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NAVA BHARAT 19 th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager (Engineering) 1. B. Srikanth - DGM-Ele (FAP). & Designated Energy Manager 3. M. Bhimeswara Rao - Assistant Manager – (Technical Cell)

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Page 1: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

19th National Award For Excellence in Energy Management - 2018

NAVA BHARAT VENTURES LIMITED

2. Nilan Ku Mohanty - Assistant General Manager (Engineering)

1. B. Srikanth - DGM-Ele (FAP). & Designated Energy Manager

3. M. Bhimeswara Rao - Assistant Manager – (Technical Cell)

Page 2: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

NBVL Global footprints Company profile

India : Ferro Alloy, Power & Sugar , Corporate OfficeSingapore : International OfficeLaos : Development of hydro-electric power projectZambia : Coal Mining & 300 MW Thermal Power PlantTanzania : Identifying opportunities for mining and setting up agri projects

Kharagprasad (Odisha): Chromium Alloy Plant & Power Plant

Samalkota (AP): Sugar Plant & Power Plant

Paloncha (Telangana): Manganese Alloy Plant & Power Plant

Hyderabad: Corporate Office

Dharmavaram (AP): Power Plant

Page 3: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Unit profile

Ferro Alloy Division

Smelters: 2 x 22.5 MVAProducts: Ferro ChromeOutput Capacity: 75,000 TPA

Power Division (CPP)

Capacity: 30 MW + 60 MWType: Coal Based TPPFuel: Domestic Coal from MCL

Page 4: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Process Flow

PRODUCT YARD

BED CASTING

MRP

CCM CASTING SLAG GRANULATION

SKIP HOIST

DAY BUNKERS

BA

TC

HIN

G

SYST

EM

RAW

MATERIAL

YARD

BRIQUETTING PLANT

SCREENING

GROUND HOPPER

REDUCTANTS& FLUXCHROME ORE

FURNACE

GCP

COOLING TOWER

SILO SILO

STEAM TURBINE

GENESP

BED ASHFLY ASH

CHP DMP

BOILER

FERRO ALLOY PLANT (2 X 22.5 MVA):

POWER PLANT 90MW (30MW + 60MW):

X X

X

TO FAP TO GRID

132 / 11 KV SWITCH YARD :

Page 5: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Energy Effectiveness at NBVL

Principles we follow for Energy Effectiveness:

❖ Ensuring quality of raw materials

❖ Proper blending of raw materials

❖ Ensuring 100 % equipment availability

❖ Procurement of energy efficient products

❖Maintaining the power quality and Power Factor

❖ Energy conservation projects and management action plans

❖ Reducing the idle running of crushers, conveyors and other equipments

❖ Efficient operation of plants in accordance with the documented criteria

❖ Systematic approach (PDCA Cycle) of Energy Management System (ISO 50001 : 2011)

Page 6: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Specific energy consumption

0.7

0.75

0.8

0.85

0.9

0.95

1

14-15 15-16 16-17 17-18

0.98

0.91

0.86

0.82

CPP Specific Coal Consumption ( kg / kWh)

16.42 %

0

10000

20000

30000

40000

50000

60000

14-15 15-16 16-17 17-18

52620 5136348806

43557

Specific Thermal Energy Consumption (kJ / kg)

(Including Coal Consumption)

17.22 %

Page 7: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Specific energy consumption

10

10

11

11

12

12

Target 15-16 16-17 17-18

10.28

11.62

11.14

10.58

CPP % Auxiliary Consumption

8.95 %

1.1

1.12

1.14

1.16

1.18

1.2

1.22

1.24

1.26

14-15 15-16 16-17 17-18

1.26

1.23

1.171.16

GtG Specific Energy Consumption (MTOE / MT)

7.48 %

3350

3400

3450

3500

3550

3600

3650

3700

14-15 15-16 16-17 17-18

3676.2

3595.3

3482.03464.7

FAP Specific Electrical Energy Consumption (kWh / MT)

