Bijay Kumar Agrawal
Head(Electrical), CEA(EA-11295)
S.K Sahoo, Manager(Operation)
S.B.Mohanty, Dy. Manager (Mechanical)
Energy Management Practices at Tata Sponge
DRI Capacity : 390,000 MT/Yr Power Generation: 26 MW
Consistently earning YoY profits for the past 20 years & paying dividends
1st DRI Company to receive TPM Certification in the World.
First DRI company to earn CDM benefits
Frost & Sullivan Green Manufacturing Award (Gold Category)
First DRI company to be certified in ISO-9001, ISO 14001 & OHSAS 18001 16 safety awards, 4 appreciation on
CG, 2 on HR, 1 on value creation,….
Energy Conservation award from CII (ER) for 2013-14
13 on Quality {4 from CII (ER)} 15 awards on Environmental care
Tata Sponge Fact File
1
3
1
2 3
4 4
2
5
1
1
Thermal Energy Use/Loss
Electrical Energy
WHR/Power Gen/Export
Manufacturing Process
Energy Management
WITH WHAT (Philosophies & Tools)
•Rotary Kiln equipment •Power plant equipment. • 220KV System equipment •Right Mix of Coal Procurement •TPM Methodology/ Statistical Tools
INPUTS
• BEE/PAT Targets in ToE • Energy Policy • Energy Audit recommendations • Best Practices & Benchmarks
HOW (Procedures & Methods)
• Energy Awareness Campaign • Approach to Energy Efficiency Improvement
Activities • Implementation of energy audit
recommendations • IT Based Systems (KPI tracking, ERP) • Automations to check energy wastage
WITH WHOM (Competence/Support)
• Support from Promoter • 3 level structure • Competent & skilled Workforce • Professional Consultants
WHAT RESULTS
OUTPUTS
• Reduction in Sp. Energy consumption • Compliance to PAT target • Reduction in tCO2 emission per ton of
DRI
Reduction in C/Fe Ratio Increase in Power Export to Grid
Reduction in Coal per ton of DRI
Reduction in SEC(Elec),
Sp. Steam Consumption
Reduction in SEC (Thermal)
Effi
cie
ncy
Effe
ctiv
e
The “Q” Approach
• Baseline SEC : 0.581 ToE /MT of SI
• Target SEC : 0.551ToE /MT of SI
• Baseline production : 359333MT
• PAT cycle :2012-2015
Y1 Y2 Y3
SE
C Baseline SEC
Target SEC Reduction in SEC
PAT SEC reduction target by BEE
As an energy intense manufacturer of Sponge Iron through Coal based DRI Kilns & Power Generation through WHRB strives to reduce its energy consumption and costs and promote the long-term environmental and economic sustainability of its operations.
We are committed to:
Reduce energy use per ton of production by 7.5 % in 5 years in our operations.
Ensure continual improvement in our energy performance.
Deploy information and resources to achieve our objectives and targets.
Uphold legal and other requirements regarding energy.
Consider energy performance improvements in design and modification of our facilities, equipment, systems and processes.
Effectively procure and utilize energy-efficient products and services.
Managing Director
Tata Sponge
Energy Policy
A
Managing Director
Energy Auditor
Production
Power Plant
Maintenance & Utilities
Core Group1 Core Group2 Core Group3 Core Group 4
Working Group
Working Group
Working Group
Working Group
Chief Operating Officer
3 Levels Energy Team Structure
•Assign role & responsibilities •Gather & Prepare promotional materials •Launch programme
Planning
Implementation
Checking & Review
Maintaining
•Support & Resources •Current level •Target Audience •Message & communication Channel
•Compare present energy consumption level with target level •Measure the success of the programme •Feedback •Report to staff & Management
•Energy awareness section in start up kit to new employees •Maintaining the momentum •Campaign tool: suggestion scheme, competition, reward & recognition,
Process for Energy Awareness Campaign
Awareness Training on ISO 50001(EnMS)
3 days in-house training on awareness on ISO 50001 conducted
25 persons from various functional areas participated
Effectiveness of the training was evaluated through a test
Implementation plan was formulated & it is in progress.
