 3.46

0.80

9.00

4.99

2.53

1.20

50.1

418

0.53 0.13

0.12 0.06

42.5

390

SEC

in F

Y-1

5

Inst

alla

tio

n o

f LE

D

Inst

alla

tio

n o

f P

LTC

M

SEC

in F

Y-1

8

(Cu

rre

nt)

SEC

in F

Y-1

9

(Tar

gete

d)

Pro

cess

Co

ntr

ol

Inst

alla

tio

n o

f V

FD in

Cra

nes

Ener

gy E

ffic

ien

t Eq

uip

men

t's

Inst

alla

tio

n o

f V

FD

Inst

alla

tio

n o

f LE

D

Au

tom

atio

n

Pro

cess

Co

ntr

ol

Ener

gy E

ffic

ien

t Eq

uip

men

t's

Inst

alla

tio

n o

f Ec

on

om

izer

Bo

iler.

loca

l bu

rner

CC

L-1

Road Map of Specific Energy Consumption Reduction

Energ

y

Consum

ption

(Mega C

al/t)

34.9

loca

l bu

rner

CC

L-2

2.Benchmarking

12157

852

Rs Lac

FY 16 FY 17 FY 18

28322600

22241

GCal

FY 16 FY 17 FY 18

191

131

1095

Rs Lac

FY 16 FY 17 FY 18

Energy Savings & Investment

Energy Savings

Investment

Total Energy Saving (FY-16 to FY-18)

27673 GCal

Total Saving by Zero Investment Projects (FY-16 to FY-18) – 2170 GCal

Potential Investment in

FY 19 – 103.2 cr

Potential Saving In

FY19 – 86251.6 GCal

3.Energy Saving Projects Implemented

12

ENCON Measures.04Energy Saving(kWh)

Savings(Rs Million)

Investment (Rs Million)

Payback (Months)

Auto speed control of CCL Oven Recirculation Fan 89000 0.534 0 0

Speed Control of CAG1 blower with strip temperature

in CGL#184672 0.47 0 0

CAG-2,3,4 & 5 blowers operation with TPH in CGL#1 701568 3.9 0 0

Reduction of idle power consumption 120000 0.72 0 0

CGL2 and CRM3 unit water supply system connected

with each other and made CGL2 one 30 KW pump off180576 1 0 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

CRM#3 & CRM#473000 0.438 0.05 1.4

Provision of AC Drive for Pickling Squeeze Roll Hyd Power

pack42000 0.052 0.2 46.2

Installation of LED Lights 64800 0.38 0.35 10.8

VFD Drives installation for CGL#1 Non ox blower with

pressure close loop108864 0.6 0.2 3.9

Total 3293480 19.05 12.1 7.6

ENCON Measures FY - l6

ZERO INVESTMENT Projects


13

ENCON Measures

Energy Saving

Saving

(Rs Million)

Investment

(Rs Million)

Payback

(Months)Electrical

(kWh)

Thermal

(Gcal)

Optimization of CGL#2 cooling towers 218000 1.3 0 0

VFD Installation in CRM#4 & CRM#3 Fume

Exhaust blower360000 2.16 1.8 10

Optimization of Air compressors at CGL#1 &

CRM#4680000 4.04 1.2 3.6

Installation of high efficiency 380 CFM

Compressor180576 1.01 1.2 14

Installation of booster pump for CCL AC

210000 1.26 0.2 1.9

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 5.2

ENCON Measures FY – 17



14

ENCON Measures

Energy SavingSavings

(Rs Million)

Investment

(Rs Million)

Payback

(Months)Electrical

(kWh)

Thermal

(GCal)