5.75 %

Page 8: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

3200

3300

3400

3500

3600

3700

3800

Benchmark 17-18

3800.00

3464.67

1.10

1.12

1.14

1.16

1.18

1.20

1.22

1.24

1.26

PAT Target 17-18 17-18

1.26

1.19

1.16

Improvement over PAT Cycle-2 Target ( MTOE / MT)

Improvement over Benchmarks & Target

Source of National Benchmark: Specific electrical energy Consumption norm for charge chrome industry is 3800-4000. As per Department of Scientific & industrial research , Technical report on Technology in Indian Charge Chromeindustry, Executive summary ( no: tsr079).

Improvement over National Bench Mark (kWh / MT)

7.48 %8.82 %

Wit

ho

ut

No

rmal

izat

ion

Wit

hN

orm

aliz

atio

n

Page 9: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Roadmap for the future

❖Performance evaluation of Air Preheater and upgrading the tubes

❖Replacing tubes bundles of HP Heater-1 for enhancing of heat ratein Unit-2

❖Upgrading the Plant lighting with LED lights

❖Providing the VFD to one of the CEP in Unit-2

❖Smoke Blower Common duct modification in Furnace -1

❖ Optimization Roots Blower speed with ZIG process requiredpressure

❖ Providing VFD to Press-1 at Briquetting Plant.

❖ Replacement of sprocket wheels & providing VFD for Dryer Drumof Dryer-2

❖Installation of Solar Street Lights in plant premises

Page 10: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Energy Conservation projects implemented in 2015-16 & 2016-17

Title of the Project Savings MU

2015-16

Installation of VFD for Reverse Air Fan Motor at both gas cleaning Plants 0.448

Reducing the RWPH pumping energy consumption by Recycling of DM Plant Filter back wash water in clarifier & Reusing of blow down water of boilers in Cooling tower

0.0012

Installation of VFD for 2 no's of Cooling Tower 0.020

2016-17

Modification and providing thermal insulation around hopper heaters of ESP 1&2 in Unit-2 0.010

Installation of Variable Frequency Drive for MRP slurry pump 0.030

Installation of Variable Frequency Drive along With Energy Efficient motors for Cooling Towers 0.029

Installation of VFD for smoke Blower motor at Furnace -1 0.018

Total Savings 0.556

Flow Diagram Of BDC & FBCRA Fan VFD ESP Hopper Heaters Mechanization System CT Fan VFD

Page 11: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Energy Conservation projects implemented in 2017-18

Title of the Project Savings MU

Installation and commissioning of Automized system for Weighing, Packing and loading 3.0 kL

Upgradation of VFD with Latest version in Gas Cleaning Plant of Furnace-1 0.030

Replacement of sprocket wheels of dryer drum and installation of VFD in dryer no-2. 0.018

Application of corrocoat paint to impeller blades of furnace cooling water circulation pumps ( 3 no's) 0.0346

Replacing the 110 kW Horizontal pump motor with 55 kW, 450 m3 pump at River Water Pump House. 0.050

Reducing the running hours of 45 kW additional ACW pump by providing 0.75 kW Booster pump in Unit-2 ACW line for efficient operation of control room AC Units in absence of VAM.

0.116

Application of corrocoat paint to all the three CW pumps internals and its impellers in U-2 0.284

Total Savings 0.531

Corrocoat Paint to ImpellerDryer Sprocket Wheels 55kW Horizontal Pump AC Unit Booster Pump VFD for Dryer

Page 12: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Energy Conservation projects with Zero Investment

Utilizing existing Unit-1 ID fan Old VFD for chilled water pump of VAM

Implemented in :2016-17

Annual Savings:0.151 MU

Conserving AHP Compressor energy by changing the bed ash conveying time in Unit-2

Implemented in:

2016-17

Annual Savings:

0.034 MU

Redesigning the Ash silo dewateringpumping system near Fly ash silo in Unit-2

Implemented in :2015-16

Annual Savings:0.007 MU

Optimizing the compressed air consumption in bed ash system by blocking orifice plate holes.

