Bhushan Steel Ltd. Khopoli - Knowledge Platform...Bhushan Steel Ltd. Khopoli Bhushan Steel Ltd is...
Transcript of Bhushan Steel Ltd. Khopoli - Knowledge Platform...Bhushan Steel Ltd. Khopoli Bhushan Steel Ltd is...
Our Products :-
• Precision Tubes
• Colour Coated Steel
• CR Steel/Strips/Sheet/Coil
• CR alloy Coated Strip/Sheet
• High Tensile Steel Strapping
• Hardened and Tempered CR
Steel Strips
•Large Dia. Pipe (Bare &
Coated)
Baseline Parameters Identified by
BEE Baseline
SEC (Yr-2014-15) 0.0367 mtoe /ton
Target SEC (Yr-2018-19) 0.0345
mtoe/ton
Bhushan Steel Ltd. Khopoli
Bhushan Steel Ltd is one of the prominent players in the
Indian Steel industry. Backed with more than 27 years of
experience, we are now India's 3rd largest Secondary Steel
Producing Company with an existing steel production
capacity of 5.6 million ton per annum.
As one of the largest integrated steel players in India, BSL is
a source for vivid variety of products such as Hot Rolled
Coil,CRCA,CRFH,Galvanized Coil and Sheet,Galume Coil
and Sheet,Color Coated Coils,Color Coated Tiles,High Tensile
Steel Strips,Hardened & Tempered Steel Strips,Precision
Tubes,HFW/ERW Pipe (API Grade),3LP Coated Pipes,Billets
and Sponge Iron.
2
Base line Audit
Aug-2011
3
Energy
Conservation
Cell
Formed
4
En-Con
Team
Formation
6
Optional Energy
Audit
&Implementation
Recommondation
8
Manadatory
Energy
audit conducted
dec,15 7
Detailed
Energy
audit
conducted
dec,13
Road
map
Won 9th State Level
energy conservation
award
Energy Policy
Renewed
(EnMS Policy)
Won National Energy
Conservation Award
award
8
Merged With
IMS (Integrated
Management
System)
Merged with
IMS Policy
Won 8th State Level
energy conservation
award
5
energy
policy
launched
1
Declared
D.C.
2010
9
EnMS
ISO 50001
Implementation
Training and awareness on Energy
Conservation Techniques Workshop & awareness session for ladies on energy
conservation in household appliances by PCRA
Painting and drawing competition Energy walk Oath ceremony
Creation of Awareness in the Employees- Energy Conservation Week
Prize Distribution
0
10
20
30
40
50
60
70
80
2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
Budget
25
50
6570
25 25
75
Financial year
Rs
in l
acs
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
JSW Vasind
BSL Raigad
BSL Sahiba
badM/S M
ukund
Llyods Cha
ndrapur
MTOE/ton
0.0414 0.0345 0.0215
0.1086
0.6889
Budget Allocation Trend
SEC Benchmarking based on
PAT Notification
Year Saving
(lakhs of
Rupees)
Investment
(lakhs of
Rupees)
2010-11 250.81 24.42
2011-12 110.61 54.93
2012-13 149.492 65.39
2013-14 55.09 124.62
2014-15 286.28 27.88
2015-16 241.65 6.834
2016-17 452 74
Expenses & Savings
Energy Policy Yr.2012
Changed During EnMS
Yr.2015
IMS Policy Yr.2018
Projects Implemented in FY 2016-17
S.no Project Investment (Rs in lacs)
Saving (Rs in lacs)
Savings(KWh in
lacs)
Savings Fuel (Million Kcal )
1 Centac Compressor no.2 Efficiency improved by replacing Air end.
55 65 10.84 0
2 Waste Heat Recovery 15.1 309.52 3 569967
3 Energy saving through Drive & Motor control logic modification.
0 54 9 0
4 VFD Installation 0 5.72 0.95 0
5 Revamping of Steam Distribution Network 2.79 17.34 0 673.55
Centac no.2 Efficiency improved
by replacing Air end.
Total Energy Saving Implementation Cost
Rs. 65 Lacs Rs. 55 Lacs
Re-insulation of Ammonia
cracker furnace
Total Energy Saving Implementation Cost
Rs. 9.67 Lacs Rs. 05 Lacs
Total Energy Saving Implementation Cost
Rs. 52.25 Lacs Rs. 02 Lacs
Use of waste heat for Chemical dryer
instead of RLNG burner at CCL
Total Energy Saving Implementation Cost
Rs. 15.69 Lacs Rs. 01 Lacs
Use of waste heat for Product Sheet Dryer at CCL
Preheating Arrangement Before
Hardening Furnace
Total Energy Saving Implementation Cost
Rs. 29.63 Lacs Rs. 0.29 Lacs
DC Motor Running & Economy Field Current
Total Energy Saving Implementation Cost
Rs. 3.78 Lacs NIL
Total Energy Saving Implementation Cost
Rs. 5.72 Lacs NIL (Old Spare Available)
VFD Installation (02 nos)
Revamping of Steam Distribution
Network replacement of 32
Thermodynamics Steam Traps
Total Energy Saving Implementation Cost
Rs. 17.34 Lacs Rs. 2.79 Lacs
Total Energy Saving Implementation Cost
Rs. 24.23 Lacs Rs. 0.21 Lacs
Annealing area sump pump motors
controlled by using Level Switch
Energy Saving Projects Planned in FY2017-18
Sr.
