mahindra sanyo special steel pvt...

1

Mahindra Sanyo Special Steel Pvt Ltd

CII - 18th NATIONAL AWARD FOR

"EXCELLENCE IN ENERGY MANAGEMENT 2017”

Copyright © MSSSPL Elect. Dept. Aug 2017

2Copyright © MSSSPL Elect. Dept. Aug 2017

CONTENTS Company Profile & Process Flow

ISO 50001:2011 – Energy Management System

Specific Energy Consumption (SEC) reduction trend

Bench Marking (Global and National Bench Marking)

Utilization of Renewable Energy Source

GHG Emission reduction trend

Monitoring & Reporting , Implementation Methodology

ENCON Projects Implemented in last 3 years

Road map for next 3 years for ENCON projects

Employee Involvement & Team Work

Utilization of Waste as fuel

Sustainable Supply Chain Management

Innovation Projects

3

Company Profile

Mahindra Sanyo Special Steel Pvt. Ltd (MSSSPL), following a joint venture between MUSCO (51%), Sanyo Special Steel Co., Ltd (29%) and Mitsui & Co., Ltd (20%). • Location : Khopoli, Maharashtra, India• Established : 1962• Employees : ~2400• Business : Manufacturing & sales of special

steel products• Products : As-cast Ingots, CC-rolled products,

rolled & ingot-forged bars, rings


Electric Arc Furnace

Ladle Furnace

Vacuum Degassing

ContinuousCasting

Ingot Casting(Bottom pouring) Forging

Blooming Mill

Bar Mill

Continuous Mill

Heat TreatmentFurnaces

QuenchingTank

StraighteningMachine

Peeling

Inspection

Ring Plant

Dispatch

New Delhi

Kolkata

Chennai

Pune

Mumbai

Khopoli

4

Certification Journey

ISO 9001-Certified in 1993

ISO/TS 16949 -2009 –Re-Certified in 2017

ISO 50001:2011 – Certified in 2013

ISO/TS 16949 -2002 –Re-Certified in 2008

ISO/TS 16949 -2002 –Certified in 2005

ISO 9001 –2000 –Upgradation in 2002

ISO 14001:2015 –Certified

BS OHSAS 18001-2007 –Certified in 2011

ISO 14001 -2004 –Certified in 2010

ISO/IATF 16949:2016 –Audit Completed –Recommended for

CertificationCertification Journey


5

ISO 50001 : Energy Management System Journey

20082011Comprehensive Energy Audit by TERI

Energy Audit by Schneider Electric India Pvt. Ltd

Developed Energy Monitoring and Reporting System

Established Energy Management Policy

Set objectives, targets & action plans

2012

2012

2012

2012

ISO 50001:2011 Certified by TUV 2013

Siemens Audit 2013

Must Do Objective

2014 Measurement & Verification by

Schneider

2015 Re-Certification Audit

2017

2016 Re-Certification Received

A journey of a thousand miles begins with a single step in the right direction


6

Energy Policy & Policy Matrix


S.N. Description

Establishin

g norms for

all process

Capital

expense /

equipment

modification

Sustanbility

/Energy

team/MPRM

/FSC/Goal

sheet

Solar /

wind

energy

External

InternalBEE / MSEDCL / MEDA Budget

1Reduce specific energy

consumption

2Use energy efficient

a) Process

b) Equipment

3 Employee involment

4Information disimenating /

communication

5Establishing energy cons.

Norms

Bench

marking

6 Usage of renevable energy

7 Energy audits

TERI /

Schinder /

TUV/

Internal

8Complying legal

requirements

BEE certified Energy

Auditor & Manager / audit

by accredited auditor /RPO

Fullfill MEDA

9 Resources provisionBudget /

CEP

10Purchase of energy

efficient product

7

Energy Management Team

Top Management MD,COO,CTO,CFO

Management Representative

Energy Manager (BEE Certified

Energy Auditor)

Steel Melting

Shop

Forge Shop

Blooming Mill

Rolling Mill

Heat Treatment

Project & Purchase

PIR/HR

Cross Functional Team –Trained & Certified as Internal Auditor by TUV - Certification Authority

Allocate resourcesManagement ReviewTarget for Energy Performance Indicators

Planning & Implement Energy Management ActivitiesReport Energy Performance to Top Management

