Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED

PUBLIC INFORMATION

Pranab Sarkar

Vice President Energy

Energy Intelligence Helps JSW Steel Monitor Energy KPIs and

Reduce Usage Rockwell Automation Solutions Help JSW Steel to Monitor and Manage Gas, Water and Electricity Consumption Across the Facility –

Capture, Histories, and Analyze the Energy Usage

Agenda

JSW Steel at a glance

Project Background, Drivers, & Challenges

Reports, Dashboard & Overview reports

Benefits & Lessons learned

Future Road Map

Introduction Video

JSW Steel at a glance

JSW Steel is India’s fastest growing steel conglomerate.

It started in 1999 with 1.67 Mtpa integrate plant using Corex-BOF, but latter added BF-BOF & DRI-EAF route for Iron and steel making.

Today it is single location 12 Mtpa of steel mill & is largest single location plant in India.

It operates 20 Mtpa Ore beneficiation Plant. Sintering capacity is 32000 TPD & Pelletizing capacity is 20000 TPD.

Coke making is 4.7 Mtpa. 3.5 Mtpa is through By Product Recovery route with CDQ and 1.2 Mtpa of Heat Recovery with power plant.

Iron making facilities are 2*2400 TPD Corex, 4 BF’s of 1300 (Being upgraded to 2300), 1800 & 2*4013 Cubic meter respectively.

JSW Steel a glance (Contd …)

SMS comprises of 3*140 Tons of converter in SMS – I, 4*175 Tons converter in SMS – II and 1*160 Tons EAF in SMS – III.

Down stream comprises of HSM of 3 & 5 Mpta, BRM of 1 & 1.2 Mtpa each, WRM of 0.6 Mpta & 2 CRM of 1 & 2 Mtpa.

It operates 155 MW of waste heat power Plant, 170 MW of Gas based power plant.

It operates 11255 TPD of Oxygen plant on BOO basis.

A 1600 TPD micro pellet unit for handling waste fines on BOO basis.

A pilot plant for converting slag as alternative to river sand. And

A 0.2 Mtpa Mills Scale briquetting unit.

Agenda

JSW Steel at a glance

Project background, Drivers, & challenges.

Reports, Dashboard & Overview reports

Benefits & Lessons learned

Future Road Map

Why Energy online ?

Energy comprises 40-45% of total cost of steel production in India

A one percent reduction in energy consumption improves bottom line by 0.45%

The foremost requirement of reduction programme is to establish actual consumption pattern.

Identify gaps between achieved and benchmark.

Needed detailed gap analysis and trend analysis. Assign balanced cost and bridge the gap.

A plant wide energy scheduling and accounting solution was necessary. … and that explains what is energy online.

5 levels of Energy Online – JSW Approach

Optimization models.

Regulate power use based on sparks from EMS .

Energy use control based on EMS

Heat Arrest and loss capture (HALC) based on input data and on line energy balancing system.

Comprehensive energy monitoring, Stage wise, balanced input and output for entire operation.

5.45 GCal /TCS

6.63 GCal /TCS

Key Deliverable of Energy Online

EMS identifies gaps between energy generation, transmission & distribution and guides EMC to optimize the use.

Trend analysis indicates the need in next hour and shift to divert excess to sink and if warranted avoid inefficient uses.

Dashboards provide techno economics of best alternatives and accordingly EMC decides the priority.

Similarly power Dashboards provide sparks for idle running of motors to put them on idle or stop.

It also helps in reducing peak power during start of large loads with high initial torque by switching off or reducing not important loads.

Challenges

Ensure correctness of data being gathered and what is critical.

To understand the correlation between the data and the production – thereby the impact of the data on the production.

To communicate with shop server, they have various configuration.

Transmission mode of data (A plant spread in 10 thousand hectares)

Passing through impossible obstacles, tracks, Gas line Roads of the

running plant.

Energy Online launched

Energy On line was launched in 2007.

Schneider Electric, Honeywell, Automation engineers and Rockwell Automation® were sent the RFQ and JSW wish list.

4 Key Criteria: Technology, Compatibility with existing system, Ease of installation & Cost were parameters for evaluation.

Rockwell Automation was selected as they matched competitors in 3 criteria, they were L2 & 100% matching our wish list.

Rockwell Automation became natural choice as

– FactoryTalk® architecture allowed for integration to basic automation and was compatible to various automation systems.

– Future scope of expanding.