Implemented in:

2015-16

Annual Savings:

0.053 MU

Annual savings0.244 MU

GHG Reduction375.43 MT Co2e

Page 13: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Energy Conservation projects with Zero Investment

Conserving the AHPC

energy by changing the bed ash dome valve opening time in both the CPPs.

Implemented in :2017-18

Annual Savings:0.026 MU

Changing the bed ash conveying system operation from timer mode to probe mode in Unit-2

Implemented in:

2017-18

Annual Savings:

0.0205 MU

Reduce the energy consumption of Briquetting plant by addition of Muller mixer to Alfa mixer operation

Implemented in :2016-17

Annual Savings:0.080 MU

Optimizing the energy consumption of main fan by reduction of fan speed.

Implemented in:

2016-17

Annual Savings:

0.005 MU

Annual savings0.131 MU

GHG Reduction202.12 MT Co2e

Page 14: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Controlling constantsteam ventingthrough startup ventvalves by Providingsteam trap instartup vent drain ofU-1 Boilers

Implemented in :2017-18

Annual Savings:1318 MT

Up gradation of glasswool insulation withceramic fiber type, AtTG cross over pipes inUnit-2 and TG Steaminlet in Unit-1

Implemented in:

2017-18

Annual Savings:

32 MT

Performanceevaluation ofHeaters in Unit-2and replacing thedamaged tubebundles of LPHeaters.

Implemented in :2015-16

Annual Savings:1200 MT

Normalizing the sp.steam consumption,Vacuum & heat rate ofU-2 by rectifying theejector problem andarresting the leakagefrom TG bottom casing

Implemented in:

2016-17

Annual Savings:

11600 MT

Thermal Energy Conservation Measures

Annual savings14150 MT

GHG Reduction26602 MT Co2e

Page 15: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Measures taken for reducing the Plant lighting consumption:

❖ Replacing of 6 nos. 85W street Lights with 45W LED lights in Unit-2 DM Plant.

❖ Replacing of 10 nos. 150 W MH lights with 45 W LED at Furnace building.

❖ Replacing of 35 nos. 250 W MH lights with 45 W LED flood light in Plant area.

❖ Replacing of 27 nos. 250 W HPSV lights with 45 W LED light in gate-5 area.

❖ Replacement of HPSV Lights and M H lights with LED lights in FAP

❖ Replacing of 4 nos. 18 W Gate lamps with 2 no of 15 W LED at PP Entrance gate

❖ Replacing of 38 nos. 70 W HPSV lights with 42 W LED in all the Units

❖ Replacing of 199 nos. T5 lights with 18 W LED tube light in all the Units

❖ Replacing of 44 nos. 400 W HPSV lights with 125 W LED flood light and 9 nos. 400W HPSV lights with 42 W LED in all the Units

Optimization of lighting consumption

Annual savings0.2094 MU

Investment (Rs.)0.983 Million

GHG Reduction322.41 MT Co2e

Page 16: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Waste Heat Utilization at Dryer Innovative project-1

Implemented In 2015-16

Description of the Project :

The Chrome ore being dried by using Furnace oil in double shell rotary dryerto minimize the moisture in the ore up to 2%, before being used inmanufacturing of Briquettes.

Innovation:

Utilization of available heat of Furnace waste flue gasses, taken from the inletof Gas Cleaning Plant to feed directly in to Rotary Dryer inner shell throughwell designed thermally insulated pipeline.This hot gas helped in reducing the fuel injection and resulted in reduction offuel consumption.

Annual savings 40.18 KL

Investment (Rs.)0.49 Million

GHG Reduction316.05 MT Co2e

Page 17: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT Connecting Smoke Blower duct for Furnace-2 Air Cooling

Implemented In 2016-17

Annual savings 0.172 MU

Investment (Rs.)0.75 Million

GHG Reduction264.40 MTCo2e

Description of the Project :

Submerged Electric arc furnaces will be having several air blowers to coolthe equipment of the furnace, such as air seal blowers, chute blowers etc. Allthese blowers will be running throughout the day, consuming electric energy.These blowers force the atmospheric air into furnace. We have a tappingsmoke blower which will be operated during tapping time, to extract the hotair from tap hole, approximately 6 Hours a day.

