Excellence in Energy Management - 2018

TATA STEEL PROCESSING AND DISTRIBUTION LIMITED

PUNE BUSINESS UNIT

1

Excellence in Energy Management - 2018(Hyderabad International Convention Centre, 29th to 31st August, 2018)

Presented By

Mr. Vivek Pattewar (Head of Operations)

Mr. Chetan Patni ( Senior Manager Maintenance & Energy Manager)

Mr. Tonmoy Paul (Manager, Production)

TSPDL AT A GLIMPSE

2

Tata Steel Processing and Distribution Limited (TSPDL) was set up in 1997 as Tata Ryerson Ltd , a JV between Tata

Steel of India and Ryerson Inc. of USA. In 2009, It became a 100% subsidiary of Tata Steel.

TSPDL was created to bring steel service centre solutions for the first time to the value-seeking Indian Industrial

customers with a mission to be a trusted and irreplaceable bridge between steel producers and steel

consumers.

TSPDL presently operates from ten world class Steel Processing Centres and thirteen Sales and Distribution

locations across India.

3

Product basket HR/HRPO/HRSPO/CR/GP Slit Coils & Blanks.

STEEL SERVICE CENTRE

STEEL SUPPLIERS

STEEL CONSUMERS

Value Addition• Steel Processing

• Customized Sizes in Small & Large lots

• Supply Chain Management

• Stocking

• Just - In - Time Delivery

HR Slitter

Thk: 1.6 –7 mm

Width : 1680 mm

Capacity: 94 KT p.a.

P & O

Thk: 1.6 -7 mm

Width: 800 mm


HRNCTL

Thk: 1.6 -7 mm

Width: 800 mm


HRWCTL

Thk: 1.6 -12 mm

Width: 1680mm


CR Slitter

Thk: 0.3-3.2mm

Width: 1550 mm


CRWCTL

Thk: 0.3-3.2mm

Width: 1600 mm


CRNCTL

Thk: 0.3-2.0 mm

Width:1200mm

Capacity: 15KT p.a.

Material Handling :EOT Cranes (5 Ton to 35 Ton) – 9 no.10 Ton Forklift Truck – 1 no.

Weighing Facility :60 Ton Weigh Bridge – 1 no.Electronic Weigh scale (5 Ton to 40 Ton) – 7.

Other Utilities :• ETP• STP• Boiler (1.35 Ton/hr)• 1.6 MVA Electrical Substation• 1 MVA DG Set

TSPDL PUNE FACILITY

4

White GoodsAutomobiles

Yellow Goods

Our Customers

5

Certifications & Awards

6

IATF 16949:2016

OHSAS 18001:2007

ISO 14001:2015

2013: JRD QV Award

2017: GreenCo Gold

2017: Prashansha Patra from NSIC for Best Safety Practices

2017: CII National Energy Management - Energy Efficient Unit

2018 : Quality Circle - Silver Trophy from QCFI

7

TSPDL Energy Policy

• Comply regulations

• Efficient Energy Management

• Renewable Energy

• Create Awareness

8

Specific Electrical Energy Consumption

YearReduction

%Major Cause / Action

FY 16 - 6.8 %

o Skin Panel Introduction in CR Plant – High

Inspection, Low line productivity.

o Migration of Auto customers to lower thickness

high tensile material.

FY 17 12.3%

o Stoppage of Idle Running of Equipment.

o Increase in campaign size through

engagement with end users and effective

production planning,

o Replacing HPSV Lamps with LED Lamps

FY 18 11.9%

o Productivity Improvement Projects – CRWCTL

Offline Packaging, CRNCTL Stacker

Modification

o Eco-Clean Chemical in STP

8.969.57

8.39

7.39

0

2

4

6

8

10

12

FY 15 FY 16 FY 17 FY 18

Specific Electrical Energy Consumption

(KWh / MT)

9

Specific Thermal Energy Consumption

1248911792

1053510929

9556

0

2000

4000

6000

8000

10000

12000

14000

FY 15 FY 16 FY 17 FY 18 FY 19 Q1

Specific Thermal Energy Consumption

(Kcal / MT)Year

Reduction

%Major Cause / Action

FY 16 5.6 %Conversion of Boiler to Briquette Fired in Feb 2016

FY 17 10.7 %o Use of Briquette Fired Boilero Installation of Water Pre-Heater

FY 18 -3.7%Low Productivity of Pickling line due to poor product mix, ash deposition of boiler