– ROI was only 6 months.

Sinter Plant # 2, 3 & 4 & LCP#11

WRM , BRM-I & Process Blr#1

BRM #2 & SMS#3

CPP #1

Blast Fce # 3&4 Gas Holder

System Architecture- FactoryTalk Suite of Products Delivering the Connected Enterprise

Energy Data Source

Context

Information

Decision

Pellet Plant # 1& SP#1

CRM # 2 & Process Blr#3

Corex Unit 1&2

Blast Fce # 1&2

Blast Fce # 3&4

Pellet Plant # 2

Coke Ovens

Oxygen Plants

Blast Fce #1&2 Gas Holder

LD Gas Holders

HSM - I

CPP #2 & Process Blr #2

CPP #3,4 & JSWEL

CRM# 1

LCP Kiln # 1 to 10 & 12

Main Electrical sub Station

SMS # 1&2

HSM - II

GMS# 4

GMS# 1

GMS# 2

GMS# 3

DRI

EMC Display

Dy. MD President

(Oprn)

VP Energy

Steel Business AVP

Energy

Vjnr

32 systems

captures 700

parameters

across plant

Server

1 Version

of Truth

Overview of System Architecture

MicroLogix™ & ControlLogix® across the network from different location.

FactoryTalk® Historian was used to collect data

FactoryTalk® VantagePoint EMI to convert the data to Actionable Information

– Advanced portal, reporting, and analytics tool

Reports Specified:

– Shop wise Gas Consumption Report

– Energy Utilization Report (Gas generation, Liquid stocks of Ar,o2 N2 details, LPG day consumption)

– FactoryTalk VantagePoint Trends ( Pressure, Flow, Temperature)

FactoryTalk® AssetCentre to manage automation Assets –

– A complete record of who made what change in the PLC’s

JSW Steel At a Glance

Project Background, Drivers, & Challenges.

Reports, Dashboard & Overview reports

Benefits & Lessons learned

Future Road Map

Agenda

Energy Center in Action- EMD control room

Accounting of By-Product fuel gasses

The On-Line Fuel Values

On line accounting of gaseous fuels

Real Time Data helps in Effective Manage & Control

Real Time data helps in effective control

Sample Reports and Trend- Better Analysis Real Time & Historical data

Trend Analysis Report Summary Report with Trend

Gap analysis based on Real Time & Historical data Better Analysis – Helps Decision Making

Stage BM Actual Gap Analysis

Coke Making

U/F Heat Rate

0.55

GCal/TP

0.62GCal/TP 0.07

GCal/TP

More Coking time

Agglomeration

Solid Fuel Rate

51 Kg/TP 62 Kg/TP 11 Kg/TP High Alumina in Base Mix

BF Coke Rate 430

Kg/TP

452 Kg/TP 12 Kg/TP Low HBT due to less rich

fuel in stove heating.

High Oxygen

blowing Rate

52

m3/THM

58 m3/THM

6 m3/THM High Al in HM

RHF Heat Rate 0.28

GCal/TP

0.29 GCal/TP

0.01GCal/T

P

High Cold charging due to

mismatch in planning

High Power

Rate

480

KwH/TCS

480 KwH/TCS 480

KwH/TCS

High idle running hours

JSW Steel at a glance

Project Background, Drivers, & Challenges.

Reports, Dashboard & Overview reports

Benefits & Lessons learned

Future Road Map

Lessons Learned

Planned Happened Learning

Monitoring of generation

& consumption suffice

accounting of fuel

Generation does not

match flare+consumption

in practice

Small unaccounted

consumers. It is

necessary to measure

To ensure micro control it

is important to measure

heat rate of each micro

product.

On line CV monitoring for

correct accounting of heat

input is essential.

Online CV, flow &

software for computing

heat input in a dashboard

is very effective.

By only accounting,

limiting flare to nearly

zero.

The wide fluctuations

both in generation &

consumption can not be

totally managed

Sinks for dumping fuel

and withdraw, almost

instantly became a major

requirement.

Benefits

Pre Energy Online Post Energy Online

Gas Flaring to the tune of 200 G Cal/Hr or

0.24 million INR/Hr

Flaring reduced to 30 G Cal/Hr or 0.036

million INR/Hr

Though accounted, many uses of energy is

not optimized, but not possible to pinpoint.

By gap analysis based on trends helps to

identify wasteful use of energy.

