Download - Excellence in Energy Management - 2018
TATA STEEL PROCESSING AND DISTRIBUTION LIMITED
PUNE BUSINESS UNIT
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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
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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.
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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
Capacity: 55 KT p.a.
HRNCTL
Thk: 1.6 -7 mm
Width: 800 mm
Capacity: 40 KT p.a.
HRWCTL
Thk: 1.6 -12 mm
Width: 1680mm
Capacity: 72 KT p.a.
CR Slitter
Thk: 0.3-3.2mm
Width: 1550 mm
Capacity: 66 KT p.a.
CRWCTL
Thk: 0.3-3.2mm
Width: 1600 mm
Capacity: 48 KT p.a.
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
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Certifications & Awards
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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
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TSPDL Energy Policy
• Comply regulations
• Efficient Energy Management
• Renewable Energy
• Create Awareness
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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)
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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
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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
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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
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Energy Saving Projects FY17
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 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
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Energy Saving Projects FY18
Sl No Title of ProjectEnergy Saving
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
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Energy Saving Projects FY18
Sl No Title of ProjectEnergy Saving
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
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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
Use of Eco-Clean 2300 & Eco-Lime 2300 in STP
Eco- Health Technology
Page 3 of 4
19Innovative Projects FY 18
Use of Eco-Clean 2300 & Eco-Lime 2300 in STP
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
20Innovative Projects FY 18
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
21Innovative Projects FY 18
Use of Sonic Soot Blower for Boiler Tubes CleaningPage 2 of 2
Online & Continuous Cleaning of Boiler Tubes25.6
21.35
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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
22Innovative Projects FY 18
Replacement of Drop Stacker with Rotary Stacker
Before After Video
Page 1 of 2
23Innovative Projects FY 18
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
24Innovative Projects FY 18
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
Specific Emissions Scope 2 ( TC02e/t))
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
Specific Emissions Scope 1 ( TC02e/t))
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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
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Green House Emission
Life Cycle Cost
Green House Emission
Supplier awareness and Green Initiatives
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
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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
34Team Work, Employee Involvement &
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
35Team Work, Employee Involvement &
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
38Team Work, Employee Involvement &
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
91 - 100
91 -100
91 - 100
91 - 100
71 - 80
81 - 90
131 - 140
71 -80
51 - 60
61 - 70
71 - 80
51 - 60
61 - 70
71 - 80
91 - 100