CGL #1 Line Fix Power Optimization by

increasing Line Speed from 120 to 150 MPM 862529 5.13 0 0

Induction oven output optimization 267000 1.6 0 0

CGL #2 Line Fix Power Optimization by increasing

Line Speed from 150 to 200 MPM .2131240 13.12 31.2 28.33

Closed loop speed control of CGL#2 APC Blowers by

using VVVF drive135000 0.8 0.6 9

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

fuel consumption 20,16000 17357 65 20 3.7

Pump Motor Speed Optimization by increasing VFD

in two nos Re-Circulation Pumps119184 0.73 0.12 1.9

Old motor of 11KW replaced with IE-3 efficiency 7.5

KW motor20106 0.12 0.025 2.42

Total 5679059 17357 109.56 85.28 9.3

ENCON Measures FY - 18



15

ENCON Measures

Electrical

Savings

(kWh)

Thermal

Savings

(GCal)

Savings(Rs Million)

Investment(Rs Million)

Payback(Months)

Developing CGG Alloy to reduce RLNG and Power

consumption at Alloy Furnace73000 1334 3.8 0 0

Installation of 1.3 million ton Pickling Linked Tandem

Coldrolling Mill with advance energy efficient technology48000000 15120 374.5 1000 32.04

Replacement of conventional lights by 150 Nos LED

lights .85410 0 0.58 0.5 10.33

Using excess Steam of CCL at CRM 4 to heat Coolant in

place of RLNG.60000 1200 3.96 1 3.03

Modification of CGL-1 Pump house with Energy Efficient

Equipment and pipe line redesigning.49275 0 0.33 0.4 14.32

Installation of new common pump house for CRD &

CGL-2 with Energy Efficient Equipment63875 0 0.43 0.4 11.05

Reduction of Fuel consumption by optimizing Air Fuel

Ratio by installing Oxygen analyser at CGL-1 Stack0 257 0.75 0.5 7.94

Reduction of Fuel consumption by optimizing Air Fuel

Ratio by installing Oxygen analyzer at CGL-2 Stack0 171 0.5 0.5 11.88

Provision of local burner at CCL-2 oven to reduce fuel

consumption 2250000 17010 66 20 3.6

ENCON Measures Planned FY 19

3.Energy Saving Projects Planned


16

ENCON Measures

Electrical

Savings

(kWh)

Thermal

Savings

(Gcal)

Savings(Rs Million)

Investment(Rs Million)

Payback(Months)

CGL-2 furnace modification to Operate in Strip Temperature

control mode, in place of Zone temperature control mode.0 1058.4 3.1 0.2 0.77

Replacement of CGL-1 Furnace water cooled type Hearth roll

with Non Water cooled Earth rolls (7 Nos)262800 5518.8 17.99 2.2 1.46

Installation of 200 KW VFD in CRM3 Air compressor and close

loop the motor speed with Header pressure to avoid unloading

of compressor.

146000 0 0.99 0.7 8.4

Installtion of VFD for LT and CT operation of crane in 3 nos

cranes.54750 0 0.37 1.5 48.3

Replacement of Old motors with Energy efficient IE-3 motors

(45 KW 8 Nos)112128 0 0.76 1.6 25.1

Replacement of inefficient old ventilation blowers of CRM-4 mill

motor with high efficiency blowers.429240 0 2.91 1.5 6.1

Replacement of inefficient old ventilation blowers of CRM-3 mill

motor with high efficiency blowers.254040 0 1.72 1.5 10.4

Total 51840518 41668.8 478.69 1032.5 25.8

ENCON Measures Planned FY 19

3.Energy Saving Projects Planned

Power 107 kWh/t

Cold Rolling PicklingHRS Pickling Linked Tandem Cold Mill (PLTCM)

RLNG0.1

MMBtu/t

Power 60 kWh/t

RLNG0.05

MMBtu/t

BEFORE IN FY - 19

Energy Consumption0.081 Gcal/t

Energy Consumption0.064 Gcal/t

Turn

around

Estimated Energy Saving-42792 Gcal/A @ 1.3 Million Ton Production

Investment Rs.800 Cr

Combination of three

process

Use of Energy

Efficient AC motors

MV VFD drives & advance

Level –II automation

Pickling Linked Tandem Cold Mill

18

Project Selection

A) Annual Saving Potential of Energy

Consumption in GCal

5 More than 1000 GCal




1 Less than 100 GCal

0 Not Identified

B) Investment required (Rs. In

lacs)

5 Less than 10 lacs

4 More than 10 lacs

3 More than 15 lacs

2 More than 25 lacs

1 More than 50 lacs

0 Not Identified

C) Required down time (excluding lead time

of resources.)

