JSW Steel Vijayanagar

21st National Award for Excellence in Energy Management 2020 - CII

Mr. Anand Kulkarni , ManagerMr. Mahammad Shafi, Assistant Manager

Company Profile : JSW Steel

JSW Steel – At a Glance

With the largest product portfolio in steel, we are India's

largest steel exporter, shipping to over 100 countries

across 5 continents. Over the last 35 years, we have been

at the forefront of science and cutting-edge technology.

Laying the Groundwork

Starting with a single plant in 1982, we are now India's

leading manufacturer of value-added and high-grade steel

products. With plants in Karnataka, Tamil Nadu and

Maharashtra, we have the capacity to produce 18 million

tons per annum (MTPA).

Ability to perceive and use opportunities to our leverage with high execution speed• Fastest Growing Indian Steel plant (20% YoY)• Fastest consolidation in Indian Auto Steel Market (despite being late entrant)• Setting Global Benchmarks in ramp-up projects (Blast Furnace ramp-up,

Converter relining, Converter Shell replacement)

Speed

Ability to develop solutions through innovative experimentation• Pioneering solid waste utilization with in-house technologies developed

first time in the worldo Slag Sand (Replacement for River Sand)o Zero Liquid Discharge (at Coke Ovens)

Innovation

Ability to convert threats into opportunities with skilful dexterity• Global Benchmark for liquid metal productivity with high Slag Rates• Delivering UHSS steels with Raw Materials consisting of highest

Gangue proportions and widely varying chemistry• 1st Steel Plant in India to use Ore as low as 46% Iron content

Agility

Our Core Strengths: Our DNA elements

(1)

Hot Rolled

CoilsCorex (2)

VJNR Schematic Process Flow

HSM (2) CRM (2)

Billet Caster

CokeIron ore Fluxes

Coke Ovens (4)

Converter (7) LHF, RH Slab Caster

HMPT

Pellet Plant (2)

Ore

Beneficiation

Plant (1)

Blast Furnace (4)

Lu

mp

ore

Wire Rod (1) / Re Bar Mill (2)

Coal

DRI

(1)

EAF (1)

Coke

Hot Metal

SinterPellets

Billets

Slabs

TMT Re-bars

Wire Rods

Cold Rolled

Coils

Sinter Plant (4)

Coke-making

Steel Making ShopsIron Making Mills

Legend

xxx Product of the Plant Unit

xxx Plant Unit Type

(xxx) Number of the Plant Unit

xxx Final Product of VJNR

Hot Rolled

Coils

Iro

n O

re F

ines

Coke

Fin

es

4

Total Energy distribution scenario:

5 Energy consumption of the plant : 7,625,738 mtoe

Power Scenario:

Power Generation %

Coal 58

Gas + TRT + CDQ + SIP 42

Power Generation Scenario Power Consumption

Process Steam Scenario : ZERO Coal Fired

Steam Generation

Energy Source

BEE PAT II Specific Energy Consumption :

1.4

%

5.7

%

Aw

arde

d

87

,65

9 ESce

rts

Technology upgradation through revamping of Blast furnace 1

Improved production throughput by better maintenance practices

Improved waste heat recovery

Implementation of energy conservation projects

Stopping and dismantling of age old inefficient coke oven

PAT-II Performance Major Improvements

Benchmarking :

Stage wise Energy

Consumption

Gcal/TCS

JSW Steel

Performance

Gcal/TCS

Internal

benchmark:

India’s best

Gcal/TCS

External

benchmark:

Global best

Gcal/TCS

Iron Making 5.19 4.64 3.2

Steel Making 0.29 0.25 0.04

Rolling & Finishing 0.65 0.47 0.85

Boilers & Power

house0.09 0.14 0.03

Auxiliaries & Losses 0.11 0.22 0.19

Energy Saving Initiatives : FY 2016-17

Sl. No. Description of energy efficiency improvement measuresInvestment(Rs in Lakhs)

Verified savings²(Lakh Rupees)