FY 19

Q112.56 % Sonic Soot Blower

10

Benchmarking & Road Map to Global Best

8.969.57

8.397.398.11 8.03 7.79

7.06

0

2

4

6

8

10

12

FY 15 FY 16 FY 17 FY 18

TSPDL Pune vis-a-vis Global Best

TSPDL PUNE SEC (KWh/ MT) Metal One SEC (KWh/ MT)

FY 18

Eco-Clean Chemicals in STP

Productivity Improvement Projects & Energy Efficient Luminiaries & EnCon Projects

FY 19

Energy Audit by Dynamic Consultant & work on Projects Identified

FY 20

Eco-Friendly Pickling

TSPDL working with M/S Ralsonics through GTIO: Concept of Plasma and ultrasonic energy for breaking the oxide layer.

Global Best

11

Energy Saving Projects FY16

Sl No Title of ProjectEnergy Saving

KWh/Annum

Energy Saving

MKCal/Annum

Energy Saving in

Lacs. Rs./Annum

Investment Lacs.Rs.

Pay-back Months

1 Conversion of LDO Fired Boiler into Briquette Fired 36 45 15.0

2Poly Carbonate Transparent Sheets Installed for Day Light

Harvesting in HR Plant27623 2.07 4.6 26.7

3 WPH Installation for Briquette Fired Boiler 0 180 5.80 2 4.1

Total 27623 44 52 46

Polycarbonate Sheets Water Pre-HeaterBriquette Fired Boiler

12



KWh/Annum

Energy Saving

MKCal/Annum

Energy Saving in

Lacs. Rs./Annum

Investment Lacs.Rs.

Pay-back Months

1 Reduction in Idle running of Motors in Processing Lines 287794 21.5 1 0.6

2VFD Installation in Water Pumps And Hydraulic Power

Pack 999278.49

2129.7

3

Energy efficient lighting usage instead of conventional luminaires

129940 11.04 11.016 12.0

Total 517661 41 33 10

13



KWh/Annum

Energy Saving

MKCal/Annum

Energy Saving in

Lacs. Rs./Annum

Investment Lacs.Rs.

Pay-back Months

1Distribution Transformer voltage optimisation: Reducing LT voltage to 220VAC for lighting transformer. (Present: 234VAC)

7455 0.62 Nil Immediate

2 AC setting from 22 deg to 25 degree in all ECR. 34272 2.86 Nil Immediate

3 Compressed air leakage reduction 11040 0.92 Nil Immediate

4 Use of Eco-Health Chemicals in STP 40736 0.34 Nil Immediate

5Cooling tower idle running stoppage by interlocking with lines.

8079 0.68 Nil Immediate

6Replacement of Drop Stacker with Rotary Stacker in CRNCTL

13382 1.12 5.0 54

14



KWh/Annum

Energy Saving

MKCal/Annum

Energy Saving in

Lacs. Rs./Annum

Investment Lacs.Rs.

Pay-back Months

7 Sonic Soot Blower for online cleaning of Boiler 0291 3.81 2.0 6

8 Restoration of insulation & steam traps in steam line 0

9 Occupancy sensor for office lightings & AC 2160 0.18 0.2 12

10 360 KW VFD installed in Pickling water pumps 25128 2.10 14 7

11Energy efficient lighting usage instead of conventional luminaires

25620 2.14 1.938 9

12Cetralized switches installed for switching off lights when not required.

1872 0.16 0.05 4

Total 169744 291 14.9 23.2 19

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Planned Energy Saving Projects FY19

Sr. No. Description Suggested MeasuresEnergy Saving (KWh/Annum)

Energy Saving in Lacs. Rs./Annum

Investment Lacs.Rs.