Review of Objectives & TargetsGAP Analysis with CFT


8

Energy Policy Deployment


Sl. Description Compliance

1Reduce specific energy

consumption

7 % Electrical Energy reduced in last 3 years

13 % Oil consumption reduced in last 3 years

Use energy efficient▪Optimization of Scrap Mixing & Early foaming started through

use of Lump coke through DRI Belt conveyer

▪ 3 Ladles recirculation, Better insulation practice to avoid

temperature drop after VD

▪ Improvement in Ladle Slag lining

▪HTFS Furnace Revamping

▪LED Light & procurment of Star rated AC'S

▪Transparent sheets on roof tops

▪Theme based Energy Month

▪12 Nos. of TUV certified EnMS internal Auditor

▪ 1 BEE certified Energy Auditor & Manager

▪ External Training : 4 , Internal Training for all shop

▪ Total 45 suggestion have been received & 24 have completed

▪ Daily Power analysis in sunrise/DWM meeting

▪ Aspect Document with Top Management

▪ Sustainability report /Flyer

▪ International Benchmarking with BSE Germany

▪ Shop wise & Grade wise monitoring of Power & Fuel

▪Solar Roof Top 20 KWH plant

▪Wind & Solar power procurement through Open Access

▪TUV Recertification Audit completed in F16

▪TUV Surveillance Audit completed

▪ External & Internal Technical Audit completed

▪ Power survey Report Submitted

▪ RPO fulfillment report submitted to MEDA

▪ Completed capex allotment : HTFS furnace revamping etc.

▪ Future Capex required: LED , CC Pit revamping, Transformer

replacement

▪Procurement of IE3 Motors

▪ Procurement of Star rated AC'S

▪ Procurement of Energy Efficient Transformer

7 Energy audits

a) Process

6 Usage of renewable energy

b) Equipment

2

Employee involvement3

4Information disseminating /

communication

Establishing energy cons.

Norms5

8 Complying legal requirements

9 Resources provision

10Purchase of energy efficient

product

9

Specific Energy Consumption (SEC) Reduction


There Is Continuous Improvement In Specific Energy Consumption.

10

Specific Energy Consumption (SEC) Reduction


10098

9694

91

80

85

90

95

100

F14 F15 F16 F17 F18 Q1

%

Electrical SEC (GJ/MT) reduction trend (%)

100

7969 69 66

30405060708090

100

F14 F15 F16 F17 F18 Q1

%

Thermal SEC (GJ/MT) reduction trend (%)

9 % Reduction

34 % Reduction

Reduction in Specific Power Consumption from 997 to 878 KWH/MTcs• Electrode Regulation in Arc Furnace• Better Ladle Management in Steel

Melting Shop• Reduction in Cycle Time at Arc Furnace• Heat Treatment Furnace Revamping • Energy Efficient Equipment• Best practices at all shops

Reduction in Specific Fuel Consumption from 121 to 86 Ltrs/MTcs

• Oxy- Fuel technology for reheating Furnaces

• Replacement of Recuperator • Efficient Ladle circulation for heat

optimization• Improvement in planning to

optimize heat sequence

11

National & Global Benchmarking Specific Energy Consumption at Steel Melting Shop [KWH/MT]


Commodity Steel

Special Steel BENCHMARK Asia/Pacific

Electrical Arc Furnace = 451 KWH/MT

Ladle Furnace = 64 KWH/MT

Source: BSE Data base 2015

Mahindra Sanyo Electrical Arc Furnace = 454 KWH/MT

Ladle Furnace = 120 KWH/MT**Tool & Die (High Alloy)steel production % higher

12

National & Global Benchmarking

Benchmarking for Electrical Arc Furnace (EAF) Power


Asia /Pacific EAF = 451 KWH/MT

Mahindra SanyoEAF –451 KWH/MT

Source: BSE (Germany) Data base

525

451

501

475

454 451

400

420

440

460

480

500

520

540

Sanyo Asia/Pacific MSSSPL F15 MSSSPL F16 MSSSPL F17 MSSSPL F18 YTD

KW

H/M

T

Benchmarking MSSSPL Journey

13

Renewable Energy


Road Map to Achieve the Target :

