TATA Steel BSL Limited, Khopoli. - CII - Sohrabji Godrej ...

21-09-2019

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TATA Steel BSL Limited, Khopoli.

Mr. Brajesh Nahar (VP-Operation)

Mr. Hemendra Tiwari (DGM)

Mr. Vijay Patil (Jr. Manager)

Confidential & Privileged21 September 2019 1

20th National Award for Excellence in Energy Management 2019. CII, Hyderabad.

Company Profile :-

21 September 2019 2

In 2018, Tata Steel acquired Tata Steel BSL Limited (formerly known as Bhushan Steel Limited) through its wholly owned subsidiary.Tata Steel BSL Ltd is one of the prominent players in the Indian Steel industry. Backed with more than 27 years of experience, we are now India's 3rd largest Secondary Steel Producing Company with an existing steel production capacity of 5.6 million ton per annum.As one of the largest integrated steel players in India, Tata Steel BSL is a source for vivid variety of products such as Hot Rolled Coil ,CRCA ,CRFH ,Galvanized Coil and Sheet ,Galume Coil and Sheet ,Color Coated Coils, Color Coated Tiles, High Tensile Steel Strips, Hardened & Tempered Steel Strips, Precision Tubes, HFW/ERW Pipe (API Grade),3LP Coated .Being amongst the prime movers of the technological revolution in Indian Cold Rolled Steel Industry, Tata Steel BSL has emerged as the country's largest and the only Cold Rolled Steel Plant with an independent line for manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm. Along with this we also have a Galvanized Coil and Sheet line up to a width of 1350 mm.In addition, strengthening us to grow from pillar to pillar is our robust network of sales and marketing units across Indian continent and other countries helping us reach our global customer base.At Tata Steel BSL, we are living tomorrow today; because the endeavor to a brighter future starts from today. In superior community building, in harnessing safety, by nurturing the environment and by adopting world-class technology for producing outstanding products, Tata's resilient approach to its impeccable vision makes it a global Integrated Steel producer.

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Company Profile :-

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Company Profile :-

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47%

53%

Thermal & Elctrical Energy Use FY2018-19

Electrical Energy

Thermal Energy

41%

19%

4%

5%

7%

11%

Productwise Electrical Energy Share (FY2018-19)

Cold Rolled Steel

Galvanising & Galume

Colour Coating Line

Precision Tubes

HTSS

H&T

LDP Bare & Coated

1. Energy Consumption Overview :-

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FY2015-16 FY2016-17 FY2017-18 FY2018-19

165018

169688

157363

151815

Annual Thermal Energy Consumption in million kcal

FY2015-16 FY2016-17 FY2017-18 FY2018-19

159.15

171.13 169.41

155.38

Annual Electrical Energy Consumption in million kWh

34%

23%

19%

0%7% 1%

Productwise Thermal Energy Share (FY2018-19)

Cold Rolled Steel

Galvanising & Galume

Colour Coating Line

Precision Tubes

HTSS

H&T

LDP Bare & Coated

2. Specific Energy Consumption (SEC) Without Normalization

Target of BEE (Bureau of Energy Efficiency) for FY2018-19 is

0.0345 mtoe/tonne. TSBSL achieved 0.0322 mtoe/tonne (With

Normalization) Achieved 2129 ESCerts

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FY2015-16 FY2016-17 FY2017-18 FY2018-19

179249

173564

168660

160081

Specific Thermal Energy Consumption (kcal/tonne)

FY2015-16 FY2016-17 FY2017-18 FY2018-19

172.88175.04

181.57

163.84

Specific Electrical Energy Consumption (kWh/tonne)

FY2014-15 FY2015-16 PAT-II Target FY2016-17 FY2017-18 FY2018-19

0.03640.0328 0.0345

0.0324 0.03250.0301

Specific Energy Consumption (mtoe/tonne)

Year SEC % Improvement

FY2014-15 0.0364 Base line

FY2015-16 0.0328 10%

FY2016-17 0.0324 1%

FY2017-18 0.0325 -0.25%

FY2018-19 0.0301 7%

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3. Benchmarking

TSBSL Sahibabad Uttam Wardha welspun Anjar JSW Nagpur TSBSL Khopoli

0.0229

0.0427

0.0582

0.0281

0.0345

Specific Energy Consumption

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4. Energy Conservation Projects – FY2016-17

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4.Re-insulation of Ammonia cracker furnace

22.Use of waste heat for Chemical dryer instead of RLNG burner at CCL

1.Revamping of Steam Distribution Network

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23.Flue gases used in dryer to dry the strip, thus by eliminating steam consumption (GP02 Prod)

Steam Line cut off & Flue

exhaust gas used in

degreasing dryer

HAG exhaust flue gases

used in SPM dryer.