Pay-back Months

1Electrical

System

To Stop one 1600 KVA transformer and save no load losses 10410 0.87 Nil Immediate

Bypass / To stop one no. lighting transfor and cater load by only one TR 8137 0.68 Nil Immediate

Provide interlock in heavy level DC Motor blower 16872 1.41 Nil Immediate

2

Water

Pumping

System

Replace CR Plant Cooling tower pump with higher energy efficient 56958 4.76 0.5 1.26

Replace HR Plant Cooling tower pump with higher energy efficient 22257 1.86 0.3 1.93

Eliminate the throttling and install proper duty point RO Raw water pump 4906 0.41 0.3 8.85

Clean the RO membrane & reduce pressure drop from the High Pressure pump & reduce raw water consumption 12445 1.04 0.75 8.65

Install proper duty point condition higher energy efficient submersible pump 5863 0.49 0.5 12.17

3Compressed

Air System

Arrest leakages from Plant compressed air system 52291 4.37 Nil Immediate

Replacement of present fixed speed compressor with VSD compressor 63000 5.04 4.45 10.6

Arrest leakages from Plant compressed air system 49779 4.16 0.2 Immediate

4Cooling

Tower SystemTo stop cooling tower pump and CT fan in both CR & HR during lunch and shift changing time 8077 0.68 Nil Immediate

5Fan / Blowers

SystemInstall PID based VFd in ID fan and eliminate throttling from the system 14359 1.2 0.75 7.7

6 Process Fan

Eliminate throttling from the system Force Air Blower and install proper duty point higher energy efficient fan 21539 1.8 0.75 4.9

To stop idle running of force blower by interlocking arrangement 5983 0.5 Nil Immediate

Total 352877 28.77 8.50 3.5

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A combination of extracts of:

Azadirachta indica (Neem)

Moringa olifera (Drumstick)

Occimum sanctum (Tulsi) and

Strychnos potatorum (Clearing

nut)

Innovative Projects FY 18

Use of Eco-Clean 2300 & Eco-Lime 2300 in STP

o Ecoclean-2300 is a unique water treatment formulation of herbal extracts, with proven water-purifying

capabilities, bound together using a water-soluble organic solvent

o Ecolime 2300 is a concentrated liquid extract of lime that increases pH level of effluents to neutral or anionic

levels without additional sludge formation.

o Separates suspended and dissolved solids from the water and causes it to precipitate as sludge

o Simultaneously eliminates fecal coliforms and E-coli making the water safe

Page 1 of 4

17

ECOCLEAN-2300

AGITATOR

SAND FILTER CARBON FILTER

INLET

TREATED WATER FOR RE-USE

OZONATOR

FLOCCULATOR

Innovative Projects FY 18

Use of Eco-Clean 2300 & Eco-Lime 2300 in STPPage 2 of 4

GARDENING

18Innovative Projects FY 18


Eco- Health Technology

Page 3 of 4



Before - Activated Sludge - Continuous Process

Sl No. EquipmentPower

rating (HP)Running Hours

Units Consumed per day (24 hrs )

Cost of electricity (@ Rs 8.3574 / Unit)

1 Blower 5 16 59.7 498.6

2 Sewage Transfer Pump 2 16 23.9 199.4

3 Sludge Transfer Pump 1 16 11.9 99.7

4 Filter feed Pump 2 16 23.9 199.4

119.3 997.1

After - Eco Health Technology - Batch Process

Sl No. EquipmentPower

rating (HP)Running Hours

Units Consumed per day (24 hrs )

Cost of electricity (@ Rs8.3574 / Unit)

1 Blower 5 0.67 2.5 20.8

2 Sewage Transfer Pump 2 1 1.5 12.5

3 Sludge Transfer Pump 1 1 0.7 6.2

4 Filter feed Pump 2 2 3.0 24.9

7.7 64.4

KWh Rupees

Energy Saving (Per Annum) 40736 340450

Page 4 of 4


Use of Sonic Soot Blower for Boiler Tubes CleaningPage 1 of 2

o Sonic Cleaning is based on kinetic activation

of soot particles by sound waves of

frequency 240 Hz.

o Its pneumatically operated and compressed

air is consumed only during the isonation

cycle of 10 sec after every 1 hour. Required

Air flow is 50-60 CFM.

o Regular isonation cycle doesn’t allow soot to

built up. This gives best possible heating

effect. Thereby making most efficient use of

the fuel.

