Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace...

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1 Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra CII - 19th National Award for "EXCELLENCE IN ENERGY MANAGEMENT 2018” Copyright © MSSSPL Elect. Dept. Aug 2018

Transcript of Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace...

Page 1: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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Mahindra Sanyo Special Steel Pvt Ltd,

Khopoli , Maharashtra

CII - 19th National Award for

"EXCELLENCE IN ENERGY MANAGEMENT 2018”

Copyright © MSSSPL Elect. Dept. Aug 2018

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Company Profile

Mahindra Sanyo Special Steel Pvt. Ltd (MSSSPL), following a joint venture between Mahindra & Mahindra (29%), Sanyo Special Steel Co., Ltd (51%) 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

Copyright © MSSSPL Elect. Dept. Aug 2018

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

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1.a. Specific Energy Consumption (SEC) Reduction

Copyright © MSSSPL Elect. Dept. Aug 2018

There Is Continuous Improvement In Specific Energy Consumption.

23 % reduction in total Energy Consumption

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1.b. Specific Energy Consumption (SEC) Reduction

Copyright © MSSSPL Elect. Dept. Aug 2018

Reduction in Specific Power Consumption from 997 to 887 KWH/MTcs• Electrode Regulation in Arc Furnace• Better Ladle Management in Steel

Melting Shop• Reduction in Cycle Time at Ladle

Furnace Furnace• Heat Treatment Furnace Revamping • Energy Efficient Equipment• Best practices at all shops

Reduction in Specific Fuel Consumption from 121 to 87 Ltrs/MTcs

• Oxy- Fuel technology for reheating Furnaces

• Replacement of Recuperator • Efficient Ladle circulation for heat

optimization• Improvement in planning to

optimize heat sequence

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

Copyright © MSSSPL Elect. Dept. Aug 2018

Special Steel BENCHMARK Asia/Pacific

Electrical Arc Furnace = 451 KWH/MT

Ladle Furnace = 64 KWH/MT

Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT

Ladle Furnace = 113 KWH/MT**Tool & Die (High Alloy)steel production % higher

Road Map to Achieve Global /National Benchmarking : Carbon- Oxygen Injector for ARC Furnace – Reduction in EAF Power by 40 KWH/MT

Page 6: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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3.a. Energy Saving Projects Implemented in FY 2015-16

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

Copyright © MSSSPL Elect. Dept. Aug 2018

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 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

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

Total annual saving (Rs Mio)

Invest Made (Rs Mio)

Tons of CO2 Mitigated (Tons CO2)

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

Electrical Energy Savings :• 7.1 Mio KWH• 49.7 Mio Rs• 5822 Tons CO2

Thermal Energy Savings :• 1437 KL • 31.12 Mio Rs• 4267 Tons CO2

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

total power

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3.b. Energy Saving Projects Implemented in FY 2016-17

*Note : Savings mentioned for F 17 includes projects, suggestions, EnMS process controls and best practices . Copyright © MSSSPL Elect. Dept. Aug 2018

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 (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

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

Total annual saving (Rs Mio)

Invest Made (Rs Mio)

Tons of CO2 Mitigated (Tons CO2)

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

Electrical Energy Savings :• 3.7 Mio KWH• 26.0 Mio Rs• 3030 Tons CO2

Thermal Energy Savings :• 439 KL • 10.09 Mio Rs• 1330 Tons CO2

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

power

Page 8: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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3.c. Energy Saving Projects Implemented in FY 2017-18

*Note : Savings mentioned for F 18 includes projects, suggestions, EnMS process controls and best practices .

