JSW Steel Ltd Tarapur

For a greener tomorrow JSW Steel is synonymous with high quality Galvanized Steel Products (GP). The Tarapur unit, has an annual sales turnover of more than Rs. 1600 crore and is one of the Quality-conscious units of this conglomerate. With several six-sigma projects currently on and many more in the pipeline, JSW aspires to continuously raise the benchmark, thereby reducing wastage and conserving the depleting resources. Our products meet worldclass benchmarks and more than 80% is exported. As an organization we understand the importance of conservation of natural resources. Our EMS (Environment Management System) policy also lays emphasis on this. We declare different yearly mottos like EARN for the year 2001-02, TURNAROUND for the year 2002-03, FOCUS for the year 2003-04 and PRAGATI for the year 2004-05 under which we improvise our own saving targets over and above the budgeted norms which give motivation and guidelines to achieve exacting standards. Energy Conservation / power saving has been a prime area of focus. These efforts have resulted in substantial savings which are to the tune of Rs. 245.10 Lakh in FY 03-04 without much investment but simply by optimizing the power consumption in different processes. For conservation of energy we are consistently exploring all the possibilities. For example, in blowers we have installed AC Drives, and instead of running individual Boilers at process areas for steam production, the WHRB installed in DG Set (Captive Power) compound supplies it centrally. Further, installation of lighting transformers, planning our shutdown for maintenance in the peak hours so as to avail maximum benefit as per MSEB tariff, provision of steam heating in coolant tank for rolling mill instead of electrical heaters et al, have all helped to reduce the overall energy consumption. To synchronize all the energy activities we have constituted an Energy Conservation Cell that gives impetus to all the energy conservation related activities.

Looking at the undiverted focus and immense effort that JSW Steel, Tarapur, puts in conserving energy, we believe that we are the most eligible for this award.

Brief Summary of Steps Taken to Conserve Energy at JSW

1. Switch over from energy consuming DC to energy efficient AC motors in Galvanizing Line 1

2. Use of AC drives and energy-efficient motors with common DC bus in the new projects also (one Galvanizing line and one Colour Coating Line)

AC motors in newly commissioned Colour Coating Line

3. Variable speed (VVVF) drives installed for all major fans/blowers and compressors

4. Provided VVVF drive with PID closed loop control for cooling blower after galvanizing

Drive retrofitted in panel replacing Soft Starter

5. Replaced Galvanizing line furnace brick-lining with glass-wool block insulation

Oven insulation changed

6. Replaced electrically heated Vaporizer for LPG with special heatless vaporizer which runs on normal water

Heatless Vaporizer in LPG Yard

7. Shut down standby Ammonia cracker in Galvanizing Line 1

8. Replaced existing Ammonia cracker brick lining with special insulating blocks in Galvanizing Line 2

Ammonia Cracker in GL-2

9. Lighting energy-saver transformer with panel was installed for all the shed lighting as well as street lights

Lighting Transformer

10. Use of energy saving devices like electronic fan regulators, programmable timers, LCD monitors
LCD monitors have replaced conventional CRTs

11. Translucent sheets for natural illumination inside sheds

Translucent Shed Panels Transparent panels

12. Huge glass windows in rooms allow daylight to permeate through, negating the need for any lighting during day hours.

Main Office

13. Software program developed to switch off energy intensive loads during breakdown and line-stop, automatically

Easy, GUI based PLC program

14. Replaced 3x30kW motors for hydraulic pumps with 1x37kW motor with AC drive

15. Converted lightly loaded motors from delta to star after a complete analysis

Replaced with smaller motors and changed delta to star

16. Converted Accumulators Hydraulic operation to AC drive controlled Electrical operation

AC Drive controlled accumulator in Colour Coating Line

17. Installed 3 WHRB in the DG sets and CCL to recover waste heat

2 Waste Heat Recovery Boilers

18. Chimney height increased to reduce load on ID Fan

Increased chimney height

19. Compressor bank to meet the compressed air demand of Galvanising Line 1 and 2 centrally.

20. Regular audits were carried out for water and compressed air consumption 21. Maintenance of compressor is carried out regularly based on volumetric efficiency