5 Less than One day

4 Less than three days

3 Less than five days

2 Less than seven days

1 More than seven days

0 Not Identified

" * " = Priority of SEU to be decided based on above methodology in descending order of score . Eg. P1 top priority and so on…

Projects

Annual

Energy

Savings

Investment

Required

Required

Down

Time

Annual

Energy

Saving

Investment

required

Required

down

time

Score

Priority

(P1..P2

… etc.,)

GCal Rs in Lacs Days A B C A X B X C *

Speed Optimization of CAG 676.2 0 1 4 5 5 100 P1

CGL #1 Line Fix Power Optimization 741.8 0 1 4 5 5 100 P1

Closed loop speed control of CGL#2 APC

Blowers 116.1 8 0 2 5 5 50 P2

Pickling Pump Motor Speed Optimization 102.5 1.2 1 2 5 5 50 P2

Provision of local burner at CCL-1 oven 19090.8 200 6 5 1 2 10 P3

CGL #2 Line Fix Power Optimization 2062.5 312 10 5 1 1 5 P4

4.Innovative Projects Implemented

176

Received

45

Selected

29

Implemented

16

Planned

Suggestions

19RTOPrimary Heat

Exchanger

Secondary Heat

Exchanger

Waste Heat

Recovery Boiler

Hot By Pass Valve

Oven Zone

RC Fan

Chimney

Project Area

Localize Heating Arrangement in Colour Coating Line

• No of Ovens – 2 Nos

• Each Oven - 5 Zones

VOC to RTO

Combustion Blower

Fresh Air

To Process

Steam

Innovation Project and Case Study-

Before


20IM

Major Challenges

In CCL all zones of prime and finish ovens were heated with centralised RTO (Regenerative Thermal Oxidizer). The Temperature Required in Ovens is approximately 400 deg C, For achieving the same we need to increase the RTO Temperature more.

Huge Losses due to indirect heating and to Maintain Oven temperature, Required High Volume of hot air Resulting High RLNG Consumption- 0.86 MMBtu/t

To fulfil high hot air volume in Ovens, All Blowers running at full speed resulting High Power Consumption - 47 kWh/t

Less Utilization due to Frequent Maintenance required for the RTO System

It takes longer time, around 4 hrs for Oven heating during Line start up

Solution Proposed

Provision of ZONE WISE LOCAL BURNER in Ovens

Provision of FIRING CONTROL

Installation of LEL (Low Explosion Level) Sensor to

monitor VOC Concentration

Use of Hot Air bypass only for safety

Optimization of Valve Blower Speed wrt Product Mix

Before AfterSaving

(Rs Lac/A)

RLNG Consumption (MMBtu/T) 0.86 0.65 263

Power Consumption (KWh/T) 47 43 46

309

Avg Production Per Month 11000 12500 1260

Diversion due to RTO Tripping (%) 0.2 0 30

RTO Tripping (Nos/ Month) 8 0

Productivity ( Ton/Hr) 20 25

1290

1599

Saving in Energy

Saving due to Productivity

Total Saving

Potential Saving

Localize Heating Arrangement in Colour Coating LineInnovation Project and Case Study-


21RTOPrimary Heat

Exchanger

Secondary Heat

Exchanger

Waste Heat

Recovery Boiler

Hot By Pass Valve

Oven Zone

Chimney

VOC to RTO

Combustion Blower

Fresh Air

To Process

Steam

RC FanMainPilot

Main RLNG Valve

After

Localize Heating Arrangement in Colour Coating LineInnovation Project and Case Study-