Copyright © MSSSPL Elect. Dept. Aug 2018

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 (Months)

1

Reduction in cycle time for LF, Use of Mark-7 thermocouple instead of Mark-3, Standardization of Alloy Addition at Ladle furnace

1.31 8.96 0 1073 0

2Revamping of GCT of Fume extraction system of Primary FES of ARC furnace

0.946.46 4.0 773 7

3 Blooming Mill & Forge shop repairing 0.39 2.74 1.40 319 6

4Cycle time reduction of 5 grades of Heat treatment

0.16 1.10 0 132 0

5KAIZENS, Suggestion, Best Practices, Efficient Operation

1.12 7.67 0 918 0

6Installation of Motion sensor & Light Detective relay for Street Light 0.17 1.14 0.03 136 0

Total 4.09 28.07 5.43 3351 2

Electrical Energy Savings :• 4.09 Mio KWH• 28.07 Mio Rs• 3351 Tons CO2

Renewable Energy & REC (Wind+ Solar) • 4.73 % of

total power

Cumulative Saving from FY 16 to FY 18Electricity MIO Kwh 14.89

Fuel KL 1876

T-CO2 MT 40952

Cost Mio Rs. 145

Page 9: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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3. d. Energy Projects FY 2019-23

Copyright © MSSSPL Elect. Dept. Aug 2018

Sl.No. Project Description FY 19 FY 20 FY 21 FY 22 FY 23 Scope- (Kg CO2-e

/ MT )Impact

1 13

2 33

2

Conversion of Reheating Furnaces from Furnace Oil to NG

(20 T WHF BAR Mill, 40 T WHF BLM Mill, 7 & 8 Chamber

Furnace BLM, Ladle Preheating)

1 33

4 Waste Heat Recovery for Hot flue Gas from Arc Furnace 2 33

5 Digital regulation system for both Ladle Furnace

6 Transformer Replacement of both Ladle Furnace

7

Conversion of Reheating Furnaces from Furnace Oil to NG

( Chamber Furnace BLM, Boiler, Forge Shop Furnaces, CC

Tundish heating)

1 41

1 5

2 16

1 5

2 16

1 1

2 16

1 Installation of 4 MW Solar Roof Top Panel 2 20

2 Solar Power through Open Access_6 MW 2 25

3 Wind Power through Open Access 2 110

Conversion of Heat Treatment 4 Nos. of Annealing furnace

from Electrical to NG heating8

Carbon-Oxygen Injector for Electric Arc Furnace1

2 8

Renewable Energy

9

10 Conversion of all CC pit from Electrical to NG heating

Conversion of Heat Treatment 5 Nos.of Annealing , 2 Nos.

of Quenching furnaceS from Electrical to NG heating

Page 10: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

10Copyright © MSSSPL Elect. Dept. Aug 2018

4 . a. Bloom uniform heating in WHFBy increasing bloom exposure to heat for 250X200 sections

Observation & Possible cause for difficulties in rolling from 250X200 Bloom

Observation :

After completion of re-heating there was more

temperature difference (>40°C ) between top bottom

of Bloom

Effect of this temperature difference

a. Bending of Bloom during rolling was observed

due to reduction force

b. Delay in completion of rolling process

c. Dimension variation due to delay in rolling

process

d. Chances of Rolling defect like shearing

e. More damage of entry guide boxes

Page 11: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

11Copyright © MSSSPL Elect. Dept. Aug 2018

Innovation Details

No Uniform

Temperature for

250X200 Bloom –

Temperature

difference between

top & bottom is

>40°C

Root Cause Action Taken

Maximum Traverse stroke design– 360 mm- This stroke is used for 250X200 & 200X180 Blooms

Increase Bloom to Bloom gap by 20 mm

for 250X200

Installed 1 extra proxy sensor at 190 mm traverse stroke – Mid way 360 mm

Bloom to Bloom Gap design – 110 mm for 250X200 & 160 mm for 200X180

Temperature difference is more for 250X200

Bloom after re-heating – due to less surface

exposure of Bloom- as Bloom to Bloom gap is

less

Proxy is connected to selector switch in PLC & design a new program in PLC

360 mm traverse stroke program is split into 2 consecutive stroke of 190 mm – Result in increase in traverse stroke from 360 to 380 mm (increase gap by 20 mm)

Page 12: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

12Copyright © MSSSPL Elect. Dept. Aug 2018

4 a. Bloom uniform heating in WHFBy increasing bloom exposure to heat for 250X200 sections

Before:

250X200 250X200 250X200250X200

110 110 110

250X200

After:

250X200 250X200

130 130

❖ Surface exposure of Bloom to radiation has increased after implementation of this project – by increasing gap by 20 mm between Blooms