No.
Description of energy efficiency improvement measure. Investment
(Rupees)
Verified
Savings
(Rupees)
Verified
Energy
savings
Units Remarks
1 Hot air steam dryer to be replace with direct hot air from
incinerator exhust blower stack.
100000 2,73,020 49,640 KWh Under Progress
13,31,520 701 Ton Under Progress
2 Chemical Coater burnner to be replace with direct hot air from
incineration stack (CCL Prod).
200000 51,14,003 8,370 mmBTU Under Progress
1,87,902 34,164 KWh Under Progress
3 New Drive instalation in Prime Oven Fume Recirculation Fan (CCL
Prod)
200000
2,43,667
44303 KWh Under Progress
4 TCV Installation at Brush tank (CCL Prod) 110000 2,66,304 140 Ton Completed
5 TCV Installation at Alkali tank (CCL Prod) 110000 2,50,958 132 Ton Under Progress
6 LED Light 150W (CCL Prod) 400 W HPSV Lamp (Shed light)
replaced with 150W LED (18Nos)
93600 43882 7978 KWh Completed
7 To maintain Air/Gas ratio by modification of firing system
(GP01Prod)
700000 0.960 0.866 mmbtu/mt Completed
8 Exhaust heat of pot furnace to Hot air dryer to maintain temp
(GP01Prod
100000 Under Progress
9 Optimisation of Unit consumption of Makeup pump by changing
pre-established system (Tube Div)
68000 1,68,480 28080 KWh Completed
10. Replacement of HPSV lamps with LED lamps (Tube Div) 540000 1,29,600 21600 KWh Planned
11 Planning for automatic off of mill utilities (Tube Div) 50000 1497916 249653 KWh Planned
12 Flue gases used in dryer to dry the strip, thus by eliminating steam
consumption in May'17 (GP02 Prod)
202000 2577207 16.71 Kg/mt Completed
13 Furnace tuned close to psychometric ratio and gap of entry seal
reduced (GP02 Prod)
Nil 3222828 0.049 Mmbtu/mt Completed
14 Thyristor control for NH3 cracker furnace (Power Plant Elect) 120000 114306 19051 KWh Planned
15 VFD for CT Fan (Power Plant Elect) 170000 641670 106945 KWh Planned
16 In Belling press Hydrolic system (Power Plant Elect) 2000 30000 5000 KWh Planned
17 Automatic control of substation outdoor lighting by photo sensor
(Power Plant Elect)
5500 32222 5723.2 KWh Completed
18 ENTRY HOT AIR DRYER BLOWER MOTOR (37KW) (GP1-Elect) 0 1080000 216000 KWh Completed GP1
19 SHED LIGHT (SHED NO 4) (GP1-Elect) 63700 38325 7665 KWh Completed GP1
20 SHED LIGHT (SHED NO 1 ) (GP1-Elect) 45000 10950 2190 KWh Completed GP1
21 HOT AIR DRYER (shed 2) (GP1-Elect) 55000 80788 17953 KWh Completed GP1
22 Chemical combustion blower motor(Motor stopped due to waste heat
recovery) (GP1-Elect)
Nil 189172 34395 KWh Completed
CCL
23 Hot air dryer #1 motor.( Motor stopped due to waste heat recovery)
(GP1-Elect)
Nil 273735 49770
KWh Completed
CCL
24 LED Light 150W (GP1-Elect) 93600 43882 7978 KWh Completed
CCL
25 Prime Oven Fume Recirculatin fan motor to be run with
VFD.Presently running with Star delta starter. (GP1-Elect)
200000 81000 18000 KWh Completed
CCL
26 LED Light 150W 135000 81000 16200 KWh Completed
27 Provided V.F. drive of trimmer-2 hdyraulic power pack system (GP1-
Elect)
49000 88128 17625 KWh Completed
28. PHF COMB. BLOWER-2 (GP1-Elect)
250000 241080 48216 KWh Planned GP2
29 HAD COMB. BLOWER (GP1-Elect) (GP1-Elect) 0 72000 14400 KWh Planned GP1
30 SHED LIGHT 400W (SHED NO 4) (GP1-Elect) 225000 136875 27375 KWh Planned GP2
31 SHED LIGHT 250W (SHED NO-1,2 &5) (GP1-Elect) 450000 109500 21900 KWh Planned
32 Hot air dryer #1 motor (22KW) to be run with VFD(Due to use of flue
gases for drying motor is completely stopped.Hence VFD not connected
(GP1-Elect)
100000 77143 14026 KWh Planned GP1
33 V.F. Drive 11kw in trimmer -1 power pack hydrolic system (GP1-
Elect)
49000 88128 17625 KWh Planned
34 LED Light 150W (GP1-Elect & API) 2835000 1336000 205538 KWh Under Progress
35 Refurbishing of furnace insulation (NCRM Annealing) 550000
1858216 2667 mmbtu Planned
Flue gases used in dryer to dry the strip, thus by eliminating steam consumption in
May'17 (GP02 Prod)
Steam Line cut off & Flue exhaust gas
used in degreasing dryer
HAG exhaust flue gases used in
SPM dryer.