22

0.86

0.55

0.45

0.3

0.4

0.5

0.6

0.7

0.8

0.9

Without Local Burner With Local Burner After ProcessOptimization

RLNG Consumption (MMBtu/T) 47

41

35

30

34

38

42

46

50

Without Local Burner With Local Burner After ProcessOptimization

Power Consumption (KWh/T)

Saving/Annum RLNG- 68880 MMBtu ( Rs 5.1 Cr) Saving/Annum Power- 20.1 Lac KWh (Rs 1.5 Cr)

Achieved -Total Energy Saving-19091 Gcal (Rs 6.5 Cr) at CCL-1

Potential- Total Energy Saving-18945 Gcal (Rs 6.6 Cr) at CCL-2

Before AfterAfter Process

Optimization

Saving

(Rs Lac/A)

RLNG Consumption (MMBtu/T) 0.86 0.55 0.45 513

Power Consumption (KWh/T) 47 41 35 137

650

Avg Production Per Month 11000 14000 14000 2520

Diversion due to RTO Tripping (%) 0.2 0 0 30

RTO Tripping (Nos/ Month) 8 0 0

Productivity ( Ton/Hr) 20 25 25

2550

3200

Saving in Energy

Saving due to Productivity

Total Saving

Localize Heating Arrangement in Colour Coating Line Innovation Project and Case Study-

Innovative Projects

Energy Rs Lac

1.7 0.8 67500 500

95 65 2250000 150

4200 6000 1512

0.2 0 14

8 0

8 12.5

1526

2176

Before After Saving Per Annum

650

H

O

R

I

Z

O

N

T

A

L

D

I

P

L

O

Y

M

E

N

T

At

CCL-2

23

PROBLEM STATEMENT

61%

39%

Fixed Power Variable Power

High Fixed Power Consumption, 60% t of Total Power Consumption

Specific Power Consumption-130 kWh

Huge Variation in Product Mix Causing Less Productivity

Furnace controlling with Zone Temperature Control (ZTC)

No. of Break Downs were high

Energy

Consumption

Product Mix

Automation

Previous Galvanizing Line Flow Diagram

Power Distribution

Fixed Power Can be Optimized by Speed Increase

Reduction of Power Consumption in CGLInnovation Project and Case Study-


24

Solution Proposed

One more Recoiler and Bridle added to reduce coil

changeover time at exit section

Welding time reduced from 160 to 120 secs by

reducing the sequence time

PID closed loop logic made by taking TPH and

Output in closed loop for Induction Oven

Drive parameter optimization for process line speed

200 MPM

Furnace operation In Strip Temperature Control

(STC) in place of Zone Temperature control (ZTC)

New Pendant Blower(75 kW) added in place of After

Coating Blower(160 kW) to reduce fixed power

optimization

Furnace Length increase

Both Exit and Entry Looper Height increase to

increase the accumulation capacity

Mix Product Wise Power Consumption

and Production

Identification of Fixed and Variable Power

Consuming Equipment's

Sheet Accumulation Capacity of

Accumulators

Timings of Welding and Cutting during Coil Change Over

Data Collection

Average Power Consumption

130 kWh/T

Variable Power-39%

Fixed Power-61%

Induction Oven consuming 100%

Power at all products.

Sheet Accumulation Capacity of

Accumulators-350mtr

Timings of Welding and Cutting during Coil Change Over-

160 sec

Analysis

Implemented

Budget Req

330 Lac

Dropped

Budget Req

700 Lac



25

Total Energy Saving of 48 Lac kWh/A.

Highest Production in FY 18- 2.17 Lac Ton

Energy Saving of Rs 280 Lac per Annum.

Productivity Increased by 18%

Total Energy Consumption Reduced by20 kWh/t from 120 kWh/t to 101 kWh/t.