❖ Shadow effect is eliminated – result in uniform heating of Bloom❖ Temperature difference is <20 ° C

Heat radiation

Heat radiation

Heat radiation

Heat radiation

Heat radiation

Page 13: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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Benefits

Production rate for 60-75 mm dia

Before-Nov’17

10 T/Hr

After-Nov’17

Saving from Dec’17

11.8 T/Hr

1. Productivity Increase with improvement in Quality

2. Bending of Bloom issue are eliminated

3. Reduction in rolling defect4. Reduction in rolling

processing delay 5. Charge to Discharge time

decrease from 4 to 3.7 hrs

8.5 T/Hr 9.4 T/Hr

40.7 Ltrs/MT

37.5 Ltrs/MT

3.2 Ltrs/MT

16 KL/Month

Net Saving : MiO Rs. / Month

0.55

Net Saving : MiO Rs. / Year 6.6

Production rate for 50-60 mm dia

Oil consumption at Walking Hearth

Furnace

Project Implemented

with no

INVESTMENT

Page 14: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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Materials

ManMethod

VD Problem LF Breaker Breakdown

Desulphurization time more due to Lime Hopper

Wire Feeder

Problem Vessel Car

Breakdown

Sulphur Wire Break

Ladle Side

gate failure

Ladle Porous Plug Jam

Wrong Addition

Sop not followed

High

Chromium

Heats

Start Temperature LowPit Side Delay

High LF Power

Machine

100T Crane

Break down

Wrong Chemistry

reference written

Variations in grade

compositions

Inadequate Ladle

heating

Skill

Dependent

Ladle puncture

Temperature Lance Variation

Unidentified scrap in

charging

Improper

Sampling

Continuous

CC heat / BP

heat

Out of Circulation

Ladle

Special Heat

processing

Power

Failure

Missing Ladle Sequence

Temperature Variation

Heat Return

Tapping Addition

variation

Identify possible causes: For High LF Power

4. Innovation Projectsb. Ladle Furnace Specific Power Consumption Reduction

Copyright © MSSSPL Elect. Dept. Aug 2018

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15Copyright © MSSSPL Elect. Dept. Aug 2018

Innovation Details

High LF Power

Root Cause Action Taken

Start Temperature Low -Insufficient ladle heating

Temperature variations _Ladle Circulation

Missing Ladle Sequence (Gap Ladle) –

Temperature variation

Desulphurization time more

Ladle Heating time increased

3 Ladle circulation instead of 4

Mark 7 temperature tips are in use against Mark 3 for better accuracy in temperature measurement.

New lime hopper installed on LF platform

Page 16: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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Benefits

Ladle Power Consumption

Before-Nov’17

120 KWH/MT

After -Nov’17

Saving from Dec’17

103 KWH/MT

17 KWH/MT

1.9 MiO Rs./Month

6.2 Ltrs/MT

8 Ltrs/MT

-1.8 Ltrs/MT

-0.8 MiO Rs./Month

0.92 Kg/MT

0.74 Kg/MT

0.18 Kg/MT

1.9 MiO Rs./Month

Net Saving : MiO Rs. /Month : 3 Net Saving : MiO Rs. /Year : 36

Oil Consumption _Ladle preheating

Electrode Consumption at Ladle Furnace

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Observation for Possible cause

Charge

preparation

Charging

& Melting

at EBT

Spectro

analysisRefining

LF,VD

Ingot

CastingIngotSpectro

analysis

Final

Chemistry

SUSPECTED

AREA FOR

DEFECT

GENERATION

Yield in EN36C grade, 125 RCS made with 3.01 T input size is down by ~ 1 %. Yield is

less due to rejection occurring during ingot casting process .

4. c. Increase in Yield of EN36C 125 RCS by 1% by reducing rejections

Copyright © MSSSPL Elect. Dept. Aug 2018

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18Copyright © MSSSPL Elect. Dept. Aug 2018

Innovation Details

Sl

No

Probable

CauseTesting and Observations Conclusion

1.High casting

speed

Data was collected 25 heats and co-

relation was observed of OK and Not OK

heats.

Hypothesis

is found

invalid.