The identification of non productive fuel

supply were not identifiable

It is easily identifiable

Delay tactics were not possible to

implement as dashboards. Were not

available to give sparks for idle running

Sparks from online monitoring have

reduced the consumption by 2%

Every authorized user can access the data he needs from various data sources- Take Corrective

action, has ability to make decisions based on Real time data with details

Specific Energy Consumption

Relentless

efforts to

reduce

Specific

Energy

Consumption –

inspite of

switching to

poor grade iron

ore with high

alumina &

silica content

in 2012-13.

6.41 6.22 5.98

6.77 6.46

6.22

5.26

5.85

6.81

7.49

8.49

9.26

0

1

2

3

4

5

6

7

8

9

10

1 2 3 4 5 6

Axis

Tit

le

Years

SEC and Production

SEC Prodn

JSW Steel at a glance

Project Background, Drivers, & Challenges.

Reports, Dashboard & Overview reports

Benefits & Lessons learned

Future Road Map

Agenda

Future Road Map- Mobility Providing Information to the Users-When and Where they need

Optimization by linear programming.

7

EMD

6b

5b

MSDS

5a

6a Shops

PPC

2 3 4

1

S&M

PP

Pur

JSW EL

?

?

1. Order Book Status

2. Plant Capacity Availability

a. Shutdown Plan

b. Plant Capacity

3. Hot Metal Availability

4. Raw Material Availability

5. Energy Availability

a. Electricity

b. Gases & Oxygen

6. Shop-wise Energy Requirement

a. Electricity

b. Gases & Oxygen

7. Actual Production

PP. Production Plan

Data Items

Sales & Marketing

Purchasing

JSW Energy Limited

Production Planning & Control

Energy Management Department

Main Step Down Station

Departments

S&M

Pur

JSW EL

PPC

EMD

MSDS

Energy Requirements not

considered during Production

Planning

Accept ad hoc Sales orders

Shops responsible for meeting

production plan only

Production Plan made available

to shops alone, and only on the

day of the production

Shop Maintenance Planning by

individual shops alone

Issues related to daily deficit or

excess energy, discussed in

daily morning HoD meetings

Spikes and Valleys in Energy Requirement

Frequent Changes to Plan, sometime during the production day

Allows for shops to not address idle load and hence carry higher specific consumption

No visibility of plan and hence potential issues beyond 2-3 days for all stake holders

Reactive Production Planning by PPC & Energy Planning by MSDS & EMD

Scalability issues possible in the future

Optimization by linear programming.

Optimization by linear programming. Maximizing the

contribution profit in the short & long

term

Greater production planning rigor &

hence scalability of planning process

Better shop shut-down planning and hence maximizing the utilization of

mills

Optimally use the facilities like the

oxygen plant

Meet the various demands and

commitments made to customers

Reducing the Specific Energy Consumption

Integration of energy data into

production planning & hence

better energy balance

Rockwell Automation’s Presence @ JSW Steel-

Tornagallu, Bellary. » Blast Furnace 1 – 2501 M3 Capacity – Under execution

» Blast Furnace 2 – 1600 M3 Capacity - 2007

» Blast Furnace 1 &2 – 1000 Tags FT Historian - 2010

» RMHS – 4 MT & 7 MT Department – 1998 & 2007

» Coke Oven 1 &2 - Year 1999 & 2005

» Pellet Plant 1 – Balling Disc application – Drives - 2011

» Steel Melting Shop 1,2 – Caster 1,2,3 &4 Drives & Automation – 2007,2008,2010

» Tunga badra Dam Water Pumping scada - 2011

» Almatti Dam Water pumping scada - 2012

» Laddle Heating furnace LHF4 – 2008

» Mill supply & Distribution system – MSDS Scada – 1999

» Lime Klin 9,10,11 & 12 – 2013/2014

» Energy Management Centre – 4 MTPA/7 MTPA & 10 MTPA

» JSW Praxair

» JSW Energy – DM Water Plant

» JSW Cement – 0.55 MT Cement Plant

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED

Please take a couple minutes to complete a quick session survey to tell us how we’re doing. On the mobile app:

1. Locate session using Schedule or Agenda Builder.

2. Click on the thumbs up icon on the lower right

corner of the session detail

3. Complete survey

4. Click the Submit Form button

Thank you!!

3

1

2

4

We Care What You Think!

www.rsteched.com

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RSTechED 2014 @RSTechED #RSTechED

PUBLIC INFORMATION