Innovation:

A study was conducted and redesigned the capacity of smoke blower andconnected its delivery line to the inlet of auxiliary furnace blowers. Thetapping smoke blower (55 KW) is kept in operation continuously with VFDand all the auxiliary blowers are stopped.

Innovative project-2

Page 18: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Replacing the Furnace Oil with LPG

Implemented In 2017-18

Annual savings 38.07 KL

Investment (Rs.)0.85 Million

GHG Reduction104.70 MT Co2e

Description of the Project : The chromite ore is being dried up with the help of

Furnace oil as fuel in Dryer plant. The average specific Oil Consumption was 7.63 Ltr / MT. Moreover, we were facing several dis advantages such as high maintenance, low production and mainly corrosion due to the presence of Sulphur Di-oxide in its flue gas.

Action Taken: To overcome the difficulties with Furnace Oil Burners, we started

studying other options like electrical Heating and Use of LPG as fuel. On ExperimentalProject, M/s BPCL came forward to install LPG system with LOT station. It is 1st suchinstallation in India for drying Chromite ore.

We have got the following advantages and benefits :❖ Specific Energy Consumption is reduced to 5.46 Kg/ MT❖ Environmental friendly : NO Co, NO SOx, NO NOx❖ User friendly – Maintenance Free❖ Efficient Combustion – High Productivity

Technology Upgradation

Page 19: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Solar Power Harnessing

The sun provides a tremendous resource for generating clean andsustainable electricity without toxic pollution or global warmingemissions

Recognizing the importance of solar energy, NBV harnessing solarenergy in following ways:

❖ Installing solar water heaters at guest house and Bachelorhostel with a capacity of 2200 Ltrs / Day (0.150 MU)

❖ Utilising passive sun lighting at applicable areas in the plant

❖ Installation of NoriKool double glazed transparent sheet

❖ Construction of office building with Eco Friendly lighting

Page 20: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Recycling and Reusing Waste

NBV believes that waste prevention, reusing and recycling areimportant practices to reduce greenhouse gas (GHG) emissions, sofollowing initiatives were taken in waste prevention and recycling

❖Utilizing coal washery rejects, Extracted coal fines from coal yarddischarge water and rejected coal fines from FAP

❖Utilizing slag and fly ash in manufacturing of fly ash brick

❖Vermiculture Programme by using canteen and colony waste

❖Recycling & Reusing the waste water for gardening & Constructions

❖Reusing the bed ash as bed material after proper sieving

❖Reusing the waste Turbine Lube Oil and Transformer oil for mudgun preparation in Furnace

❖Reusing the damaged conveyor belts after reconditioning

❖Utilization of Slag for Road making.

Page 21: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

GHG Management

Managing Green House Gas (GHG) emissions :

Nava Bharat Ventures Ltd, Dhenkanal, Orissa adoptedEmission based calculation approach for calculating the Co2eand 2013-14 as a base line year

YearScope 1

emissions CO2e (MT)

Scope 2 emissions CO2e (MT)

Total CO2e (MT)

Baseline 680562.03 3.97 680565.9

2015 - 16 656457.08 11.16 656468.24

2016 - 17 617243.22 38.90 617282.13

2017 - 18 697981.89 1.75 697983.65

Activity DataEmission

FactorTonnes of

Emission (t)Global Warming Potential (GWP)

Carbon Dioxide Equivalent (CO2e) of

Emissions

X =X=

Scope 1 emissions : Fuel used in power generation, FAP DryerHSD , FO ,LPG & PP Startup oil consumption

Scope 2 emissions : Import Power from Grid

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

15.95

0.00

12.20

0.00

9.52

0.00

10.20

0.00

Green House Gas Emissions Intensity (MT CO2e / MT)