Online & Continuous Cleaning of Boiler Tubes

Video


Use of Sonic Soot Blower for Boiler Tubes CleaningPage 2 of 2

Online & Continuous Cleaning of Boiler Tubes25.6

21.35

19

20

21

22

23

24

25

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Before After

Briquette Consumption (Kg/MT)

o Reduction in Briquette Consumption – 12.6%

o Annual Thermal Energy Saving – 291 million Kcal

o Annual Cost Saving – Rs 381154

Before After


Replacement of Drop Stacker with Rotary Stacker

Before After Video

Page 1 of 2


Replacement of Drop Stacker with Rotary Stacker

Before - 2 Nos. Double Acting Pneumatic Cylinders

Calculated Free Air Delivery in CFM of Air Compressor required to run 5" Bore X 4" Stroke Single acting Pneumatic

cylinder)4.069 CFM

For Double Acting(4.0690 X 2) 8.138 CFM

2 Cylinders used ( 8.1381 X 2) 16.276 CFM

i.e. 16.27 CFM Air required/ Minute

Air Required/ Year = ( 22 Hrs X 60 Min X 26 Days X 12 Months) 6703215 CFt

1 KWh generates 273 std cubic feet of air

Power Required to generate required Cft of Air 24554 KWh

Cost Incurred @ Rs 8.357/Unit 205197 Rs

After- 2 Nos. Servo Motors with gear box

Siemens make Servo Motors (2Nos) Model 1FL6061-1AC61-

0AA1 rated at 0.75kW, 3.58NM, 2000RPM, shaft height 65mm,

suitable for driving rotating shafts of Rotary stacker throughsuitable gearbox

5586 KWh

Power Required for 2 Motors 11172 KWh

Cost Incurred @ Rs 8.357/Unit 93365 Rs

Power Saving Per Annum 13382 KWh

Cost Saving Per Annum 111832 Rs

Page 2 of 2


Cooling Tower Idle Running Stoppage

Sl No. Item DescriptionUnits Saved @2.5

hrs/Day

Units Saved Per

annum (KWh)

Cost Saved Per

annum (Rs)

1HR Cooling tower fan motor current = 1.6 A

1.643 599.5 5010Power input = 415 x 1.6 x 0.99 = 657 W

2HR Cooling tower pump load current = 6.5 A

6.6775 2437.3 20369

Power input= 415*6.5*0.99 = 2671 W

3CR cooling tower fan motor current = 3.7 A

3.800 1387.0 11592Power input= 415*3.7*0.99 = 1520 W

4CR cooling tower pump load current = 9.75

10.015 3655.5 30550Power input= 415*9.75*0.99 = 4006 W

Savings 22.135 8079 67522

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Utilization of Renewable Energy Sources

010.78 10.78

61.84

10089.22 89.22

38.16

0

20

40

60

80

100

120

2013 2014 2015 2016

Renewable Energy Substitution(in %) w.r.t Plant overall Energy consumption Non Renewable Energy

Renewable Energy SubstitutionSolar Water Heater

installed in Dec-2014Conversion of Boiler from LDO

fueling to Briquette in 2016

Sl No. Energy FY 18 Consumption UoM FY 18 Consumption UoM Percentage of Total

1 Electrical Energy 2334960 KWh 8405.89 GJ 35%

2 Thermal Energy (Briquette) 1055702 Kg 15470.1 GJ 65%

23875.99 GJTotal Energy Consumption

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Utilization of Waste Material as a Fuel

Water Pre- Heater to exchange heat from flue gas coming out of Boiler at 165 deg. cent. temp..

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GHG Inventorisation

0.01332 0.013500.01206

0.01020

0.00000

0.00500

0.01000

0.01500

FY 15 FY 16 FY 17 FY 18

Specific Emissions Total (TCO2e/t)

0.00543 0.00517 0.00496

0.00388

0.00000

0.00100

0.00200

0.00300

0.00400

0.00500

0.00600

FY 15 FY 16 FY 17 FY 18

Specific Emissions Scope 3 ( TC02e/t))

0.007340.00790

0.006850.00606

0.00000

0.00200

0.00400

0.00600

0.00800

0.01000

FY 15 FY 16 FY 17 FY 18


0.00054

0.00043

0.00025 0.00026

0.00000

0.00010

0.00020

0.00030

0.00040

0.00050

0.00060

FY 15 FY 16 FY 17 FY 18


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Green Supply Chain Guideline