BSI Certified Lead Auditors for ISO 50001 EnMS: 2 nos
Various forms & formats were developed as a part of implementation of the EnMS
• External Energy Audits • PAT Targets/Obligation • ISO 50001 methodology • Best Practices/Benchmark • Climate Change Policy • New Technologies • Training
Target achieved?
No
R&R
Training
Upload in Knowledge Portal
Approach to Energy Efficiency Improvement Activities
Yes
Check & Review
Daily review through KPI Tracker, ERP/SAP, Fortnightly review by COO(SB) Monthly review by MD
Mapping of Energy Consumptions(Electrical & Thermal)
Identifying Thermal & Electrical Energy Losses
Formulation & Prioritization of Action plans for both Thermal &
Electrical ENCON projects
Form C F Team for Implementation of the ENCON Projects
Data Collection
Analysis of Energy losses
Develop Kaizen Ideas for ENCON
Prioritization of options & kaizen Implementation
• Replacement of Impeller of Kiln #2 ID fan motor (3.3KV,260KW motor)
• Replacement of under loaded LT motors with correct size motors of DE system of Kiln#1 & Kiln#3
• Auto Operation of Cooling Tower fan motors (2X22KW) of Kiln#3 with Sponge Temperature.
• VFDs for pump motors running in throttled condition( 2X90 KW Hot Well Pump Motor & Cold well pump motor of Kiln#3)
• Different VFD panels for odd & even set of SAB motors of Kiln#1
• Delta to star connection for cooling tower motors (2X15KW)of Kiln #1
• Use of day light in mechanical workshop & conveyor galleries by replacing some of the GC sheets with transparent sheets.
• Improvement of power factors at MCC level and maintain at >0.95
• Lighting control through timers.
Encon Projects(illustrative) implemented-Electrical Energy
• Use of 100% South Africa Coal (both feed & injection) and use of 0-3
mm fines in feed side without rejecting any fines. Changing the coal ratio
from 60:40 to 45:55 (feed: injection) (Period 15th Jun'2014 to Till date)
• Kiln Shell Painting with heat resistant Paint to reduce the radiation
temperature by 20 degree cent.
• Covering the coal heap from exposure to moisture at Paradeep Port to
reduce moisture absorption.
• Covering the coal heap at TSIL yard to reduce wind loss.(0.19% in
2014-15 from 0.31% in 2013-14)
• Covering coal in transit (wagon & truck) to reduce loss. (Transit loss
reduced from 1.08% in 2013-14 to 0..55% in 2014-15 )
• Use of "Thermact" as additives in feed coals for proper combustion of
coal inside the Kiln-2(efficiency improvement)
• Top Management’s involvement in enhancing productivity. Operative plants at more than
design value( daily production is ranging between 1250 to 1350 MT /day against design
capacity of 1250MT/day, 7.8 MW from 7.5MW PP and 19.2MW from 18.5MW PP)
Encon Projects(illustrative) implemented-Thermal Energy
After application of Heat Shield
Paint on the kiln shell
Arrangement showing feeding of
Thermact (catalyst) inside the Kiln
Covering of Coal at Yard
Brining Coal in covered wagon Covering of Coal
at Paradip Port
Snap Shot of the KPI tracking system
0.465 0.460
0.454 0.451 0.447
0.438
0.428
0.420
0.390
0.400
0.410
0.420
0.430
0.440
0.450
0.460
0.470
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16(Upto
Dec'15)
2015-16(Target)
Rat
io
Carbon to Iron(C/Fe) Ratio Good
Lead/KPI/Efficiency Measures
1.242 1.26 1.281 1.208
1.112
0.892 0.888 0.85
0
0.2
0.4
0.6
0.8
1
1.2
1.4
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16(Upto
Dec'15)
2015-16(Target)
MT
of
Co
al /
MT
of
DR
I Specific Coal consumption(Ground) per ton of DRI
Good
Lead/KPI/Efficiency Measures, Contd..