2.High/low

Temperature

Data was collected 30 heats and co-

relation was observed of OK and Not OK

heats when EN36C heat was high/ low

temp.

Hypothesis

is found

invalid.

3Bloom Rolling

size

In heats with rolling size 125 RCS

scabbiness on surface was observed but

not frequently.

Hypothesis

is found

invalid.

4Frills

generation

Due to frill generation in ingots, it has to

be cut.

Hypothesis

is found

valid.

5Skilled

Manpower

Training is being given to the man power.

Skill levels are appropriate for the

teeming bay activities.

Hypothesis

is found

invalid.

Page 19: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

19Copyright © MSSSPL Elect. Dept. Aug 2018

Actions Decided

Valid

Probable

Cause

WHY WHY WHY WHY WHY

Frill

generation

Frill generation

during casting.

Due to gap

in between

mould wall &

hot top

Improper

fitment &

type of

hot tops.

Hot tops

don’t

take

shape of

wall.

Hot tops

are rigid.

Root Cause Action Plan Status

Frills

generation

Flexible hot top used

a) Monitoring heats where flexible hot top used. 100%

Implementedb) Observe ingot hot top surrounding portion

whether any frills generate & then record keeping

done.

Page 20: Mahindra Sanyo Special Steel Pvt Ltd, Khopoli , Maharashtra...Mahindra Sanyo Electrical Arc Furnace = 459 KWH/MT Ladle Furnace = 113 KWH/MT* *Tool & Die (High Alloy)steel production

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BenefitsBefore After

Reduction in

rejection due to

Scabbiness

Tangible + Non-tangible

Decrease from 3.4 to 0 MT/ Month

Reduction in

production cost

Rs. 2100 / Ingot heats

Reduction in track time- Hot

heat to BLM

Decrease by 30 mins – Oil saving at re-heating Furnaces

❖ Frills generation totally eliminated

❖ Improvement in delivery schedule

❖ Reduced rework

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Project Details :

▰ New Concept. Started in 2015. Till date, just over 400 companies have committed globally

[ including 6 from India ] to setup Science Based Target for their business.

▰ Mahindra Sanyo is the 1st Steel Company from India & 3rd Steel Company Globally to

commit to setting up Science Based target for its own business.

▰ Project conceptualized at Senior Management Level

Drivers for setting up SBT

Cost Competitiveness

Become preferred supplier

Managing ESG Risk & Opportunities in Value Chain

New Revenue Streams

Access to Capital

Safeguard future

profitabilityCommitted to

set Science

Based Target

March 2017

Developed

Science Based

Target

September –

December 2017

Submitted

Science Based

Target for

Quality Check

December 2017

Approved and Announced

Science Based Target-

(Reduce Scope-1 , 2 & 3

GHG Emission by 35 % by

2030 from baseline year

2016)

March 2018

4.d. Taking Climate Action by Setting Science Based Target (SBT)

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Tangible + Non-tangible

Environmental

▪ Emission reduction

of more than 1

million tCO2e

▪ Along with a host of

other intangible

environmental

benefits

▪ Reduction in Scope-

1 & Scope -2 GHG

emission by 35 % by

2030 from 2016 as

baseline

Social

▪ People/society

benefits

▪ Moral/motivation

▪ Skill upgradation

▪ Attitude

shift/development

Economic

▪ Increase innovation

▪ Reduce regulatory

uncertainty

▪ Strengthen investor

confidence and

credibility

▪ Improve profitability

and competitiveness

▪ Savings of ₹ 146

Crore by 2023 from

2016

2% Improvement in Specific

Electricity Consumption

3% Improvement in Specific

Scope 2 emission

5% Power from Renewable

Energy Source

4.d. Benefits of Project :

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Taking ambitious action now helps companies stay ahead of future policies and regulations to

limit GHG emissions. Companies that are seen as leaders are better able to influence policy

makers and help shape developing legislation.