TOE

1 Installed Top recovery turbine @ Blast Furnace 1 400 1,123 8,504

2 VFD Drives for CEP & ID fan of CPP 4 257 83 605

3 Condensate heat recovery system @ 60 TPH Boiler 34 1221063

4 Gas mixing station 1 strengthening : Capacity enhancement 152 2,268 23,901

5Reduction in venting losses of oxygen by optimizing pressure setting

Nil 72 421

Selected few

Sl. No. Description of energy effeiency improvement measuresInvestment(Rs in Lakhs)

Verified savings²(Lakh Rupees per annum)

TOE Reduced

1Captive Power Plant-3 & 4 : CEP Header Pr reduced from 2.4 to 2Mpa

Nil 43 597

2 Captive Power Plant-3 : Condenser cleaning AOH Nil 1,106 5923

3 Blast Furnace 4 : Increased performance of TRT at BF4 50 1,619 10512

4 Pipeline Comissioning: Blast Furnace gas reliability 1,900 4,200 40165

5Sinter Plant 1: Sinter Waste heat utilisation for BF 1 & 2 coke drying

1,567 2,012 8115

6Blast Furnace : Overall reduction in solid fuel consumption by increasing PCI and process optimisation

Nil 29 36163

Selected few

Energy Saving Initiatives : FY 2017-18

Selected few

Energy Saving Initiatives : FY 2018-19

Sl. No. Description of energy effeiency improvement measuresInvestment(Rs in Lakhs)

Verified savings²(Lakh Rupees per

annum)TOE Reduced

1Comissioning of 150 TPH BF gas fired boiler for Captive Power Plant 2 for power augumentation

5,900 10,811 78624

2Improving the net sinter production @ Sinter plant 1 there by improving the sinter availability to BF

Nil 560 4669

3Reduction in Oxygen venting by optimisation of delivery pressure set points

Nil 1,180 5931

4Maximising the capacity utilisation of existing system of all BF & installation of additional PCI stream at BF4

1,636 7,230 28435

6 Increase in LD gas recovery by process optimisation Nil 586 4834

7Reduction in SMS-3 power consumption by increasing Hot metal consumption

Nil 1,858 13511

8Reduction in Fuel consumption in Corex by increasing the gas utilisation

Nil 2,000 23086

Increasing PCI Rate in Blast Furnace : Energy Saving Project-1Increase in Injection Capacity1 Real time hearth liquid level2

Dynamic Burden Distribution Model3 Process Parameter Changes4 Layer Thickness5 Layer Thickness6

Challenges and Target for High PCI Blast Furnace Developing Robust HLL Model to Improve Accuracy of Prediction through AI

BDM works based on live top temp profile & optimized based on feedback

Increasing PCI Rate in Blast Furnace : Energy Saving Project-1

Energy Contribution of solid fuel rate has reduced around 5.2%. In other furnaces also similar improvements are deployed.

Reduction of specific solid fuel consumption in Sinter Plant-1Energy Saving Project-2

Background: Solid fuel is used to produce heat duringsintering process for making sinter agglomerate. which is asemi coked iron ore used as raw material in blast furnace.Increase in Coke rate per ton of sinter will directly increasesinter cost.

Implementation:

Increase Micro pellet consumption in Sinter Plant 1

Problem : Frequent jamming of micro pallet hopper

Action 1: Pneumatic hammers to be installed

Action 2: Air blasters all around to be installed

Action 3: Mechanical Hanging manual hammers installed

Action 4: Polymer liners in side the bin to be done

Action 5: Vibro feeder wire mesh size increased

Pneum. Vibro motor

Air blasters 5 nos fixed

Mech. hanging hammer fixed

Micro pallet bin polymer liners fixed

Vibro feeder wire mesh size increased

64

58.4

5556575859606162636465

Before After

Solid

Fu

el R

ate,

Kg/

TP

0.485

0.454

0.430.440.450.460.470.480.49

Before After

He

at

Ra

te,

Gca

l/T

P

Solid fuel consumption Heat Rate Reduction in SP-1

18.5

30.3

0

5

10

15

20

25

30

35

Before After

Mic

rop

elle

t C

on

sum

pti

on

, K

g/TP

Micropelet Consumption

Reduction of specific solid fuel consumption in Sinter Plant-1Energy Saving Project-2

Coke drying using Sinter Plant waste heat: Innovative Project-1

Development of HMI with fully automatedcontrol facility of Coke Drying Unit

Coke moisture Reduced from 8.2 % to 5.4% Average. Leads to coke reduction around 10 to 12 Kg//thm. Approximately 200TPD hot metal production has increases

Reduce Coke Rate by 15 Kg/thm from Current level.( Present level : 482kg/thm ) to increase production to 3650 TPD (Present level: 3156 TPD)

Hot Air at 220°C is supplied to coke bunkers with temperature control with nozzles providedon the bunkers. After drying coke exhaust gas escape from top of the bunker.