1. Installation of 4 MWh Solar Plant ( Roof Top & Ground) within Plant premises

2. Renewable Power procurement through Open Access

[CATEGORY NAME], [VALUE]



Power Utilisation from Different Sources (%)

For FY 18 MTOA Permission is given from July’17 – Total Renewable % will be greater than Plan

Actual

14

GHG Emission


1. Reduction in scope-1 : 30% (7650 MT)

100%

81%

73%70%

40%

50%

60%

70%

80%

90%

100%

FY 14 FY 15 FY 16 FY 17

Scope-1 Emission Reduction 100%

99%

90%87%

70%

80%

90%

100%

FY 14 FY 15 FY 16 FY 17

Scope-2 Emission Reduction

1. Reduction in scope-2 : 13% (9120 MT)

15

Energy Monitoring & Measurement System

• Over 90 state of art energy meters installed in the plant for strengthening the monitoring system . Monitoring through SACADA System provided by Schneider.

• Initiated IoT study for next level automation for process monitoring & control.

• Planning for motor management with advance Technology like SIMOCODE

Overall Energy Consumption Breakup/Month


Steel Melting Shop, [VALUE]Ring Division,

[VALUE]

Blooming Mill, [VALUE]

Heat Treatment & Finishing Shop,

[VALUE]

Forge Shop, [VALUE]

Rolling Mill, [VALUE]

Continous Mill,

[VALUE]

Conditioning, [VALUE]

Miscellaneous, [VALUE]

Utility, [VALUE]

16

Energy Review

Activities Time Slot 15 Min Daily Weekly Monthly Quaterly Half Yearly Annually

Recording

Monitoring

Max Demand Control

Main Receiving Station Shift Incharge

Shift Incharge

Shop HOD/Team

COO

Managing Director

Analysis &

Corrective Action GAP Analysis

Setting Target Shop wise targets

Meetings

Monitoring &

Controlling

112836365No. of reviews in

a year

Top management involvement in day to day activities of energy management . GAP analysis carried out for deviations.


Power & Fuel

Shop Unit Budget F 18 Jun-17 Q1 GAP

A B A vs B

SMS Production MT

KWH/Ton on SMS prod - Varibale Power KWH/T

KWH/Ton on SMS prod - Overall Power KWH/T

SMS MT

EBT KWH/T

LF KWH/T

Auxiliaries KWH/T

SMS - Total KWH/T

CC Pit KWH/T

Blm KWH/T

C Mill

Forge Shop Total KWH/T

Bar-Production MT

Bar - Total KWH/T

Heat Treatment kwh/t (HT + Cnd+ Frg ) KWH/T

Heat Treatment kwh/t (HTFS Fce Only ) KWH/T

SMS -Ltrs / Ton (FO) Ltrs/T

SMS -Ltrs / Ton (Bio Diesel) Ltrs/MT

BLM O2 M3/MT ( Oxy-Fuel Fce 1,2,3,4,5,6) M3/T

BLM Oil Lts/MT ( Oxy-Fuel Fce 1,2,3,4,5,6) Ltrs/T

BLM Oil Lts/MT (Fce 7,8 W/o Oxy Fuel) Ltrs/T

BLM WHF Oil Lts/MT Ltrs/T

Bar Mill - Ltrs / Ton Ltrs/T

Forging - Ltrs / Ton Ltrs/T

Forging ( Fuel Only . Lts/Ton) Ltrs/T

Forging ( Oxygen Only . Lts/Ton) Ltrs/T

Ltr/Ton on SMS prod Ltrs/T

Oil Only Lts/MT in SMS Prod Ltrs/T

Reasons for

variance

17

Energy Projects F 15


Electrical Energy Savings :• 2.7 Mio KWH• 18.9 Mio Rs• 2214 Tons CO2

S.N Name of Project (Electrical Energy)

Annual Electrical Saving achieved (KWH Mio)

Total annual saving (Rs Mio)

Investment Made (Rs Mio)

Tons of CO2 Mitigated (Tons CO2)

Paybacks (Year)

