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Our Working Philoshphy

“We can’t manage and control what we don’t measure”

Cost of Steel Making %

Raw Material Cost --50

Energy Cost --40
Labour --2
Other cost –8

*Above data is taken from CII & BEE.

3-Sep-18
2
Our Proposal ON ENERGY EFFICIENCY

• Lowest Energy Consuming unit amongst

Integrated Steel Plant in India
• Continuously Improving Energy Efficiency for
each of the production units
• Usage of Innovative process & equipment
technologies for the manufacturing
• Continuous endeavor to utilize energy waste:
either in form of process waste and /or hidden
chemical & thermal energy
• Energy sources optimization for Input cost
efficiency
• Energy Management center for proper
monitoring & control
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Specific Energy Consumption Summary for Angul, Raigarh and
Oman
Sr.No. Plant GCal Remarks
/TP
Angul Raiga Oman JSW India Global
rh Bench Bench
mark mark
1 Sinter
Plant
2 Blast
Furnace
3 SMS
4 Caster
5 Plate
Mill
6 Bar Mill
7 Aux
Losses

-3 September 2018- 4
Energy Consumption of different processes in a typical steel plant

-3 September 2018- 5
Energy saving Opportunities with high investment

• Installation of waste heat recovery boiler in FES.

• Installation of waste heat recovery Vapour absorption
refrigeration Chiller.
• Installation of VFD in FES I.D. fans.
• Installation of power factor correction panels where we are
getting lesser power factor.
• Installation of vapour absorption chiller instead of small A.C.
unit.
• Installation of fanless cooling tower instead of traditional
cooling towers.
• Installation of control air and air optimization unit in supply
side and demand side management.

-3 September 2018- 6
Energy saving Opportunities with high investment

• Replacement of all low energy efficiency pumps with high

efficiency pumps.
• Replacement of Ejectors operated V.D.system with V.D.system
engaging mechanical vacuum pump.(Working in our Oman plant)
• Replacement of pneumatic dust conveyor with mechanical dust
conveyor in FES.(Working in our Oman plant)
• Replacement of low efficiency air dryer with high efficiency
refrigerant air dryer.
• Replacement of all low efficiency or rewinded motors with new
high efficiency motors.
• Installation of oxyfuel burners in Reheating furnaces.
• Replacement of all air cooled chiller unit with water cooled chiller
unit. We completed this exercise in Auditorium in Raigarh)

-3 September 2018- 7
Energy saving Opportunities with medium investment

• Replacement of solid fan blade with hollow blades or airofoil

design blade in all cooling towers.
• Replacement of all metal shaft with composite material shaft in all
cooling tower.(Composite shaft is in operation in our Oman plant)
• Installation of VFD in one compressor or one pump in a group
where more than one unit is running and demand is flexible.
• Repairing of all damaged insulation and provide insulation where
required.
• Installation of blowdown water heat recovery system and
condensate recovery system.

-3 September 2018- 8
Energy saving Opportunities with medium investment

• Application of coating in all impellers and pump housing to reduce

friction and increase the efficiency by 3 to 4 %.
• Replacement of all timer based auto drain valve with zero
discharge auto drain valve.
• Installation of nozzles where compressed air is used for cooling
purpose.
• Replace all leaking steam trap with zero discharge steam trap.
• Install online stack analyzer and control of excess air in all
furnaces.

-3 September 2018- 9
 Energy saving Opportunities
with zero investment or
minor investment.

-3 September 2018- 10
Air Compressor

• Clean and change air filter periodically and maintain minimum

delta P.
• Change the oil filter regularly.
• Periodically inspect compressor intercoolers for proper functioning.
• Establish a compressor efficiency-maintenance program. Start
with an energy audit and follow-up, then make a compressor
efficiency-maintenance program a part of your continuous energy
management program.
• Reduce air compressor discharge pressure to the lowest
acceptable setting. (Reduction of 1 kg/cm2 air pressure (8 kg/cm2
to 7 kg/cm2) would result in 9% input power savings. This will also
reduce compressed air leakage rates by 10%)

-3 September 2018- 11
Air Compressor

• Turn off refrigerated and heated air dryers when the air
compressors are off.
• • Use a control system to minimize heatless desiccant dryer
purging.
• • Minimize purges, leaks, excessive pressure drops, and
condensation accumulation. (Compressed air leak from 1 mm hole
size at 7 kg/cm2 pressure would mean power loss equivalent to 0.5
kW)
• • Use drain controls instead of continuous air bleeds through the
drains.

-3 September 2018- 12
Similar points in other areas

• Boilers
• Steam system
• Chillers
• Water Pumps
• Cooling Towers
• Fan and Blowers
• Heat Exchangers

-3 September 2018- 13
-3 September 2018- 14
THANKS

-3 September 2018- 15