25.Centac no.2 Efficiency improved by replacing Air end.


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Sr. No. Energy Conservation MeasuresElectrical

Energy Saving (Lakh kWh)

Thermal Energy Saving

(M kcal)

Annual Savings

(Rs in lakhs)

Investment (Rs in lakhs)

1 Revamping of Steam Distribution Network - 673.6 17.34 2.79

2 All 24 Nos Soot Blasters of both Waste Heat Recovery Boilers are modified and made operational to remove soot from tubes (Power Plant)

- 1357.3 34.95 0.56

3 Cleaning (water washing) frequency of Waste Heat Recovery Boilers reduced from 90 days to 45 days (Power Plant)

- 2714.5 69.90 0.00

4 Re-insulation of Ammonia Cracker Furnace- 3 & 2 (Utility) 1.38 - 9.67 5.00

5 Modification in Drinking Water Plant provided automatic level sensor based tank with booster pump which finally reduced the running time of booster pump (Utility).

0.35 - 2.49 0.03

6 Preheating arrangement before hardening furnace at furnace#01 (H&T) - 1189.0 29.63 Nil

7 Flue gases of furnace , utilize for dryer at Grinding m/c#01 (H&T) - 1062.0 32.40 0.82

8 Fine tuning of bell annealing Furnace system (NCRM) - 1184.0 29.51 2.50

9 Fine Tuning of burners and servicing of EBNER facility (CRCA) - 1213.2 30.24 2.50

10 PHF Blower-1 in GP2 VFD installed 75kW (Wider Electrical) 0.88 - 5.29 0.00

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Sr. No. Energy Conservation MeasuresElectrical Energy

Saving (Lakh kWh)


(M kcal)

Annual Savings

(Rs in lakhs)


11Air knife blower in VFD tuning done (v/f to sensor less vector mode) & reduced consumption (GP-1 wider electrical).

0.63 - 3.78 0.00

12Shed no.4 400 watt shed lights replaced with 150 watt LED lights (wider electrical)

0.07 - 0.39 0.54

134 HI Mill-2 POR DC motor:- Used economic current control system in drive software for field current control in idle condition (NCRM elect.)

0.10 - 0.57 0.00

144 HI Mill-2 MILL DC motor:- Used economic current control system in drive software for field current control in idle condition (NCRM elect.)

0.16 - 0.96 0.00

154 HI Mill-2 ETR DC motor:- Used economic current control system in drive software for field current control in idle condition (NCRM elect.)

0.19 - 1.13 0.00

164 HI Mill-2 DTR DC motor:- Used economic current control system in drive software for field current control in idle condition (NCRM elect.)

0.19 - 1.13 0.00

17Mill 1 & 2 area transformer room exhaust fan controlled by using auto timer circuit (NCRM elect.)

0.39 - 2.33 0.00

18Mill -3 area transformer room exhaust fan controlled by using auto timer circuit (NCRM elect.)

0.19 - 1.17 0.00




Saving(Lakh kWh)


(M kcal)

Annual Savings

(Rs in lakhs)


19 H&T area Sump pump motor controlled by using level switch (NCRM elect.) 3.20 - 19.18 0.00

20Annealing area Sump pump motor controlled by using level switch (NCRM elect.)

4.04 - 24.23 0.21

21 CRS-1 to 4 Control room AHU Motor controlled By VFD (NCRM Elect.) 0.07 - 0.43 0.00

22 Use of waste heat for chemical dryer instead of RLNG burner (CCL Prod) 0.34 2014.8 25.25 2.00

23Flue gases used in dryer to dry the strip, thus by eliminating steam consumption (GP02 Prod)

0.50 466.0 15.59 1.00

24Temperature controlled valve (TCV) installed for Degreasing tank-brush tank (CCL Prod)

- 93.2 2.52 1.10

25 CENTAC NO-2 air end replacement for efficiency improvement (Utility) 10.84 - 65.00 55.00

Total 23.51 11967.6 452.08 74.05

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12.Centac no.1 & 3 Efficiency improved by replacing Air end.