26

CA

G-

CAG-3 CAG-2 CAG-1

Colling After Galvanization BlowerInnovation Project and Case Study-


Earlier all CAG blowers use to run at full speed despite of low TPH resulting excess power consumption – 174 Unit /Hour.

Optimization and controlling of

CAG blowers speed in accordance of TPH

PROBLEM STATEMENT Solution Proposed

Installation of VFD at all the CAG Blowers

Logic can be made by taking TPH in closed loop

with the speed of the blower

Solution Implemented

Installation of VFD at all CAG Blowers

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



28

174 174 174 174 174 174 174174

155

120

95

75

5845

0

20

40

60

80

100

120

140

160

180

200

35 & MORE

33-35 30-32 28-30 25-28 20-25 LESS THAN 25

Pow

er

Consum

ption

Line TPH Before After

Power Consumption Vs Line TPH

Results

Annual Power Consumption

4167

2458 2356 2247 2314 2245

APRIL TO NOV

DEC JAN FEB MARCH APRIL

Pow

er

Consum

ption

(kW

h)/

Da

y

Months FY-16



Total Energy Saving of 676.16 GCal/A. Energy Saving of Rs 43.7 Lac/A

FY Total Power (MU)

RPO TARGET REC PURCHASEDValue Rs LacSOLAR

NON SOLAR

SOLARNON

SOLAR

FY 16 72 364 6196 379 6442 109

FY 17 84 847 8469 868 8431 156

FY 18 84 1671 8771 1671 8771 118

TOTAL 240 2882 23436 2918 23644 383

29

Roof top Solar Power

Project has finalised to install 1500 kWp roof top

solar power system in FY-19

4.07 Lac Units Solar power purchased through Open access from M/s Modern

India

Use of Transparent

Sheet for natural

lighting in plant

Installation of Root Top

Solar Panels JVM

School

Roof top Solar Power

School

Renewable EnergyInstallation of 1500 KWp Roof Top

Solar Power system is on progress

Use of

ECO -VENTILATORRain Water Harvesting

Rain Water Collection From

Plant Shed

Capacity- 300 KL

Size- 10 M*10M*3M

5.Utilization of Renewable Energy Sources

30

SOLAR ROOF TOP SURVEY

5.Utilization of Renewable Energy Sources

31

Year Name of Fuel Quantity Used

(MT)

GCV

(KCal/Kg)

Energy Utilized

Gcal/Year2015-16 Paint Solvant 3240 7000 22680

2016-17 Paint Solvant 3892 7000 27244

2017-18 Paint Solvant 3988 7000 27916

22680

27244

27916

20000

21000

22000

23000

24000

25000

26000

27000

28000

29000

2015-16 2016-17 2017-18

Weast Energy Utilized Gcal/Year

6.Utilization of Waste Material

32

91.6

72.4

84.5

15-16 16-17 17-18

GHG Emission Scope-1 (Kg Co2 /Ton)

0.56

0.59

0.57

15-16 16-17 17-18

GHG Emission Scope-2 (Kg Co2 /Ton)

Installation of RTO

Tree Plantation

Installation of WHR Boiler

7. GHG Inventorization

33

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)

Procurement of Energy Consuming Products based on Life

Cycle Cost and considering most Energy Efficient Product

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)

PR To Payment Total Paperless Invoicing

8. Green Supply Chain

34

You shall comply with the Business

Responsibility/Sustainability policies of JSW

Steel Coated Products Limited which can be

referred to on our website:

"http://www.jsw.in/companies/Sustainability_P

olicy.shtml"

We expect our supplier to be in line with JSW

Vision, Mission & Values to achieve common

goal of the Organization.

Vision: Nurture Leadership in Coated

Products by Creating Value for Stake Holders

in Environmentally Sustainable Way

Mission: Supporting India's growth in core

economic sectors with Speed and Innovation

Values:

Transparency, Strive for Excellence,

Dynamism & Passion for Learning.