Entry Seal Gap reduced from
190 mm to 141 mm
Exhaust gas used in chromic
dryer
Furnace tuned close to psychometric ratio and gap of entry seal reduced
Total Energy Saving
Rs.25.77 Lacs
Implementation Cost
Rs.0.20 Lacs
Total Energy Saving
Rs.32.22 Lacs
Implementation Cost
Nil
ELIMINATION OF HOT AIR DRIER AT CCL, HEAT RECOVERY FROM INCINERATOR
EXHAUST FLUE GAS
ELIMINATION OF LNG CONSUMPTION AT
CHEMICAL DRIER ( CCL)
Total Energy Saving Implementation Cost
Rs. 55.84 Lacs Rs. 1.70 Lacs
ELIMINATION OF HOT AIR DRIER AT
DEGREASING GP02
Total Energy Saving Implementation Cost
Rs. 15.40 Lacs Rs. 1.00 Lacs
Total Energy Saving Implementation Cost
Rs. 13.29 Lacs Rs. 1.00 Lacs
●Previously we were using Unikleen 68 B which was in
powder form & require heating of solution at 70 to 80 °C.
●Currently we are using Unikleen 70 L which is in liquid form
& can be used at roomtemperature.
Total Energy Saving Implementation Cost
Rs. 7.52 Lacs Rs. Nil
Eliminationof Steam usage
Degreassing section of GP-02
line
Shed Lights of conventional type
(400/250watts)Replaced With LED
Lights (150 Watts, 460 no.s)
Total Energy Saving Implementation Cost
Rs. 18 Lacs/Year Rs. 39 Lacs
Projects Implemented in FY 2015-16
Sr. no.
Project Investment (Rs in lacs)
Saving (Rs in lacs)
Savings(KWh in lacs)
Savings Fuel (million Kcal )
1 VF drived used in plant 5.570 62.634 14.465 0
2 Energy Saving through PLC logic modification
0 6.928 1.600 0
3 Condensate recovery from RFO yard 1 1.620 0 73.04
4 Lighting Projects 0.264 0.296 0.069 0
5 Fine tunning & Setting A/G ratio 0 168.454 0 4149.824
6 Use of Smaller size Lovejoy coupling 0 1.715 0.396 0
Energy Saving Recommendations/Scope of Major Energy Saving Options in
External Energy Audit- Bedmutha
Audit Culture shows our committment
About Energy Conservation
Base Line Energy Audit-Yr.2010
Optional Energy Audit-Yr.2013
Steam Walk Through Audit-
Yr.2014
MEA-yr.2015
Pump Audit-Yr.2016
Steam Detailed Audit-Yr.2017
Insulation Audit-Yr.2017
Air Distribution Audit-On Going
MEA-Praposed April2018
Water Balance Audit-Future
Planned
Harmonics Audit-Future Planned
Project 1 : Installation of solid waste based hot water generation system
Total Energy Saving Implementation cost
Rs 5,77,336 Rs 5,47,000
Previously Implemented Projects
Total Energy Saving Implementation cost
Rs 1,13,81,076 Rs 36,00,000
Project 2 : Installed KVX system on gas fired boiler to enhance the overall
efficiency by 10% by facilitating better combustion.