15.Total 1200 lights of 400 watt are replaced with 150 watt Led light.

11.Construction / Heater mode Modification at Colour Tempering Line (H&T)6. Entry hot air dryer blower motor

(37KW) made idle by providing direct flue gas heat. (GP-2)

9.Furnace tuned close to psychometric ratio and gap of entry seal reduced

Entry Seal Gap reduced

from 190 mm to 141 mm




Saving (Lakh kWh)


(M kcal)

Annual Savings

(Rs in lakhs)


1Trimmer -2 Hydraulic power pack Motor (15KW) were running on DOL starter at rated speed. Provided VF Drive for above and set frequency 25 Hz when it is idle i.e 50% of rated speed. (6HI)"

0.10 - 0.58 0.45

2Roll Coolant Pump motor (132KW) of Mill (1&2) were running with VFD at rated speed 50 Hz when line is running. Set frequency 25 Hz when it is idle i.e. 50 % of rated speed (6HI)

1.11 - 6.65 0.00

34 Nos of Brush Roll Motors (5.5KW) were running on DOL starter at rated speed. Provided VF Drives for all. Set frequency 30 Hz i.e 60% of rated speed (CCL)

0.49 - 2.95 0.88

4Hot air dryer 1 Motor (22KW) was running on star/delta starter at rated speed (50Hz) for drying sheet (CCL)

0.50 - 2.99 0.00

5Prime oven fume re-circulation blower Motors (22KW) was running on star/delta starter at rated speed (50Hz). Provided VF Drive for above and set frequency 35 Hz i.e 70% of rated speed (CCL)

0.33 - 1.98 2.00

6Entry hot air dryer blower motor (37KW) made idle by providing direct flue gas heat. (GP-2)

2.16 - 12.96 0.00

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Sr. no. Energy Conservation MeasuresElectrical Energy

Saving (Lakh kWh)


(M kcal)

Annual Savings

(Rs in lakhs)


7 Hot air dryer motor (22KW) made idle by providing direct flue gas heat. (GP-2) 0.18 - 1.08 0.00

8

Optimization of Unit consumption of Makeup pump by changing pre-

established system commercial cent. pump to submersible pump at tube mill #

04. (Tube Electrical)

0.28 - 1.68 0.68

9Furnace tuned close to psychometric ratio and gap of entry seal reduced (GP02 Prod)

- 1384.8 42.19 0.00

10Automatic control of substation outdoor lighting by photo sensor (Power Plant Elect)

0.06 - 0.34 0.06

11 Construction / Heater mode Modification at Colour Tempering Line (H&T dept) 0.05 - 0.30 3.41

12Improvement of specific power consumption of air compressor (CENTAC) no.1 & no.3 by replacing old air end (Utility)

20.00 - 120.01 104.00

13 Optimization of Air/Fuel ratio of NON-OX furnace. (GP1 prod.) - 920.3 28.04 0.00

14 Pot firing system modification (GP1 prod.) - 139.6 4.25 13.00

15 1200 nos of 400 Watt Shed lights replaced with 150 Watt LED lights 10.80 64.80 98.10

Total 36.05 2444.6 290.80 222.58




Saving (Lakh kWh)


(M kcal)

Annual Savings

(Rs in lakhs)


1Temperature of PMP reduced from 640 C to 630 C during galvanizing & idle

condition in GP-2 (Production)1.83 - 15.62 0

2Enhance the effectiveness of HAG to reduce the use of HF furnace at chromic

cycle in GP-2 (Production)2.23 - 19.00 0

3 Install 260TR X 4no. chillers with new energy efficient chiller (Utility). 5.74 - 48.96 87.97

4

JET Cooler Motor Of H&T Line 2 & 3 Controlled By VFD With Line stopes &

Tempering Zone Temperature (Reduced current from 21A to 14A) (NCRM

Electrical)

0.48 - 4.05 1.0

5 120 nos HPSV Shed light replaced by 150W LED Shed light (NCRM Electrical) 1.36 - 11.60 13.16

6Installed 83 Nos of LED Light (150W) to be install In Place of HPSV Lamp fitting

(400W) of shed lights (In shed no. 6 & 8 NCRM Electrical)0.98 - 8.39 6.35

7

Optimization of Unit consumption of Makeup pump by changing pre-established system commercial cent. pump to submersible pump at TUBE MILL # 05 & 06. (Pump installed, to be taken into circuit till Dec. 2018 Tube Electrical).