• Total Cost of Ownership (TCO) or Life Cycle Cost (LCC)

• High Shelf Life

• Develop competency

• Eco – Friendly material

Green Supply Chain

Supplier Awareness Session

18

Green House Emission

Life Cycle Cost

Green House Emission

Supplier awareness and Green Initiatives

Green Supply Chain

Vehicle Inspection Check sheet & Training Session

18

Green Supply Chain

Supplier Audits

18

M/s SP Enterprises being awarded for deploying initiative of using 100% used/second wood & developing

adjustable metal pallets

M/s Rajmudra Transport being awarded for deploying initiative of double delivery to our

customer.Result is reduction of Scope -3 Emissions

32

Green Supply Chain

Supplier Recognoition Programme

33Team Work, Employee Involvement &

Monitoring

Vivek PattewarHead of Operations

Chetan Patni(Sr. Manager, Maintenance)

Tonmoy Paul(Manager, Production)

Anshuman Prusty(Manager, Electrical Maintenance)

K Kunal(Manager, Supply Chain Management)

Implementation Coordinator

Team Member Team Member

Strategic Level

Implementation Level

Team Member

Energy Management Cell


Monitoring

Strategic Level Implementation Level

Provide Direction Monitor energy consumption

Set Targets Monitor trends of specific energy consumption & take corrective measures

Identify Improvement Projects Implementation of energy saving projects

Allocate Resources Identify & Monitor performance of energy intensive equipment in plant

Review Status of various projects Take actions to ensure energy efficiency of equipment

Review KPI trends Training & Creating awareness among workforce on energy saving measures.

Roles and Responsibility of Team

Approach

Monitoring Energy consumption at equipment level.

Installation of Energy Efficient Drives & Luminaires

Use of best available technology (Retrofit, Modernization, Automation, Capacity Enhancement)

Optimizing Processing Lines Performance (Line & Speed Utilization)

Minimization Idle Running of Equipment

Awareness amongst Operation crew


Monitoring

Energy Performance is

recorded and is one of the

Major KRAs of Plant officers

Identification of Energy

Captains in each work-

station, training & mentoring

and implementation of

Energy Score card.

Brain Storming Sessions &

Ideation Workshops

Recognition of officers,

associates or CWs

participating in Energy

saving projects, CIPs &

kaizens

Employee Involvement


Monitoring

Kaizen


Monitoring

Monitoring

Date Shift No. Of trolleys

Briquette

consumption

(Kg)

PKL ProductionConsumption

Kg/MTRemarks

12-May B 28 1344.0 52.2 25.7 Cold Start

12-May C 25 1200.0 43.4 27.7

13-May A 24 1152.0 30.3 38.0 Breakdown -Uncoiler

13-May B 20 960.0 27.0 35.6

13-May C 24 1152.0 54.8 21.0

14-May A 21 1008.0 72.7 13.9

14-May B 25 1200.0 58.3 20.6

14-May C 24 1152.0 42.9 26.9

15-May A 22 1056.0 44.9 23.5

15-May B 24 1152.0 31.6 36.4

15-May C 23 1104.0 47.2 23.4

16-May A 17 816.0 17.3 47.1 Breakdown -Acid Pump

16-May B 23 1104.0 27.0 41.0 Breakdown -Acid Pump

Briquette Consumption Trends - May '18

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Implementation of GreenCo

HIGHLIGHTS

Energy Policy, Energy Management Cell, VFDs, Stoppage of

equip. idle running, T5 lamps, Natural Roof lighting, Right

sizing of motors

61.84% Renewable Energy – Briquette Fired Boiler

Scope 1,2 & 3 Emissions Inventorisation, 63.5% Reduction in

TCO2e

Water Policy, Water Management Cell, Water Balancing ,

47% reduction in specific water consumption

ZLD Unit – ETP, STP, Acid Regeneration

Systematic Monitoring (SAP & Excel based tools), Specific

Consumption Reduction – Reuse of Packaging Material

Green Procurement Guideline, Awareness Creation, Audit &

Recognition Programme for suppliers

Innovation Framework & Innovations - Laser Encoder at

CRWCTL, Analog Loop Sensor, Return Line Filter at PKL etc.91 - 100

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Excellence in Energy Management - 2018

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Transcript of Excellence in Energy Management - 2018