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