Waste Gas from Cooler of SP1

Sinter Plant 1

Blast Furnace StockHouse Bunker

Waste Gas Recirculation in Sinter Plant-4 : Innovative Project-2

The aim of the recirculation system is to recirculate apart of the waste gas to the Sinter process.

The benefits of a WGR system are to reduce

1. Particulate Matter2. SO23. NOx.

During sinter process the recirculated CO reactsexothermal to CO2. Thus, part of the fuel respectivelycoke/anthracite can be replaced.

58

56

Before After

General Layout of WGR System

Site View of WGR System SP-4 Solid Fuel Reduced by 2kg/Tp

Adoption of Energy Saving Technologies :

Process BEST Available TechnologyImplementation of facility*3

Unit 1 Unit 2 Unit 3 Unit 4

Coke PlantCoke dry quenching (CDQ) - -

Coke moisture control (CMC) - - x x

Sinter Plant

Sinter Plant heat recovery (steam recovery form sinter cooler waste heat)

Sinter Plant heat recovery (power generation form sinter cooler waste heat) x x x x

High efficient (COG) Burner in ignition furnace for sinter plant x x x x

Blast Furnace

Top pressure recovery turbine (TRT) x

Pulverized coal injection (PCI) system

Hot stove waste heat recovery

BOF Steel MakingConverter gas recovery device (BOF gas recovery)

Converter gas sensible heat recovery device x x

Electric Arc FurnaceEcological and economical arc furnace (ECOARC) x

Waste heat recovery from EAF x

General

Inverter (VVVF; Variable voltage variable frequency) device for motors Partial

Regenerative burner total system for reheating furnace x

Energy monitoring and management systems

Cogeneration (including gas turbine combined cycle (GTCC)) x

Management of compressed air delivery pressure optimization Partial

Power recovery by installation of steam turbine in steam pressure reducing line x

Environment Management Facilities :

Water management:

Ceramic membrane at CRM-2 for oil removal

6 nos of RO Plants producing 20,700 m3/day

3nos Guard Ponds having storage capacity of 2,35,000 m3

45000 m3/d GP water recycle

4000 m3/day ZLD Plant at Coke Oven

Membrane Bio Reactor for treatment of township sewage and reused in CRM process

Ceramic membrane * First in World*

Guard Pond ZLD Plant at Coke Oven

*First in World*

RO Plant

Membrane Bio Reactor

Solid Waste utilization :

Solid Waste Management:

Innovative technologies adopted for utilizing the solid wastes (dust, sludge and slag):

Mill Scale Briquetting: For converting high Fe content waste into briquettes. Used as coolant in the convertors

Micropelltization: Converting medium Fe content waste into homogeneous agglomerate and used in Sinter Making

Low Fe waste is processed through SRP & WWP to recover Iron and Carbon and used in Pellet and Sinter making

Precious Slag Balls: Produced from EAF slag. Used in shot blasting and road making

MPP (1950 TPD)*First in India*

MSB (550 TPD)*First in India*

WWP (1000 TPD)*First in India*

PS Balls*First in India*

Slime (2000 TPD)*First in India*

With the capacity enhancement of waste handling facilities at VJNR the solid waste utilization has increased from 77% in FY18 to 89% in FY19

Further improvement was achieved by usage of slag by Gammon India for National Highway, enhanced capacity of MPP and increased sale of slag sand

Solid Waste Utilization :

Air Pollution Control Systems At JSW :

Bag House at HMDS-1 (SMS-2) Converter (SMS-2) Sec. Fume Extraction at SMS 2

Stock House Fume Extraction at BF3 – 7.5 lakhs m3/hr (1)