36.05 %

: Scope-1 Emissions : Scope-2 Emissions

Baseline 2015-16 2016-17 2017-18

Page 22: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Replacing ofConventional Tubelights with EE lightsat contract workerscolony

Name of vendor : Related Vendors

Vendors/Associate involvement

• Creating awareness, Distributing Energy Efficient lights and required technical assistance• Evaluation of performance delivered by the suppliers and service providers

Type of inputs / projects provided:

Replacement ofExisting weldingtransformers withwelding rectifiers

Name of vendor : Mech. Contractors

Replacing of 3 ph.Jet cleaning machine

with 1 ph. small jetmachine

Name of vendor : M/S Utsab Samal

Replacing thepetrol operatedweed cutter withElectric operatedweed cutter

Name of vendor : M/S B Ramana

Green Supply Chain

Page 23: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Extent of team work

EnMS Structure: NBVL has formed a team for implementation of EnMS, the team underthe guidance of MR and Designated Energy manager will work for resource conservation,implementation of projects and action plans

Core teammembers

Head - Plant

Head - PPHead - FAP

MR-2

DepartmentChiefs

CEM & CEA

DepartmentChiefs

MR-1

Shop floor employees representatives

Certified Energy Auditors : 2, Certified Energy managers : 2 & Certified EnMS Lead Auditors : 4

Page 24: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Workers Involvement

S. no

Title Of the ProjectSource of

IdeaYear Status

1Replacing of conventional tube lightswith T5 lights

Electrician 13-14 Completed

2Utilization of FD fan discharge airinstead of compressed air for self-cooling of bearing

Workmen 14-15 Completed

3Replacing the 22 kW silo pump withexisting old 15 kW pump at Ashsettling pit near ash silos

Mechanical Fitter

15-16 Completed

4Changing of bed ash conveying system operation from timer mode to probe mode in Unit-2

Boiler 2nd

class operator

16-17 Completed

5Replacing of 4 nos. 18 W Gate lamps with 2 no of 15 W LED at PP Entrance gate

Electrician 17-18 Completed

Page 25: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Employee Involvement

S. no

Title Of the ProjectSource of

IdeaYear Status

1Replacing of 54 nos. of 250 W MHlamps with 85 W CFL

Supervisor 13-14 Completed

2Switching off of first field ESP hopperheaters during normal operatingconditions

Engineer 14-15 Completed

3Providing window opening at BFP areain U-2 for utilizing day light

Engineer 15-17Under

Progress

4Modification of ESP Hopper Heaterarea and providing thermal insulation

Supervisor 16-17 Completed

5Providing Booster pump in Unit-2ACW line

Supervisor 17-18 Completed

Page 26: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

❖ Improving awareness through internal training : ConductingInternal training classes to all employees and contract workers

❖ Display of awareness posters: Display of energy policy, resourceconservation and GHG awareness posters with in the plant forimmediate attention

❖ Showing the external presentations to core team: Showing thepresentations down loaded from different forums to create theawareness among the core team members

❖ Providing Training on Sig En Uses and its Variables: Identification ofsignificant energy uses and providing awareness training to theconcerned on the variables & controls affecting the SEU

❖ Deputing the staff to External Seminars: Improving the knowledgeby deputing the employees for external training classes /seminarsconducted by BEE, CII,TERI, BSI etc…

❖ Utilizing the whatsApp for sharing the Tips: Sharing the energyconservation tips and best practices through “whatsApp”

Awareness on Resource conservation

Page 27: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Monitoring and reporting

❖ Installation of Energy meters / Flow meters: Energy meters / Flowmeters were installed at preferred points of consumption & for allthe identified Significant energy uses

❖ Utilizing Portable Measuring Instruments: Utilizing portableinstruments like Power Quality analyzer and Thermal imager forcondition monitoring of equipments

❖ Logging the consumption data in SAP: Energy consumption in plantis logged daily in SAP, reviewed by Section Heads and appropriateaction taken