C C
C H
High fuel consumption
High CO emissions Before
Modification
After
Modification
C C
C H
Fuel consumption
reduced by 10%
CO emissions reduced
by 30%
Strong C-C &
C-H bond
Weak C-C
& C-H bond
SEC (Electrical + Thermal) in TOE/tonne of Product without
Normalization
Year
SEC
TOE/tonne
(of
Product)
Production
(Mt)
Consumptio
n
MKcal
2010-11 0.0397 1034500 410277
2011-12 0.0399 1078824 430681
2012-13 0.0413 1086367 448429
2013-14 0.0405 983041 398434
2014-15 0.0364 753837 274212
2015-16 0.0329 920604 302708
2016-17 0.0324 977670 316926
0.0320
0.0340
0.0360
0.0380
0.0400
0.0420
2010
-11
2011-
12
2012-
13
2013
-14
2014
-15
2015-
16
2016
-17
0.03970.0399
0.0413
0.0405
0.0364
0.0329
0.0324
TO
E/t
on
ne
Specific energy consumption (TOE/tonne of product)
Plant Capacity Utilization Except Large Dia Pipe Plant After
PAT Cycle-I
0%
20%
40%
60%
80%
100%
2014-15
2015-16
2016-17
Capacity Utilization
70%
85%92%
Financial year
Financial year
Total Plant
Capacity
Total Production
Capacity Utilization
2014-15 1040000 722954 70%
2015-16 1040000 884886 85%
2016-17 1040000 953728 92%
Installation of Polycrack system with 50 kg I/P Charge of polythene & plastic
product & produce diesel , gas & carbon
Total Energy Saving Implementation cost
Rs 5,34,000 Rs 12,00,000
Future Plans For Energy Conservation
Planning to put industrial solar water
heating system of capacity 30000LPD
at 80degC . Heated water will go to
boiler in place of normal feed water
Planning to extend our capacity of solar
water heating system with 8000LPD for
colony
Planning to install Solar PV plant of
capacity 500KWp-1MWp in
forthcoming years
Planning to put Heat Pump for heating coolant water of mill up to 65 degC which will
replace existing heating system of steam heat exchanger and will save 40% of energy.
Expansion Valve
Ambient Air
Inlet
Cool
Air Outlet
Cold Water
Inlet
Hot Water
Outlet
Air Source Heat Pump
Water Heating System
Compressor
Planning to install Fuel Enhancer Kit in our company vehicle to save fuel
10-40%
Co-generation WHR Boiler On Power Plant
Inlet
flue gas
Steam
generatio
n
Exhaust
Enviormental projects & New Technologies Implemented
Clean Development Mechanism
The Clean Development Mechanism (CDM), defined in Article 12 of the KYOTO Protocol,
allows a country with an emission-reduction or emission-limitation commitment under the
Protocol to implement an emission-reduction project in developing countries. Such projects
can earn saleable certified emission reduction (CER) credits, each equivalent to one tonne of
CO2, which can be counted towards meeting Kyoto targets.
The mechanism stimulates sustainable development and emission reductions, while giving
industrialized countries some flexibility in how they meet their emission reduction or limitation
targets.
Bhushan Steel Ltd has registered 2 projects under UNFCCC with consultation of Frenz
Greenearth Technologies Pvt Ltd totalling a prospective Certified Emission Reduction (CER)
capacity of around 18000 T CO2 per year. Projects are:
1.UNFCCC CDM Project No-.8802: 24 MW Power Plant .For
reference:http://cdm.unfccc.int/Projects/DB/TUEVSUED1355561731.08/view
2.UNFCCC CDM Project No-.8801: Industrial Boiler.For reference:
http://cdm.unfccc.int/Projects/DB/TUEV-SUED1355560177.97/view
Bhushan Steel Ltd has actively maintained its GHG inventory according to ISO 14064-
1:2006(certification under process).
The ISO 14064 standards (published in 2006 and early 2007) are the most recent additions to the
ISO 14000 series of international standards for environmental management. The ISO 14064
standards provide governments, businesses, regions and other organisations with an integrated set of
tools for programs aimed at measuring, quantifying and reducing greenhouse gas emissions. These
standards allow organisations take part in emissions trading schemes using a globally recognised
standard.
CDM (Clean Development Mechanism) is also an integral part of GHG inventory managment and we
are active in that field also.
GHG Inventory Development
Multi Effect Evaporator Reverse Osmosis Plant
TCR for Harmonics Filtration &
Power Factor Correction
Assessed P.F. Unity and Load Factor
94% in MSEDCL bill
0.998 0.94
28
Electrolytic Cleaning Line Rain Water Harvesting
Acid Regeneration Plant Organic Waste
Compositing
Re-Generative unit
at API-1
BSL Won 8th State Level EC Award
Year 2011-12
BSL Won 9th State Level EC Award
Year 2012-13
BSL Won NECA Award Year 2015-16
CREDITS
Mr. KD Sahni-Plant Head
Mr. B.Nahar- Divisional head Wider CRM
Mr. Padam Agrawal -Divisional head commercial
All production and electrical,mechanical maintenance
department
THANKS