Cast House Fume Extraction at BF3 – 9 lakhs m3/hr (2)

Ground De-dusting of CO – 2.3 lakhs m3/hr (2)

Long Term Climate Change Mitigation Plan :

Gas to Power Plant

OG, CDQ WHRB, TRT

Increase In PCI in BF

CH4 in DRI

CO2 Emission in ton-CO2/TCS

9%8.4%

Pipe conveyor:

Zero Accidents

34 road accidents in FY17

Safety Cost

Presently Rs. 495/Ton; very high for the short distance

With pipe conveyor price will be Rs. 100 / T (Capex + Opex)

Environment

High Pollution due to spillage High CO2 emissions by trucks

No Pollution, CO2 reduction by 3.86 kgs/ton of ore transported

Present

With pipe conveyor

The first steel plant in India to have Raw material supply

through pipe conveyor

An innovative solution to an age old problem

Employee Engagement council :

Elements of Employee Engagement

Team Work, Employee Engagement & Energy Monitoring :

Energy Management Center - Online Monitoring & Controlling

Daily Energy Performance Review at All DepartmentsOnline Specific Energy Calculation Tool

Training Program on Energy Improvement and CO2 Emission Reduction by IIT Professors

Kaizen & Innovative Projections Suggestions were gathered. QC Teams Participation in CCQC2018 at Bangalore

Award Distribution by TOP management

Team Work, Employee Engagement & Energy Monitoring :

Biodiversity around Vijaynagar :

Sloth Bear, Leopard or Panther,

Indian PangolinStar Tortoise.

Tickell's Blue Fly Catcher Indian Pea fowl, (Pe Cock)

Black Crowned Night Heron,

Blue-tailed Bee Eater

Clean & Green Steel Works :

J SW Pla n ted 1 .7 Million

Trees a t Vija ya n a ga r

Technology Roadmap 2030 : Technology 2030

Mid Term (FY 22-25) Long Term (FY 25-30)

Waste heat recovery systems

Partial replacement of flux with steel making slag

Direct use of Coke oven gas in DRI

Successful adoption of KR for pre-treatment and EMS for casting

Injection of Coke Oven gas in COREX

Injection of producer gases in BFs

Iron Making with Iron ore lump, Pellet, Sinter and other combinations

Installation of automatic inspection/ detection systems

Integration of process control systems across the value chain

Direct reduction of low-grade IO fines

Harvesting renewable sources like Solar

Fluidized bed roasting and micro roasting to enhance efficiency of beneficiation

Slurry Pipeline from ports

Improve carbonization of Coke by catalytic addition

Solid Waste Utilization technologies (Micro Pellets,

WWP), Usage of Low Grade IO through OBP and MSBQ

Pipe Conveyor from IO mines ensuring stable supplies

Development of DP 600, 900

Weather resistant steel

Commissioning of large converter shells to increase cast output & reduce no. of handlings

Moving to larger BFs to economy of scale

TRT in BF-5

1.NPD (AHSS/ UHSS)2.Capability Development3.Service Differentiation through Digitization

Raw MaterialProducts & Markets1.To reduce Specific RM

consumption2.Lower RM transportation

cost3.For flexi RM operations

1.Reduce SEC2.To increase overall efficiency of Iron

Making and Steel Making3.Reduction in COPQ4.Faster stabilization of Value Added

Products

Operations

Data Mining of customer experience to design solutions

Development of Hot forming grades

Surface engineering technology

3rd Generation Automotive

Steel

Joinery design

Long Term (FY 25-30) Mid Term (FY 22-25)

2*30TPH WHRS in SMS3 & HSM1&2

CDQ in CO5

OG Boiler in SMS-4

Achievements :

World Steel Dynamics ranked JSW Steel seventh among the Top 20 World Class Steelmakers

WSA Steel Sustainability Champions Award for two consecutive years - 2018 and 2019

Vijayanagar Works conferred with Sustainability Award 2019 by The Indian Institute of Metals

Awarded Corporate Governance & Sustainability Vision Awards 2020

BEYOND QUALITY.BEYOND EXCELLENCE.JSW wins the prestigious Deming Prizefor its excellence in TQM-2018

THANK YOU

#BetterEveryday