❖ Monitoring of Energy performance indicators , Variables & Controls:EnPI, Variables & Control were reviewed by departmental chiefs andappropriate action on significant deviation will be taken

❖ Reviewing the Status of Action Plans, Objectives & Targets : Reviewof area wise Specific energy consumption, status of energyobjectives & targets and Energy management action plans

Page 28: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Monitoring and reporting

❖ Submitting of Energy performance report to top management: Daily,monthly and annual performance reports are submitted to topmanagement for information and necessary review

❖ Submitting the Form-1 to BEE: Details of information regardingtotal energy consumed ( FORM - I ) submitted to BEE

❖ Submitting the monthly returns to CEIG: A Statement indicating themonthly self-consumption details is submitted to CEIG - Odisha

❖ NBVL has installed Stack gas analyzer for monitoring of indirectgreenhouse gases and the analyzers are connected to PCB server

❖ One real time display board is provided at the Plant main gate forthe Public

Monitoring of Indirect Green House Gases:

Page 29: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Learning from EnMS

Non-Conformity : Energy Objective and Target in FAP- Pump House not evidenced. Objective Evidence: Reference Objectives & Target and Action Plans Form no. FORM/MR/104 &105

Corrective and Preventive Action: As the departmental O&T is for Utility area is considered in last year & closed. The new objective & target will be set & status will be monitored. Objective & target will be recorded in FORM/MR/105 & review in MR.

Non-Conformity : The findings of the internal audits though are good and focused on

the energy performance, the closure of these non conformities are based on corrections and not on corrective action and preventive action for non occurrence is not evident

Corrective and Preventive Action: Refresher training was provided on Auditing

process, identification NC's/Observation and subsequent actions to be taken for closure & verification of effectiveness

Minor Non-conformities raised by EnMS External Auditor in last two assessments:

Page 30: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Accreditations / Certifications

The operating facility of Nava Bharat group have been certified withfollowing Accreditations & Certificates for it’s constant endeavor as anEnvironmentally responsible corporate citizen & Strong believer ofCorporate Social Responsibility

ISO 9001 for adhering to stringent international quality norms

ISO 14001 for adhering to environmental management standards

OHSAS 18001 for adhering to stringent Occupational health and safetymanagement system

ISO 50001 for adhering to stringent Energy management system

ISO 9001 ISO 14001 ISO 18001 ISO 50001

9001

Page 31: NAVA BHARAT VENTURES LIMITED...NAVA BHARAT 19th National Award For Excellence in Energy Management - 2018 NAVA BHARAT VENTURES LIMITED 2. Nilan Ku Mohanty - Assistant General Manager

NAVA BHARAT

Environmental concern

❖ Installation of Oil traps: Installation of Oil traps at LDO pump house ,coal stacking system (CSS) , gate-5 area and Unit-3 GT yard

❖ Installation of dust extraction system: Erection and commissioning ofdust extraction system at Unit-2 CHP secondary crusher house

❖ Installation of Ammonia dosing system: Installation of Ammoniadosing system in both the ESP’s of Unit-2 to reduce stack emissions

❖Providing Water Spray System: Providing and enhancing Water SpraySystem for fugitive dust suppression at applicable areas

❖ Installation of Ambient Air Quality Monitoring Stations: Erection of 3no of Ambient Air Quality Monitoring Stations and its RT-DAS

❖ Installation of On-Line Effluent Monitoring System: Installation of On-Line Effluent Monitoring System and real time data transmission to PCB server

❖Providing Atomizing water spray nozzles at ash silos: ProvidingAtomizing water spray nozzles at fly ash and coarse ash Silos

❖ Installation of LPG Liquid Off Take System: Installation of LPG LOT forchrome ore dryer by replacing furnace oil burner system.