We are an ISO 9001:2015 company. We

take utmost care of our environment. We

encourage our suppliers to have QMS and

EMS certification, please inform us if you

need any type of assistance in the

process of certification. Please help us to

save our environment

Communication Through Purchase order-

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

into an active two-way dialogue.

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

Management and Board dealings. Our executives contribute to the ideologies and work towards

embedding robust corporate governance principles in their practices. Cutting edge technology

combined with our application and customer service skills help us to create value for all our

stakeholders.

With growing scarcity of primary and non-renewable sources of energy, we are striving

to minimize our energy consumption through process optimization and energy

conservation initiatives while deploying new technologies.

Since inception, we have consistently aggregated competencies from diverse cultures,

educational backgrounds and domain experience with a singular objective: to accelerate growth.

We reinforced this focus through an institutionalized multi-hierarchical training extending from

steel manufacturing to holistic personality development which commences from day one of

employment, followed by specialized trainings at regular intervals.

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

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.

The JSW group believes in the policy of ‘People First’ and the objective of our activities is to

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

towards community development. Employees are encouraged to contribute upto 40 hours

towards community development activities per employee per year.

Promoting on a wider platform The JSW Earth Care Awards is aimed at highlighting action of

direct relevance to tackle challenges posed by climate change. The award extending over

SAARC region is for excellence in climate change mitigation and adaptation.

JSW is fundamentally committed to sustainable business and the 9 principles of National

Voluntary Guidelines on Social, Environmental and Economic Responsibilities of Business

(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

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

the same, quarterly. CSO structure implements the sustainability oversight reporting.

All of us at the JSW Group are committed to live by these tenets.

Corporate Citizenship at JSW

Supplier Meet


35

Engagement With Stack Holders

Installed 400

Nos LED

Street Lights

in Vasind

Village

Distribution of Energy

Efficient 2500 Chulha

in Near By Villages It

is High Efficiency and

Low Smoke Generate

Energy Awareness and Recognition to Employee and Society.


Energy Management System (EMS)

• The EMS is On-line real time measuring

system, captures data from 170 nos.

Digital power & RLNG 7 meters.

• Unit wise online

reporting.

• Unit wise average power

consumption as required.

• Diagnostic facility available for any

interruption in system.• SAP Integrated.

• Facility to analyse

variable.

9. Team Work, Employee Involvement & Monitoring

Management of energy conservation programs

Energy Policy Board Displayed Awareness sessions

ISO 50001 Energy Review, SEU , EnPI

Annual Objective EC--> COC→ OPCOM→ Individual KRA

Review SPICE, Daily, Weekly, Monthly

Reward Quiz, Suggestion, Slogan, Best performer

Benchmarking Processes, Practices

Training Internal, External, Technical, EnMS trainings

Audits Internal Cross location audits, External Audits

Monitoring Power & Fuel consumption Monitoring through EMS

Review

Safety Systems, Compliance & Governance

People

Customer Delight

Energy, Environment & Safety

S

P

I

C

E

Innovation & Quality Management

ISO Audits

Audit

BEE Energy

Audit

External

Audits

Energy Conservation Awareness

Society

2250 Nos. Energy Efficient Chulla Distribution

40 Nos Solar Street lights in near by Villages

2500 Nos LED Bulbs distributions

Auditors Training,

Awareness

Technical Trainings (Drive/ PLC/ automation

In House Trainings

Trainings


Energy Conservation Target Setting & Monitoring

38

Management

Commitment

▪ Appointment of MR, Scope &

Boundaries

▪ Energy Management Team – 10 Nos

▪ Establishment of Energy Policy,

Resources

Assess current

situation

▪ Energy Review, Base Line calculation

▪ Power chart preparation

▪ SEU identification:JJ-EnMS-PR-01

▪ Upcoming Energy conservation

measures

Goal Setting

Implementation Monitoring Review

▪ Monthly review in EC/COC/OPCOM bytop management

▪ Monthly review by EMT ▪ CAPA preparation for deviation

▪ SPICE based goal from topManagement.