Huge replication potential

▰ Universal application: Science Based Target applicable to all sectors and types of

businesses

▰ Methods of calculation: Methods are available to calculate SBT for all sector

Replication potential of project within sector:

▰ Steps initiated: Awareness session on SBTi within the company and across the group

▰ Achievement sharing Mode:Presented case of SBTi in different seminars organized by WRI

and CDP

▰ Based on MSSSPL’s success 10 Mahindra Group companies committed to set Science

Based Target for their Business in May 2018

▰ We have started engaging our Supply Chain to encourage them to adapt SBTi

4.d. Replication Potential within group and companies

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5. Utilization of Renewable Energy

Copyright © MSSSPL Elect. Dept. Aug 2018

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

MSEDCL, 38%

Conventional Source,

53%

Renewable Energy

source, 9%

Power Utilisation from Different Sources (%)

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6.a. Utilization of Waste as Fuel

Copyright © MSSSPL Elect. Dept. Aug 2018

Waste Utilization Process Flow

Canteen Food Waste Waste Transport

Bio Gas generation

& Storage Gen-SetStreet Lighting

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6.b. Utilization of Waste

Copyright © MSSSPL Elect. Dept. Aug 2018

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 18

Total Refractories Recycle = 544 MT

Total Power saved under scope III at manufacturing end =129496 KWH (238 KWH/MT Specific Electricity Consumption)

Total Mill Scale Recycle = 6867 MT

Total Power saved = 13734 KWH

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7. GHG Inventorisation

Copyright © MSSSPL Elect. Dept. Aug 2018

1.Reduction in scope-1 : 30% (62872 T CO2-e) 1.Reduction in scope-2 : 13% (52187 T CO2-e)

Public disclosure :1. Through Mahindra Sanyo Annual Sustainability Report2. Annual CDP reporting3. Through SBT

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Aspect Vision

❖ Scope - 1 emission reduction by 10%

❖ Scope - 2 emission reduction by 5%

❖ Scope - 3 emission reduction by 5%

❖ Water consumption reduction by 10%

❖ Collaborate to have environmentally and socially responsible suppliers only

Mode of Engagement

Copyright © MSSSPL Elect. Dept. Aug 2018

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

8. a. Sustainable Supply Chain Management

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❑ 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

Copyright © MSSSPL Elect. Dept. Aug 2018

8. b. Actions & Initiatives

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9.a. 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

Copyright © MSSSPL Elect. Dept. Aug 2018

Steel Melting Shop, 64%Ring Division, 9%

Blooming Mill, 7%

Heat Treatment & Finishing Shop, 6%

Forge Shop, 4%

Rolling Mill, 2%

Continous Mill, 0.5%

Conditioning, 2%

Miscellaneous, 3%

Utility, 3%

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9.b. 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.

Copyright © MSSSPL Elect. Dept. Aug 2018

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

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32Shaswati Council Meeting

Energy Month Celebrations

9. c. Team Work In Energy Conservation

Cross Functional Teams

Copyright © MSSSPL Elect. Dept. Aug 2018

Energy Team

Shop Floor Training for Energy Conservation

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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

2014 Measurement & Verification by

Schneider

2015 Re-Certification Audit

2016 Re-Certification Received

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

Copyright © MSSSPL Elect. Dept. Aug 2018

2017 Energy Audit by TERI & SGS

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Key AchievementsSustainability has been embedded in Mahindra Sanyo’s business strategy to shoulder their economic, environmental and social responsibility.

Achievements:❑ Reduction in water lift by 35% in last 4years❑ Reduction in Specific Energy consumption by 29% in last 6 years❑ Reduction in Oil consumption 50% by Oxy fuel technology❑ Reduction in GHG emission in 55%

❑ Power consumption from Renewable Energy – 5 %

❑ National Award for Excellence in Energy Management in 3 successive years 2015, 2016 and 2017

❑ The secondary steel sector Trophy for Excellence in Performance for the year 2016-17 – By Ministry of Steel Govt. of India

❑ Mahindra Sanyo is the first steel Company globally and first company from India to receive approval of its Science Based Targets

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MSSSPL | Awards & Recognitions

Copyright © MSSSPL Elect. Dept. Aug 2018

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

18th National Award for Excellence in Energy Management 2017:Energy Efficient Unit in Steel Sector

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36Copyright © MSSSPL Elect. Dept. Aug 2018

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Mould Hot Tops