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CSR Activities

Education:❖ Providing Grant Aid, Library books , Play and Lab equipments to Brahmani Public

School❖ Donating Furniture and Distribution Of Blankets to Sibapur sevasram students❖ Construction of boundary wall to Government and private schools❖ Development of Play ground and Construction of Toilets in near by schools

Health:❖ Conducting Rural Health , Free Diabetic , Eye Checking , Dental and Blood Donation

Camps❖ Construction of community health center❖ Providing Safe drinking water to the surrounding villagers by installing RO Plant

Livelihood:❖ Plantation of Medicinal plants , Construction of Drains, Installation of Bore well,

Providing Street Lights, Construction of bus shelter, Distribution of disable Aids toDifferently abled persons and Supply of Fly Ash Bricks to villagers and Schools

We make constant efforts for development of communities around our plant and our CSR initiatives focus on Education, Health and Livelihood

In national level, NBVL has been awarded ITC Trophy as the best performer in CSR activities by CII for the year 2017. That shows management’s commitment towards social responsibility.

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Awards & accolades

❖Pollution Control Excellence Award By Odisha SPCB for 2007

❖Prakruthi Mithra award by Odisha Forest and Environ Departmentfor 2011

❖National award as Water Efficient unit by CII for FY 2011 - 12

❖National award as Water Excellent unit by CII for FY 2012 - 13

❖Pollution Control Appreciation Award By Odisha State PCB for2013

❖National award as Energy Efficient unit by CII for FY 2013-14(General Category)

❖Pollution Control Excellence Award By Odisha SPCB for 2015

❖National award as Energy Excellent unit by CII for FY 2015-16(Metal Category)

❖National award as Energy Excellent unit by CII for FY 2016-17(Power Category)

Rewards In the Field of Environment and

Resource Conservation

NBVL has won numerous Awards from prestigious professional bodies & stategovernment for its performance in energy management, water management,environment protection, safety

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Awards & accolades

❖ State Safety award by Odisha –Director of Factories & Boilers for theyear 2007

❖ State Safety award by Odisha –Director of Factories & Boilers for theyear 2008

❖ State Safety award by Odisha –Director of Factories & Boilers for theyear 2009

❖ Best Performance in Safety & Environment Management for the year2011

❖ Kalinga state Safety Award in power category for 2012❖ Best Performance in Safety & Environment Management for the year

2012❖Winner of First prize in Longest Accident free period for the year 2012❖ Best Performance in Safety & Environment Management for the year

2013❖Winner of Second prize in Longest Accident free period for the year

2013❖ 1st Prize for Lowest Severity Rate of Accidents for the year 2014❖ Best Performance in Safety & Environment for the year 2015❖ 1st Prize for Lowest Weighted Frequency Rate of Accidents for the year

2016❖ 2nd Prize for Longest Accident Free Period for the year 2017

Rewards In the Field of Safety, Health and

Environment

Safety Env Energy Water

2007-092011-17

2007201120132015

20132014201520162017 ER

20112012

14 4 5 2

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Energy Conservation Day-2017 celebrations

Group Photo with School Children's Drawing Competition in BPS Competition in Government School Drawing Competition (Colony Kids)

Competition to Workers / Employees Inter Plant Knowledge Exchange Prize Distribution to Winners Rewarding Employee Contribution

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Tree Plantation

Trees remove carbon dioxide from the atmosphere through the natural process of photosynthesis

Hence NBVL taken a initiative towards plantation & development of green belt in and around the Plant area,Peripheral villages and development of social forestry

❖ No. of trees planted so far : 61160❖ Survival percentage : 94.4 %

With the initiatives taken by NBVL in environmental protection and greenery development, the government body andnear by industries prefer to conduct environmental week program in our plant so as to learn from us how to developand protect the plantation.

NBVL Nursery Sapling Distribution to Employees Tree Plantation by IEI Members at NBVL

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Green Belt in and around the Plant

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Green Belt in and around the Plant

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Eco Friendly Environment

Migrating Birds

Migrating Birds

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Thank You for your attention

Water Conservation

Zero Accident

Energy Conservation

Eco Friendly