1 Heat Treatment cycle time reduction for another 8 grades(HTFS) 0.02 0.11 0 12.6 Immediate

2 Switching of continuous mill transformer whenever plant is off for more than a shift 0.01 0.04 0 5.04 Immediate

3 Saving on HT relay coordination (plant Electrical) 0.02 0.13 0 15.06 Immediate

4 Impeller trimming in 110 KW cold well pump 0.06 0.42 0.01 48.38 Immediate

6 MD monitoring through PLC and SCADA system(SMS) 1.44 10.36 0.3 1205.82 0.002

7 EBT Electrode regulation (SMS) 0.79 5.68 11.66 661.21 0.22

8 Blooming Mill reheating furnace no.3 & 4-Incoopertion of Oxy fuel Technology 0.3 2.17 5.77 252 0.41

9 Transperent sheets in plant roof (Total Plant) 0.01 0.04 0.05 5.04 1.17

10 VFD for combustion blower of Forging chamber furnace 0.01 0.08 0.02 9.66 2.89

Total 2.66 19.03 17.81 2214.81 0.94

S.N Name of Project (Thermal Energy) Annual Thermal Saving achieved (KL)


Invest Made (Rs Mio)


Paybacks (year)

1 Blooming Mill reheating furnace no.3 & 4-Incoopertion of Oxy fuel Technology 445 12.02 5.77 1188 0.41

Total 445 12.02 5.77 1188 0.41

Thermal Energy Savings :• 3993 KL • 140.5 Mio Rs• 11860 Tons CO2

18


*Note : Savings mentioned for F 16 includes projects, suggestions, EnMS process controls and best practices .




Total annual saving (RsMio)



Paybacks (Year)

1 Impeller Trimming Cold Well Pump House 0.1 0.8 0.01 120 Immediate

2 LF Cycle time reduction 2.8 19.5 0 2790 Immediate

3Electrode Regulation SMS and effect of scrap Mix , delays & operational factors. 3.1 22 0 3140 Immediate

4 Pipeline modification from Scale pit pump house 0.1 0.8 0 121 Immediate

5 HTFS Power reduction through furnace revamping 0.1 0.5 0.1 70 26 Modification of HT Breaker 0 0 0.05 5 19

7Replacement of incandescent lights . 145 Nos 40 W lights replaced with T5 Lights 0.004 0.03 0.15 4 57Total 6.2 43.63 0.31 6250





Paybacks (year)

1 Oxy Fuel for BLM Furnaces no. 5 & 6 445 12.02 5.77 1188 0.41

Total 445 12.02 5.77 1188 0.41



Renewable Energy (Wind+ Solar + RPO) • 5.8% of

total power

19


*Note : Savings mentioned for F 17 includes projects, suggestions, EnMS process controls and best practices .




Total annual saving (RsMio)



Paybacks (Months)

1Optimization of Scrap Mix, Early Foaming started through use of Lump coke in EAF 2.08 15.0 0 1700 Immediate

2LF Cycle time reduction & Better insulation practice to avoid Temp. drop after Vacuum Degassing 0.96 6.92 0 787 Immediate

3HTFS Furnace Revamping & Refractory work

0.6 4.29 1.25 490 4

4Installation of Energy Efficient Equipment like Transformer, LED Light , Star rated AC’S, IE3 Motors 0.04 0.27 1.02 35 22

5 KAIZENS, Suggestion, Best Practices 0.03 0.21 0 25 Immediate

Total 3.7 26.0 2.27 3030





Paybacks (Months)

1

Replacement of Old Manifold with new result in Delay reduction, Saving in Oil consumption at FRG Shop

263 6.05 2.50 800 5

2Modification of Burner Block in Furnace at FRG shop

176 4.04 0.25 530 1

Total 439 10.09 2.75 1330



Renewable Energy (Wind+ Solar) • 6.95% of total

power

Cumulative Saving from FY 15 to FY 17

Electricity MIO Kwh 14

Fuel KL 5869

T-CO2 MT 28523

Cost Mio Rs. 276

20

Energy Projects F 18– 20

Road Map from FY 18 - FY 22

1. Reduce Specific Power Consumption by 20 % 2. Reduce Specific Fuel Consumption by 35 %3. Utilization of Renewable Energy : 20 % of

total power consumption4. Reduction of Scope-1 emission by 35 %5. Reduction of Scope -2 emission by 40 %

* Base year is FY 13


Projects F 18 F 19 F 20

Control Cooling Pit Revamping –BLM & FRG

Solar Power 4 MW Installation

Waste Heat Recovery

Natural Gas – All reheating Furnace

Sl.No. Projects Description Estimated Saving (MU/Year)