0.28 - 2.39 0.7

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Sr. no.

Energy Conservation MeasuresElectrical Energy

Saving (Lakh kWh)


(M kcal)

Annual Savings

(Rs in lakhs)


8

Optimization of Unit consumption of Makeup pump by changing pre-established

system commercial cent. pump to submersible pump at TUBE MILL # 07. (Running

from May 2018 - Tube Electrical)

0.28 - 2.39 0.7

9Cooling zone Id pump 02 nos 18.5 kw high head pump motor set were replaced

with 22 kw one id pump with 200 LPM pump motor (Coating Plant).1.31 - 11.21 0

10Installed 140 Nos LED light (150W) in Place of HPSV Lamp fitting (400W) at VDI

area (Pipe Coating plant Electrical)1.53 - 13.08 10.71

11Total 121 HPSV lights replaced with LED lights Power plant utility LED lighting

(Power Plant Electrical)0.48 - 4.08 8.0

12 VFD provided for cooling tower CT Fan (Power Plant Electrical) 1.06 - 9.08 1.5

13Automatic switching of substation lighting by photo sensor of Substation &

Switchyard Lighting. (28 no's 250 watts lights- Power Plant Electrical).0.06 - 0.49 0.06

14Provided Variable frequency drive on 2no.s AHU blower motor at Main Electrical

Control Room (API Electrical).0.34 - 2.86 0.80

Total 17.97 - 153.2 130.95

4. Innovative Projects Implemented


Project Title :- Revamping of Steam Distribution Network

Problem Statement :- Steam condensate going waste through steam trap system & difficulties in monitoring of operation of steam trap system.

Action Taken :- Replaced 22 Thermodynamics steam traps, provided additional 5 TD traps at new location where required, 13 Sight glasses along with disc check valves provided after close loop steam trap & 10 valves replaced with glandless pistonvalves.

Saving :- Rs. 17.34 Lakhs

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Project Title :- Pre-Heating arrangement before Hardening Furnace in H&T line.

Problem Statement :- Heat in the furnace exhaust flue gas going waste & consuming the fuel to heat the sheet prior to enter into the furnace

Action Taken :- Utilized waste heat of furnace exhaust flue gas by making pre-heater inhouse & provided at furnace entry for heating the metal sheet.

Pre-Heating

arrangement before

Hardening Furnace

in H&T line




Project Title :- Construction/Heater mode modification at Colour Tempering Line (H&T)

Problem Statement :- 1,Heatloss due to air heating in between tank heating surface & Heaters (Radiative Heating). 2,Heat Loss due to openings present in each zone. 3,Frequent Breakdown due to heater failure by contact with humid air in presence of salt fumes.

Action Taken :- Provided Electrical heaters inside the tank by making provision of SS pipes & utilized radiative & convective heat for salt heating.

Heater

Before Modification

Color Tempering (Salt Tank)

Heater

After Modification


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5. Utilisation of renewable energy sources


Solar water heating system with 8000LPD for colony


Installation of solid waste based hot water generation system

6. Utilisation of waste material as fuel

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7. GHG Inventorisation :-


Clean Development Mechanism The Clean Development Mechanism (CDM), defined in Article 12 of the KYOTO Protocol, allows a country with an emission-reduction or emission-limitation commitment under the Protocol to implement an emission-reduction project in developing countries. Such projects can earn saleable certified emission reduction (CER) credits, each equivalent to one tonne of CO2, which can be counted towards meeting Kyoto targets.

The mechanism stimulates sustainable development and emission reductions, while giving industrialized countries some flexibility in how they meet their emission reduction or limitation targets.

Bhushan Steel Ltd has registered 2 projects under UNFCCC with consultation of Frenz GreenearthTechnologies Pvt Ltd totalling a prospective Certified Emission Reduction (CER) capacity of around 18000 T CO2 per year. Projects are:

1.UNFCCC CDM Project No-.8802: 24 MW Power Plant .For reference:http://cdm.unfccc.int/Projects/DB/TUEVSUED1355561731.08/view

2.UNFCCC CDM Project No-.8801: Industrial Boiler.For reference:

http://cdm.unfccc.int/Projects/DB/TUEV-SUED1355560177.97/view

Bhushan Steel Ltd has actively maintained its GHG inventory according to ISO 14064-1:2006.