Compressor Bank

22. Vermiculture is being carried out in the premises 23. Rain Water Harvesting (figures per year) Supply of Rain Water in 30 acre campus is 3,00,000 kL Water Demand in plant is 2,50,000 kL Surplus of 50,000 kL Helps meet plant requirement during 4 6 months a year

Vermiculture Pits

24. All the 2x40W tube light fittings were replaced with 1x36W energy-efficient fluorescent lamps 25. HPMV lamps were replaced with HPSV lamps of less wattage, wherever possible 26. Rearranged power distribution system for optimum utilization of captive power generation 27. Laid one more power cable between Power Plant and Substation to reduce cable losses. 28. Replaced obsolete and inefficient fans and pumps 29. Prime Mover Optimization in all units 30. Optimization of speed of fans and blowers as per system requirement 31. Developing and popularizing other general energy conservation technologies and Six Sigma Projects which have demonstrated their maturity and remarkable economic benefits.

32. Extensive training of all personnel in Handling equipment Energy saving methods 33. Training of employees family members for domestic energy conservation

I think it should be switched OF F when not in use

ID Fan
takes

72 units / hour
or

34. Motivating the workers to save energy through small group and project team activities

Rs. 288 / hour

*@

35. Increasing awareness amongst the workers by putting placards on the motors

Rs. 4 / unit

To focus on Savings is to focus on Effectiveness

Prototype placard that was put on power-intensive motors

Management Initiatives 36. Maintaining an environment of Coordination and Collaboration organization Cooperation, within the

Thus, squabbles are minimised reduced time needed to manage them. That is, we try not to waste our energy. Instead, we aim to utilise it constructively. 37. Developing an environment of Switched On people who WILL NOT WASTE TIME.

Conclusion JSW realizes the importance of energy conservation, especially in the wake of increasing energy demands and dwindling resources. Consequently, it sincerely attempts to reduce its energy consumption and does not hesitate to invest in the latest technology which helps towards this end. It also believes in developing and sustaining an environment of increased learning and awareness so that each and every employee understands the Energy Scenario and does his bit to conserve energy, not only in the plant but also at home.

Project A

This Project comprises of two sub-projects: 1. Saving in Plant Auxiliary Power Consumption, and 2. Power Saving in TM 4 and TM 5 rolling mills

Sub-project I The Project Charter giving the Background, Objective and other details, is given hereunder.

Sub-project II

Project Impact
Reference power consumption as per project charter

Status for reference is as tabulated below ( average of April to Oct. 2004 ) : UNIT Bud. Power Actual Power. CR Thi. CR Width Savings Production. TM4 149.6 U/Mt 135.4 U/Mt 0.275 mm 926.7 mm 14.2 U/Mt 9182 Mt/m TM5 86.57 U/Mt 83.4 U/Mt 0.711 mm1197.0 mm 3.17U/Mt 16640 Mt/m
Actual power consumption and savings for the month of April 05

Savings Production. UNIT Bud.Pow Act. Pow. CR Thi. CR Width Savings Net TM4 186 U/Mt166 U/Mt 0.22 mm 939 mm 20 U/Mt 5.8 U/Mt 1.18 Lac 7537 Mt/m TM5 114 U/Mt 107 U/Mt 0.57 mm 1057 mm 7 U/Mt 3.83 U/Mt 1.56 Lac 15099 Mt/m
Annual benefit : 32 Lac

Proposed Savings ( Units/Mt )

Annual Production ( Mt )

Annual Power Savings ( Units )

Proposed Annual Savings @ 2.85 Rs/Unit ( lakh Rs. ) 5.01

TM4 Mill

87844

175688

TM5 Mill Total

196820

393640

11.22

284664

569328

16.23

Project B Project Name: Conservation of Energy in Colour Coating Line Background This line was commissioned very recently (July 2005). In the beginning the wastage (of time, energy, money) was very high. The workers were relatively new. Systems were not in place. The running line had not stabilized its operation. It was new and as is the case with new lines, it takes time to get into the groove. However, along with this came the opportunity of drastic savings by some very simple measures and steps. The scope of savings was huge and therefore it was decided to take up this project to save energy in CCL.