Estimated Tons of CO2 Mitigated(T CO2/Year)

1.Waste Heat recovery for Power Generation from EBT Furnace waste flue gases

8.64 7084

2. Control Cooling Pit Revamping at Blooming Mill & Forge Shop 0.92 755

3. Installation of Solar Plant of 4 MWh in Plant premises 6.96 5700

4. Natural Gas for all reheating Furnace instead of Furnace Oil 0.6 3200

21Shaswati Council Meeting

Energy Month Celebrations

Team Work In Energy Conservation

Cross Functional Teams


Energy Team

Shop Floor Training for Energy Conservation

Nos. of KAIZENS during FY 17 : 346

Nos. of suggestions received during Energy

Month : 45

Total suggestions implemented : 24

Total saving achieved after implementation all

suggestions : 34641 KWH/Year

22

Utilization of Waste as Fuel


Waste Utilization Process Flow

Canteen Food Waste Waste Transport

Bio Gas generation

& Storage Gen-SetStreet Lighting

23

Utilization of Waste as Fuel


Food Waste Utilization For Promoting Green & Clean Energy –

MSSSPL has initiated food waste utilization drive in collaboration with KMC (Khopoli Municipal Corporation) –To generate Electricity from Food Waste.

MSSSPL Contribution

KMC Responsibility Waste collection- 0.3 T / Day

Waste transfer to KCM Facility Waste segregation Gas generation Electricity generation Plant Capacity

Energy saved by recycle of waste during FY 17

Total Refractories Recycle = 423 MT

Total Power saved under scope III at manufacturing end =100674 KWH (238 KWH/MT Specific Electricity Consumption)

Total Mill Scale Recycle = 4626 MT

Total Power saved = 9252 KWH

24

Aspect Vision

Scope - 1 emission reduction by 10%



Water consumption reduction by 10%

Collaborate to have environmentally and socially responsible suppliers only

Mode of Engagement


Organized sector 7 workshops65% Tier I Suppliers engaged

Capacity Building & Alignment, Deep Engagement

Unorganized Sector4Workshops + 2Follow-up sessions

25 Tier-1 Suppliers engaged

Capacity Building through Story Telling, Mitigation of Social Hotspots

Sustainable Supply Chain Management

25

Sustainable Supply Chain Policy and CoC in placed

Collection of baseline data and audit framework in place

Use Of SoFi for supplier data base

Capacity Building of Suppliers through supplier meet

Best Supplier award

collaborative projects based on circular economy

Participating in Road Testing of a GHG footprinting tool by India GHGP and

Climate Miles

Creating a pool of certified Internal Auditors on BS 8903 Framework


Actions & Initiatives


Innovation Project 1 Resource Intensity & Recycle Input – Improved Liquid Metal Yield (%)

Action taken for Improved Liquid Metal Yield1. Controlling of Scrap Quality wrt contamination and density2. Preventing over oxidised of bath by controlling oxygen during Melting &

Injecting more carbon.3. Use of Smaller Slag Pot for Liquid Metal dumping after Casting.

Need of the Moment : To recycle waste efficiently and promptly so as to save time, energy and environment.

Specific Contribution: The recovery time of Skull was drastically reduced, ease of recovery increased, liquid metal wastage reduced.

Method Implemented: As compared to earlier, where the liquid metal was directly dumped on the ground, Now collecting the liquid metal in small slag pots and then using the solidified mass for steel making helped to achieve the specific contributions as mentioned above.

27

Results

Innovation Description: Earlier, process involved dumping of liquid metal on ground after casting. This

process led to formation of irregular skull and inclusion of dust in the skull hence making the recovery hard.

The recovery of skull consumed more time and also it required Oxygen to cut that skull.

After the introduction of small slag pots, the dust contamination and irregularities in shape were diminished & Recovery time reduced

In future, direct hot metal can be used to charge back in Electrical Arc Furnace to decrease power greatly while increasing efficiency.