▪ Prioritizing Opportunities▪ Objectives & Action Plan▪ Verification Plan- EMT

▪ Process Owner▪ Action plan and monitoring of

energy Targets▪ Review Metering Plan▪ Energy conservation projects

▪ Daily energy consumption monitoring

through EMS▪ Calibration of measuring Equipment▪ Audits▪ Energy conservation projects

PLAN

CHECK DOACT


Budget Allocation and Review Meetings

Energy Conservation Measures

for FY 18

Budget

Allocated

(Rs Lac)

CGL #2 Line Fix Power Optimization by increasing Line Speed from 150 to 200 MPM .

312

CGL #1 Line Fix Power Optimization by increasing Line Speed from 120 to 150 MPM

0

Induction oven output optimisation for CCL PPGI material 0

Closed loop speed control ofCGL#2 APC Blowers by using VVVF drive

6

Installation of LED Lights 5.2

New Energy Efficient Pump(7.5 kW) Installed at ARP 1.8

Provision of local burner at CCL-1 oven to reduce fuel consumption 200

DOL Starters replaced with VFD at Pickling Recirculation pumps and optimized energy consumption by reducing speed to 1075

1.2

Old motor of 11KW replaced with IE-3 efficiency 7.5 KW motor 0.25

Total 326.4

RPO Compliance

Solar REC

(Nos)

Non Solar

REC (Nos)

Budget

(Rs Lacs)

1685 8846 202

Review Meetings


Review by HOD & EnMS

M.R. with Energy

Management Team (10 Nos)

MONTHLY REVIEW

Review by Plant

Head with all HOD's

Review by

Departmental Head

with Energy Team

DAILY REVIEW

Review at Director level in

EC Meeting

Review at President level in

COC Meeting

Review at Plant Head level in

OPCOM meeting

Fig 8

40

150

357

450

0

100

200

300

400

500

FY 15-16 FY 16-17 FY 17-18

No. of people trained

5

1416

25

7

0

5

10

15

20

FY 16 FY17 FY 18

No. of Energy training

No. of In house Training External Trainings

Awareness & Involvement of Employees in Energy Conservation programme

Contd….


Energy Exhibition Mega Quiz

Slogan

Awareness & Involvement of Employees in Energy Conservation programme


42

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.

We shall encourage use of renewable energy and

promote awareness of energy conservation among

persons working for and on behalf of our organization.

Date : 01.11.2015 Dileep Bhatt Revision No. 5 President

10. Implementation of ISO

QMS 9001 2015

EnMS 50001 2011

OHSAS 18001 2007

EMS 14001 2015

I

S

O

FY-18

Turn Over - 2867 cr

ENCON Spent – 8.52 cr

43

Using advance Technology PLTCM First in Maharashtra, Estimated Energy Saving of 42792 Gcal/A .

Achieved 1875 ESCerts in PAT-1 and already achieved 0.042 MTOE/T by FY-18 in PAT-2

Total 29 Energy Conservation Measures completed.

Total Energy Saved- 27673 Gcal, Rs 1417 Lac.

Total 9004 Tons CO2 Emission reduced by reducing Energy Consumption.

Ro Installation of Roof Top Solar Power of 1500 kWp, Procured 4.07 Lac Solar Units & 100% RP RPO Compliance.

PLTCM

PAT

ENCON

Saving

CO2

Emission

Renewable

Energy

Highlights

CFBP – Council for Fair Business Practices Award-

2017

44

IMC RBNQA -2016Excellence Trophy

CII -2017Commendation

Certificate

MEDA 12th State Level EC Award

Awards….

Steel Coated Product Limited, Vasind · 100% Subsidiary of JSW Steel India’s Leading Coated Steel...

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