Steps taken Changed shed lights in Shed 2 (where white-light is not of importance) from 400W HPMV to 250W HPSV lamps The ID Fan was pre-fitted with a soft starter (as part of turnkey project). This was replaced with a VVVF drive. Replaced the spare water-cooled compressor with an air-cooled compressor. This allows us to switch off the 75kW pump house motor used for water cooling. We have tried to standardize operations by clearly defining all the steps in any process. We have also tried to improve the Quality of our product, by reducing defects, thereby leading to less wastage. Training programs along with awareness drives have slowly but surely demonstrated their benefits by way of reduced power consumption (35kWh/mT reduction).

Illustrative Analysis for ID Fan Drive Saving incurred due to installation of 160kW ID Fan Drive

Energy Consumed Before Drve After Drive 2328 1616 712 Saving per ton = =

Actual Prod 214 201 21360 3.39 13.56

Approx Prod 210 210 85440 kWh/ton Rs/ton

kWh/ton 11.09 7.70

Assuming an average production of 200 tons in a day, Saving is = 678.10 kWh = Rs. 2712.38 per day Saving of Rs. 80,000 per month

Impact of Implementation S.No 1 2 3 Action taken Installation of AC Drive for ID Fan Drive Installation of Air-cooled compressor Awareness drives etc. reduced power cons. by 35kWh/mt Saving in Kwh/month 20340 6120 140000 Saving in Rs./month 81360 24480 560000

TOTAL

1,66,460

6,65,840

Project C

Project Name: Installation of VVVF Drives in place of Soft Starters in the plant

Background There were several motors (small and large) which were running from Soft Starters in our plant. However, as the universal demand for energy has increased and the need for some serious Energy Conservation measures was felt, it was decided to undertake a project in which we would replace the Soft Starters of certain motors with VVVF drives. This would not only help in reducing the power consumption but also provide for better speed-torque control of the motor. In spite of the investment-intensive character of this project, it was taken up since it would benefit everybody in the long run.

Observations, Technical and Financial Analysis Several motors such as the 160 kW ID Fan, 75 kW and 160 kW Air Knife fans, 132 kW and several 37 kW blowers in Galvanizing Lines 1, 2 and 3 were throttled in suction (damper was kept half closed to reduce load) and also consuming heavy power during the process. On the other hand, if drives were installed for all these it was calculated that the total power consumption would reduce significantly even after opening the damper fully. Assuming a 20% reduction in power consumed, the ROI was calculated to be 6 months.

Motor Rating 22kW (with panel) 160kW (with panel) 110kW (with panel) 160kW 55kW 110kW Total

Quantity 3 1 1 1 1 1 8

Investment for Drive 4 lakh 6 lakh 4 lakh 4 lakh 2 lakh 3 lakh 23 lakh

Savings/month Rs. 50,000 Rs. 1,00,000 Rs. 60,000 Rs. 60,000 Rs. 30,000 Rs. 40,000 Rs. 3,40,000

Savings/year Rs. 6,00,000 Rs. 12,00,000 Rs. 7,20,000 Rs. 7,20,000 Rs. 3,60,000 Rs. 4,80,000 Rs. 40,80,000

Impact of the Implementation The power consumption of these motors reduced by 32% It was decided that the new Colour Coating Line would be commissioned with the latest Allen Bradleys PowerFlex 700 AC drives, unlike the other sections which have DC drives.