Average Yield Improvement (%) 1%

Reduction in Electrical Arc Furnace Power (KWH/MT) 3

Power saving /Year (KWH) 4,80,000

Cost saving / Year (MIO Rs.) 3.36

Reduction in CO2 Emission (T-CO2 )/Year 394


After Implementation

250X200 ɸ Cast No-CXXXX

Grade- XYZ


Grade- XYZ


Grade- XYZ

Dummy Bloom

160x160 ɸ

250X200 ɸ Cast No-CXXYY

Grade- ABC


Grade- ABC


Grade- ABC

FURNACE (20 T)To Roller Table for Rolling Process

Dummy Bloom is removed with help of crane


Grade- XYZ


Grade- XYZ


Grade- XYZ


Grade- XYZ


Grade- ABC


Grade- ABC

FURNACE (20 T)To Roller Table for Rolling Process

Innovation Project 2 :

Reduce use of cast separator (partition) of Continuous Casting Route Material in

Furnace

29

Project Details


Before After implementation

A dummy Bloom of lesser size is used to identify / Separate two different cast charge in Furnace

A smaller tapper cut on both ends in last Bloom of each heat cast in Continuous Casting Route material Now we are charging such Bloom at

end of cast & it is use to identify /separate cast charge in furnace.

Benefits :Average Rolling /Month = 4800 MT Average Dummy Bloom / Month = 150 Nos.Average Wt. of Partition = 250 KGTotal Wt. / Month = 37.5 MTTotal Oil Saving /Month = 1.5 KL @ 40 Ltrs/MTTotal Oil Saving /Year = 18 KL Cost Saving /Year = 5.4 LakhsT-CO2 reduced / Year = 55 MTAlso it leads to Human Safety - Reduce work in Hot Condition

30

Innovation Project 3

Replacement of Housing Colony Transformer


As per previous records we can reach to a conclusion that we have almost achieved savings at major areas so after brain storming we have decided to go for further energy losses in equipment section. Major gateways of power to an industry are power transformers. So we have started analysis of power transformers.

After Power analysis & Test report – Concluded to replace 1000 KVA Transformer

Problems Addressed : Transformer is 48 years old – outdoor open bushing type transformerAs per test report – Furan content found more than 2.5 mm/Kg, Which is not permissible limitTransformer Loading – 20 %, Breakdown were more, Total Loss -825 Min.No- load loss – 2000 W & Load Loss – 7000 W

Conclusion Drawn : As Transformer is 20 % loaded – Decided to Install 500 KVA Transformer


Before After

RESULTTransformer Capacity : 1000 KVATransformer Loading : 20 %Transformer No-Load Loss : 2 KWHTransformer Load Loss : 7 KWHBreakdown Time : 825 Minutes

(Past Three years Data)

500 KVA60 %0.8 KWH3.2 KWH0 Minutes (1 year Data)Yearly Power saving of 8500 KWHCost Saving : Rs. 60,000T-Co2 saved : 7 MT

32

Water Management Resulted In Energy Saving

Initiatives taken to reduce specific water consumption

Use of STP treated water for industrial top up after filtration Underground piping is taken above ground Rain water harvesting

More than 400 hrs.

Pumping Saved per year

23,011 Kwh /Year

Energy Saved

Results :

Total Water withdrawal decreased by 13%

Specific Water consumption per ton of production Improved by 25%


33

MSSSPL | Awards & Recognitions


16th National Award for Excellence in Energy Management 2015:Energy Efficient Unit in Steel Sector & Most useful presentation in Steel

Sector

17th National Award for Excellence in Energy Management 2016:Excellent Energy Efficient Unit in Steel Sector & Most useful presentation in

Steel Sector

Article on Best Practices case study at MSSSPL had been published in Institute of Industrial Productivity –BEE NEWSLETTER magazine

34

MSSSPL | Awards & Recognitions

Excellence in Energy

Management 2015 & 2016Energy Efficient Unit

Game Changer Award

2015

Mahindra Sustainability

Award 2013

Innovation Award

2015

Best Improved Plant

Safety 2014



Way ahead..

Mahindra Sanyo becomes 1st steel

company from India to signed SBT Commitment

in March 2017

Announce Science Based Target for

Mahindra Sanyo by March 2018

To anticipate government legislation on carbon pricing To avoid intermediary/transaction costs associated with

trading permits in national schemes in favor of factoring in these prices internally

To justify investments that may have smaller margins without a carbon price

To manage risk for future investments To monetize and record social cost

Internal Carbon Pricing

mahindra sanyo special steel pvt...

Documents