The ISO 14064 standards (published in 2006 and early 2007) are the most recent additions to the ISO 14000series of international standards for environmental management. The ISO 14064 standards providegovernments, businesses, regions and other organisations with an integrated set of tools for programs aimedat measuring, quantifying and reducing greenhouse gas emissions. These standards allow organisations takepart in emissions trading schemes using a globally recognised standard.

CDM (Clean Development Mechanism) is also an integral part of GHG inventory managment and we areactive in that field also.

GHG Inventory Development


Be1 Initiative Platform

Capture idea from employee in which conservation of energy & environment have separate desk like quality, Productivity etc.

8. Green Supply Chain

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Training and awareness on Energy Conservation TechniquesEnergy walk

Prize Distribution

Inauguration

Painting and drawing competition Quiz competition

9. Team Work, Employee Involvement & Awareness


Tree Plantation in Plant & TSBSL Township Environment Day walk

Environment Stewardship Training and Awareness Prize Distribution

9. Team Work, Employee Involvement & Awareness

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10. Implementation of ISO 50001


EnMSISO50001

ISO 50001 Implemente

d in year 2015

02 Certified Lead

Auditors

05 BEE Certified Energy

Auditors/Managers

24 Internal Auditors

Total 879 Employees covered in

Energy Awareness Training.

Conducting Quarterly

Review meeting on

energy Conservation Practices .

Energy Week

Celebration

Presentation for energy

conservation & current

scenario given from MEDA

person

Awareness session for employees on

Energy Conservation opportunity & for ladies on energy conservation in

household appliances

Painting Competition, Essay

Competition & Departmental

Energy Conservation Presentation

Training and awareness on Energy

Conservation Techniques by PAT

Consultant Mr. Puneet Hegde.

Pick and win Contest on energy

conservation, global warming,

environment, renewable energy.

Audit Culture

Base Line Energy Audit-

Yr.2010

Optional Energy Audit-

Yr.2013

Steam Walk

Through Audit-

Yr.2014

Pump Audit-

Yr.2016

Steam Detailed

Audit-Yr.2017

Insulation

Audit-Yr.2017

Water Balance Audit-Future

Planned

Harmonics Audit-Future

Planned

Hired Energy Auditor who

conducts training & auditing of

energy conservation

measures.

MEA Audit

Yr.2018

11. Other Innovative Technologies Implemented


Inlet flue

gas

Steam

generation

Exhaust

0

20000

40000

60000

80000

FY2015-16 FY2016-17 FY2017-18 FY2018-19

62825 6677757235

27466

Ste

am

Ge

ne

rati

on

In

MT

Steam Generation Through Waste Heat Recovery Boiler

4.2 TPH Waste Heat Recovery Boilers installed on DG sets (02 no.s DG sets of 12 MW), waste in the exhaust flue gas recovered through these boilers and Saved Fuel by reducing load on Steam Generation Boiler running on 8TPH Fuel fired boiler.

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Installed KVX system on gas fired boiler to enhance the overall efficiency by 10% by facilitating better combustion.

C CC H

High fuel consumption

High CO emissions

Before

Modification

After

ModificationC C

C H

Fuel consumption

reduced by 10%

CO emissions reduced

by 30%

Strong C-C &

C-H bond

Weak C-C

& C-H bond

11. Other Innovative Technologies Implemented

Awards :-


BSL Won 8th State

Level EC Award

Year 2011-12

BSL Won NECA Award

Year 2015-16

Won 89h State Level

EC Award Year

2012-13

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12. Long Term Vision on EE


Sr no. Energy Conservation Measures Approx. Savings (₹ in cr)

1 Reducing air pressure from 7 kg to 6 kg in main header 3.9

2 Install 260TR x 4 nos. chillers with new energy efficient chillers 1.7

3 Install solar PV system of capacity 10 MWp roof top with net metering facility 6.6

4 Replacement of existing thermal oxidizer by energy efficient RTO (Regenerating Thermal Oxidizer)

3.3

Energy Conservation Planned :-


Installation of Polycrack system Charge of polythene & plastic product & produce diesel , gas & carbon

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Thanks [email protected],

Cell : 9987578385

[email protected],

Cell : 9503113041

mailto:[email protected]

mailto:[email protected]

TATA Steel BSL Limited, Khopoli. - CII - Sohrabji Godrej ...

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