1.091 1.052 1.03
0.983 0.974 0.863 0.843 0.85
0
0.2
0.4
0.6
0.8
1
1.2
1.4
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16(Upto
Dec'15)
2015-16(Target)
MT
of
Co
al /
MT
of
DR
I Specific Coal consumption(Fed to Kiln) per ton of DRI
Good
Lead/KPI/Efficiency Measures, Contd..
4.38
4.30
4.25
4.20 4.20
4.1
4.15
4.2
4.25
4.3
4.35
4.4
2012-13 2013-14 2014-15 2015-16 (UptoDec'15)
2015-16 (Target)
Ste
am in
To
n/M
W
Specific Steam consumption (7.5MW Power Plant)
Lead/KPI/Efficiency Measures, Contd..
Good
4.37
4.14 4.11 4.11
4.05
3.8
3.9
4
4.1
4.2
4.3
4.4
2012-13 2013-14 2014-15 2015-16 (UptoDec'15)
2015-16 (Target)
Ste
am in
To
n/M
W
Specific Steam consumption (18.5MW Power Plant)
Lead/KPI/Efficiency Measures, Contd..
Good
Lag/KPM/Effective Measures, Contd…
0.575 0.570
0.567
0.540 0.540
0.520
0.530
0.540
0.550
0.560
0.570
0.580
2012-13 2013-14 2014-15 2015-16 (UptoDec'15)
2015-16 (Traget)
Kca
l/K
g o
f D
RI
Specific Thermal Energy Fed to kiln(Kcal/Kg of DRI) Good
100.54
94 92.42
86 85
75
80
85
90
95
100
105
2012-13 2013-14 2014-15 2015-16(Upto Dec'15)
2015-16(Target)
kWh
/MT
of
DR
I
Specific Electrical Energy Consumption
Lag/KPM/Effective Measures, Contd…
Good
Lag/KPM/Effective Measures, Contd…
123.78
140.91
121.42
81.08
131
0
20
40
60
80
100
120
140
160
2012-13 2013-14 2014-15 2015-16 (UptoDec'15)
2015-16 (Target)
Mill
ion
Un
its
Power Export
Good
30.4
28.8
24.9
22
20
22
24
26
28
30
2012-13 2013-14 2014-15 2015-16(Target)
MJ/
MT
of
SI
Specific Energy Consumption (MJ/MT) including losses
Good
Status of Specific Energy Consumption (SEC) achieved as per M&V
report under Perform Achieve Trade(PAT) methodology
We are the only Designated Consumer under Iron & Steel sector in Odisha state
who has submitted all the requirements of PAT compliance within deadline
of 30th Jun’15 .
Total DCs under Iron & Steel sector:- India:67nos ; Orissa:15 nos
Notified Baseline SEC: 0.581ToE/MT
Notified target SEC: 0.551 ToE/MT.
Reduction target: 0.03ToE/MT
Over Achieved SEC reduction target.
We have claimed quite a good nos of Energy Saving Certificates for our effort.
1.97
1.91
1.87 1.85 1.85
1.83 1.8
1.75
1.8
1.85
1.9
1.95
2
2.05
2.1
2.15
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16(Target)
tCO
2/t
of
DR
I
Good CO2 emission
Environmental Concerns
The following pilot projects have been taken up with the help of external
agencies to improve thermal energy efficiency of the plant.
1) Working further with supplier to improve life of the paint to reduce the
radiation loss.
2) Exploring technological options (Oxygen Enrichment) to improve utilization
of Thermal Energy.
3) Exploring technological options for recovery of heat which is being lost
a)from exhaust gas (which is at 170-180°C )
b)Indirect cooling of product from 1050°C to 100°C
ENCON Projects- Ongoing
Thank You